Large size cast monolithic refractory repair modules and interfitting ceiling repair modules suitable for use in a coke over repair

Claims

What is claimed is:

1. A first repair module for a coke oven comprising:

a large size cast monolithic refractory repair module for use in the repair of existing heating walls between coking chambers in a coke oven battery, each heating wall being built from a plurality of courses of bricks, each course of bricks including a plurality of small size refractory bricks which are used to form wall surfaces of adjacent coking chambers and to define spaced apart vertically extending flues within the heating walls, which flues may be used alternately for burning fuel gases or for drafting, the flues having tops and bottoms, each flue having a gas nozzle and an air port at the bottom thereof, the large size cast module being formed from a castable refractory which, when cast, has high dimensional stability and good thermal shock resistance in the temperature range which may be encountered in a coke oven, the large size cast module being a generally rectangular parallelepiped having first and second opposed vertically extending sidewalls spaced apart from each other a distance substantially equal to the width of the heating wall at the location of the repair, said sidewalls being capable of forming the wall surfaces of adjacent coking chambers, first and second opposed generally vertically extending rends, and upper and lower generally horizontal surfaces, the distance between the horizontal surfaces being at least equal to one course of bricks, and the large size cast monolithic refractory repair module having at least one vertically extending flue defining cavity extending upwardly from the lower generally horizontal surface to the upper generally horizontal surface.

2. The first large size cast repair module as set forth in claim 1 wherein the first cast repair module is of a height equal to two courses of bricks.

3. A first repair module for a coke oven comprising:

a large size cast monolithic refractory repair module for use in the repair of existing heating walls between coking chambers in a coke oven battery, each heating wall being built from a plurality of courses of bricks, each course of bricks including a plurality of small size refractory bricks which are used to form wall surfaces of adjacent coking chambers and to define spaced apart vertically extending flues within the heating walls, which flues may be used alternately for burning fuel gases or for drafting, the flues having tops and bottoms, each flue having a gas nozzle and an air port at the bottom thereof, the large size cast module being formed from a castable refractory which, when cast, has high dimensional stability, negligible expansion on heating, good abrasion resistance, good compressive strength and good thermal shock resistance in the range of 0.degree. to 2700.degree. Fahrenheit, the large size cast module being a generally rectangular parallelepiped having first and second opposed vertically extending sidewalls spaced apart from each other a distance substantially equal to the width of the heating wall at the location of the repair, said sidewalls being capable of forming the wall surfaces of adjacent coking chambers, first and second opposed generally vertically extending ends, and upper and lower generally horizontal surfaces, the distance between the horizontal surfaces being at least equal to one course of bricks, the large size cast monolithic refractory repair module having at least one vertically extending flue defining cavity extending upwardly from the lower generally horizontal surface to the upper generally horizontal surface, and wherein one end of the first cast repair module is adapted to be disposed to one end of a heating wall, the module having a vertical end surface which conforms to the vertical end surface of the existing heating wall being repaired, and wherein the second end of the first cast repair module is adapted to form one surface of a flue in the heating wall.

4. The first large size cast repair module as set forth in claim 1 wherein the first cast module is provided with two or more vertically extending flue defining cavities.

5. The first large size cast repair module as set forth in claim 2 wherein the first cast module is provided with two or more vertically extending flue defining cavities.

6. A second repair module for a coke oven repair, the second cast repair module being capable of being used in conjunction with a first cast repair module comprising a first large size cast monolithic refractory repair module for use in the repair of existing heating walls between coking chambers in a coke oven battery, each heating wall being built from a plurality of courses of bricks, each course of bricks including a plurality of small size refractory bricks which are used to form wall surfaces of adjacent coking chambers and to define spaced apart vertically extending flues within the heating wall, which flues may be used alternately for burning fuel gases or for drafting, the flues having tops and bottoms, each flue having a gas nozzle and an air port at the bottom thereof, the first large size cast module being formed from a castable refractory which, when cast, has high dimensional stability, negligible expansion on heating, good abrasion resistance, good compressive strength and good thermal shock resistance in the range of 0.degree. to 2850.degree. Fahrenheit, the first large size cast module being a generally rectangular parallelepiped having first and second opposed vertically extending sidewalls spaced apart from each other a distance substantially equal to the width of the heating wall at the location of the repair, said sidewalls being capable of forming the wall surfaces of adjacent coking chambers, first and second opposed generally vertically extending ends, and upper and lower generally horizontal surfaces, the distance between the horizontal surfaces being at least equal to one course of bricks, and the first large size cast monolithic refractory repair module having at least one vertically extending flue defining cavity extending upwardly from the lower generally horizontal surface to the upper generally horizontal surface; the second repair module comprising:

a second large size cast monolithic refractory repair module for use in the repair of existing heating walls between coking chambers in a coke oven battery formed of a plurality of courses of bricks, each course of bricks including a plurality of small size refractory bricks which are used to form wall surfaces of adjacent coking chambers and to define spaced apart vertically extending flues within the heating wall, which flues may be used alternately for burning fuel gases or for drafting, the flues having tops and bottoms, each flue having a gas nozzle and air port at the bottom thereof, the second large size cast module being formed from a castable refractory which, when cast, has high dimensional stability, negligible expansion on heating, good abrasion resistance, good compressive strength, and good thermal shock resistance in the range to 0.degree. to 2850.degree. Fahrenheit, the second large size cast module being a generally rectangular parallelepiped having first and second opposed vertically extending sidewalls spaced apart from each other a distance substantially equal to the width of the heating wall at the location of the repair, said sidewalls being capable of forming the wall surfaces of adjacent coking chambers, first and second opposed generally vertically extending ends, and upper and lower generally horizontal surfaces, the distance between horizontal surfaces being equal to one course of bricks, and the second large size cast repair module being provided with a vertically defining cavity which extends upwardly from the lower generally horizontal surface to the upper generally horizontal surface, the cavity extending a distance at least long enough so that gases in two adjacent flues in the heating wall may flow together.

7. A third repair module for a coke oven repair, the third cast repair module being used in conjunction with a first cast repair module comprising a first large size cast monolithic refractory repair module for use in the repair of existing heating walls between coking chambers in a coke oven battery, each heating wall being built from a plurality of courses of bricks, each course of bricks including a plurality of small size refractory bricks which are used to form wall surfaces of adjacent coking chambers and to define spaced apart vertically extending flues within the heating wall, which flues may be used alternately for burning fuel gases or for drafting, the flues having tops and bottoms, each flue having a gas nozzle and an air port at the bottom thereof, the first large size cast module being formed from a castable refractory which, when cast, has high dimensional stability, negligible expansion on heating, good abrasion resistance, good compressive strength and good thermal shock resistance in the range of 0.degree. to 2850.degree. Fahrenheit, the first large size cast module being a generally rectangular parallelepiped having first and second opposed vertically extending sidewalls spaced apart from each other a distance substantially equal to the width of the heating wall at the location of the repair, said sidewalls being capable of forming the wall surfaces of adjacent coking chambers, first and second opposed generally vertically extending ends, and upper and lower generally horizontal surfaces, the distance between the horizontal surfaces being at least equal to one course of bricks, and the first large size cast monolithic refractory repair module having at least one vertically extending flue defining cavity extending upwardly from the lower generally horizontal surface to the upper generally horizontal surface, and a second cast repair module, the second repair module comprising a second large size cast monolithic refractory repair module for use in the repair of existing heating walls of the type set forth above, the second large size cast module being formed from a castable refractory which, when cast, has high dimensional stability, negligible expansion on heating, good abrasion resistance, good compressive strength, and good thermal shock resistance in the range to 0.degree. to 2850.degree. Fahrenheit, the second large size cast module being a generally rectangular parallelepiped having first and second opposed vertically extending sidewalls spaced apart from each other a distance substantially equal to the width of the heating wall at the location of the repair, said sidewalls being capable of forming the wall surfaces of adjacent coking chambers, first and second opposed generally vertically extending ends, and upper and lower generally horizontal surfaces, the distance between horizontal surfaces being equal to one course of bricks, and the second large size cast repair module being provided with a vertically defining cavity which extends upwardly from the lower generally horizontal surface to the upper generally horizontal surface, the cavity extending a distance at least long enough so that gases in two adjacent flues in the heating wall may flow together; the third repair module comprising:

a third large size cast monolithic refractory repair module for use in the repair of existing heating walls of the type set forth above, the third large size cast repair module being formed from a castable refractory which, when cast, has high dimensional stability, negligible expansion on heating, good abrasion resistance, good compressive strength and good thermal shock resistance in the range of 0.degree. to 2850.degree. Fahrenheit, the third large size cast module being a generally rectangular parallelepiped having first and second opposed vertically extending sidewalls spaced apart from each other a distance substantially equal to the width of the heating wall at the location of the repair, said sidewalls being capable of forming wall surfaces of adjacent coking chambers, first and second opposed generally vertically extending ends, and upper and lower generally horizontal surfaces, the distances between the horizontal surfaces being equal to one course of bricks, and the third large size cast repair module being provided with at least one vertically extending inspection hole extending upwardly from the lower generally horizontal surface to the upper horizontal surface, the third large size cast repair module, when assembled end to end to other similar third large size cast repair modules having a plurality of inspection holes which are spaced away from eac