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Refractory Repairs - Coke Oven Managers Association

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<strong>Refractory</strong> <strong>Repairs</strong><br />

At South Bank <strong>Coke</strong> <strong>Oven</strong>s


Introduction<br />

• Ian Whittle – Process Engineer @ SBCO<br />

• Experience – over 25 years in this area.<br />

• Topic – <strong>Refractory</strong> <strong>Repairs</strong>


Main types of <strong>Repairs</strong> @ SBCO<br />

• Sole flooding<br />

• Patch and peel<br />

• Quoin repairs<br />

• Brick Patch<br />

• Ceramic Welding<br />

• End wall rebuild<br />

• Throughwall & Regenerator repairs


Sole flooding<br />

• Replace wear on sole<br />

• Method


Patch and Peel<br />

• Method<br />

• Short term<br />

• Maintain availability


Quoin <strong>Repairs</strong><br />

• End flue leakage<br />

• Frame damage<br />

• Method


Firebrick patch<br />

• Why do<br />

• Material<br />

• Benefits & drawbacks


Ceramic Welding<br />

• The process<br />

• When to do<br />

• Life


Example of damage that can be repaired by welding


The Process<br />

• Preparation<br />

• Ceramic powder<br />

• Conveying the powder


The Weld Process<br />

• Exothermic reaction (around 2000 o C)<br />

• Fluxing


End Wall Builds<br />

• Method<br />

• Tying in<br />

• Life expectancy


Charged <strong>Oven</strong><br />

Insulation Stopper<br />

Buffer <strong>Oven</strong><br />

Buffer <strong>Oven</strong><br />

Charged <strong>Oven</strong><br />

Insulation Blankets<br />

End wall set up


End wall blankets


Roof support


Wreck, build and warm up<br />

• Wreck flues from outside going in<br />

• Clean off sole<br />

• Inspect old brickwork for integrity<br />

• Build new wall tying in<br />

• Warm up – which method


Expansion


Roof tie in


<strong>Oven</strong> roof<br />

Stopper wall<br />

with holes<br />

knocked through<br />

New wall<br />

Hot<br />

chamber<br />

Traditional warm up


<strong>Oven</strong> roof<br />

New wall<br />

Stopper wall<br />

Hot<br />

chamber<br />

Burner<br />

High velocity burner warm up


Throughwalls & Regen <strong>Repairs</strong><br />

• Supporting steelwork<br />

• Insulation of adjacent walls<br />

• Expansion<br />

• Life expectancy


Stongback fitted & A-Pipes /Elbows removed, Goose necks are blanked off


Setting out bridge supports


Main support beam


Charger bridge beam


Charger Slowdown Magnets<br />

Bridge and slowdown


Main Bridge<br />

Support Beam<br />

Rail Support<br />

H<br />

H


Charge Car<br />

H<br />

H


Rail fitting


Rolling the rail in


Hanger support<br />

T bar support<br />

for rollers<br />

Rollers<br />

Blanket<br />

Blanket clamp


Blankets<br />

in position


Frame Supports


Rail Supports


Charged <strong>Oven</strong><br />

1/3 rd Bracing stopper about 6 flues in<br />

Buffer <strong>Oven</strong><br />

Buffer <strong>Oven</strong><br />

Charged <strong>Oven</strong><br />

Insulation Blankets<br />

Example of oven set up


Gas isolated<br />

• Gas is isolated to all the flues on the wall to<br />

be wrecked<br />

• Fitting of wire brushes into the Heating<br />

Flues<br />

• Pipe work may be dismantled and cleaned<br />

out/ renewed as required.


Wrecking from top


Wreck complete


Blankets secured ready for build


On completion of wreck<br />

• Flues are all rodded clear<br />

• An inspection of flues is carried out via camera<br />

• Work starts on regenerators<br />

• End bottles are renewed or inserts fitted as reqd.<br />

• Grouting from top to fill at raft level<br />

• Flues are again rodded<br />

• Pressure plates fitted


Video footage of heating flue<br />

• Video footage of heating flue on<br />

throughwall repair showing damage.<br />

Play Video


Flues/ Regenerators<br />

• Regenerator damage<br />

• Adjacent ovens set up<br />

• Method<br />

• Flue damage<br />

• Grouting<br />

• Inserts


Regenerator opened up to cool


Corbel and chequer damage


Corbels replaced by arches


Bus flue repair beneath regenerator


Side wall repaired


Sole wear


Sole wear


Course 29 and below flue damage


Repair to course 29


Course 29 and sole


Sole and<br />

29<br />

complete


Setting out<br />

first course (30)


Build started


Burning block tie in


Completed high burner


Scaffold as build rises


Plate supports as build rises


Courses staggered


Roof level


Forming chargehole


Facia plates and tie bar


Completed chargeholes


Forming ascension pipe bases


Roof insulation


Completed wall prior to heat up


Prepare for warm up monitoring<br />

• Insert thermocouples<br />

• Connect to recorder<br />

• Set tie bar springs and pressure plate bolts.


High velocity burners in position


Typical Expansion of Dense Silica<br />

(OCL India)


Warm up cycle<br />

900<br />

800<br />

700<br />

600<br />

500<br />

400<br />

300<br />

200<br />

100<br />

0<br />

3 9 69 117 127 144<br />

• Ambient to 150 o C in 3 hrs<br />

• 150 o C to 180 o C at 5 o C/hr<br />

• 180 o C to 360 o C at 3 o C/hr<br />

• 360 o C to 6000 o C at 5 o C/hr<br />

• 600 o C to 680 o C at 8 o C/hr<br />

• 680 o C to 850 o C at 10 o C/hr<br />

• Total = 8 days


Pressure plate bolt


‘Strike up’<br />

• Flues rodded over the 8 days<br />

• Airports checked<br />

• Waste gas cycle set up (dampers)<br />

• Strike up at around 750 o C to 800 o C<br />

• Check burning conditions<br />

• Confirm burner pull out<br />

• Soak for 24 hours @ 1000 o C<br />

• Pull blankets


Chamber after warm up complete and<br />

blankets removed


Build completion<br />

• Complete roof build<br />

• Fit chargehole rings and lids<br />

• Fit ascension pipes<br />

• Concrete quoins<br />

• Reset or renew door frames<br />

• Remove bracing stoppers from buffer ovens<br />

• Remedial work to buffer ovens


Commissioning<br />

• Crosswall and set profile of walls<br />

• Clean soles of ovens<br />

• Note chamber conditions<br />

• Decide charging sequence<br />

• Bring walls to temperature<br />

• Charge ovens<br />

• Monitor first push and again note chamber<br />

condition


Chamber<br />

after<br />

first push


Which repair?<br />

• Availability/ Schedule<br />

• Resources – money, materials, manpower<br />

• Temporary?<br />

• What road do you choose for major repairs?<br />

• No choice


No choice

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