Retention mechanism for refractory inserts for reformer flue gas tunnel

A refractory block assembly comprising:

• a refractory block having at least one opening formed therein;
• and
• at least one refractory insert that resides within the at least one opening in the refractory block;
• wherein the at least one refractory insert comprises a main body part having a first surface defining a first sidewall, an opposed second surface defining a second sidewall, and an outer peripheral surface separating the first and second surfaces, and a mechanical mating member provided on at least a portion of the outer peripheral surface thereof, the mechanical mating member comprising a retention mechanism for controlling and retaining a position of a corresponding mating member provided on an inner surface of the at least one opening in the refractory block,
• wherein the retention mechanism of the mechanical mating member of the refractory insert comprises at least two diametrically opposed channels in the outer peripheral surface of the refractory insert, the channels being circumferentially defined by the first sidewall and the second sidewall.

A refractory block assembly for a steam reformer furnace tunnel, the refractory block assembly comprising:

• a refractory block comprising
• a hollow main body portion having outer peripheral surfaces defining a first end, an opposed second end, an upper surface, an opposed lower surface, a first side and an opposed second side,
• at least one through-hole having openings formed in the first side and the opposed second side of the main body portion,
• at least one first mechanical mating portion defining a protruded portion extending from a portion of the upper surface of the main body portion, and
• at least one second corresponding mechanical mating portion defining an opening corresponding to the protruded portion formed in a portion of the lower surface the main body portion;
• and
• at least one refractory insert that resides within at least one of the at least one though-hole, the refractory insert comprising a main body part having a first surface defining a first sidewall, an opposed second surface defining a second sidewall, and an outer peripheral surface separating the first and second surfaces, and a mechanical mating member provided on at least a portion of the outer peripheral surface thereof, the mechanical mating member comprising a retention mechanism for controlling and retaining a position of a corresponding mating member provided on an inner surface of the at least one through-hole of the refractory block.

A refractory tunnel assembly for a steam reformer furnace, the refractory tunnel assembly comprising:

• a plurality of refractory base components;
• a plurality of refractory wall blocks, wherein at least a portion of the plurality of refractory wall blocks comprise at least one through-hole having openings formed in opposed side surfaces thereof;
• a plurality of refractory lid components;
• and
• a refractory insert residing within one or more of the though-holes in the refractory wall blocks, the refractory insert having a main body part having a first surface defining a first sidewall, an opposed second surface defining a second sidewall, and an outer peripheral surface separating the first and second surfaces, and a mechanical mating member provided on at least a portion of the outer peripheral surface thereof, the mechanical mating member comprising a retention mechanism for controlling and retaining a position of a corresponding mating member provided on an inner surface of the at least one through-hole of the refractory wall blocks;
• wherein the refractory base components are arranged to extend in a horizontal arrangement direction defining a width of the refractory tunnel assembly and a longitudinal arrangement direction defining a length of the refractory tunnel assembly;
• wherein the refractory wall blocks are stacked upon the refractory base components in a vertical arrangement direction and along the longitudinal arrangement direction, and are stacked upon one another in both the vertical and longitudinal arrangement directions, to define two parallel tunnel walls, spaced a distance apart from one another in the horizontal arrangement direction, wherein the two parallel tunnel walls extend upwardly from the refractory base components in the vertical arrangement direction and along the length of the refractory tunnel assembly on the refractory base components;
• and
• wherein the plurality of refractory lid components are stacked upon the refractory wall blocks in the vertical arrangement direction and along the longitudinal arrangement direction, so that the refractory lid components extend along the longitudinal arrangement direction and the horizontal arrangement direction in order to cover the distance between the tunnel walls along at least a portion of the length of the refractory tunnel assembly.