Refractory anchor
CROSS-REFERENCES TO RELATED APPLICATIONS 
     This application is a continuation-in-part of application Ser. No. 331,181, filed Dec. 16, 1981, U.S. Pat. No. 4,479,337, issued Oct. 30, 1984, entitled &#34;Refractory Anchor&#34;, which is a continuation of application Ser. No. 140,174, filed Apr. 14, 1980, entitled &#34;Refractory Anchor&#34;, abandoned. 
    
    
     BACKGROUND OF THE INVENTION 
     This invention relates to monolithic refractory linings in process vessels and equipment such as reactors, conduits, furnaces, incinerators and the like and, more particularly, to anchors for reinforcing and protecting refractory linings from erosion. 
     Refractory liners have been used for many years in process vessels, reactors, conduits, furnaces and the like to provide thermal insulation and in environments such as fluidized catalytic reactors, regenerators, or stacks, to provide resistance to abrasion and erosion. Refractory liners not only serve to thermally insulate a vessel, but also prolong the useful life of the vessel by shielding it from erosion and abrasion. In fluid catalytic cracking units for petroleum hydrocarbons, the abrasive effect of entrained cracking catalyst is very pronounced because of high fluid velocities on the order of 50 to 150 ft/second. High temperatures also occur in both the fluid bed reactor and the regenerator. For example, in the reactor the temperature may be 800°-1100° F. In the regenerator, the temperature of gases exiting through the cyclones may be on the order of 1250°-1450° F. It has been the usual practice to line vessels, conduits and cyclone separators, through which fluid with entrained catalyst flows, with refractory liner to prevent erosion of the metal surfaces and to provide thermal insulation. The refractory liner can be a refractory cement, or concrete. 
     In order to retain the refractory, various anchoring arrangements have beem employed. U.S. Pat. No. 3,076,481 to Wygant, which is hereby incorporated by reference, describes many of the problems involved in anchoring refractory concrete linings and of a particular anchorage arrangement. 
     Heretofore, a preferred anchorage arrangement which provided some erosion protection was the use of hexagonal steel grating which was welded to the vessel or conduit wall. The refractory was deposited in the hexagonal spaces defined by the hexagonal grating. The hexagonal grating provided the desired erosion resistance for the refractory by projecting to the exposed surface of the refractory. The many disadvantages of hexagonal grating, however, are its relatively high cost, lack of flexibility which makes it difficult to apply to curved surfaces, its tendency to separate from the vessel or conduit wall over relatively large areas when welds fail, and its unsuitability for use with fiber reinforced refractories or with refractory concretes containing coarse aggregate particles. 
     In situations where hexagonal grating is not suitable, weldable studs, such as those described in U.S. Pat. No. 3,657,851 to Chambers et al and U.S. Pat. No. 3,336,712 to Bartley, have been proposed. Such studs are suitable for use with fiber reinforced refractory or with refractory concrete but do not provide erosion protection for the refractory. 
     Over the years, a number of refractory anchors and other devices have been suggested. Typifying these prior art refractory anchors and other devices are those shown in U.S. Patent Nos. 78,167; 1,624,386; 2,340,176; 2,479,476; 3,076,481; 3,177,619; 3,424,239; 3,429,094; 3,449,084; 3,500,728; 3,564,799; and 3,587,198. These prior art refractory anchors and other devices have met with varying degrees of success. 
     It is therefore desirable to provide an improved refractory anchor which overcomes most, if not all, of the above problems. 
     SUMMARY OF THE INVENTION 
     An improved refractory anchor is provided to minimize erosion and increase the useful life of refractory linings in reactors and other vessels. The novel refractory anchor has a unique overhead elongated crossbar and a specially configured base. The overhead crossbar has an intermediate portion with opposite ends. At least one of the opposite ends of the crossbar has an arcuate portion that provides a curved baffle to arcuately deflect and substantially block high velocity gases which flow along the refractory lining adjacent to the refractory anchor. The uniquely shaped base extends downwardly from the intermediate portion of the crossbar to reinforce the refractory lining. The base has upwardly diverging flared sides which intersect the crossbar. The sides of the base intersect the opposite ends of the crossbar at obtuse angles of inclination and cooperate with the ends of the crossbar to provide pockets which receive the refractory linings. 
     In one preferred form, the specially configured base of the refractory anchor has a generally planar or flat, frustroconical body portion. The frustroconical body portion is positioned in general coplanar relationship with the intermediate portion of the crossbar. The frustroconical base preferably has at lease one hole, along its vertical centerline and axis to receive and engage the refractory lining. The base cooperates with the crossbar to provide a generally T-shaped member as viewed from the front. 
     In the preferred embodiment, an S-bar or S-shaped refractory anchor is provided. The opposite ends of the crossbar of the S-bar refractory anchor have reverse bent arcuate portions which cooperate with each other and an intermediate portion of the crossbar to provide an S-shaped crossbar. 
     In another embodiment, a C-bar or C-shaped refractory anchor is provided. The opposite ends of the crossbar of the C-bar refractory anchor have laterally symmetrical C-shaped arcuate portions. The C-shaped opposite ends of the crossbar face generally inwardly towards each other and cooperate with each other and the intermediate portion of the crossbar to provide a C-shaped crossbar. 
     The refractory anchors of this invention are particularly adapted for installation by welding to a metal surface together with a number of similar anchors to provide anchorage for a monolithic refractory lining applied to the metal wall or surface. 
     Each refractory anchor is preferably fabricated and formed from a metal strip having its width substantially equal to the thickness of the refractory lining to be applied to the surface. The metal strip is cut on each end to provide cut-away portions on the side of the refractory anchor to be welded to the surface. The slanted tapered sides of the frustroconical base are preferably cut to intersect the outwardly extending arms of the crossbar at an angle of inclination of 95 degrees to 150 degrees. Holes and accompanying optional tabs can be punched in the base of the refractory anchors. Desirably, the refractory anchor is stamped from sheet metal so that its crossbar has extending arms with opposite ends which extend outwardly from the intermediate portion of the crossbar and the base. At least one of the outwardly extending arms is bent to provide an arcuate portion. 
     In the preferred embodiment, both of the outwardly extending arms are bent in opposite directions away from the plane of the base and intermediate portion of the crossbar to form an S-shaped crossbar. 
     In order to form a C-bar refractory anchor, the outwardly extending arms of the crossbar are bent towards each other away from the plane of the base and the intermediate portion of the crossbar to form symmetrical C-shaped arcuate portions at the ends of the crossbar. 
     Each of the arcuate portions of the S-shaped and C-shaped crossbars extend arcuately from 60 degrees to 270 degrees from the beginning to the end of the arcuate portion. The outwardly extending curved arms of the crossbar provide an erosion resistant barrier to help protect and reinforce the refractory lining. 
     In the preferred method of installation, the refractory anchors are arranged in alternate rows oriented at different angles and welded or otherwise securely attached to the walls of a reactor or another vessel. 
     Advantageously, the refractory anchors are relatively inexpensive and easy to install. The refractory anchors are suitable for use with fiber or needle reinforced refractory cement or concrete to help protect the refractory from erosion. The refractory anchors can be utilized on curved surfaces such as within the interior walls of cyclones, conduits, riser reactors, transfer lines, etc. 
     A more detailed explanation of the invention is provided in the following description and appended claims taken in conjunction with the accompanying drawings. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a top plan view of an S-shaped refractory anchor from the side adapted to be welded to the walls of the reactor or other vessel to which the refractory is to be applied in accordance with principles of the present invention; 
     FIG. 2 is a front view of the S-shaped refractory anchor; 
     FIG. 3 is a front view of the S-shaped refractory anchor welded to the walls of the reactor with the refractory in place; 
     FIG. 4 is a fragmentary isometric view of an array of S-shaped refractory anchors attached to the walls of the reactor with the refractory linings in place; 
     FIG. 5 is a perspective view of an X-shaped refractory anchor in accordance with principles of the present invention; 
     FIG. 6 is a perspective view of another S-shaped refractory anchor in accordance with principles of the present invention; 
     FIG. 7 is a top view of the S-shaped refractory anchor of FIG. 6; 
     FIG. 8 is a front view of the S-shaped refractory anchor of FIG. 6; 
     FIG. 9 is a perspective view of a C-shaped refractory anchor in accordance with principles of the present invention; 
     FIG. 10 is a top view of the C-shaped refractory anchor of FIG. 9; and 
     FIG. 11 is a front view of the C-shaped refractory anchor of FIG. 9. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     The S-shaped refractory anchors 10 in FIGS. 1-4 and 6-8, which are also referred to as S-bar refractory anchors, are preferably stamped from a strip of sheet metal, such as stainless steel, having its width equivalent to the thickness of the refractory liner to be applied. By stamping or otherwise cutting refractory anchors with outwardly extending arms 11a and 11b (FIGS. 1-3) on opposite ends of the strip, considerable metal can be saved. At the time of stamping, at least one hole or opening 12 (FIGS. 2 and 3) and projecting tab 13 can be formed along the vertical centerline of the central intermediate generally planar or flat frustroconical body portion 14a (FIG. 2) of the strip. If desired, no holes or a plurality of holes can be provided and the holes optionally can be with or without tabs. As will be described, the holes and tabs perform useful functions in the application of the refractory and in most cases their incorporation in the anchor will be desirable. Each of the arms 11a and 11b of the anchor 10 can be bent simultaneously during stamping to a curvature ranging from 60 degrees to 270 degrees from the beginning to the end of each arm (arcuate portion) and preferably from about 100 degrees to about 180 degrees relative to the intermediate portion 11c of the crossbar at the time of stamping or cutting of the anchors or in a subsequent operation depending on the availability of appropriate equipment. 
     The S-bar refractory anchor 10 has a generally S-shaped crossbar 11 with an elongated, generally planar or flat, intermediate portion 11c and reverse bent arcuate opposite ends 11a and 11b that provide outwardly extending arms. The reverse bent ends are cantilevered from the intermediate portion 11c and provide complimentary curved baffles to arcuately deflect and block gases flowing along the refractory linings 17 and 18 (FIG. 3) adjacent to the refractory anchor. The reverse bent ends of the crossbar are bent in a transverse direction, normal to and away from the plane of the frustroconical base. Advantageously, the crossbar provides an erosion resistant barrier which protects the structural integrity of the refractory linings. 
     The S-shaped refractory anchor has a generally frustroconical, planar or flat base 14 (FIG. 2) which integrally extends from and is connected to the intermediate portion 11c of the S-shaped crossbar 11 to reinforce the refractory lining. The frustroconical base 14 has a lower bottom portion, bottom edge, or bottom 14b which spans a lateral distance less than the intermediate portion 11c of the crossbar. The frustroconical base has flared, slanted, tapered sides 14c and 14d which diverge generally towards and intersect the reverse bent arcuate ends of the S-shaped crossbar at obtuse angles of inclination ranging from 95 degrees to 150 degrees, preferably a maximum of 135 degrees for best results, to define obtuse pockets 14e and 14f therewith for receiving the refractory lining 18. The base has a generally planar or flat frustroconical body portion which is positioned in coplanar relationship with the intermediate portion 11c of the crossbar. The base and the crossbar cooperate with each other to provide a generally T-shaped member as viewed from the front, as best shown in FIGS. 2 and 8, as well as during the fabrication process preparatory to bending the outwardly extending arms of the crossbar. 
     The frustroconical base 14 can have an overall height ranging from 0.25 inch to 6 inches and preferably from 0.5 inch to 3.75 inches for best results. The S-shaped crossbar has a total curved overall length or flattened length of 2 to 6 inches and preferably a maximum of about 5.5 inches for best results. The overall length or flattened length of the crossbar can be at least twice the height of the frustroconical base. 
     The holes 12 (FIGS. 2 and 3) in the frustroconical base receive and engage a refractory lining 18 and should be substantially smaller than the total surface area of the base 14. The hole can be circular, arch-shaped, or N-shaped. Other shaped holes can be provided. 
     The top edge of the crossbar 11 is generally straight, planar, and flat and extends across the ends 11a and 11b and the intermediate portion 11c of the crossbar. The flat top edge of the crossbar is perpendicular to the vertical axis of the frustroconical base 14. 
     The size of the anchors can be varied as desired for use with the surface to be refractory lined and the thickness and type of the refractory to be employed. A convenient anchor for securing a refractory one-inch thick is made from 16 gauge Type 304 stainless steel strip one inch wide. The length of the anchor prior to bending the arms 11 is approximately 5.5 inches and each arm is bent to a one-half inch radius. The width of the arms 11 can be 1/4 to 1/2 inch, as desired. The spacing of the anchors when they are welded to the surface to be refractory coated is a function of the size of the anchors. For the above-described size anchor, the anchors can be spaced apart over the surface upon three-inch centers. Thicker linings may have anchor spacings of 2 to 3 times the thickness or height of the anchor. 
     In FIG. 3, the anchor 10 is shown welded to a surface 15 of a reactor or other vessel, with the weld being indicated at 16. A similar weld can be utilized on the back side of the anchor. Two layers of refractory 17 and 18 are shown. The layer 17 next to the surface 15 is preferably of a refractory material having a high insulating value and the other layer 18 has a higher resistance to abrasion and erosion. Either or both of these layers can be reinforced by fibers (sometimes referred to as needles) which are preferably formed of stainless steel. Typically, the fibers will be approximately 3/4 to 11/2 inches in length and about 20 mil (0.020 inch) in diameter. The quantity of fibers usually employed is between about 2 and 6% by weight of the refractory on a dry basis. 
     In cases where it is desired to utilize a refractory concrete, layer 17 can comprise expanded shale or vermiculite having high insulating value and layer 18 can comprise tabular alumina having high resistance to abrasion. In such cases, the projecting tabs 13 or holes 12 can be used as very convenient indicators as to the desired thickness of the insulating layer 17. This ability to conveniently measure the thickness of the applied layer is particularly useful when very thick layers of total refractory are involved. 
     In FIG. 4, the preferred composite structure is illustrated. Initially, the individual anchors 10 are affixed to the surface 15 to be protected by the refractory. As shown, alternate rows of the S-shaped refractory anchors are disposed at substantially different angles to each other and because of their curving arms an effective grid of metal is provided over the surface for preventing erosion. The preferred angular difference between the S-shaped refractory anchors of adjacent rows is about 45° or somewhere between about 30° and about 60° for achieving maximum erosion protection with a minimum number of anchors. 
     The anchors can be held in the desired position by means of a small bar having a slot in one end to receive the intermediate portion or top 11c of the anchor and welded to the wall or surface 15 by forming the welding bead 16 (FIG. 3) on one or both sides. When the weld is completed, the bar is pulled free for use to hold the next anchor. Alternatively, multiple tack welding or brazing, if appropriate to the metals involved, may be employed. When the anchors are all attached, the layer or layers of refractory cement, refractory concrete, or fiber reinforced refractory can be applied utilizing conventional procedures such as casting and trowelling or pneumatic application such as the Gunnite procedure. 
     Suitable refractories are the hydraulic calcium aluminate cements and the high alumina phosphate bonded materials which are heat setting and have superior erosion resistance. Once the refractory layer or layers have been applied and cured, they are very effectively held in place by the refractory anchors of this invention. When installed, the refractory lining is held against the surface or wall 15 by the arms 11a and 11b and tab(s) 13 and other portions of the refractory anchors and is continuous through the hole 12. Because the refractory anchors are not interconnected and have relative flexibility in their structure, thermal expansion and contraction can readily occur on a localized basis. Moreover, the protective blocking effected by the refractory anchors prevents abrasive erosion especially by streams of particulates such as fluidized catalyst which move transverse to the surface of the refractory. In contrast, the use of prior art hexagonal grating, while providing some erosion protection, has relatively little holding power to safely secure the refractory to the wall or interior surface of the vessel which is being protected. Moreover, when such prior art gratings separate from the surface, large sections are likely to pull loose from the surface. 
     The S-shaped refractory anchor 10a, shown in FIGS. 6-8, is also referred to as an S-bar refractory anchor, and is similar to the S-shaped refractory anchor shown in FIGS. 1-3, except that it is taller and has a set of vertically aligned holes 12a-e and tabs 13a-e along its vertical centerline. The refractory anchor 10a also can have horizontal score, break, or cutting lines 14g-j. The cutting lines 14g-j indicate where the refractory anchor can be cut to shorten the height and overall size of the anchor. 
     The X-shaped refractory anchor 20 of FIG. 5 is similar in many respects to the S-shaped anchors shown in FIGS. 1-4 except that the crossbars 21 have flat noncurving ends 21a and 21b and are slotted as shown at 22 so as to be interlockable in the form of a cross or X with similar anchor sections. Assembled in this manner, a pair of anchor sections 20a and 20b can be welded to a wall or other surface of a reactor or other vessel to protect and reinforce the refractory linings. The anchors shown in FIG. 5 can be readily arranged with the arms 21a and 21b of adjacent assemblies lying in non-touching but overlapping relationship to obtain a protection from erosion similar to that obtainable with hexagonal grating but without the disadvantages of continuous gratings. 
     The C-shaped refractory anchor 30 shown in FIGS. 9-11 is also referred to as a C-bar refractory anchor, and is similar to the S-shaped refractory anchor 10a shown in FIGS. 6-8, except that the C-shaped refractory anchor has a C-shaped crossbar 31 instead of an S-shaped crossbar. The C-shaped crossbar has a generally flat or planar intermediate portion 31c with symmetrical C-shaped opposite ends 31a and 31b which provide outwardly extending arms. The C-shaped opposite ends are cantilevered from the intermediate portion 31c and generally face each other to provide symmetrical curved baffles to arcuately deflect and block gases flowing along the refractory lining adjacent to the refractory anchor. The intermediate portion 31c of the crossbar extends between and connects the C-shaped opposite ends 31a and 31b. The generally planar or flat, straight top edge 31 of the crossbar extends across the crossbar and is generally perpendicular to the vertical axis and centerline of the frustroconical base 34. 
     The frustroconical base 34 of the C-shaped refractory anchor anchor 30 is structurally and functionally similar to the frustroconical base of the S-bar refractory anchor described above with respect to FIGS. 6-8. The flared, tapered slanted sides 34c and 34d of the frustroconical base diverge generally towards and intersect the C-shaped arcuate ends 31a and 31b of the crossbar of the overhead crossbar 31 at obtuse angles of inclination ranging from 95 degrees to 150 degrees and preferably at a maximum of 135 degrees to define obtuse pockets 34e and 34f therewith for receiving the refractory lining. The frustroconical base has a generally planar or flat frustroconical body portion which is positioned in coplanar relationship with the flat intermediate portion 31c of the crossbar. The base can have one or more holes 32a-e with optional outwardly extending tabs 33a-e along the vertical axis of the base. The C-shaped opposite ends 31a and 31b provide outwardly extending arms which are curved in transverse direction normal to and away from the plane of the base. Each of the C-shaped ends (arcuate portions) 31a and 31b arcuately extends at an angle ranging from 60 degrees to 270 degrees and preferably from about 100 degrees to about 180 degrees from the beginning to the end of the C-shaped end relative to the intermediate portion 31c of the crossbar. The score, break, or cutting lines 34g-j have a similar orientation and function as the cutting lines 14g-j of the S-shaped refractory anchor in FIGS. 6-8. The overall dimensions and proportional relationships of the crossbar 31 and base 34 of the C-shaped refractory anchor are similar to the dimensions and proportional relationship of the crossbar and base of the S-shaped refractory anchor of FIGS. 6-8. 
     The S-shaped, C-shaped, and X-shaped refractory anchors can be installed in new reactors or other units and can be used to repair or patch existing units. During repair, the damaged refractory can be stripped to have access to the vessel or conduit surface, the refractory anchors can then be welded to the exposed surface, and the refractory redeposited. 
     The S-shaped, C-shaped, and X-shaped refractory anchors are particularly useful to resist erosion and increase the useful life of refractory linings in reactors and other vessels. 
     Although embodiments of this invention have been shown and described, it is to be understood that various modifications and substitutions, as well as rearrangements of parts and components, can be made by those skilled in the art without departing from the novel spirit and scope of this invention.