Field of the Invention

[0001] The present invention relates to a specific insulation structure for lining furnaces such as a furnace in continuous bright annealing lines (BAL), which can be vertical or horizontal. More particularly, the insulation structure is intended to improve the thermal insulation performance of the annealing furnace and to ensure high quality of the steel.

[0002] The present invention is more generally applicable in technical field of continuous processing lines for strips of steel or aluminium, such as continuous annealing lines.

Prior Art

[0003] It is known that bright annealing is an annealing process performed in a controlled atmosphere generally containing an inert gas and hydrogen. This controlled atmosphere reduces the surface oxidation to a minimum which results in a brighter surface mirror finish. As residual oxygen is entrained by the strip in the furnace, hydrogen should always be present in the furnace atmosphere, preferably with a content greater than 75%, the rest being inert gas such as nitrogen or argon. However in some annealing furnaces, hydrogen content can be lower than 75%.

[0004] In the vertical bright annealing furnace technology, the heating section of furnace is made in general of a stack of casing modules, comprising refractory bricks and an additional insulation. The traditional refractory bricks are often high purity bricks comprising 99% of alumina (AI2O3), made from bubble alumina, and typically with a bulk density of about 1800 kg/m ³ and a porosity of 55%. The thermal conductivity of these traditional refractory bricks is typically 1.4 W/m°C at 1200°C, for a maximum service temperature of 1850°C. The additional insulation can be made from kaowool (ceramic) bulk fibres of silica and alumina, the composition of bulk fibres being for example of 53% of SiO2 and 47% of AI2O3. A classic thickness of bricks I additional fibre insulation is comprised between 200 and 250mm.

[0005] Such a particular stack of casing modules is a proven technical solution comprising a lot of advantages, as the low maintenance and the facility to support scaffolding for this maintenance. Furthermore, it is easy to fix the heating elements thanks to embedded molybdenum anchors, and to provide protruding shield bricks to protect the heating elements. This is also a robust solution against strip breakage.

[0006] However, there are also some disadvantages, such as in particular a high thermal inertia which is the biggest issue, in particular with a high external casing temperature. Moreover, this solution is particularly heavy, with a large wall thickness (e.g. between 450 and 500mm) and a long time needed for erecting the walls of the furnace. Further brick supports are needed, being a source of large heat loss and thermal bridge. Another problem is that cracks can occur in the bricks, leading to pieces of brick and dust falling in the vertical furnace, possibly damaging the strip. These pieces of bricks and dust can also cause fire at the outlet of the furnace, owing to possible contact of very hot pieces with air containing hydrogen at this location.

[0007] Solutions not involving ceramic bricks assemblies anymore are known. For example, Unifrax LLC (Tonawanda NY 14150, USA) has provided furnace lining (temperatures up to 1300°C) under the form of polycrystalline fibre modules (Saffil® M-Fil Anchor-Loc® Modules), for example in forging applications.

[0008] Document US 2005/055940 A1 discloses a lining for a furnace, the lining having insulating material attached to an inside wall of the furnace, the insulating material in use having a hot face which faces inwardly of the furnace and a cold face at or adjacent the furnace wall, wherein a protective element is provided at least partially to cover the hot face, the protective element being secured relative to the hot face by a securing means which co-operates with a member which is embedded in the insulating material, and wherein the securing means is adapted to engage the member after the member is embedded in the insulating material. The furnace lining includes a plurality of individual blocks or modules of insulating material, each attached at the inside wall of the furnace, each module including a ceramic blanket which is folded to a block-like shape with the folds extending transversely to the furnace wall.

[0009] The protective element is made at least substantially of one or more of a ceramic material, a blanket of silica free insulation, a high-temperature resistant textile material, and a higher temperature resistant high alumina insulation than other insulation material of the lining.

[0010] Is also disclosed a fixing attached by one or more fasteners to the furnace wall made of a steel panel, the fixing having a hooked part which is embedded in the fibres of the module in a position where fixing rods (or tubes) are inserted through the folds to co-operate with the hooked part. The rods may cooperate with a plurality of fixings attaching modules to the inside of the furnace wall.

Aims of the Invention

[0011] The present invention aims to provide an insulated wall structure for e.g. a vertical bright annealing furnace which does not present the drawbacks of the above-mentioned prior art structures, and which optimizes both thermal insulation performances and thermal inertia, while ensuring high quality of the thermally-treated steel strip.

[0012] The aimed low thermal inertia of the structure of the present invention should provide a more flexible furnace temperature with a shorter response time, allowing to recover expected operating conditions more quickly and the possibility to quickly switch off the furnace if necessary.

[0013] The invention also aims to provide an innovative solution, having elements which are light and fast to erect. The structure of the present invention should allow to avoid the risk of cracks related to the use of insulating bricks, and of pieces of bricks and dust falling in the vertical furnace and thus minimize possible damage on the strip when it is travelling.

[0014] Further the present invention aims at replacing the insulating bricks in their role of mechanical support of the heating elements, also considering that the new support should not react with the hydrogen atmosphere in the furnace.

[0015] Finally the invention should render not necessary to have brick support at the base of the furnace, avoiding thermal bridges.

Summary of the Invention

[0016] A first aspect of the present invention relates to a furnace for performing a thermal treatment of a continuously moving metal strip, preferably under hydrogen protective atmosphere, having :

- a hybrid wall lining facing inwardly of the furnace, wherein said hybrid wall lining comprises a stack of polycrystalline fibre modules or graphite rigid felt boards, and graphite lintels being fixed between or in said modules or boards, and

- electric heating elements provided inside the furnace along one or more vertical walls and fixed on the side of the hybrid wall lining facing inwardly of the furnace, wherein said polycrystalline fibre modules comprise fibres with at least 95% of AI2O3, and preferably at least 97% of AI2O3, so as to be compatible with a hydrogen protective atmosphere, the thickness of the polycrystalline fibre modules (3) or graphite rigid felt boards being comprised between 200 and 500mm, and wherein the electric heating elements are attached to the graphite lintels thanks to a first anchoring system.

[0017] According to preferred embodiments of the invention, the furnace is further limited by one of the following features or by a suitable combination thereof : - each of the polycrystalline fibre modules is provided with a second anchoring system suitable to fix said module to at least one adjacent module and/or to the external casing of the furnace ;

- said wall lining comprises additional bulk fibre or fibre blanket or board between the stack of polycrystalline modules or graphite rigid felt boards and the external casing of the furnace ;

- the additional bulk fibre or fibre blanket or board has a thickness between 20 and 250mm ;

- the graphite lintels are suitable to protect the heating elements against strip deviations, by being cantilevered above the heating elements and protruding from the wall lining inside the furnace ;

- supporting tubes are, at one end, attached inside the graphite lintels and, at the other end, welded, perpendicularly, to the casing of the furnace in order to support the graphite lintels ;

- a space is provided between the interior end of each graphite lintel and the casing of the furnace, said space comprising the tube supporting the lintel and being filled with bulk fibres ;

- the heating elements are forming a continuous planar serpentine and the graphite lintels are arranged in horizontal rows and are provided with the first anchoring system made of vertical hooks, so that adjacent vertical hooks located in two vertically adjacent lintel rows are respectively supporting the lower and upper successive loops of the heating element ;

- the furnace is a furnace in a continuous annealing line ;

- the furnace is a vertical furnace ;

- the furnace is a horizontal furnace.

[0018] A second aspect of the present invention relates to the use of the furnace described above, for performing a thermal treatment of a continuously moving metal strip, preferably under a controlled hydrogen protective atmosphere. [0019] Preferably, the controlled hydrogen protective atmosphere has a hydrogen content greater than 75%, the rest being inert gas. [0020] Advantageously, the thermal treatment of a continuously moving metal strip is a treatment for strips of steel or aluminium, preferably in continuous annealing lines.

Brief Description of the Drawings

[0021] Figure 1 represents a cross-sectional longitudinal view of a vertical bright annealing furnace of prior art.

[0022] Figure 2 represents a cross-sectional lateral view of a vertical bright annealing furnace of prior art.

[0023] Figure 3 represents a 3D view of a part of a furnace with a lining comprising polycrystalline fibre modules according to the present invention.

[0024] Figure 4 represents a first cross-sectional view of the furnace of Figure 3.

[0025] Figure 5 represents a second cross-sectional view of the furnace of Figure 3.

[0026] Figure 6 represents a third cross-sectional view of the furnace of Figure 3.

[0027] Figure 7 represents a detailed cross-sectional view of an anchoring system of a heating element in a common vertical bright annealing furnace of prior art.

[0028] Figure 8 represents a detailed cross-sectional view of an anchoring system of a heating element in a module of a vertical bright annealing furnace according to the present invention.

[0029] Figure 9 shows the temperature distribution in the thickness of a wall of a vertical bright annealing furnace of prior art.

[0030] Figure 10 shows the temperature distribution in the thickness of a wall of a bright annealing furnace with a lining comprising polycrystalline fibre modules according to the present invention.

[0031] Figure 11 represents a detailed view of a system for anchoring the polycrystalline fibre modules to the furnace casing according to prior art. [0032] Figure 12 represents a detailed cross-sectional view of an anchoring system of a heating element in a module of a vertical bright annealing furnace according to the present invention, in which the polycrystalline fibre modules have been replaced by graphite rigid felt boards.

Description of Preferred Embodiments of the Invention

[0033] The present invention relates to a new wall structure 2 for a vertical bright annealing furnace 1. This specific structure comprises a stack of insulating polycrystalline fibre modules 3 as illustrated by Figures 3 to 6. Once the modules 3 are assembled and fixed to form the wall 2, an additional fibre blanket 4 can be added in the furnace 1 between the polycrystalline fibre modules 3 and the casing.

[0034] Each module 3 has preferably a thickness between 400 and 500 mm, and more preferably of 450 mm. The additional fibre blanket 4 has preferably a thickness between 20 and 50mm, and more preferably of 25 mm.

[0035] The insulating polycrystalline fibre modules 3 preferably comprise fibre with at least 95-97% of AI2O3.

[0036] As explained below, and illustrated by Figures 3-4, 6 and 8, electric heating elements 6 are provided inside the furnace 1 . The heating elements 6 are fixed to the modules 3 by an anchoring system 5. In order to protect the heating elements 6 against shocks due to the contact with the running or broken strip in the furnace 2, graphite lintels 11 are provided, preferably provided with chicanes. Graphite lintels 11 are fixed in the wall 2 between and/or within modules 3, and are cantilevered just above each heating element 6 (see Figures 6 and 8). This is more detailed in the following sections of the description.

[0037] The wall 2 obtained with the modules 3 of the present invention exhibits an improved thermal insulation and thermal inertia offering a more flexible furnace temperature. This new solution will give the opportunity to have a wall lighter and easier to build, with no risk of cracks or fire in operation. Polycrystalline fibre modules

[0038] Polycrystalline fibre modules 3 of the present invention can be for example a polycrystalline Saffil® M-Fil prefabricated modules (source: Unifrax documentation). Saffil® M-Fil modules 3 are manufactured from polycrystalline wool into a standard edge-stacked construction format. The modules are made of fibre compressed with cardboard (ou wooden) side plates with banding straps. These prefabricated modules 3 are specifically designed to meet the thermal insulation requirements of industrial furnaces. As illustrated in Figure 11 , Saffil modules can be produced with various anchoring systems 14, 16, known perse of the skilled person and often commercially available, to enable quick, easy and efficient installation for most lining applications.

Graphite rigid felt boards

[0039] In an alternative embodiment shown on Figure 12, polycrystalline alumina fibre modules can be replaced by a stack of graphite rigid felt boards 7, preferably horizontally arranged. This material has a carbon content of 99.5% and is very light (bulk density of about 0.2 g/cm ³ ).

Polycrystalline fibre modules and heating elements : assembly and anchoring method

[0040] Polycrystalline fibre modules 3 according to the present invention can be assembled and fixed according different fixing methods known from prior art (see for example Unifrax documentation).

[0041] A first system, named “RX2 anchoring system" is a patented metal support in 321 stainless steel, which provides rapid attachment of the module 3 to the furnace casing via the external side fastener which is screwed onto a prewelded stud. Rail, washer, nut, stud and ceramic arc shield are supplied (see US 2005/055940 A1 , ref. 14, 15, 18).

[0042] A second system, named “Thread Lock (TL) anchoring system" 14 and illustrated in Figure 11 , is attached to the furnace casing 15 by a central anchor in 304 stainless steel. Threaded studs 16 are pre-welded on the internal side of the furnace casing and the module anchor 14 is screwed on the stud by using a tool 20 such as a ratchet drive. The module anchor 14 has two wings terminated each with a hole 17 for supporting an assembly tube or rod linked in the same manner to adjacent module anchors.

The “TL anchoring system" has been especially designed for three reasons:

- as a complementary assembly system to RX2 or similar ; for the lining of small furnaces ;

- to repair all types of lining installations.

Other similar systems are available off the shelf.

Heating Element Protection

[0043] In the bright annealing vertical furnace technology of prior art, as illustrated in Figure 7, shield bricks 10 containing 99% AI2O3 are provided to protect the heating elements 6. These shield bricks are easy to implement, because they are refractory bricks 8 being placed so that they protrude inside the furnace 1 , just above the vertical heating elements 6. In this manner, the travelling strip is prevented to hit the heating elements 6 being below the shield bricks 10.

[0044] In the case of the present invention, the fibre modules 3 per se do not allow to protect the heating elements 6 while forming the walls 2 of the furnace 1 . Another shielding solution is therefore needed.

[0045] As illustrated in Figures 6 and 8, according to the present invention, graphite lintels 11 have been provided between fibre modules 3, just above the heating elements 6.

[0046] Graphite lintels 11 can be advantageously obtained from machinable extruded graphite. Graphite is dense, has high temperature resistance and does not react with hydrogen. See example of data sheet below (mechanical data : “with the grain”) :

[0047] In a vertical furnace or in a horizontal furnace with heating elements arranged along vertical walls, the graphite lintels 11 advantageously protrude from a vertical wall line inside the furnace 1 to protect the heating elements 6. Additionally, the graphite lintels 11 have also the function of supporting and guiding the heating elements 6, via an anchoring system 5, for example under the form of molybdenum hooks.

[0048] The heating elements 6 are preferably electric heating elements arranged according to a planar serpentine connected at each of its two ends to an insulated connector 30 going through the wall lining 2 and the external casing 15 of the furnace 1 to the power supply.

[0049] The graphite lintels 11 are arranged in horizontal rows and are provided with anchoring system 5 made of vertical hooks, preferably made of molybdenum, so that adjacent vertical hooks located in two vertically adjacent lintel rows are respectively supporting the lower and upper successive loops of the heating element.

[0050] Still according to the invention (see Figure 8), supporting tubes 12 are welded to the casing 15 of the furnace in order to support the graphite lintels 11 in the insulation assembly. Further, a space 13 is provided between the back of the lintel 11 and the casing 15 of the furnace. This space 13 encloses the tube 12 supporting the lintel 11 , and can be filled with bulk fibres known per se of the skilled person. In case the wall lining 2 comprises boards of graphite rigid felt, said boards are supported by the horizontal layers of graphite lintels 11 and attached to the casing with usual anchoring means (such as for bricks).

[0051] Such as polycrystalline alumina fibre modules, graphite lintels 11 do not have the defects of the shield bricks 10 of prior art, such as cracks or breaks prone to occur in the bricks, possibly leading to pieces of brick and dust falling in the vertical furnace, and possibly damaging the strip or causing fire at the outlet of the furnace.

[0052] In a horizontal furnace, two configurations can be adopted :

- in a first configuration, the heating elements are located in the vertical walls of the furnace. To take over the protection role of the insulation bricks against the deviation of the strip, the insulation fibre structure should be provided with a protective frame with at least two vertical lintels and two horizontal lintels, as described above, for each heating unit (not shown) ;

- in a second configuration, the heating elements are provided in the dome of the furnace. In this case, there is no (or less) need for protecting the heating elements.

Performances

[0053] The performances of the polycrystalline fibre modules 3 of the present invention are compared to the stack of casing modules of prior art, comprising refractory bricks and additional insulation. The results are illustrated in Figure 9 representing the temperature distribution in the thickness of a wall of the vertical bright annealing furnace of prior art, and in Figure 10 representing the temperature distribution in the thickness of a wall of the bright annealing furnace with the structure of the present invention.

[0054] The calculation hypotheses are the same for both cases.

[0055] In the example, the wall of the bright annealing furnace of prior art comprises stack of casing modules with refractory bricks 8 and additional insulation 9 (made of bulk fibres). The wall of a bright annealing furnace according to the present invention comprises a structure with polycrystalline fibre modules 3 having a thickness of 450 mm and an additional fibre blanket (backup layer faced with aluminium foil, e.g. Insulfrax® S blanket, documentation Unifrax) having a thickness of 25 mm.

[0056] As illustrated by Figure 9, in case of the furnace of prior art, the external casing temperature of the furnace is 132°C, leading to a thermal flux of 1460 W/m2.

[0057] As illustrated by Figure 10, in case of the furnace of the present invention, the external casing temperature of the furnace is 115°C, leading to a thermal flux of 1122 W/m2. [0058] The lining of the furnace walls in the present invention allows a reduction of external casing temperature of 17°C and of thermal flux of 23%.

Reference Symbols

1 Vertical bright annealing furnace

2 Wall of the furnace (with lining)

3 Polycrystalline fibre modules

4 Additional fibre blanket

5 Anchoring system of a heating element

6 Heating element

7 Graphite rigid felt board

8 Refractory brick

9 Additional insulation

10 Shield brick

11 Graphite lintel

12 Supporting tube

13 Space between the lintel and the furnace casing

14 “Thread Lock” anchoring system of the module

15 Furnace casing

16 Threaded stud

17 T ube supporting wing

18 Flange hex nut

19 Sliding collar

20 Tool

30 Insulated connector