Densification method and apparatus

1. A method of densification of refractory material in a gap between a tap hole sleeve of a furnace and a surround block of the furnace, the surround block surrounding the tap hole sleeve, the method comprising:

positioning a tool in the gap, the tool including a support having opposing surfaces and a sidewall connecting the opposing surfaces, the opposing surfaces having an arcuate shape and defining an arc length, the opposing surfaces extending from a first end of the sidewall located at a first point along the arc length to a second end of the sidewall located at a second point along the arc length spaced from the first end, a plurality of elongated members extending from one of the opposing surfaces, and a connector arranged on the other of the opposing surfaces;

filing the gap with dry material; and

applying vibration to the connector to densify the dry material.

2. The method according to claim 1 , wherein filling the gap with dry material includes using at least one of magnesia, dolomitic magnesia or dolomitic material as the dry material.

3. The method according to claim 1 , wherein applying vibration includes attaching a vibration machine to the connector, wherein the vibration machine applies a vibrating motion to the tool.

4. The method according to claim 1 , wherein positioning the tool includes maneuvering the tool through a sump panel sanding hole of the furnace.

5. The method according to claim 1 , wherein applying vibration includes using at least one of a mechanically-powered vibration device, a pneumatically-powered vibration device or an electrically-powered vibration device to apply the vibration to the tool.

6. The method according to claim 1 , wherein filing the gap with dry material includes filing the gap in layers having a prescribed thickness.

7. The method according to claim 6 , wherein the prescribed thickness is less than a length of elongated members.

8. The method according to claim 1 , wherein the steps of filing the gap and applying vibration are performed simultaneously.

9. The method according to claim 1 , wherein the steps of filing the gap and applying vibration are performed sequentially.

10. A tool for densification of refractory material in a tap-hole of a furnace, the tool configured to be positioned in a gap between a tap hole sleeve of a furnace and a surrounding block of the furnace, comprising: a support having opposing surfaces and a sidewall connecting the opposing surfaces, the opposing surfaces having an arcuate shape and defining an arc length, the opposing surfaces extending from a first end of the sidewall located at a first point along the arc length to a second end of the sidewall located at a second point along the arc length spaced from the first end, a plurality of elongated members extending from one of the opposing surfaces; and a connector arranged on the other of the opposing surfaces, the connector comprising a fastener configured to selectively and fixedly couple the connector to a vibrating member.

11. The tool according to claim 10 , wherein at least some of the plurality of elongated members include a channel formed within the respective elongated member, the channel opening at an end of the respective elongated member distal from the support.

12. The tool according to claim 11 , wherein at least some of the plurality of elongated members comprise a pipe.

13. The tool according to claim 10 , wherein the arcuate shape is dimensioned to correspond to the tap hole of the furnace.

14. The tool according to claim 10 , wherein the plurality of elongated members extend in a direction perpendicular to a major face of the opposing surfaces.

15. The tool according to claim 10 , wherein the support comprises a metal plate.

16. The tool according to claim 10 , wherein an end of at least some of the plurality of elongated members that is distal from the support is tapered.

17. The tool according to claim 10 , wherein at least some of the plurality of elongated members are welded to the support.

18. The tool according to claim 10 , wherein at least some of the plurality of elongated members are threadedly attached to the support.

19. The tool according to claim 10 , wherein an end of at least some of the plurality of elongated members extends through the support, a first fastener is threadedly coupled to the respective elongated member and arranged on one of the opposing surfaces, and a second fastener is threadedly coupled to the respective elongated member and arranged on the other of the opposing surfaces.

20. The tool according to claim 10 , wherein an outer radius of the opposing surfaces is between 14-16 inches, and an inner radius of the opposing surfaces is between 10-12 inches.

21. The tool according to claim 10 , wherein the connector comprises a sleeve configured to receive to a vibrating member.

22. The tool according to claim 21 , wherein the fastener comprises one of a clamp or a bolt.

23. The tool according to claim 10 , further comprising a vibration device coupled to the connector.

24. The tool according to claim 10 , wherein the opposing surfaces are planar surfaces that are substantially parallel to each other.

25. The tool according to claim 10 , wherein the support has a length defined along a major axis of the support, and a width defined along a minor axis of the support, and a height defined between the opposing surfaces, the length being greater than the width, and the width being greater than the height.

26. The tool according to claim 10 , wherein the fastener comprises a through hole formed in a portion of the connector.

27. The tool according to claim 26 , wherein the fastener further comprises one of a threaded bolt configured for insertion into the through hole and a nut threadedly engagable with the bolt, or a pin configured for insertion into the through hole and a clip attachable to the pin.