Abstract:
This invention relates to an apparatus and a method for at least partially isolating a zone of an industrial furnace. The apparatus includes a hanger block and a hanger clamp. The method includes removably mounting a hanger block with respect to a furnace structure. A hanger clamp is engaged with the hanger block. A curtain structure is mounted in the hanger block, and the hanger clamp is mounted to an adjustable support or mechanism.

Description:
BACKGROUND OF THE INVENTION 
   1. Field of the Invention 
   This invention relates generally to industrial furnaces and, more particularly to, an apparatus and a method for at least partially isolating zones of the industrial furnace. 
   2. Discussion of Related Art 
   Industrial furnaces are used in many applications such as, but not limited to, producing glass on a tin bath, heat treating, smelting and/or refining metals, calcining coke, incinerating waste and the like. Industrial furnaces are often constructed of refractory materials, such as taught by U.S. Pat. Nos. 6,427,610 and 4,960,058, the entire teachings of which are incorporated by reference into this specification. The use of hanger brick for construction of a static wall or a roof structure is particularly effective in furnaces for making glass. 
   Often, industrial furnaces have multiple zones and thus require isolation between the zones. A stationary refractory wall can provide isolation but cannot meet the need, such as during furnace operation, to adjust the level of isolation between the zones. For example, moving a product between zones can be accomplished with an adjustable mechanism, apparatus and curtain structure. 
   The apparatus can be moveably mounted between structures of the industrial furnace, to isolate the zones. The conventional apparatus, in contact with the curtain structure, is raised or lowered by the adjustable mechanism. The apparatus is often constructed of stainless steel. High operating temperatures of the industrial furnace can warp the apparatus and prevent reliable adjustment of the isolation between the zones. Warping problems can result in a shutdown of the industrial furnace, to allow replacement or repair of the apparatus. 
   SUMMARY OF THE INVENTION 
   It is one object of this invention to provide an improved apparatus for isolating industrial furnace zones. 
   The above and other objects of this invention can be attained, at least in part, with an apparatus that at least partially isolates a zone of an industrial furnace. A hanger block with sides, ends, a bottom, a channel and a recess can be engaged with a hanger clamp. The hanger clamp is preferably, but not necessarily, moveably mounted with respect to the furnace structure. 
   The prior art generally does not teach an apparatus that avoids warping when exposed to high temperatures of an industrial furnace, particularly which provide a seal during furnace operation. 
   This invention also relates to a method for movably mounting a curtain structure within a void of a furnace structure. A moveably mounted hanger clamp can be engaged with a hanger block. The curtain structure can be removably mounted in a channel of the hanger block. 
   Other objects and advantages of this invention will be apparent to those skilled in the art from the following detailed description taken in conjunction with the appended claims and drawings. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The above and other objects of this invention can be better understood when the specification is read in view of the drawings, wherein: 
       FIG. 1  is a partial sectional side view of an industrial furnace, according to one embodiment of this invention; 
       FIG. 2  is a partial sectional view of a portion of an industrial furnace, according to one embodiment of this invention; 
       FIG. 3  is a perspective view of a hanger block, showing a channel and a recess, according to one embodiment of this invention; and 
       FIG. 4  is a perspective view of the hanger block opposite the view as shown in  FIG. 3 . 
   

   DETAILED DESCRIPTION OF THE INVENTION 
     FIG. 1  shows a partial sectional side view of industrial furnace  30 , according to one embodiment of this invention. Industrial furnace  30  can have many applications such as, but not limited to, producing glass on a tin bath, heat treating materials, smelting and/or refining metals, calcining coke, incinerating waste and any other similar method or process. 
   Apparatus  20  of this invention can at least partially isolate zone  22 , such as formed between one or more structures  24 . Structure  24  can comprise load bearing elements, such as beams and trusses or non-load bearing elements, including walls, roofs, covers, refractory dividers and the like. Zone  22  can be located at any suitable position, including the end portion of industrial furnace  30  and/or any other intermediate portion of industrial furnace  30 . According to one embodiment of this invention, apparatus  20  comprises hanger block  34  and/or hanger clamp  50 . 
   In another embodiment of this invention, hanger block  34  substantially fills void  54  between structures  24 . Hanger block  34  can substantially seal void  54  to minimize leakage of internal atmosphere of industrial furnace  30 , such as to a surrounding environment. Void  54  also can include the end portion of industrial furnace  30 , so that apparatus  20  forms a door type closure. Void  54  between structures  24  includes void  54  internal to industrial furnace  30  as well as any void  54  that can extend to one or more perimeter walls of industrial furnace  30 . 
   Hanger block  34  can be fabricated of metal, refractory, or any other suitable material capable of withstanding operating temperatures of industrial furnace  30 . Such materials can include, but are not limited to, stainless steels, refractory, or engineered resins. Fabrication of hanger block  34  into shapes and of various materials is known in the arts. Outside corners of hanger block  34  can be rounded, squared and/or chamfered. The inside corners of hanger block  34  can be squared and/or curved. 
   According to another embodiment of this invention, hanger block  34  can be made from refractory materials, including refractory materials that can withstand relatively high temperatures and not become warped. Common refractory materials can include zircon, fireclay, silica, dolomite, magnesite, alumina, chromite and/or silicon carbide. However, one skilled in the art can choose any one or more of other suitable refractory materials. 
   In one embodiment of this invention, such as shown in  FIG. 1 , hanger clamp  50  engages or structurally mounts hanger block  34 . Hanger clamp  50  can be fabricated of metal, refractory, or any other suitable material capable of withstanding operating temperatures of industrial furnace  30 , including but not limited to steels, stainless steels, alloys, refractories and the like. Any suitable conventional structural clamp or other device known to those skilled in the art can be used as hanger clamp  50 . Hanger clamp  50  preferably but not necessarily is movably mounted with respect to structure  24  of industrial furnace  30 , for example to move curtain structure  64  into and out of zone  22 . 
   Curtain structure  64  can be mounted or positioned within or with respect to hanger block  34 . According to certain embodiments of this invention, curtain structure  64  is movable along longitudinal axis  49  of hanger block  34 . Curtain structure  64  may be positionable in an inserted position and/or a withdrawn position with respect to zone  22 . The withdrawn position can be useful for periodic maintenance or replacement of curtain structure  64 , such as due to warping and/or other operational reasons. Replacement of curtain structure  64  can be performed while hanger block  34  is positioned within void  54  or after hanger block  34  has been removed from industrial furnace  30 . 
   Curtain structure  64  can be fabricated from such materials capable of withstanding relatively high temperatures of industrial furnace  30 . These materials can include steels, stainless steels, alloys, fiberglass, asbestos, refractory, rock wool, polyaramids and the like. In one embodiment of this invention, curtain structure  64  is made from stainless steel. 
   According to some embodiments of this invention, apparatus  20  is movably mounted with respect to structure  24  by linearly adjustable mechanism  66 , which is capable of incrementally increasing or decreasing a partial isolation and/or a complete isolation between two or more zones  22  of industrial furnace  30 . Linearly adjustable mechanism  66  can comprise an actuator with a hand operable wheel and/or one or more mechanical linkages, such as gears, screws, drive shafts and the like. 
   Other actuating devices can comprise electric motors, pneumatics, hydraulics and/or any other suitable implements, as readily adapted by one skilled in the mechanical arts. According to certain embodiments of this invention, linearly adjustable mechanism  66  is oriented in a substantially vertical position, allowing raising and lowering of curtain structure  64 . 
   In other embodiments of this invention, linearly adjustable mechanism  66  can be oriented at any suitable angle, such as at 45 degrees or even horizontally, depending upon the design needs of industrial furnace  30 . Operation of linearly adjustable mechanism  66  can be carried out during operation of industrial furnace  30  as well as during a shutdown mode. 
     FIG. 2  is a partial cross sectional view of an industrial furnace  30  comprising zones  22  and structures  24 . 
     FIG. 3  and  FIG. 4  show perspective views of hanger block  34 . In some embodiments of this invention, hanger block  34  is elongated in a direction of or along first side  38  and/or second side  40 . The length can be based on convenience during fabrication of hanger block  34  and/or design and installation of industrial furnace  30 . In one embodiment of this invention, a cross section of hanger block  34  taken transverse to longitudinal axis  49  is generally rectangular. 
   According to certain embodiments of this invention, first side  38  and second side  40  are preferably but not necessarily generally parallel to each other. 
   Bottom  36  can be generally rectangular and can form channel  46 . Channel  46  can be centrally positioned on bottom  36 . In other embodiments of this invention, channel  46  can be offset from the center of bottom  36 . First side  38  and/or second side  40  can form channel  46 . In other embodiments of this invention, channel  46  runs generally parallel to at least one of first side  38  and/or second side  40 . 
   Channel  46  may extend along at least part of or an entire length of hanger block  34 . Channel  46  can end as a closed bore or channel within hanger block  34  or can extend to first end  42  and/or second end  44 . Channel width  60  can narrow to form at least one shoulder  62 . In other embodiments of this invention, two shoulders  62  are formed, such as by channel width  60 . 
   According to one embodiment of this invention, shoulders  62  contact curtain structure  64 . 
   Hanger clamp  50  may engage hanger block  34 , such as at recess  48  formed in hanger block  34 . Recess  48  can extend along part of or the entire length of hanger block  34 . In other embodiments of this invention, two or more recesses  48  are formed in one or more external surfaces of hanger block  34 . Each recess  48  can extend along first side  38  and/or second side  40 . 
   According to one embodiment of this invention, at least one lug  52  fixes the position of hanger block  34  with respect to hanger clamp  50 . Lug  52  can be a raised protuberance that contacts hanger block  34  and/or hanger clamp  50 . One skilled in the mechanical arts understands that lug  52  can have any number of shapes including, but not limited to, a triangle, a square, a circle and/or any non-circular shape. Lug  52  can be separate and/or integral to hanger block  34  and/or hanger clamp  50 . 
   In some embodiments of this invention, two lugs  52  are located or positioned within each recess  48  near the top and/or proximate to each of first end  42  and second end  44 . In other embodiments of this invention, lug  52  is positioned on first side  38  and/or second side  40 . 
   According to some embodiments of this invention, first end  42  has or forms ridge  56  and second end  44  has or forms groove  58  corresponding with ridge  56  of first end  42 , and for example can include the same or substantially similar shape but possibly a negative image. A second hanger block  34  with groove  58  at an end position can engage or couple ridge  56  to extend the length of apparatus  20  when longitudinally positioned. According to one embodiment of this invention, a plurality of hanger blocks  34  can be arranged so that first end  42  is adjacent to second end  44 , and so that ridge  56  and grove  58  contact or engage with each other to provide structural stability. Any other suitable structural arrangement can be used to lockingly position two or more hanger blocks  34  adjacent, abutting or next to each other. 
   In other embodiments of this invention, hanger blocks  34  are arranged so that first end  42  is next to, adjacent or abuts second end  44 , without ridge  56  and/or groove  58 . Ridge  56  preferably but not necessarily forms an inverted T shape and groove  58  can be shaped to correspond to or engage with the inverted T shape of ridge  56 . 
   While in the foregoing specification this invention has been described in relation to certain embodiments thereof, and many details have been set forth for purpose of illustration, it will be apparent to those skilled in the art that the invention is susceptible to additional embodiments and that certain of the details described herein can be varied considerably without departing from the basic principles of the invention.