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INVE NTOR
1, 8 3 3 , 712
' C . E . HA WKE
ME THOD OF OPE RA TING FURNA C E S
Nov. 24 , 19 3 1
. 19 25
ig in a l Fil e d A u g . 2O Or
4 S h ve e t l s - S h e e '
l Pa t e n t e dl Nov. 24 , 19 3 1
_ ' UNITE Ds TA TE s
1, 8 3 3 , 712
_ PA TE NT' ' o1- FIC E
C L A RE NC E E . HA WKE , F ME IUC HE N, NE W JE RS E Y, A S S IG- NOR T0 THE C A RBORUNDUM
C OMPA NY, 0F NIA GA RA FA L L S , NE W YORK, A C ORPORA TION OF PE NNS YL VA NIA
l ME THOD oF OPE RA TING FUn Nl A cE s
A p p l ica t ion ? l e d A u g u s t 20, 19 25 , S e r ia l
Th is in ve n t ion r e l a t e s b r oa dl y t o a n im
p r ove me n t in t h e con s t r u ct ion of f u r n a ce s
' a n d p a r t icu l a r l y me t a l l u r g ica l f u r n a ce s , w l t h
- p a r t icu l a r r e f e r e n ce t o a n e w me a n s f or p r e
5 ve n t in g t h e e r os ion of t h e r e f r a ct or ie s b y
con t a ct w it h s l a g s , me t a l s a n d' ot h e r f u s e d
ma t e r ia l s . p . , _ \ . g
In a l l in du s t r ia l f u r n a ce s in w h ich f u s e d
ma t e r ia l s come in con t a ct w it h t h e r e f r a ct or y
' 10 l in in g s , t h e r e is con t in u a l dis s ol u t ion or e r o
t h e l in in g a n d e ve n t u a l w e a r in g dow n u n t il
r e p l a ce me n t is n e ce s s a r y . In ma n y in s t a n ce s
t h is e r os ion is s o r a p id t h a t f u r n a ce s mu s t b e
15 r e b u il t q u it e f r e q u e n t l y , s ome t ime s ~ da il y ,
w it h a con s e q u e n t l os s of ' u s e a n d e x p e n s e of
r e p l a ce me n t . a l
~In s ome f u r n a ce s vt h is e r os ion of t h e r e f r a c
t or - y ma t e r ia l s is de t r ime n t a l b e ca u s e of t h e
20 con t a min a t ion t o t h e ma t e r ia l b e in g me l t e d.
_ Th is ca s e is il l u s t r a t e d b y e n a me l s me l t in g .
f u r n a ce s , g l a s s t a n k f u r n a ce s , a n d t h e l ik e .
Th e r a t e of We a r in g a w a y , or dis s ol u t ion
or e r os ion of r e f r a ct or y . ma t e r ia l s in con t a ct
s ion of t h e r e f r a ct or y ma t e r ia l comp os in g `
No. 5 1, 3 23 . ~ Re n e w e d Nove mb e r 2s , 19 3 0. - '
t h e r e f r a ct or y l in in g ) ' ma y b e a l mos t e n t ir e l y
p r e ve n t e d b y t h e u s e of h ig h l y r e f r a ct or y
ma t e r ia l s w h ich h a ve t h e p r op e r t y of con
du ct in g t h e h e a t a w a y f r om t h e s u r f a ce e X
p os e d t o t h e f u s e d ma t e r ia l a t s u ch a r a t e t h a t
a s ol idif ie d or vis cou s l a y e r of t h e f u s e d ma
t e r ia l f or ms a t t h e b ou n da r y . Th e n e t r e
s u l t is t h a t t h e s l a g , me t a l , g l a s s , or ot h e r
f u s e d ma t e r ia l is r e t a in e d in a con t a in e r l in e d
w it h a s ol idif ie d l a y e r of t h e s a me ma t e r ia l .
Not on l y mu s t t h e f u r n a ce con s t r u ct ion b e
s u ch t h a t f or e a ch p a r t icu l a r ca s e t h e r a t e of
dis s ip a t ion of h e a t t h r ou g h t h e ` l in in g s w il l
ca u s e t h e f u s e d ma t e r ia l t o ch il l a t it s con t a ct v
w it h t h e l in in g , b u t t h e r e f r a ct or y ma t e r ia l
, u s e d mu s t a l s o h a ve t h e r ma l a n d p h y s ica l
p r op e r t ie s , w h ich w il l p e r mit t h e a t t a in me n t
5 5
60
65
of t h e de s ir e d t e mp e r a t u r e g r a die n t t h r ou g h '
t h e l in in g , w h il e a t t h e s a me t ime g ivin g a
s t r u ct u r a l l y s ou n d f u r n a ce l in in or w a l l .
In a l mos t a l l ca s e s t h e r e mu s t e p r ovis ion
1 f or t h e con s e r va t ion of t h e . h e a t w h ich p a s s e s
t h r ou g h t h e w a l l , a s ot h e r w is e t h e op e r a t ion
of t h e f u r n a ce w ou l d b e h ig h l y in e f f icie n t -
z l w it h - f u s e d ma t e r ia l s , s u ch a s me l t e d s l a g , H f r om t h e f u e l con s u mp t ion p oin t of vie w .
me t a l s , g l a s s , e n a me l s a n d t h e l ik e de p e n ds
n ot on l y u p on t h e n a t u r e of t h e f u s e d ma t e
r ia l a n d . t h e r e f r a ct or y s t r u ct u r e , b u t a l s o
` t o a l a r g e e x t e n t u p on t h e p e n e t r a t ion of t h e
8 0 f u s e d ma t e r ia l in t o t h e p or e s of t h e r e f r a c
t or y l in in g s . In a s mu ch a s a l l common l y - u s e d
r e f r a ct or y ma t e r ia l s a r e ma de u p of mor e or .
l e s s in e r t p a r t icl e s h e l d t og e t h e r b y a f r it t e d
or - s l ig h t l y f u s e d b on din g ma t e r ia l b e t w e e n
t h e s e p a r a t e p a r t icl e s , it is ob viou s t h a t t h e
dis s ol u t ion of a s ma l l a mou n t of ma t e r ia l ,
' i. e . , b on d, w il l r e l e a s e or ca u s e t o b e e r ode d a
mu ch l a r g e r a mou n t of t h e comp os it e r e f r a c
t or y ma t e r ia l . ` Th is r e s u l t s in t h e w a l l b e in g
q u ick l y e r ode d u n t il it b e come s s o t h in a s t o
b e s t r u ct u r a l l y u n s ou n d. ' ' _ '
On e me t h od of de cr e a s in g t h is u n de s ir a b l e
p e n e t r a t ion of t h e f u s e d s l a g or ot h e r l iq u id
ma t e r ia l is b y t h e u s e of r e f r a ct or ie s of vde n s e
s t r u ct u r e , t h a t is , w it h a min imu m a mou n t of
p or e s p a ce in t o w h ich t h e me l t e d s l a g . ma y
p e n e t r a t e . ` ,
I h a ve dis cove r e d t h a t t h is de l e t e r iou s
p e n e t r a t ion in t o > t h e p or e s of t h e r e f r a ct or y
a b
4 0
4 5
5 0v ma t e r ia l ( u l t ima t e l y ca u s in g de s t r u ct ion of
I h a ve f ou n d t h a t of _ t h e comme r cia l l y
a va il a b l e r e f r a ct or y ma t e r ia l s w h ich s u g
g e s t t h e ms e l ve s f or u s e in t h is con n e ct ion ,
t h e r e is on e w h ich is p a r t icu l a r l y de s ir a b l e
a n d occu p ie s a f ie l d p r a ct ica l l y b y it s e l f in
h a vin g t h e r e q u is it e ch e mica l , a n d p h y s ica l
p r op e r t ie s r e q u is it e t o a ccomp l is h t h e . , im
p r ove me n t s in me t a l l u r g ica l Vf u r n a ce s in a c
' , cor da n ce w it h t h e vp r e s e n t in ve n t ion , a n d
f u r t l h e r de s cr ip t ion w il l ' r e f e r t o t h is p a r
t icu l a r ma t e r ia l , n a me l y , s il icon ca r b ide , a l
t h ou g h t h e u t il it y of t h e in ve n t ion _ is n ot
in a l l r e s p e ct s l imit e d t h e r e t o.
_ Th e t w o ou t s t a n din g p r op e r t ie s of s il icon '
ca r b ide r e f r a ct or ie s ~ a r e it s h ig h t h e r ma l
con du ct ivit y a n d it s _ g r e a t me ch a n ica l
' s t r e n g t h , t h e comb in a t ion of w h ich p r op e r t ie s
s o
8 5
- a r e e s s e n t ia l t o t h e p r a ct ica l a p p l ica t ion ' of
t h e p r e s e n t in ve n t ion .
For e x a mp l e , in a r e f r a ct or y w a l l t r a n s
f e r r in g h e a t f r om- on e s ide t o t h e ot h e r , t h e
t e mp e r a t u r e dif f e r e n ce on t h e t w o s ide s is
f if t y ( 5 0% ) p e r ce n t g r e a t e r w it h f ir e cl a y
t h a n . w it h s il icon ca r b ide r e f r a ct or ie s . E x
p r e s s e d dif f e r e n t l y , if t h e s a me a mou n t oi
9 5 . .
2
h e a t e n e r g y l iow s t h r ou g h v a iir e cl a y w a l l
a s t h r ou g h a s il icon ca r b ide w a l l of t h e
s a me dime n s ion , t h e r e s p e ct ive t e mp e r a t u r e
' g r a die n t s w ou l d b e l in t h e r a t io of a b ou t
10
15
1: 9 . S t il l a n ot h e r w a y of e x p r e s s in g t h is `
ma r k e d dif f e r e n ce b e t w e e n t h e t h e r ma l p r op
e r t y of or din a r y r e f r a ct or ie s ( a s r e p r e s e n t e d
b y f ir e cl a y ) a n d t h os e of s il icon ca r b ide
r e f r a ct or ie s is t h a t w it h a f ix e d t e mp e r a t u r e
dr op t h r ou g h t h e t w o w a l l s , t h e r a t io of t h e
q u a n t it y of h e a t p a s s e d b y t h e iir e cl a y t o
t h e s il icon ca r b ide w a l l is a b ou t 1: 20. To
g e t t h e s a me t e mp e r a t u r e g r a die n t a n d a t
t h e s a me t ime t r a n s mit a n e q u a l a mou n t of
h e a t a s a 4 1/ 2 in ch s il icon ca r b ide r e f r a ct or y
w a l l , a l ir e cl a y w a l l mu s t b e r e du ce d t o
a b ou t 1/ 2 in ch in t h ick n e s s . It is ob viou s
A t h a t a comme r cia l f u r n a ce s t r u ct u r e of 1/ 2
Y20
25
3 5
4 0
5 0
5 5
in ch t h ick w a l l s w ou l d b e u n s ou n d a n d u n
s t a b l e in comp a r is on w it h a 4 1/ 2 in ch w a l l of
s il icon ca r b ide r e f r a ct or ie s , n ot on l y on a c
cou n t of t h e de cr e a s e d t h ick n e s s , b u t a l s o on
a ccou n t of t h e l ow e r s t r e n g t h of f ir e cl a y .
Th e me ch a n ica l - - s t r e n g t h of s il icon ca r
b ide r e f r a ct or ie s is We l l k n ow n . For e x a m- "
p l e , a t 15 000 C . , t h e ve r y b e s t f ir e cl a y or
s il ica b r ick w il l b r e a k u n de r a modu l u s
of r u p t u r e of 200 p ou n ds p e r s q u a r e in ch .
A s il icon ca r b ide r e f r a ct or y comp os e d of
a b ou t 10% ce r a mic b on din g ma t e r ia l a n d
9 0% s il icon ca r b ide h a s a b ou t t e n ( l 0) t ime s
t h is s t r e n g t h . L ik e w is e , u n de r comp r e s s ive
l oa ds , s e ve r a l t h ou s a n ds of p ou n ds p e r s q u a r e
in ch a r e r e q u ir e d t o cr u s h t h e a b ove l s il i
con - ca r b ide b r ick ; w h e r e a s 5 0 p ou n ds p e r
s q u a r e in ch is s u f f icie n t t o cr u s h t h e b e s t
ir e cl a y , s il ica or ot h e r or din a r y r e f r a ct or y
ma t e r ia l .
I h a ve dis cove r e d _ t h a t t h e s e p e cu l ia r p r op
e r t ie s of s il icon ca r b ide r e f r a ct or ie s ma k e it
p a r t icu l a r l y a da p t a b l e f or imp r ove d f u r
n a ce con s t r u ct ion e mb ody in g t - h e p r e s e n t in
ve n t ion . In or de r t o de cr e a s e or p r e ve n t t h e
e r os ion of r e f r a ct or ie s b y t h e me l t e d ma t e
r ia l s in con t a ct w it h t h e m, me t a l l u r g ica l f u r
n a ce s a r e p r e f e r a b l y con s t r u ct e d in s u ch ` a
w a y t h a t t h e con t a ct s u r f a ce b e t w e e n v me l t
a n d r e f r a ct or ie s is cool e d b y vcon du ct in g
a w a y k h e a t t h r ou g h t h e r e f r a ct or y . Th is
ca u s e s t h e me l t e d ma t e r ia l t o s ol idif y or
b e come ve r y vis cou s a t t h e s u r f a ce con t a ct ,
s o t h a t it doe s n ot e n t e r t h e p or e s of t h e
r e f r a ct or y ma t e r ia l . Th e t h ick n e s s of t h e
h e a t con du ct in g w a l l is ma de y s u ch t h a t it
is s t r u ct u r a l l y s ou n d, a n d a t t h e s a me t ime
g ive s t h e de s ir e d a mou n t of cool in g t o s ol id
if y or t h i- ck e n t h e mol t e n f u r n a ce ch a r g e .
Th e h e a t t h u s w it h dr a w n f r om t h e me l t e d
ma t e r ia l t h r ou g h it s con t a in in g w a l l s is r e
cove r e d b y u t il iz in g t h e h e a t e d a ir u s e d f or
cool in g r e f r a ct or y w a l l s u r f a ce s e x t e r n a l t o
t h e mol t e n ch a r g e . '
In t h e a ccomp a n y in g dr a w in g s t h e r e a r e
s h ow n f or - p u r p os e s of il l u s t r a t ion on l y ce r
t a in p r e f e r r e d e mb odime n t s of t h e p r e s e n t
1, 8 3 3 , 712'
in ve n t ion , - it b e in g u n de r s t ood t h a t t h e s e
dr a w in g s do n ot de f in e t h e l imit s of my in
ve n t ion a s ch a n g e s in t h e con s t r u ct ion a n d
op e r a t ion dis cl os e d t h e r e in ma y b e ma de
w it h ou t de p a r t in g e it h e r f r om t h e s ir it of
t h e in ve n t ion or t h e s cop e of my r oa de r
cl a ims . - v
In t h e dr a w in g s : , ,
Fig u r e 1 is a ' ve r t ica l s e ct ion a l vie w il l u s
t r a t in g a p or t ion of a cu p ol a or s h a f t me l t
in g f u r n a ce ; ~
Fig u r e 2 is l a vie w s imil a r t o Fig u r e 1 il l u s
t r a t in g a s l ig h t l y modif ie d e mb odime n t of
t h e in ve n t ion ; Y .
Fig u r e 3 is a de t a il p e r s p e ct ive Vie w il l u s
t r a t in g on e f or m of b l ock s u it a b l e f or a
f u r n a ce s t r u ct u r e of t h e k in d s h ow n in Fig
u r e s 1 a n d 2;
Fig u r e 4 is a t r a n s ve r s e s e ct ion a l vie w
t h r ou g h a n op e n h e a r t h f u r n a ce il l u s t - r a t in g
t h e in ve n t ion a s a p p l ica b l e f or t h e p r ot e ct ion
of t h e r oof a n d b u l k h e a d t h e r e of ; ~
Fig u r e 5 is a l on g it u din a l s e ct ion a l Vie w
on t h e l in e V- V of Fig u r e 4 ;
- Fig u r e 6 is a vie w s imil a r t o Fig u r e 4 il l u s
4 t r a t in g mor e p a r t icu l a r l y a Yb u l k h e a d con
s t r u ct ion f or a n op e n h e a r t h f u r n a ce ;
Fig u r e 7 is a h or iz on t a l s e ct ion a l vie w on
t h e l in e VII- _ VII of Fig u r e 6;
Fig u r e 8 is a . ve r t ica l s e ct ion a l vie w il l u s
t r a t in g t h e in ve n t ion a p p l ie d t o a r e ve r b e r a
t or y s me l t in g f u r n a ce ;
Fig u r e 9 is a s e ct ion a l e l e va t ion t h r ou g h
a f u r n a ce t a k e n on t h e l in e IX - IX of Fig
u r e 10;
Fig u r e 10 is a s e ct ion a l vie w on t h e l in e
X - X of Fig u r e 9 ;
Fig u r e 11 is a s e ct ion t h r ou g h a modif ie d
f or m of f u r n a ce in w h ich t h e a ir is s u p p l ie d
t o t h e f u r n a ce a b ove t h e g r a t e ; a n d '
Fig u r e 12 ' is a s e ct ion of t h e f u r n a ce w a l l
on t h e l in e X II- X II of Fig u r e 11.
In ca r r y in g ou t t h e p r e s e n t in ve n t ion a s
a p p l ica b l e t o s h a f t me l t in g or cu p ol a f u r
n a ce s , t h e r e ma y b e p r ovide d a f u r n a ce 2 of
a n y de s ir e d con s t r u ct ion a da p t e d t o b e op
e r a t e d in a ccor da n ce w it h g e n e r a l l y k n ow n
p r in cip l e s . In f u r n a ce s of t h is ch a r a ct e r
mol t e n me t a l a n d s l a g a r e con t in u a l l y { iow
in g dow n t h e s ide w a l l s a n d t h e r e f or e p r e
s e n t s e ve r e e r os ion con dit ion s . In or de r t o
ma t e r ia l l y in cr e a s e t h e l e n g t h of l if e of s u ch a
f u r n a ce , a s w e l l a s imp r ove it s op e r a t in g
ch a r a ct e r is t ics , s u ch f u r n a ce ma y h a ve a p r e
de t e r min e d z on e t h e r e of f or me d b y h ig h l y
con du ct ive r e f r a ct or y b l ock s 3 a r r a n g e d in
a n y de s ir e d ma n n e r , a s f or e x a mp l e in s u p e r
imp os e d cir cu mf e r e n t ia l l y e x t e n din g r ow s .
Th e b l ock s 3 ma y b e of t h e g e n e r a l con f ig u r a
t ion a n d con s t r u ct ion il l u s t r a t e d in Fig u r e 3
a da p t e d t o p r ovide a . cir cu mf e r e n t ia l l y e x
t e n din g a ir p a s s a g e 4 in e a ch r ow of b l ock s .
If de s ir e d, t h e b l ock s ma y b e p r ovide d w it h
s u it a b l e coop e r a t in g p r oj e ct ion s a n d g r oove s
5 w h e r e b y a dj a ce n t r ow s w il l b e e f f e ct ive l y
70
75
8 0
9 0
9 5
10Gl
105
110 ,
115
20
125
13 0
1, 8 3 3 , 712
vin t e r l ck e d a n d s e cu r e d vin p os it ion . Th e s e
' l b l ock s w il l p r e f e r a b l y cove r t h e z on e of t h e
' ` f u r n a ce in w h ich . t h e g r e a t e s t e r os ion of r e
s il icon ca r b ide
- f r a ct or ie s ~ h a s b e e n f ou n d t o t a k e p l a ce a n d
' comp r is e ma t e r ia l s u ch a s
w il l p r e f e r a b l
h a vin g a t h e r ma l con du ct ivit y
ma n y t ime s g r e a t e r t h a n t h a t of or din a r y
iir e c a y , a s a l r e a dy p oin t e d ou t in de t a il .
10
A p or t ion of t h e a ir b l a s t n or ma l l y u s e d
f or comb u s t ion p u r p os e s . - ma y b e b y p a s s e d
- f r om t h e ma in a ir p or t s or t u y r e s 6 b y p ip e s
7 t h r ou g h con t r ol va l ve s 8 t o a s ma l l e r a ir
` dis t r ib u t in g r in g I9 f r om w h ich it p a s s e s
15
t h r ou g h t h e ou t e r r e f r a ct or y l s h e l l of t h e f u r
n a ce t h r ou g h op e n in g s 10 t o t h e a ir p a s s a g e s
or ` du ct s 4 : . Pr e f e r a b l y t h e op e n in g or op e n
in g s 10 w il l dir e ct l y commu n ica t e w it h t h e
a ir . du ct f or me d b y t h e u p p e r > r ow of b l ock s
f or > in it ia l l y cool in g t h e b l ock s of t h a t r ow .
20'
Th e ` a ir du ct s in a dj a ce n t r ow s ma y b e con
- n e ct e d p r e f e r a b l y a t s u b s t a n t ia l l y dia me t r i
f ca l l y op p os it e s ide s of t h e f u r n a ce f or a l
t e r n a t e r ow s b y me a n s of ' p or t s 11. Wit h
` s u ch a con s t r u ct ion t h e a ir w il l . p a s s s u cce s
25
s ive l y t h r ou g h t h e r ow s of b l ock s u n t il it
r e a ch e s - t h e b ot t om r ovv w h ich ma y comp r is e
b l ock s h a vin g op e n in g s 12 imme dia t e l y a b ove
3 0
3 5
' 4 0
4 5
t h e r e g u l a r t u y r e s . Th is s t r e a m of a ir is s o
r e g u l a t e d, w it h a g ive n f u r n a ce a n d g ive n
t h ick n e s s of r e f r a ct or y l in in g t h a t a l a y e r of
s ol idif ie d s l a g f or ms on t h e b l ock s - t h e r e b y
p r ot e ct in g t h e m f r om e r os ion . .
A s a n a l t e r n a t ive con s t r u ct ion f r om t h a t
j u s t de s cr ib e d, I ma y u s e t h e con s t r u ct ion
s h ow n in Fig u r e 2 in w h ich ca s e a l l of t h e a ir
a dmit t e d t h r ou g h t h e t u y r e s is u t il iz e d' f or
cool in g t h e z on e of g r e a t e s t e r os ion in t h e
l in in g . ' Th e s p e cia L b l ock s 3 of r e ce s s e d b a ck
de s ig n a s il l u s t r a t e d in Fig u r e 3 a r e p r e f e r
a b l y u s e d f or l in in g t h e cu p ol a t o a h e ig h t
a b ove l w h ich t h e r e is l it t l e e r os ion . Th e a ir
f or 1comb u s t ion is in t r odu ce d t h r ou g h a p ip e
7 h a vin g a con t r ol va l ve 8 a n d de l ive r e d t o
t h e a ir r in g 9 . Th is a ir r in g de l ive r s in t u r n
t h r ou g h a n op e n in g or op e n in g s 10 in t o t h e
du ct 4 in t h e u p p e r r ow of b l ock s a n d cir cu
Y* l a t e d b y t h e b l ock s a s b e f or e de s cr ib e d. A f t e r
cool in g t h e b l ock s , h ow e ve r , t h e a ir is in t r o
du ce d in t o t h e u s u a l t u y r e r in g 6 t h r ou g h
a n op e n in g or op e n in g s 13 , a n d t h e n a dmit t e d
in t o' t h e f u r n a ce t h r ou g h t h e t u y r e s 14 . Th e ,
b l ock s a r e of s u ch t h ick n e s s , a s de t e r min e d
5 5
60
b y t h e t e mp e r a t u r e of f u s ion of t h e s l a g w it h
in t h e f u r n a ce a n d t h e r a t e of cool in g b y t h e
a ir , t h a t t h e s l a g is j u s t s ol idif ie d a t t h e s u r
f a ce a n d t h e r e b y p r ot e ct s t h e r e f r a ct or y
b l ock s . - No h e a t is l os t f r om t h e f u r n a ce , ' a s
w il l b e a p p a r e n t , f or t h e r e a s on t h a t a l l h e a t
a b s t r a ct e d. a s in t h e ca s e of t h e f or m il l u s
t r a t e d in Fig u r e 1, is in t r odu ce d a g a in t 0 t h e
f u r n a ce .
A s il l u s t r a t in g t h e a p p l ica b il it y of t h e in
i ve n t ion f or t h e p r ot e ct ion of t h e r oof a n d
65
b u l k h e a d > of a n op e n h e a r t h a f u r n a ce , a t t e n
t ion is dir e ct e d t o Fig u r e s 4 a n d 5 I in w h ich
3
cool in g a ir is - a dmit t e d b y t h e p ip e 15 h a vin g
a con t r ol l in g va l ve 16 t o t h e du ct s or p a s
s a e s 17 e x t e n din g b e t w e e n a h e a t con du ct
in g l in e r 18 of h ig h r e f r a ct or y ma t e r ia l s u ch
a s s il icon ca r b ide a n d t h e t h e r ma l in s u l a t
in g l in in g 19 t o t h e e n d of t h e f u r n a ce ove r
t h e p or t or p or t s 20 w h e r e it is con du ct e d
t o t h e p r e h e a t e d a ir s u p p l y u s e d in t h e
f u r n a ce comb u s t ion . By t h u s in t r odu cin g
p r e h e a t e d a ir in t o t h e f u r n a ce , n on e of t h e
h e a t is l os t b y t h e u s e of t h e t h e r ma l l y con
du ct ive in n e r r oof 18 , a n d a t ' t h e s a me t ime
t h e r oof is e f f e ct ive l y p r ot e ct e d. ~
Ot h e r p a r t s of a n op e n h e a r t h f u r n a ce , ' or
s imil a r me l t in g or h e a t in g f u r n a ce s ma y l ik e - 4
w is e . b e p r ot e ct e d in a s imil a r ma n n e r . Re
f e r r in g t o Fig u r e s 6 a n d 7 t h e r e is s h ow n a
vme t h od of con s t r u ct in g t h e b u l k h e a ds of a n
op e n h e a r t h f u r n a ce . C ool in g a ir ma y b e
b r ou g h t ove r a t h e r ma l l y con du ct ive r oof l 18
a s de s cr ib e d in con n e ct ion w it h Fig u r e s 4
a n d 5 t h r ou g h du ct s 17 a n d de l ive r e d b y t h e
de s ir e d- du ct or du ct s 17 t o a p a s s a g e 21
l oca t e d b e t w e e n t h e t h e r ma l l y con du ct ive
w a l l a n d t h e h e a t in s u l a t in g Wa l l . Th is p a s
70
75
8 0
8 5
9 0
s a g e ma y in t u r n de l ive r t o a p a s s a g e 22 .
e f f e ct ive f or con du ct in g t h e p r e h e a t e d a ir or
g a s b e h in d a b u l k h e a d l in in g f r om w h ich it
ma y b e dis ch a r g e d t o a p ip e 23 or t h e l ik e a n d
ca r r ie d if de s ir e d t o t h e s ou r ce of comb u s
_ t ion a ir .
Fr om a n in s p e ct ion f of Fig u r e 7 it w il l b e
u n de r s t ood t h a t t h e p a s s a g e s 22 ma y b e
/ f or me d in b l ock s 24 s imil a r t o. t h e b l ock s
de s cr ib e d in con n e ct ion w it h ' Fig u r e s 1, 2
a n d , a n d t h a t t h e r e s p e ct ive p a s s a g e s ma y
b e con n e ct e d in s e r ie s or in p a r a l l e l de p e n d
in g u p on t h e ch a r a ct e r of t h e f l ow p a t h w h ich
it is de s ir e d t o p r odu ce t h e r e t h r ou g h .
Th e f u r n a ce s h e r e t of or e de s cr ib e d a r e `
me t a l l u r g ica l f u r n a ce s , a n d t h e op e r a t ion
con t e mp l a t e d is s u ch a s t o - p r odu ce a con
g e a l e d p r ot e ct ive f il m w it h in t h e f u r n a ce of
t h e me l t t h e r e in . Th e p r in cip l e of t h e in ~
ve n t ion ma y b e e x t e n de d t o r e ve r b e r a t or y
f u r n a ce s a s il l u s t r a t e d in Fig u r e 6 a n d ma y
b e e f f e ct ive l y e mp l oy e d f or t h e p r ot e ct ion of
t h e b ot t om or h e a r t h , t h e s ide w a l l s a n d r oof ,
a l l of w h ich ma y b e s o con s t r u ct e d a s t o g ive
a ch il l e d s l a g s u r f a ce b y a ir cool in g p a s
s a g e s p os it ion e d b a ck of a s p e cia l l in in g of
h ig h l y con du ct ive ma t e r ia l , s u ch a s s il icon
ca r b ide . A s il l u s t r a t e d in Fig u r e 8 t h e r e
ma y b e u t il iz e d h e a r t h t il e 25 r e ce s s e d a s
il l u s t r a t e d in Fig u r e L 3 - t o a l l ow p a s s a g e of
cool in g a ir t h r ou g h t h e du ct s 26. Th is cool
in g a ir w il l b e e f f e ct ive f or f or min g a t h in
l a y e r of con g e a l e d me l t 27 on t h e in n e r s u r
f a ce , t h u s p r e ve n t in g e r os ion of t h e b ot t on i.
L ik e w is e , t h e s l a g or ot h e r mol t e n ma t e r ia l
9 5
100
105 l
110
115
120
125
v28 w h ich is con t a in e d in t h e f u r n a ce ma y , I
b y vol a t il iz a t ion , s p l a s h in g or ch e mica l r e - "
a ct ion f or m a t h in l a y e r of ma t e r ia l on t h e
r oof a n d s ide s w h ich is s ol idif ie d b e ca u s e of
t h e h ig h t h e r ma l con du ct ivit y of t h e w a l l s 29
13 0 '
10
15
a n d r oof 3 0, a n d t h e ca r r y in g a w a y of h e a t
in t h e du ct s 3 1 a n d 3 2 r e s p e ct ive l y b a ck of
t h e m. It w il l b e u n de r s t ood t h a t t h e w a l l s
a n d r oof a r e s o con s t r u ct e d a s t o t h ick n e s s ,
t h a t t h e r e q u ir e d a mou n t of a ir or g a s f u e l
in g f or ms t h e de s ir e d p r ot e ct ive s ol id l a y e r
of s l a g or me t a l on t h e in t e r ior s u r f a ce .
In ' Fig u r e s 9 t o 12 b ot h in cl u s ive t h e in
ve n t ion is il l u s t r a t e d a s e x t e n din g t o a com
b u s t ion f u r n a ce of a dif f e r e n t t y p e l a da p t e d
f or t h e b u r n in g of coa l or s imil a r f u e l . A t
t h e p r e s e n t t ime t h e r e is a dr a w in g t e n de n cy
t o w or k f u r n a ce s of t h is g e n e r a l n a t u r e a t
e x t r e me l y h ig h r a t e s of comb u s t ion . Un de r
t h e in cr e a s e d t e mp e r a t u r e s r e s u l t in g f r om
' s u ch p r a ct ice , t h e s e t t in g . f r e q u e n t l y b u r n s
20
3 0
3 5
4 0
4 5
ou t , a n d w h e n coa l is u s e d a s a f u e l , t h e f u s e d
a s h - r e a ct s w it h t h e b r ick w or k a n d de s t r oy s
t h e s e t t in g in a ve r y s h or t t ime . r Ih is is
e s p e cia l l y t r u e w it h l ow g r a de coa l , a n d w h e n
s u ch f u e l is u s e d it is imp os s ib l e t o ma in t a in
h e a vy f u r n a ce l oa ds r e g u l a r l y b e ca u s e of t h e
r a p id de t e r ior a t ion of t h e b r ick w or k . Th is
ma y b e e f f e ct ive l y ove r come b y a con s t r u c
t ion s u ch a s dis cl os e d in Fig u r e s 9 a n d 10 in
w h ich is il l u s t r a t e d a f u r n a ce a da p t e d t o r e
ce ive cool in g a ir b y a n y s u it a b l e me a n s , s u ch
r a s b l ow e r s n ot s h ow n - t h r ou g h a ir p ip e s or
op e n in g s 3 3 , or a da p t e d t o h a ve a s u p p l y of
a ir dr a w n t h e r e in t o b y in du ce d dr a f t . A 11'
f r om t h e p ip e s 3 3 p a s s e s t h r ou g h du ct s 3 4
in t h e f u r n a ce w a l l s . Th e s e du ct s p r e f e r
a b l y e x t e n d n ot on l y t h r ou g h t h e s ide w a l l s
3 5 , b u t a l s o t h r ou g h t h e b r idg e w a l l 3 6, a n d
t e r min a t e in ou t l e t s 3 7 b e l ow t h e g r a t e 3 8 .
Pl a t e s or b l ock s 3 9 p r e f e r a b l y of s il icon
ca r b ide f or m t h e Wa l l b e t w e e n t h e du ct s 3 3
a n d t h e in t e r ior of t h e f u r n a ce , t h is ma t e r ia l
p os s e s s in g t - h e p r op e r t ie s of l ow p or os it y , e x
t r e me r e f r a ct or in e s s a n d h ig h h e a t con du c- _
t ivit y a s p oin t e d ou t . n
In Fig u r e s l 1 a n d 12 t h e r e is il l u s t r a t e d
a s l ig h t l y dif f e r e n t f or m of f u r n a ce in w h ich
` p a r t s cor r e s p on din g t o p a r t s r e f e r r e d t o in
Fig u r e s 9 a n d l 0 a r e de s ig n a t e d b y t h e s a me
r e f e r e n ce ch a r a ct e r s h a vin g a p r ime a f f ix e d
t h e r e t o. In t h is e mb odime n t , a con ve n t ion a l
h op p e r t y p e s t ok e r is ` il l u s t r a t e d in ch a in
' l in e s , a n d p e r f or a t e d b l ock s 4 _ 0 a r e p r ovide d
5 0
f or in t r odu cin g t h e a ir a b ove t h e g r a t e . . Th e
b l ock s 4 0 f or ma p a r t of t h e comb u s t ion . w a l l s ,
a n d a ir is p r e f e r a b l y s u p p l ie d t o t h e m a f t e r
it h a s p a s s e d t h r ou g h t h e a ir du ct s 3 4 b e h in d
t h e r e f r a ct or y p l a t e s 3 9 . y A ir ma y b e s u p
5 5 p l ie d t o t h e du ct s 3 4 f r om' b e l ow t h e g r a t e
60
t h r ou g h a n in l e t 4 1, it s dir e ct ion of t r a ve l
b e in g cl e a r l y in dica t e d b y t h e a r r ow s . I
h a ve f ou n d t h a t t h e comb in a t ion of r e f r a c
t or y imp e r f or a t e p l a t e s 3 9 in comb in a t ion
w it h t h e p e r f or a t e d t u y r e b l ock s 4 0 ma t e
' r ia l l y imp r ove s f u r n a ce con dit ion s b ot h f r om
t h e s t a n dp oin t of op e r a t in g e f f icie n cy a n d
l on g l if e . It w il l b e u n de r s t ood t h a t t h e p e r
f or a t e d or t u y r e b l ock s a r e s o dis p os e d a s t o
65 l ie a dj a ce n t t h e f u e l z on e w h e r e b y t h e p r e
1, 8 3 3 , 712
h e a t e d a ir ma y b e dir e ct l y in t r odu ce d in t o
t h e comb u s t ion ch a mb e r a n d t h e f u e l z on e .
Wit h t h e f or ms of t h e in ve n t ion il l u s
t r a t e din Fig u r e s 9 t o l 2, a s w it h t h e ot h e r
f or ms r e f e r r e d t o, t h e a ir s u p p l y a n d t h ick
n e s s of t h e h ig h l y h e a t con du ct ive l in in g
w ou l d b e de t e r min e d in a ccor da n ce w it h t h e
op e r a t in g con dit ion s a n d w il l a l w a y s b e s u ch >
a s t o in s u r e t h e ma in t e n a n ce of a t e mp e r a
t u r e con dit ion a dj a ce n t t h e r e f r a ct or y l in
in g s u ch a s t o in s u r e f u s in g of t h e a s h or s l a g
a n d t h e con s e q u e n t f or ma t ion of a p r ot e ct ive
l a y e r b e t w e e n t h e r e f r a ct or y ma t e r ia l a n d
t h e in t e r ior of t h e comb u s t ion ch a mb e r . A t
t h e s a me t ime , it h a s b e e n f ou n d t h a t t h e a d
mis s ion of > a ir t h r ou g h p e r f or a t e d or t u y r e
70
75
8 0
b l ock s w il l e f f e ct ive l y p r e ve n t t h e a dh e r e n ce i
of cl in k e r s , t h e r e b y imp r ovin g t h e op e r a t in g
ch a r a ct e r is t ics of t h e f u r n a ce .
A t t h e p r e s e n t t ime it is n ot u n common in
t h e a r t t o w h ich t h e p r e s e n t in ve n t ion r e l a t e s
t o p os it ion a p l u r a l it y of p ow de r e d f u e l b u r n
e r s t a n g e n t ia l l y w it h r e s p e ct t o a comb u s t ion
f u r n a ce or ch a mb e r s o a s t o p r odu ce a s w ir l
in g mot ion in t h e ce n t e r t h e r e of , t o t h e r e b y
mix t h e f u e l a n d p e r mit b u r n in g w it h ou t t h e
n e ce s s it y of r e s or t in g t o a n e x t r e me l y h ig h
s e t t in g in or de r t o a ccomp l is h comp l e t e com
b u s t ion . Wit h s u ch f u r n a ce s , it h a s b e e n
a t t e mp t e d t o u t il iz e w a t e r cool e d r e f r a ct or ie s ,
b u t du e t o t h e in s u f f icie n cy of t h e cool in g ,
or dif f icu l t ie s e n cou n t e r e d b y r e a s on of cl og
g in g of t h e Wa t e r p ip e s , s u ch in s t a l l a t ion s
h a ve n ot b e e n e n t ir e l y s a t is f a ct or y . ' It w il l
b e a p p a r e n t t ov t h os e s k il l e d in t h e a r t t h a t
t h e p r e s e n t in ve n t ion is a p p l ica b l e t o in s t a l
l a t ion s of t h is ch a r a ct e r , or t o ot h e r in s t a l l a
t ion s e mp l oy in g e it h e r p ow de r e d f u e l , s ol id
f u e l , l iq u id f u e l or g a s e ou s f u e l , t h e u t il it y
of t h e in ve n t ion n ot b e in g l imit e d w it h r e
s p e ct e it h e r t o t h e t y p e of b u r n e r or t h e a r
r a n g e me n t t h e r e of , t h e ch a r a ct e r of t h e f u e l ,
or t h e s p e cif ic f u r n a ce con s t r u ct ion .
l Vh il e I h a ve il l u s t r a t e d t h e in ve n t ion a s
a p p l ie d t o ce r t a in f or ms of f u r n a ce s , it w il l
b e u n de r s t ood t h a t it ma y b e e x t e n de d t o
ot h e r t y p e s , s u ch a s e n a me l in g s me l t e r s , r o
t a r y k il n s , con ve r t e r s , a ir f u r n a ce s a n d t h e
l ik e , . a s w il l b e r e a dil y a p p a r e n t .
Th e a dva n t a g e s of t h e in ve n t ion a r is e f r om
a n imp r ove d f u r n a ce s t r u ct u r e a n d me t h od
of op e r a t in g t h e s a me w h e r e b y a p r e de t e r
min e d r e l a t ion s h ip is e s t a b l is h e d b e t w e e n t h e
_ cir cu l a t ion of cool in g a ir a n d t h e h e a t con
du ct ivit y s u ch a s t o ma in t a in a t a l l t ime s a
p r ot e ct ive l in in g w it h in t h e f u r n a ce .
I cl a im: l .
l . r Ih e me t h od of p r ot e ct in g Wa l l s of s il i
con ca r b ide f r om ox ida t ion a n d de s t r u ct ion
in a me t a l l u r g ica l f u r n a ce w h e r e in t h e y a r e
e mp l oy e d a n d a t a t e mp e r a t u r e a b ove w h ich
s il icon ca r b ide r e f r a ct or ie s or din a r il y ox idiz e
w h ich comp r is e s t h e s t e p of con du ct in g t h e
h e a t a w a y f r om t h e e x p os e d f a ce of t h e s il i
con ca r b ide a t a r a t e s u f f icie n t t o in s u r e t h e
8 5
9 5
100
110
115
120
125
13 0
10
15
20
25
4 5
5 . 0
5 5
1, 8 3 3 , 712
ma in t e n a n ce t h e r e ove r of a p r ot e ct ive l a y e r
con g e a l e d t h e r e on f r om b a s ic s l a g s a n d me t a l
ox ide s comin g in t o con t a ct t h e r e w it h a n d t o
p r ot e ct t h e s il icon ca r b ide f r om de s t r u ct ive
r e a ct ion t h e r e w it h .
2. Th e me t h od of ' p r ot e ct in g w a l l s of s il i
A con ca r b ide f r om ox ida t ion a n d de s t r u ct ion in
a me t a l l u r g ica l f u r n a ce w h e r e in t h e y a r e
e mp l oy e d a n d a t a t e mp e r a t u r e a b ove w h ich
s il icon ca r b ide r e f r a ct or ie s or din a r il y ox i
diz e w h ich comp r is e s t h e s t e p of con du ct in g
t h e h e a t a w a y f r om t h e e x p os e d f a ce of t h e
s il icon ca r b ide a t a r a t e s u iiicie n t t o in s u r e
t h e ma in t e n a n ce t h e r e ove r of a p r ot e ct ive
l a y e r con g e a l e d t h e r e on _ f r om b a s ic s l a g s a n d
me t a l ox ide s comin g in t o con t a ct t h e r e w it h
a n d t o p r ot e ct t h e s il icon ca r b ide f r om de
s t r u ct ive r e a ct ion t h e r e w it h b y t h e cir cu l a - _
t ion of a cu r r e n t of a ir b a ck of t h e e x p os e d
f a ce t h e r e of .
In t e s t imon y w h e r e of I h a ve h e r e u n t o s e t
my h a n d. l
' ` C L A RE NC E E . _ HA WKE .