Specification
[Title of the Invention] MONOLITHIC REFRACTORY STRUCTURE
[Technical Field of the Invention]
[0001]
The present invention relates to a monolithic refractory structure.
Priority is claimed on Japanese ]:'atent Application No. 2013-014504, filed on
,Ji\fiuary 29, 2013, the content of which is incorporated herein by reference.
r
![Related Art]
[0002]
In various types of industrial furnaces and facilities used under a high
temperature, such as ironworks, various types of refractories such as firebricks,
monolithic refractories, ceramic fiber, and the like are constructed depending on the
use environment or necessary functions. In recent years, among these, the use of
monolithic refractories ( castable and plastic refractories and the like) has increased due
to an increase in the degree of freedom of construction and shape and an increase in
quality.
[0003]
Inside the monolithic refractory, a metal support material typically called an
anchor or stud, processed to an L-shape, a V-shape, or a Y-shape is buried. An end
portion of the metal support material is fixed to a shell or pipe which is a support body
of the monolithic refractory. The metal support material has a role of preventing the
monolithic refractory from being peeled off or separated from the support body such as
the shell or pipe or suppressing the propagation of a crack that occurs in the monolithic
refractory.
[0004]
- 1 -
Specifically, as shown in FIG. 16, an existing monolithic refractory structure
includes a slipport body I, metal support materials 2 such as a metal stud or anchor
fixed to the support body 1 by welding or the like, and a monolithic refractory 3.
[0005]
The monolithic refractory 3 which covers the support body 1 has a single
layer structure or a multi-layer structure. There may be cases where a shaped
vz,fractory such as a ceramic fiber, a heat insulating board, or a heat insulating sheet is
hsed together with the monolithic refractory 3. The support body 1 is a structure
, obtained by combining metallic or ceramic members and is a furnace shell, pipe, beam,
post, or the like. For example, as the support body 1 used in an iron and steel process,
a furnace shell of a heating furnace, a water-cooling pipe of a skid, an immersion tube
for secondary refining, a gas suction lance, or the like may be employed.
[0006]
After the metal support materials 2 are fixed to the support body 1 with
predetermined intervals therebetween by welding or the like, a slurry-like monolithic
refractory raw material is poured into a molding box having an arbitrary shape
installed in the periphery of the support body 1. Thereafter, through a finishing
process such as curing process and drying process, a monolithic refractory structure as
shown in FIG. 16 is obtained.
[0007]
In a general monolithic refractory structure described above, a metal support
material is present in the vicinity of the operation surface of a monolithic refractory
exposed to a high temperature. The metal support material has a higher coefficient of
thermal expansion than that of the monolithic refractory. Therefore, cracks occur in
the monolithic refractory due to the difference in the coefficient of thermal expansion
- 2 -
! ·------
between the metal support material and the monolithic refractory. In addition, heat is
transferred tO the furnace shell, the water-cooling pipe, or the like via the metal support
material having a high thermal conductivity and thus high heat loss occurs.
Furthermore, in a case where the metal support material is used over a long period of
time under an oxidizing atmosphere, the strength of the metal support material is
reduced due to the oxidation. As a result, the holding force of the monolithic
!i7fractory is reduced, and particularly, there is a problem in that the monolithic
~efractory becomes separated from the tip end of the metal support material.
!
[0008]
During the construction of the monolithic refractory structure of an industrial
furnace, thousands to tens of thousands or hundreds of thousands of metal support
materials are used although the number of materials varies depending on the size or
structure of the furnace. In the monolithic refractory after an operation under a high
temperature, many cracks that are initiated from positions where the metal support
materials are installed are present. When such cracks propagate and are connected to
each other, a possibility of peeling or separation of the monolithic refractory is
increased. Therefore, the amount of initiated cracks is one of the factors that
determine the life-span of the monolithic refractory structure.
[0009]
Hitherto, as a countenneasure to the problem, in order to ensure the expansion
allowance of the. metal support material, a method of forming a resin film on the
surface of a metal support material or winding a plastic tape around the surface thereof
and thereafter burying the metal support material in a monolithic refractory is generally
employed. According to this method, the resin film or the plastic tape is burned down
due to the temperature increase, and thus a space (that is, expansion allowance) is
- 3 -
formed in the periphery of the metal support material buried in the monolithic
refractory.
[0010]
However, according to the countermeasure of forming the resin film on the
surface of the metal support material or winding the plastic tape around the surface
thereof, it is difficultto sufficiently supptess the occurrence of cracks even though
f>."fort and cost is consumed.
I [0011]
'
Here, hitherto, a technique of using a heat-resistant fiber rope formed of an
inorganic fiber as a support material instead of the metal support material is suggested
(refer to the following Patent Documents 1 to 3). In Patent Documents 1 and 2, a
technique of supporting a monolithic refractory using a heat-resistant ceramic rope
formed of a ceramic fiber is disclosed. In Patent Document 3, a technique of using a
rope (support cord) formed of an inorganic fiber such as glass wool, rock wool, slag
wool, asbestos, ceramic fiber, alumina fiber, or carbon fiber as a support material is
disclosed.
[0012]
The inorganic fiber is formed of an inorganic material like the monolithic
refractory and has a low coefficient of thermal expansion and has a further low elastic
modulus. Therefore, in a case where the heat-resistant fiber rope is buried in the
monolithic refractory as the support material, cracks hardly occur in the monolithic
refractory due to a small difference in the thermal expansion between the monolithic
refractory and the heat-resistant fiber rope ..
[0013]
In general, while the thermal conductivity of SUS steel or heat-resistant cast
- 4 -
·- l--- ·'- ,,
steel used for the metal support material is about 15 W /mK to 50 W /mK, for example,
the thermal cOnductivity of alumina fiber is about 0.1 W /mK to 0.2 W/mK. Therefore,
heat is hardly transferred to the furnace shell, the water-cooling pipe, or the like via the
heat-resistant fiber rope, and thus heat loss can be reduced.
In addition, for example, the ceramic fiber is primarily formed of oxides such
as Ah03 and Si02 . Therefore, even wh.en the heat-resistant fiber rope formed of the
('~ramie fiber is used over a long period of time under a high temperature oxidizing
1:tmosphere, deterioration due to the oxidation does not occur unlike the metal support
/material.
[Prior Art Document]
[Patent Document]
[0004]
[Patent Document 1] Japanese Unexamined Patent Application, First
Publication No. H09-143535
[Patent Document 2] Japanese Unexamined Patent Application, First
Publication No. 2005-42967
[Patent Document 3] Japanese Unexamined Utility Model Application, First
Publication No. H07-32493
[Disclosure of the Invention]
[Problems to be Solved by the Invention]
[0015]
As described above, most of the problems that occur due to the use of the
metal support material can be solved by using the heat-resistant fiber rope formed of
the inorganic fiber as the support material instead of the metal support material.
However, as a result of verification by the inventors, it was determined that the bearing
- 5 -
force of the monolithic refractory (a force needed to fix the monolithic refractory to the
support body) varies depen,ding on the state of the heat-resistant fiber rope in the
monolithic refractory.
[0016]
That is, there is a possibility that a sufficient bearing force for the monolithic
refractory may not be obtained depending on the state of the heat-resistant fiber rope in
~ ' . -
tt~~ monolithic refractory and the monolithic refractory may become separated from the
I ~upport body. However, in the related art described above, there is no suggestion for
'an optimal state of the heat-resistant fiber rope in the monolithic refractory by focusing
on the bearing force of the monolithic refractory.
[0017]
The present invention has been made taking the foregoing circumstances into
consideration, and an object thereof is to solve problems (a reduction in the bearing
force of a monolithic refractory) that occur when a heat-resistant fiber rope formed of
an inorganic fiber is used as a support material for supporting the monolithic refractory.
[Measures for Solving the Problem]
[0018]
In order to accomplish the object to solve the problems, the present invention
employs the following measures.
(I) According to an aspect of the present invention, a monolithic refractory
structure includes: a monolithic refractory; a support body which supports the
monolithic refractory; and a heat-resistant fiber support material which is buried in the
monolithic refractory in a state of being connected to a support surface of the support
body, in which the heat-resistant fiber support material includes a heat-resistant fiber
rope which is formed of an inorganic fiber and extends along an X-axis direction
- 6 -
perpendicular to the support surface, and a ratio L 1/L2 of an X -axis direction length L 1
of the heat-resistant fiber rope to an X-axis direction length L2 of the monolithic
refractory is 0.35 or more and 0.95 or less.
Here, the description "extends along an X-axis direction" includes not only
extension of the heat-resistant fiber rope in parallel to the X-axis direction, but also
meaning that extension of the heat-resist~pt fiber rope in a state of being inclined at a
f>/.edetermined angle from the X-axis direction is allowed as long as the condition that
i
i
,Ll/L2 is 0.35 or more and 0.95 or less is satisfied.
[0019]
(2) In the monolithic refractory structure described in (I), the heat-resistant
fiber rope may be formed of an inorganic fiber made of a material containing one type
[0020]
(3) In the monolithic refractory structure described in(!), the heat-resistant
fiber rope may be hardened by a hardener.
[0021]
(4) In the monolithic refractory structure described in(!), the heat-resistant
fiber rope may be connected to the support body via an anchor provided on the support
surface.
[0022]
(5) In the monolithic refractory structure described in(!), the heat-resistant
fiber support material may further include a connection member which connects the
heat-resistant fiber rope to the support body, and the connection member may be fixed
to the support surface of the support body.
[0023]
- 7 -
(6) In the monolithic refractory structure described in (5), the connection
member may 'be a metal ring having a hollow tube shape, the heat-resistant fiber rope
may be inserted into and fixed to the metal ring, and a direction in which a load of the
monolithic refractory is exerted on the heat-resistant fiber rope and a direction in
which the heat-resistant fiber rope is pulled from the metal ring may be the same.
[0024]
;! . (7) In the monolithic refractory structure described in (5), the connection
1lember may be a metal ring having a hollow tube shape, the heat-resistant fiber rope
/may be inserted irtto and fixed to the metal ring, and a direction in which a load of the
monolithic refractory is exerted on the heat-resistant fiber rope and a direction in
which the heat-resistant fiber rope is pulled from the metal ring may be different from
each other.
[0025]
(8) In the monolithic refractory structure described in (1), the heat-resistant
fiber rope may include one or two or more annular portions.
[0026]
(9) In the monolithic refractory structure described in (1), the heat-resistant
fiber rope may include one or two or more knots.
[0027]
(10) In the monolithic refractory structure described in (1), the monolithic
refractory may be divided into a plurality of layers along the X -axis direction, and the
heat-resistant fiber rope may have a single annular portion for each of the layers of the
monolithic refractory.
[Effects of the Invention]
[0028]
- 8 -
In the above aspect, the ratio L!IL2 of the X-axis direction (the direction
perpendicular to the support surface of the support body; in other words, the direction
where load of the monolithic refractory acts on) length L1 of the heat-resistant fiber
rope to the X-axis direction length L2 of the monolithic refractory is 0.35 or more and
0.95 or less.
By holding the state of the heat-tesistant fiber rope in the monolithic
fi\~fractory so as to satisfy the condition described above, a necessary bearing force for
~he monolithic refractory can be obtained. As a result, the monolithic refractory can
/be prevented from being separated from the support body.
[Brief Description of the Drawings]
[0029]
FIG lA is a plan view of a monolithic refractory structure according to an
embodiment of the present invention.
FIG lB is a side view of the monolithic refi·actory structure according to the
embodiment of the present invention.
FIG 2A is a view showing a case where the ratio Ll/L2 of an X-axis direction
length L1 of a heat-resistant fiber rope to an X-axis direction length L2 of a monolithic
refractory is 0.35 or more and 0.95 or less.
FIG. 2B is a view showing a case where the ratio Ll/L2 of the X-axis
direction length Ll of the heat-resistant fiber rope to the X-axis direction length L2 of
the monolithic refractory is smaller than 0.35.
FIG 3 is a view showing a knot portion of a heat-resistant fiber support
material.
FIG 4 is a view showing a heat-resistant fiber support material including the
heat-resistant fiber rope and a metal ring.
- 9 -
FIG. 5 is a view showing the heat-resistant fiber support material including the
heat -resistant' fiber rope and the metal ring.
FIG. 6 is a view showing the heat-resistant fiber support material including the
heat-resistant fiber rope and the metal ring.
FIG. 7 is a view showing the heat-resistant fiber support material including the
heat-resistant fiber rope and the metal ring.
FIG. 8 is a view showing the heat-resistant fiber support material including a
~lurality of heat-resistant fiber ropes which branch off from the metal ring into a
, branch shape.
FIG. 9 is a view showing the heat-resistant fiber support material in a case
where the monolithic refractory is divided into a plurality of layers.
FIG. I 0 is a view showing a skid.
FIG. 11 is a view showing the structure of a skid post.
FIG. 12 is a view showing the monolithic refractory structure in which the
heat-resistant fiber support material is used.
FIG. 13 is a view showing the monolithic refractory structure in which the
heat-resistant fiber support material is used.
FIG. 14 is a view showing the monolithic refractory structure in which the
heat-resistant fiber support material is used.
FIG. 15 is a view showing the monolithic refractory structure in which a metal
support material is used.
FIG. 16 is a view showing a monolithic refractory structure in which a metal
support material according to the related art is used.
[Embodiment of the Invention]
[0030]
- 10 -
Hereinafter, an embodiment of the present invention will be described with
reference to the drawings.
FIG. lA is a plan view of a monolithic refractory structure according to this
embodiment. FIG. IBis a side view of the monolithic refractory structure according
to this embodiment. As shown in FIGS. lA and IB, the monolithic refractory
structure according to this embodiment iJ1cludes a support body l, a monolithic
r0,fractory 3, a pin 4, and a heat-resistant fiber support material 5.
I [0031]
The support body l is a structure that supports the monolithic refractory 3 and
is obtained by combining metallic or ceramic members. The support body I and the
monolithic refractory 3 are the same as those of an existing monolithic refractory
structure shown in FIG. 16. Therefore, for the convenience of description, the support
body I and the monolithic refractory 3 in this embodiment are denoted by the same
reference numerals as those in FIG. 16.
[0032]
A planar support surface I a is provided on the surface of the support body I.
Hereinafter, as shown in FIGS. lA and IB, a direction perpendicular to the support
surface Ia is defined as an X-axis direction. In addition, on a plane perpendicular to
the support surface Ia, a direction perpendicular to the X-axis direction is defined as a
Y-axis direction. Moreover, a direction perpendicular to the XY plane (the plane
perpendicular to the support surface Ia) is defined as a Z-axis direction.
The pin 4 having an L-shape is installed on the support surface I a. The pin 4
has a role as an anchor to connect the support body I and the heat-resistant fiber
support material 5 to each other.
[0033]
- 11 -
The heat-resistant fiber support material 5 is buried in tbe monolithic
refractory 3 iii a state of being connected to the support surface 1 a provided in the
support body 1. The heat-resistant fiber support material 5 is formed of an inorganic
fiber aud has a heat-resistant fiber rope 7 that extends along the direction perpendicular
to the support surface 1a (the X-axis direction in the figure). The heat-resistant fiber
rope 7 is connected to the support body lyia the pin 4 installed on the support surface
?.' In addition, the pin 4 forms a portion of the support body 1 and is not a
honstituent element of the heat-resistant fiber support material 5.
[0034)
In FIGS. lA and lB, a case where the heat-resistant fiber rope 7 has an
annular portion (the shape of the heat-resistant fiber rope 7 is annular) is shown.
However, as described later, the shape of the heat-resistant fiber rope 7 is not limited to
tbe annular shape. In addition, as described above, the heat-resistant fiber rope 7 may
be fixed to the support body 1 by a method of hooking tbe annular heat-resistant fiber
rope 7 to the pin 4, a method of connecting the heat-resistant fiber rope 7 to tbe support
body 1 using a beam of the ceiling or the like of the support body 1, or the like.
[0035)
It is preferable that the heat-resistant fiber rope 7 be formed of an inorganic
fiber made of a material containing one type or two or more types of Al203, Si02,
Ah03-Si02, and Ah03-Si02-B20 3. The heat-resistant fiber rope 7 formed of the
inorganic fiber made of such the material has heat resistance and strength to bear a
high temperature of, for example, 600°C or higher, and furthermore, 1000°C or higher
at which an increase in heat loss and a reduction in strength occur in an existing metal
support material.
[0036)
- 12 -
Particularly, an inorganic fiber made of Ah03-Si02 has excellent high
temperature resistance and cost performance. Among the inorganic fibers made of
A1z03-Si02, an inorganic fiber containing 72 mass% of Al20 3 and 28 mass% of Si02 is
relatively easily available and has excellent cost performance. In addition, an
inorganic fiber containing 90 mass% of Ab03 and 10 mass% of Si02 has more
excellent heat resistance.
[0037]
By twisting a plurality of inorganic fibers, a yarn is obtained. Furthermore,
,'by joining a plurality of yarns to be processed into a rope shape, the heat-resistant fiber
rope 7 which is a primary portion of the heat-resistant fiber support material 5
according to this embodiment is obtained.
[0038]
In addition, by using the inorganic fiber containing two or more types of
Ab03, SiOz, Ah03-Si02, and Ab03-Si02-Bz03 as described above, for example, the
heat-resistant fiber rope 7 which has a multi-layer structure in which the core and the
outer layer have different materials can be obtained.
[0039]
In a case where the monolithic refractory structure is used under a low
temperature, for example, the heat-resistant fiber rope 7 formed of an inorganic fiber
(carbon fiber) made of carbon or an inorganic fiber made of AbOrSi02-CaO, Ca0-
Si02, or the like may be used.
[0040]
The heat-resistant fiber rope 7 has a rope form braided by using the inorganic
fiber. As the type of braiding, 8 strands braiding (cross rope), 16 strands braiding
(braided rope), solid cord braiding (solid cord), or the like may be employed, and the
- 13 -
type is not particularly limited. A hollow rope such as sleeve may also be used.
However, thespace in the rope is preferably as small as possible.
[0041]
In order for the heat-resistant fiber rope 7 to ensure strength to function as the
support material of the monolithic refractory 3, it is preferable that the heat-resistant
fiber rope 7 be formed of long fibers havipg a fiber length of, for example, 1 00 m or
1\•nger. Even in a case where short fibers are used, the short fibers may be braided
I
into a rope shape. However, the short fibers are only entangled and thus are easily
.pulled. Therefore, the short fibers do not accomplish the function as the support
material. In a case where the long fibers are used, a necessary tensile strength for the
support material can be adjusted by changing the rope diameter. In addition, long
fiber indicates a fiber having a long fiber length on the order of meters or longer
(typically, on the order of kilometers or longer) and is distinguished from short fiber
having a fiber length of about 1 mm to 50 mm.
[0042]
As shown in FIG. 2A, in the monolithic refractory structure according to this
embodiment, the state ofthe heat-resistant fiber rope 7 is held in the monolithic
refractory 3 so that the ratio Ll/L2 of an X-axis direction length Ll of the heatresistant
fiber rope 7 to an X-axis direction length L2 of the monolithic refractory 3 is
0.35 or more and 0.95 or less.
[0043]
As described above, as a result of verification by the inventors, it was
determined that the bearing force of the monolithic refractory 3 (a force needed to fix
the monolithic refractory to the support body) varies depending on the state of the heatresistant
fiber rope 7 in the monolithic refractory 3.
- 14 -
After the heat-resistant fiber rope 7 (the heat-resistant fiber support material
5) is fixed tothe support body!, a slurry-like raw material of the monolithic refractory
3 is poured into a molding box having an arbitrary shape installed in the periphery of
the support body I. Thereafter, through a finishing process such as curing process
and drying process, the monolithic refractory structure according to this embodiment is
obtained.
f Here, as shown in FIG. 2B, before the raw material of the monolithic
~efractory 3 is poured into the molding box, the heat-resistant fiber rope 7 is hung
, downward in the Z-axis direction (vertically downward) due to its own weight. When
the raw material of the monolithic refractory 3 is poured into the molding box in the
state where the heat-resistant fiber rope 7 is hung down as such, the heat-resistant fiber
rope 7 is fixed in the monolithic refractory 3 in the state where the heat-resistant fiber
rope 7 is hung down.
[0044]
The inventors verified an effect of the ratio Ll/L2 of the X-axis direction
length Ll of the heat-resistant fiber rope 7 to the X-axis direction length L2 of the
monolithic refractory 3 on the bearing force of the monolithic refractory 3. As a
result, it was discovered that as shown in FIG. 2B, in a case where the ratio Ll/L2 of
the X-axis direction length Ll of the heat-resistant fiber rope 7 to the X-axis direction
length L2 of the monolithic refractory 3 is smaller than 0.35 since the heat-resistant
fiber rope 7 is fixed in the monolithic refractory 3 in the state where the heat-resistant
fiber rope 7 is hung down, the bearing force of the monolithic refractory 3 is
significantly reduced.
[0045]
The reasons are as follows. That is, in a case where the monolithic
- 15 -
refractory structure according to this embodiment is used in an actual industrial furnace
or facility, the' X -axis direction (the direction perpendicular to the support surface I a)
becomes a direction in which the load of the monolithic refractory 3 is exerted. Since
the bearing force of the monolithic refractory 3 is a force that bears the load, it is
thought that when the heat-resistant fiber rope 7 is hung down and the X-axis direction
length L 1 of the heat -resistar1t fiber rope .7 is reduced, the bearing force that bears the
l:'>iid (that is, a force in a direction opposite to the load in the X-axis direction) is
I )"educed.
In a case'where the ratio Ll/L2 of the X-axis direction length L1 of the heatresistant
fiber rope 7 to the X-axis direction length L2 of the monolithic refractory 3 is
smaller than 0.35, a portion of the monolithic refractory 3 that is not supported by the
heat -resistant fiber rope 7 is about 2/3 of the X -axis direction length L2 of the
monolithic refractory 3, and thus there is a possibility that the portion that is not
supported by the heat-resistant fiber rope 7 may be easily separated from the support
body I.
In a case where the ratio Ll/L2 of the X-axis direction length L1 of the heatresistant
fiber rope 7 to the X-axis direction length L2 of the monolithic refractory 3 is
greater than 0.95, the tip end of the heat-resistant fiber rope 7 (an end portion thereof
on the opposite side to the support body I) is too close to the operation surface of the
monolithic refractory 3 (a surface thereof on the opposite side to the support body 1),
and there is a possibility that the heat resistance of the heat-resistant fiber rope 7 may
have a problem.
In addition, it was confirmed that.as long as the condition (Ll/L2 is 0.35 or
more and 0.95 or less) is satisfied, even when the heat-resistant fiber rope 7 is inclined
downward in the Z-axis direction (vertically downward) with respect to the X-axis
- 16 -
direction, if the angle between the heat-resistant fiber rope 7 and the X-axis direction is
45° or less, there is no problem in practical use.
[0046]
Therefore, by holding the state of the heat-resistant fiber rope 7 in the
monolithic refractory 3 so as to satisfY the condition (Ll/L2 is 0.35 or more and 0.95
or less) described above, a necessary bea~ing force for the monolithic refractory 3 can
~·>/.obtained. As a result, the monolithic refractory 3 can be prevented from being
Jeparated from the support body 1.
[0047]
In order to hold the state of the heat-resistant fiber rope 7 in the monolithic
refractory 3 so that the condition (LI/L2 is 0.35 or more and 0.95 or less) is satisfied as
described above, it is preferable that the heat-resistant fiber rope 7 which is hardened
in advance by a hardener or the like be used. Accordingly, before the raw material of
the monolithic refractory 3 is poured into the molding box, the heat-resistant fiber rope
7 can be prevented from being hung down due to its own weight.
[0048]
As described above, a state in which the heat -resistant fiber rope 7 is hardened
in advance by the hardener and the strength of the heat -resistant fiber rope 7 is
exhibited at room temperature during the construction of the monolithic refractory
structure according to this embodiment is preferable. Strength indicates a force that
bears deformation such as hanging, curving, or bending of the heat-resistant fiber rope
7 due to its own weight during the construction. As the hardener, a resin such as a
commercially available oil varnish which is volatilized in a temperature rising
procedure may be employed. The heat-resistant fiber rope 7 may also be molded into
an arbitrary shape by fixing the heat-resistant fiber rope 7 and hardening the heat-
- 17 -
resistant fiber rope 7 using the hardener.
[0049]
In addition, a phenolic resin or coal-tar pitch which is carbonized in a high
temperature region and maintains strength, or phosphoric acid, phosphate, silicate,
silica sol, alumina sol, or the like which forms a vitreous network in a high temperature
region may also be used as the hardener.
[0050]
The heat-resistant fiber rope 7 has many spaces in its structure and can
. contain a large amount of moisture. One of the factors that determine the quality
accuracy of the monolithic refractory 3 is the amount of added moisture. However, in
a case where the heat -resistant fiber rope 7 is used, for the above-described reason,
moisture is absorbed by the heat-resistant fiber rope 7 and the fluidity of the monolithic
refractory 3 disappears. The use of the hardener has an effect of burying the internal
spaces of the heat-resistant fiber rope 7 and thus also has an effect of preventing
moisture of the monolithic refractory 3 from being absorbed by the heat-resistant fiber
rope 7. Therefore, by using the heat-resistant fiber rope 7 that is hardened by the
hardener, the quality of the monolithic refractory 3 is also enhanced.
[0051]
In addition, in the related art documents (Patent Documents I to 3) described
above, holding the state of the heat-resistant fiber rope 7 in the monolithic refractory 3
so as to satisfy the above-described condition in order to obtain a necessary bearing
force, or means for holding the state (burying the heat-resistant fiber rope 7 in the
monolithic refractory 3 in a state of being hardened by the hardener or the like) is not
disclosed. Therefore, it is difficult for those skilled in the art to discover the present
invention based on the related art documents.
- 18 -
[0052]
The heat-resistant fiber support material 5 may have only the heat-resistant
fiber rope 7 (see FIGS. lA and !B) or may also have the heat-resistant fiber rope 7 and
a connection member (see FIGS. 4 and 5). The connection member has a function of
connecting the heat-resistant fiber rope 7 and the support body I to each other, and a
metal ring 8 and the like, which will be d~scribed later, correspond to the connection
f''~mber.
I [0053]
As shown in FIGS. lA and IB, by burying the annular heat-resistant fiber
rope 7 obtained by connecting both ends of the heat-resistant fiber rope 7 in the
monolithic refractory 3, the bearing force of the monolithic refractory 3 is increased
compared to a case where a linear heat -resistant fiber rope is buried in the monolithic
refractory 3. In addition, in a case where the heat-resistant fiber rope 7 is provided
with the annular portion, as shown in FIGS. lA and lB, the entirety of the heatresistant
fiber rope 7 may be annular, and as shown in FIGS. 5 to 7 described later, at
least a portion of the heat-resistant fiber rope 7 may be annular. The number of
annular portions installed in the heat-resistant fiber rope 7 may be one or an arbitrary
number of two or more. For example, when the number of installed annular portions
is two, the heat-resistant fiber rope 7 has an 8 shape.
[0054]
Furthermore, as shown in FIG 3, a knot 6 may be provided at an arbitrary
position of the heat-resistant fiber rope 7. The knot 6 functions as a resistive portion
and may further increase the bearing force.ofthe monolithic refractory 3. The
number of knots 6 is not particularly limited, and one or two or more knots 6 may be
provided for a single heat-resistant fiber rope 7.
- 19 -
[0055]
Particularly in a case where the heat-resistant fiber support material 5 is used
for the ceiling wall, the load of the monolithic refractory 3 is always exerted on the
heat-resistant fiber support material 5 (that is, the heat-resistant fiber rope 7). When
the shape of the heat-resistant fiber rope 7 is linear, the load of the monolithic
refractory 3 is beared by the frictional re~istance of the heat-resistant fiber rope 7
f+';ainst the monolithic refractory 3. Therefore, in this case, peeling of the monolithic
kefractory 3 off from the heat-resistant fiber rope 7 easily occurs. By providing the
. knot 6 in the heatcresistant fiber rope 7, the heat-resistant fiber rope 7 can receive the
load with the knot 6. As a result, the bearing force of the monolithic refractory 3 is
increased, and thus the monolithic refractory 3 can be prevented from peeling off from
the support body 1.
[0056]
In a case where the monolithic refractory structure according to this
embodiment is applied to various types of industrial furnaces and facilities, there may
be many cases where the heat-resistant fiber support material 5 is fixed to the support
body I made of metal, such as a shell or a water-cooling pipe. In consideration of
workability and adhesion strength to the shell, it is preferable that the heat-resistant
fiber support material 5 include the heat-resistant fiber rope 7 and the connection
member made of metal and the connection member be fixed to the support body I
made of metal, such as a shell, by welding. In a state where one end portion or both
end portions of the heat-resistant fiber rope 7 are nipped by the connection member
made of a material capable of being fixed to the support body 1 by welding, the
connection member is fixed to the support body I, thereby attaching the heat -resistant
fiber rope 7 to the support body 1.
- 20 -
[0057]
For E:xample, as shown in FIG. 4, in a case where the metal ring 8 is used as
the connection member made of metal, it is preferable that one end portion of the heatresistant
fiber rope 7 be inserted into and fixed to the metal ring 8. The metal ring 8
has a metal member having a hollow tube shape with a through-hole therein. The
metal ring 8 has a structure capable of cl~mping the end portion of the heat-resistant
fi?er rope 7 inserted into the through-hole thereof.
I )'ixed to the support body I by welding.
The metal ring 8 can be easily
In a state where the end portion of the heat-
·resistant fiber rope 7 is surrounded by the metal ring 8 (for a folded metal plate), the
heat -resistant fiber rope 7 and the metal ring 8 are crimped by a press such that a
crimped portion 9 is formed in the metal ring 8. Accordingly, the heat-resistant fiber
support material 5 having a structure in which the end portion of the heat-resistant fiber
rope 7 is not easily pulled from the connection member such as the metal ring 8 even
in a case where a load or thermal Stress is exerted on the heat-resistant fiber support
material 5 in the monolithic refractory 3 can be obtained.
[0058]
In addition, as shown in FIG. 5, the heat-resistant fiber support material 5
having a structure in which both end portions of the heat-resistant fiber rope 7 that is
bent into an annular shape are inserted into and fixed to the metal ring 8 (or a folded
metal plate) may also be used. As described above, by using the heat-resistant fiber
support materialS having the annular heat-resistant fiber rope 7, compared to a case
where the heat-resistant fiber support material 5 having the linear heat-resistant fiber
rope 7 shown in FIG. 4 is used, the contact area between the monolithic refractory 3
'-·; and the heat-resistant fiber rope 7 is increased. As a result, the friction between the
monolithic refractory 3 and the heat-resistant fiber rope 7 is increased, and an effect of
- 21 -
increasing the shape stability of the heat-resistant fiber rope 7 is obtained. Shape
stability indWates a small degree of deformation from the original shape of the heatresistant
fiber rope 7 during the construction of the monolithic refractory 3. In
addition, since the monolithic refractory 3 is present straddling the annular heatresistant
fiber rope 7, the heat-resistant fiber rope 7 can receive the load of the
monolithic refractory 3 with its surface. As a result, a higher bearing force can be
obtained.
I
1 [0059]
Even in the embodiment shown in FIG. 5, as in the embodiment shown in FIG.
4, it is preferable that by welding the connection member made of metal to the support
body 1 made of metal, such as a shell, the heat-resistant fiber support material 5 be
fixed to the support body 1. For example, it is preferable that an end portion of the
metal ring 8 in which the end portion of the heat-resistant fiber rope 7 is pressed be
welded and fixed to a region in the support body 1, such as a furnace shell or pipe,
where the monolithic refractory 3 is constructed. After the heat-resistant fiber
support material 5 is fixed to the support body 1 as described above, the monolithic
refractory 3 can be constructed in the same manner as the typical metal suppmt
material 2. When this method is used, only the same welding operation as that of the
metal support material 2 is performed, and thus efficiency in the operation of installing
support members is the same.
[0060]
Otherwise, the connection member of the heat-resistant tiber support material
5 is not welded to the support body 1, and .the connection member may be indirectly
fixed to the support body 1 by using an additional fixing member. For example, as
shown in FIG. 6, a bolt 10 having threads is welded to the support body 1 such as a
- 22 -
shell in advance, and the heat-resistant fiber support material 5 which uses the metal
ring 8 provided with an inner groove corresponding to the bolt I 0 may be screwed to
the bolt 10 such that the two are fixed to each other.
[0061]
In the embodiment shown in FIG. 5, in the portion of the heat-resistant fiber
rope 7 connected to the metal ring 8, a di,rection in which the load of the monolithic
!if),fractory 3 is exerted on the heat-resistant fiber rope 7 (the X-axis direction) and a
.~irection in which the heat-resistant fiber rope 7 is pulled from the metal ring 8 are the
, same. In other words, the metal ring 8 is fixed to the support surface 1 a so that the
center axis of the metal ring 8 is parallel to the X -axis direction.
In contrast to this, in an embodiment shown in FIG. 7, a direction in which the
load of the monolithic refractory 3 is exerted on the heat-resistant fiber rope 7 (the Xaxis
direction) and a direction in which the heat-resistant fiber rope 7 is pulled from the
metal ring 8 (theY-axis direction or the Z-axis direction) are the different from each
other. In other words, the metal ring 8 is fixed to the support surface 1 a so that the
center axis of the metal ring 8 is parallel to a direction perpendicular to the X -axis
direction (theY-axis direction or the Z-axis direction). Accordingly, the heat-resistant
fiber rope 7 is hardly separated from the metal ring 8. As a result, an increase in the
service life of the heat-resistant fiber support material 5 can be realized. Particularly,
as shown in FIG. 7, in a case where the direction in which the load of the monolithic
refractory 3 is exerted on the heat-resistant fiber rope 7 and the direction in which the
heat-resistant fiber rope 7 is pulled from the metal ring 8 are perpendicular to each
other, the heat-resistant fiber rope 7 is hardly pulled from the metal ring 8. In this
case, for example, both end portions of the heat-resistant fiber rope 7 are respectively
inserted into openings provided at both left and right sides of the metal ring 8.
- 23 -
Thereafter, in a state where both end portions of the heat-resistant fiber rope 7 overlap.
each other afthe center portion of the metal ring 8, the center portion of the metal ring
8 is clamped such that the heat-resistant fiber rope 7 is fixed to the metal ring 8.
[0062]
In addition to the annular heat-resistant fiber rope 7 described above, as
shown in FIG. 8, a plurality ofheat-resisfant fiber ropes 7 which branch off from the
1]\etal ring 8 into a branch shape may also be used. As the contact area between the r ,heat-resistant fiber rope 7 and the monolithic refractory 3 is increased, the friction
between the monolithic refractory 3 and the heat-resistant fiber rope 7 is also increased.
Therefore, by using the heat-resistant fiber support materialS having the plurality of
heat-resistant fiber ropes 7 which branch off from the metal ring 8 into the branch
shape as shown in FIG. 8, the bearing force of the monolithic refractory 3 can be
enhanced.
[0063]
Moreover, as shown in FIG. 9, in a case where the monolithic refractory 3 is
divided into a plurality oflaycrs (for example, three layers) along the X-axis direction,
the heat-resistant fiber rope 7 may have a single annular portion for each of lhe layers
of the monolithic refractory 3. Specifically, the heat-resistant fiber rope 7 shown in
FIG. 9 has a first annular portion 7a for a first layer 3a of the monolithic refractory 3, a
second annular portion 7b for a second layer 3b of the monolithic refractory 3, and a
third annular portion 7c for a third layer 3c of the monolithic refractory 3.
In addition, in FIG. 9, reference numeral 7 d denotes a knot between the first
annular portion 7a and the second annular portion 7b. In addition, reference numeral
7 e denotes a knot between the second annular portion 7b and the third annular portion
7c.
- 24 -
[0064]
As described above, by using the heat-resistant fiber rope 7 having one
annular portion for each of the layers of the monolithic refractory 3, even though the
third annular portion 7c is cut due to deterioration or the like, the bearing force of the
monolithic refractory 3 can be held by the first annular portion 7a and the second
annular portion 7b which are normal.
''·· In FIG. 9, a case where the heat-resistant fiber rope 7 is connected to the
~upport body 1 by the metal ring 8 (the connection member) is shown. However, as
,'shown in FIGS. 1A and 1B, the heat-resistant fiber rope 7 may also be directly
connected to an anchor such as the pin 4 installed in the support body 1 in advance.
[0065]
The heat-resistant fiber support material 5 according to this embodiment may
also be used together with another support material according to the related art. For
example, in a case where a large load of the monolithic refractory 3 is applied to the
support body such as a ceiling, a metal support material which obtains a relatively high
bearing force, a hanger brick, or the like may also be used together with the heatresistant
fiber support material 5.
[0066]
The heat-resistant fiber support material 5 according to this embodiment and
the monolithic refractory structure using the same can be applied to points where the
metal support material according to the related art and the monolithic refractory
structure using the same are applied in various types of industrial furnaces and
facilities. In addition, the heat-resistant fiber support material 5 according to this
embodiment may be applied to substitute the total amount or a portion of a metal
support material at a position where the metal support material is used hitherto.
- 25 -
Particularly, in a case where the support body I or the support body is cooled by watercooling
or air'cooling, heat lost from the furnace body is reduced in the heat-resistant
fiber support material 5 compared to the metal support material, and thus the heatresistant
fiber support material 5 is effective.
(0067]
As an example of the facilities, ~.skid of a heating furnace for rolling a steel
pi ~ce may be employed. A skid is a facility for supporting and transporting the steel
I
piece in the heating furnace. The skid includes pipes made of metal and has a
, structure in which the insides of the pipes are water-cooled for the purpose of
maintaining hot strength and the outer periphery thereof is coated with a refractory
insulating material to suppress water-cooling loss. At this time, when the watercooling
pipes are not insulated, heat transferred from the heating furnace to cooling
water is increased, and great heat loss occurs as a result.
(0068]
As shown in FIG. 10, the basic structure of the skid includes a beam portion
11 corresponding to a beam, and post portions 12 corresponding to posts. For
example, as shown in FIG. 11, in order to apply the monolithic refractory structure
according to this embodiment to the post portions 12, the heat-resistant fiber support
material 5 shown in FIG. 7 may be welded to a water-cooling pipe 13 as the support
body 1 of the monolithic refractory 3, and the monolithic refractory 3 may be
constructed by being poured into the periphery of the water-cooling pipe 13 so as to
cover the heat-resistant fiber support material 5.
(Examples]
(0069]
Hereinafter, heat-resistant fiber support materials and monolithic refractory
- 26 -
structures according to Examples of the present invention will be described in detail.
The present invention is not limited to the following Examples.
[0070]
The heat -resistant fiber rope 7 having a diameter of 5 mm was formed by
using long fibers having a composition of72 mass% ofAh03 and 28 mass% ofSi02 as
an inorganic fiber. The tensile strength ()fthe heat-resistant fiber rope 7 at room
tti.?Jperature was 50 MPa. The tensile strength of the heat-resistant fiber rope 7 after
I. bemg baked at 1200°C for 5 hours was 40 MPa.
[0071]
(Example 1)
As shown in FIG. 12, as a resistive portion for preventing separation of the
heat-resistant fiber rope 7, the knot 6 was provided in one end portion of the heatresistant
fiber rope 7. In addition, an annular portion was provided in the other end
portion of the heat-resistant fiber rope 7, and an end portion thereof was inserted into
the metal ring 8 (corresponding to the connection member made of metal) which was
made of SUS steel and had a height of20 mm and an inner diameter of 10 mm and was
pressed to press the rope portion of the heat-resistant fiber rope 7 and the metal portion
of the metal ring 8, thereby producing a heat-resistant fiber support material 5. At
this time, the height of the heat-resistant fiber support material 5 was set to 140 mm.
The annular portion of the heat-resistant fiber rope 7 of the heat-resistant fiber support
material 5 was hooked and fixed to an L-shaped pin 4 installed in advance at the
ceiling shell (corresponding to the support body 1) of a heating furnace. Thereafter,
the periphery thereof was enclosed by a molding box, and a slurry-like raw material of
a monolithic refractory 3 was poured thereinto, and through curing and drying
processes, a constructed body having a thickness of 210 mm was obtained (Invention
- 27 -
Example 1).
[00/2]
After operating the heating furnace at an operation temperature of 1350°C for
six months, the status of the constructed body of the monolithic refractory 3 was
checked. It was confirmed that the heat-resistant fiber support material 5 could be
used in an actual machine of the heating furnace without problems such as cracking.
[0073]
(Example 2)
Both end portions of the heat-resistant fiber rope 7 were inserted into the
metal ring 8 which was made of SUS steel and had a height of 20 mm and an inner
diameter of 10 mm to form an annular portion and were pressed to press the rope
portion and the metal portion, thereby producing a heat-resistant fiber support material
5 having the form shown in FIG. 5. Furthermore, the heat-resistant fiber rope 7 was
allowed to be impregnated with oil varnish as a hardener and thereafter was dried and
cured to increase the strength of the heat-resistant fiber rope 7.
[0074]
As shown in FIG. 13, the heat-resistant fiber support materials 5 were welded
to the inner wall shell (corresponding to the support body 1) of the side wall of the
heating furnace at an operation temperature of 1350°C with a pitch of 150 mm
vertically and horizontally, and the monolithic refractory 3 were poured and
constructed to have a thickness of 210 mm (Invention Example 2).
[0075]
ln the same manner, as shown in FIG. 14, the same construction was adopted
by using the heat-resistant fiber support material 5 having the form shown in FIG. 7.
The heat-resistant fiber support materialS shown in FIG. 14 had a different
- 28 -
--,-:--
configuration from the configuration of the heat-resistant fiber support materialS
shown in FIG. 13 in that the direction of the metal ring 8 was changed by 90°. In the
example ofF! G. 14, a direction in which the load of the monolithic refractory 3 was
exerted on the heat-resistant fiber rope 7 and a direction in which the heat-resistant
fiber rope 7 was pulled from the metal ring 8 are different from each other (Invention
Example 3).
[0076]
Furthermore, as shown in FIG. 15, for comparison, the same construction was
. adopted by using a Y-shaped metal support material 14 (Y-shaped stud) which was
made of SUS304 and had a diameter of S mm under the same conditions (Comparative
Example 1).
[0077]
At this time, the heights of all of the heat-resistant fiber support materials S of
Invention Examples 1 to 3 and the metal support material 14 of Comparative Example
1 were 140 mm.
[0078]
When the back surface temperature of the shell of the heating furnace during
an operation is measured by a thermo viewer, while the back surface temperature of the
shell was 130°C in cases oflnvention Examples 2 and 3 using the heat-resistant fiber
support materialS, the back surface temperature of the shell was 160°C in cases of
Comparative Example 1 using the metal support material 14. Therefore, there was a
temperature difference of about 3 0°C between the back surface temperature of the shell
oflnvention Examples 2 and 3 and the back surface temperature of Comparative
Example 1, and it could be confirmed that by using the heat-resistant fiber support
materialS, heat loss could be reduced by about 30 percent in terms of heat dissipated
- 29 -
from the shell.
[0079]
When each of the monolithic refractory structures was observed after the
operation of the heating furnace, in the cases oflnvention Examples 2 and 3 in which
the heat-resistant fiber support material 5 was used, no cracks on the operation surface
(the surface of the monolithic refractory o}) were confirmed. However, in the cases of
(omparative Example I in which the metal support material 14 was used, a crack
/occurred in the monolithic refractory 3 from a position where the support material 14
.. • was installed as the origin and propagated in a cross shape. When a crack propagates
by repeating heating and cooling, peeling and separation of the monolithic refractory 3
occur. However, it could be confirmed that when the heat-resistant fiber support
material 5 was used, the life-span of the monolithic refractory 3 was enhanced.
[0080]
In addition, the heat-resistant fiber support material 5 was recovered after
being used in an actual machine for about one year, and the strength of the portion of
the heat-resistant fiber rope 7 which was clamped by the metal ring 8 was measured in
a tensile test. As a result, in Invention Example 2, the strength was reduced by about
20 percent from that before use, and in Invention Example 3, the strength was rarely
deteriorated. Therefore, in the actual machine, long-term stability of the heatresistant
fiber support material 5 having the structure shown in FIG. 7 could be
confirmed. Therefore, Invention Example 2 has no problem in practical use.
However, Invention Example 3 obtains higher strength.
[0081]
(Example 3)
Both end portions of the heat-resistant fiber rope 7 were inserted into the
- 30 -
metal ring 8 which was made of SUS steel and had a height of 20 mm and an inner
diameter of 10 mm to form an annular portion and were pressed to press the rope
portion and the metal portion, thereby producing a heat-resistant fiber support material
5 having the form shown in FIG. 7. Furthermore, the heat-resistant fiber rope 7 was
allowed to be impregnated with oil varnish as a hardener and thereafter was dried and
cured to increase the strength of the heat: resistant fiber rope 7.
[0082]
As shown in FIG.ll, the heat-resistant fiber support materialS was applied to
, the water-coolingpipe 13 of the skid post of the heating furnace having an operation
temperature of 1350°C. Regarding the arrangement of the heat-resistant fiber support
materials 5, eight heat-resistant fiber support materials 5 were arranged in the
circumferential direction of the water-cooling pipe 13, and the interval between the
heat-resistant fiber support materials 5 in the height direction was set to 150 mm. At
this time, the directions of the metal rings 8 of the eight heat-resistant fiber ropes 7
arranged in the circumferential direction of the water-cooling pipe 13 were alternately
set to a vertical direction and a horizontal direction. In addition, the end portion of
the heat-resistant fiber support material 5 was welded and fixed to the outer
circumferential surface of the water-cooling pipe 13. The monolithic refractory 3 was
poured and constructed by setting the thickness thereof to 110 mm (Invention Example
4).
[0083]
In addition, for comparison, the same construction was adopted by using the
metal support material 14 (Y-shaped stud) which was made of SUS304 under the same
conditions (Comparative Example 2).
[0084]
- 31 -
At this time, the heights of both of the heat-resistant fiber support materials S
of Invention Example 4 and the metal support material 14 of Comparative Example 2
were 80 rnrn.
[008S]
The heating value of cooling water was calculated on the basis of the·
temperature difference between the inlet,and the outlet of the cooling water in the
Iw, .a ter-cooling pipe 13 in the skid during the operation. In the case oflnvention
JExample 4 in which the heat-resistant fiber support materialS was used, compared to
, Comparative Example 2 in which the metal support material 14 was used, the heating
value of the cooling water was reduced and the fuel unit consumption [Meal/ton] was
reduced by about l/2. Here, the fuel unit consumption is an index that represents
energy used per 1 ton of produced steel piece, and an increase in the fuel unit
consumption means an increase in the heating value of the cooling water through the
water-cooling pipe 13, that is, an increase in energy loss.
[0086]
In addition, as in the case of Comparative Example 1, in Comparative
Example 2 in which the metal support material 14 was used, a crack had occurred in
the monolithic refi·actory 3 from the position where the support material 14 was
installed as the origin. However, in Invention Example 4 in which the heat-resistant
fiber support materialS was used, no cracks on the operation surface (the surface of the
monolithic refractory 3) were confirmed.
[0087]
From the above-described results, it could be confirmed that the application of
the present invention contributes to a reduction in cost, energy saving, and an increase
in the life-span of the monolithic refractory structure by reducing heat loss energy.
- 32 -
,,
!i
[0088]
While the exemplary embodiments of the present invention have been
described in detail with reference to the accompanying drawings, the present invention
is not limited to the examples. It is apparent that various modified examples and
corrected examples can be made by those skilled in the art to which the present
invention belongs without departing froll), the technical idea of the appended claims,
fV1d it is understood that these examples naturally belong to the technical scope of the
I I . . present mventwn.
,[BriefDescriptiort of the Reference Symbols]
[0089]
1 SUPPORT BODY
2 METAL SUPPORT MATERIAL
3 MONOLITHIC REFRACTORY
4 PIN (ANCHOR)
5 HEAT-RESISTANT FIBER SUPPORT MATERIAL
6 KNOT
7 HEAT-RESISTANT FIBER ROPE
8 METAL RING (CONNECTION MEMBER)
9 CRIMPED PORTION
10 BOLT
11 BEAM PORTION
12 POST PORTION
13 WATER-COOLING PIPE
14 METAL SUPPORT MATERIAL

We Claim
1. (Original) A monolithic refractory structure comprising:
a monolithic refractory;
'''
a Sl[pport body which supports'the monolithic refractory; and
a heat-resistant fiber support material which is buried in the monolithic
. refractory in a state of being connected to a support surface of the support body,
wherein the heat-resistant fiber support material includes a heat-resistant fiber
rope which is formed of an inorganic fiber and extends along an X -axis direction
perpendicular to the support surface, and
a ratio Ll!L2 of an X-axis direction length L1 of the heat-resistant fiber rope to
an X-axis direction length L2 of the monolithic refractory is 0.35 or more and 0.95 or
less.
2. (Original) The monolithic refractory structure according to claim I,
wherein the heat-resistant fiber rope is formed of an inorganic fiber made of a
material containing one type or two or more types of Ah03, Si02, Ah03-Si02, and
Ab03-Si02-B203.
3. (Original) The monolithic refractory structure according to claim 1,
wherein the heat-resistant fiber rope is hardened by a hardener.
4. (Original) The monolithic refractory structure according to claim I,
wherein the heat-resistant fiber rope is connected to the support body via an
anchor provided on the support surface.
5. (Original) The monolithic refractory structure according to claim l,
wherein the heatcresistant fiber support material further includes a connection
member which connects the heat-resistant fiber rope to the support body, and
the connecticn member is fixec\ to the support surface of the support body .
. 6. (Original) The monolithic refractory structure according to claim 5,
wherein the connection member is a metal ring having a hollow tube shape,
the heat-resistant fiber rope is inserted into and fixed to the metal ring, and
a direction in which a load of the monolithic refractory is exerted on the
heat-resistant fiber rope and a direction in which the heat-resistant fiber rope is pulled
from the metal ring are the same.
7. (Original) The monolithic refractory structure according to claim 5,
wherein the connection member is a metal ring having a hollow tube shape,
the heat-resistant fiber rope is inserted into and fixed to the metal ring, and
a direction in which a load of the monolithic refractory is exerted on the
heat-resistant fiber rope and a direction in which the heat-resistant fiber rope is pulled
from the metal ring are different from each other.
8. (Original) The monolithic refractory structure according to claim l,
wherein the heat-resistant fiber rope includes one or two or more mmular
portions.
9. (Original) The monolithic refractory structure according to claim 1,
wherein the heat-resistant fiber rope includes one or two or more knots.
10. (Original) The monolithic refractory structure according to claim 1,
wherein the monolithic refractory is divided into a plurality of layers along the
X-axis direction, and
.;: the heat-resistant fiber rope has a single annular pmiion for each of the layers
Jfthe mo~10lith:ic refractory.
11. (New) A heat-resistant fiber support material which is buried in a monolithic·
refractory and is connected to a support body supporting the monolithic refractory,
compnsmg:
a heat-resistant fiber rope which is formed of an inorganic fiber; and
a com1ectionmember which connects the heat-resistant fiber rope to the
support body,
wherein the connection member is a metal ring which is fixed to the support
body, and
the heat-resistant fiber rope is inserted into and fixed to the metal ring.