Refractory Repairs - Coke Oven Managers Association
Refractory Repairs - Coke Oven Managers Association
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