X-shaped refractory anchor device and system

Abstract

Refractory anchoring devices include a main body and a mounting feature for mounting to a thermal vessel. The main body includes four anchor branch segments angled with respect to each other to form an X shape with four unenclosed cell openings, including two opposite triangular side openings and two opposite triangular end openings. In some embodiments, the main body further includes extension segments extending from and angled relative to respective branch segments to define two of the opposite openings as semi-hexagonal. Some embodiments include reinforcement segments extending from branch segments into openings, voids extending through branch segments, two anchor strips inter-engaged to form the four branch segments, and/or a single stud-welding stud for the mounting feature. Refractory anchoring systems and methods include an array of the refractory anchoring devices arranged and mounted so that the unenclosed openings of adjacent anchoring devices cooperatively form substantially hexagonal and rhombus shaped cells.

What is claimed is: 
     
         1 . An anchoring device for a refractory material for lining a thermal vessel, the anchoring device comprising:
 a main anchor body including four anchor branch segments forming an X shape, wherein the four branch segments each have a same length and are angled with respect to each other to form four unenclosed cell openings between them including two opposite side openings and two opposite end openings, wherein the two side openings are each triangular in shape, wherein the main body further includes four extension segments with each one extending from a respective one of the four branch segments, wherein the four extension segments are each angled relative to their respective branch segments to define portions of the two opposite end openings such that the two opposite end openings are each semi-hexagonal in shape; and   a mounting element adapted to mount the main body to the thermal vessel,   
       wherein the four branch segments are formed by two anchor strips that are angled with respect to each other, wherein each of the anchor strips has two outer portions defining the branch segments and a central portion therebetween, and wherein the central portions of the two anchors strips inter-engage and are attached to the mounting element, and 
       wherein the mounting element includes a first metal material that the thermal vessel is made of and the anchor body includes a second metal material selected to retain the refractory material to the thermal vessel such that the first metal material of the mounting element is different from the second metal material of the main body. 
     
     
         2 . The anchoring device of  claim 1 , wherein the thermal vessel is of a type used in an oil refinery, another petrochemical-process facility, a chemical-process facility, a chemical-manufacturing plant, a cement plant, or another industrial facility for performing an industrial process in a high-temperature, high-pressure, and/or caustic environment, and wherein the refractory material includes concrete, plastics, ceramics, another conventional refractory, or a combination thereof. 
     
     
         3 . The anchoring device of  claim 1 , wherein the four branch segments are each angled at 90 degrees with respect to each other. 
     
     
         4 . The anchoring device of  claim 1 , wherein the four branch segments each have a same maximum relative height and/or segment height, at least adjacent the mount element, to form a single top plane and/or a single bottom plane. 
     
     
         5 . The anchoring device of  claim 1 , wherein the two anchor strips each have a vertical slot, with one of the anchor strips having its slot extending downward through its upper surface and with the other one of the anchor strips having its slot extending upward through its lower surface, so that the slots receive each other and the remaining unslotted central portions to form the X-shaped main anchor body. 
     
     
         6 . The anchoring device of  claim 1 , wherein the main body further includes four anchor reinforcement segments with each one extending into a respective one of the four unenclosed cell openings so that each of the four unenclosed cell openings has a respective reinforcement segment extending into it. 
     
     
         7 . The anchoring device of  claim 6 , wherein the reinforcement segments are in addition to the branch segments, and do not define any portion of the four unenclosed openings. 
     
     
         8 . The anchoring device of  claim 1 , wherein the main body defines at least one void that extends through at least one of the branch segments, and wherein the body void allows the refractory to flow through the anchor main body when the anchor is mounted to the vessel and the refractory is being installed. 
     
     
         9 . The anchoring device of  claim 1 , wherein the main body defines four of the voids with each extending through a respective one of the branch segments. 
     
     
         10 . The anchoring device of  claim 1 , wherein each extension segment is parallel to an adjacent one of the extension segments that it cooperates with to form the semi-hexagonal end openings and is aligned with another adjacent one of the extension segments. 
     
     
         11 . The anchoring device of  claim 1 , wherein each of the extension segments has a length that is less than about half a length of the branch segments. 
     
     
         12 . The anchoring device of  claim 1 , wherein the mounting element includes a welding stud defining a recess for receiving a pilot interface element, wherein the stud is centrally attached to the X-shaped anchor main body. 
     
     
         13 . The anchoring device of  claim 12 , wherein the mounting stud is stud-welded or plug-welded to the X-shaped anchor main body. 
     
     
         14 . The anchoring device of  claim 12 , wherein the mounting stud includes an X-shaped notch in its upper surface that receives the X-shaped anchor main body. 
     
     
         15 . A system of a plurality of the anchoring devices of  claim 1 , wherein the anchoring devices are arranged in an ordered array of rows and columns in a tessellated pattern with adjacent of the openings of adjacent of the anchoring devices cooperatively defining an ordered array of cells that are hexagonal and/or rhombus shaped. 
     
     
         16 . A method of protecting a thermal vessel, comprising installing the anchoring system and the refractory material in the anchoring system of  claim 15 . 
     
     
         17 . An anchoring device for a refractory material for lining a thermal vessel, the anchoring device comprising:
 a main anchor body including four anchor branch segments forming an X shape, wherein the four branch segments each have a same length and are angled at 90 degrees with respect to each other to form four unenclosed cell openings between them including two opposite side openings and two opposite end openings, wherein the two side openings are each triangular in shape, wherein the main body further includes four extension segments with each one extending from a respective one of the four branch segments, wherein the four extension segments are each angled relative to their respective branch segments to define portions of the two opposite end openings such that the two opposite end openings are each semi-hexagonal in shape,   wherein each extension segment is parallel to an adjacent one of the extension segments that it cooperates with to form the semi-hexagonal end openings and is aligned with another adjacent one of the extension segments, and   wherein the four branch segments each have a same height to form a single top plane of the main body; and   a mounting element adapted to mount the main body to the thermal vessel, wherein the mounting element includes a welding stud defining a recess for receiving a pilot interface element,   wherein the four branch segments are formed by two anchor strips that are angled with respect to each other, wherein each of the anchor strips has two outer portions defining the branch segments and a central portion therebetween, and wherein the central portions of the two anchors strips inter-engage and are attached to the mounting stud, and   wherein the mounting stud is made of a first metal material that the thermal vessel is made of and the anchor body is made of a second metal material selected to retain the refractory material to the thermal vessel such that the first metal material of the mounting stud is different from the second metal material of the main body.   
     
     
         18 . The anchoring device of  claim 17 , wherein the two anchor strips each have a vertical slot, with one of the anchor strips having its slot extending downward through its upper surface and with the other one of the anchor strips having its slot extending upward through its lower surface, so that the slots receive each other and the remaining unslotted central portions to form the main body, 
     
     
         19 . The anchoring device of  claim 17 , wherein the main body further includes four anchor reinforcement segments with each one extending into a respective one of the four unenclosed cell openings so that each of the four unenclosed cell openings has a respective reinforcement segment extending into it, wherein the reinforcement segments are in addition to the branch segments, and do not define any portion of the four unenclosed openings, wherein the main body defines at least one void that extends through at least one of the branch segments, and wherein the body void allows the refractory to flow through the anchor main body when the anchor is mounted to the vessel and the refractory is being installed, wherein the main body defines four of the voids with each extending through a respective one of the branch segments. 
     
     
         20 . The anchoring device of  claim 17 , wherein the mounting stud is stud-welded or plug-welded to the X-shaped anchor main body, wherein the mounting stud includes an X-shaped notch in its upper surface that receives the X-shaped anchor main body.