FastWall System - Coke Oven Managers Association
FastWall System - Coke Oven Managers Association
FastWall System - Coke Oven Managers Association
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<strong>FastWall</strong> <strong>System</strong><br />
COMA <strong>Coke</strong> Conference March 2012
Kooksfabriek 2 levensduurverlenging<br />
Wall repairs in an alternative way<br />
COMA <strong>Coke</strong> Conference March 2012
Market Study<br />
Potential Applications<br />
• Batteries ≥ 5 meter<br />
• Built before1985 (typical life of 20-25<br />
years before repairs)<br />
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COMA <strong>Coke</strong> Conference March 2012
Technical Life:<br />
• Wall stability<br />
• Wall heating<br />
• Wall damage<br />
• Can we still push<br />
Battery Lifetime<br />
Environmental Life<br />
• Charging emissions<br />
• Pushing emissions<br />
+ =<br />
• Door emissions<br />
• Gas leakage on (end)flues<br />
Annual CAPEX<br />
Economical life<br />
Budget<br />
Cost effectiveness for standard<br />
Reduction!!<br />
solutions:<br />
• Battery Life extension<br />
• Battery bracing systems<br />
• End Flue & Wall replacements<br />
• Repair cost vs Production benefits<br />
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COMA <strong>Coke</strong> Conference March 2012
Traditional Repair <strong>System</strong>s<br />
• Comparison of:<br />
– End Flue Repairs<br />
– Silika-throughwall<br />
– Fused Silika-throughwall<br />
COMA <strong>Coke</strong> Conference March 2012
End Flue Repairs<br />
• Relatively short lifetime<br />
• Difficult on ovens ≥ 5 meter<br />
• Short repair time<br />
• Lower CAPEX<br />
• Always with Wall Bracing<br />
Refurbishment<br />
COMA <strong>Coke</strong> Conference March 2012
Silika-throughwalls<br />
COMA <strong>Coke</strong> Conference March 2012
SILIKA Repairs<br />
• Proven repair<br />
system (in-kind)<br />
• Low cost of<br />
materials<br />
•Labor intensive<br />
(Highly skilled<br />
Bricklayers)<br />
•Exposure to heat &<br />
dust<br />
•Large # shapes<br />
•Timely repair<br />
•Always with Wall<br />
Bracing<br />
Refurbishment<br />
COMA <strong>Coke</strong> Conference March 2012
Fused Silika Modular <strong>System</strong><br />
• Simple Concept<br />
• Tailor made<br />
Engineered &<br />
manufactured<br />
• Pre-cast Standard<br />
Modules<br />
• Applicable to End<br />
Flues & Thruwalls<br />
COMA <strong>Coke</strong> Conference March 2012
Fused Silika thruwalls<br />
• High in Material Cost<br />
• Mechanical<br />
Installation (Reduced<br />
Labor Intensity)<br />
• Less exposure to<br />
heat & dust for<br />
personnel)<br />
• Short repair time<br />
• Always with Wall<br />
Bracing<br />
Refurbishment<br />
COMA <strong>Coke</strong> Conference March 2012
Modular shapes<br />
Mechanical Installation<br />
COMA <strong>Coke</strong> Conference March 2012
Prefabricated Charge Holes<br />
COMA <strong>Coke</strong> Conference March 2012
Wall repairs<br />
Comparison Silika vs Fused Silika<br />
1. Both systems are technically proven and accepted,<br />
given the required result for emission reductions.<br />
2. In-kind repair with standard silika is cheaper than fused<br />
silika repair.<br />
3. Total cost Fused Silika - option is less, due to reduction<br />
in production losses<br />
4. Market conditions i.e. Purchase of <strong>Coke</strong> versus<br />
Variable Cost of <strong>Coke</strong> Production determine<br />
economical choice<br />
COMA <strong>Coke</strong> Conference March 2012
Combine advantages of both options!!<br />
• Fastwall Concept, an innovative breakthrough!<br />
COMA <strong>Coke</strong> Conference March 2012
The Development<br />
• Maximize mechanical deck & wall demolition<br />
– Improve Labor Conditions<br />
– Reduction of demolition dust<br />
– Strong reduction of demolition time<br />
• Enlarge modules for both wall and deck sections<br />
– Use of High Alumina and/or Fused Silika<br />
– Mechanical Installation of wall & Deck Sections<br />
• Involvement of external specialists.<br />
– Demolition Technique and Vertical/horizontal transport<br />
– How can we make a Stress Free Lift of the Prefab Wall<br />
• Engineering study is complete:<br />
HeatTeQ’s Fastwall <strong>System</strong> is a sound alternative!<br />
COMA <strong>Coke</strong> Conference March 2012
Advantages<br />
• Health, Safety & Environment<br />
– Improvement on work conditions<br />
– Reduce exposure to excessive heat & dust for<br />
personnel<br />
– Cost reduction on HS&E<br />
• <strong>Oven</strong> downtime<br />
– Up to 70% reduction in comparison with traditional<br />
repair methods<br />
– Economical Benefits (= less <strong>Coke</strong> purchase or more<br />
<strong>Coke</strong> Sales)<br />
COMA <strong>Coke</strong> Conference March 2012
Fast Wall on Bricking Base<br />
COMA <strong>Coke</strong> Conference March 2012
Prefab wall in lifting cage<br />
Equally divided load<br />
COMA <strong>Coke</strong> Conference March 2012
Static Calculations<br />
Lifting Frame<br />
Lifting <strong>System</strong><br />
COMA <strong>Coke</strong> Conference March 2012
Total Displacement of Construction<br />
Δ displacement = 1.3mm<br />
COMA <strong>Coke</strong> Conference March 2012
Situation before heatup (bracing system not shown)<br />
Silika (cold dimension)<br />
Filler brick<br />
Regenerator(deck) kept<br />
hot during repairs<br />
COMA <strong>Coke</strong> Conference March 2012
Top View Silika Spring- loaded Bracing during Heatup<br />
COMA <strong>Coke</strong> Conference March 2012
• Wall<br />
bracing<br />
during<br />
heat-up<br />
COMA <strong>Coke</strong> Conference March 2012
Deck Section, situation during heat-up<br />
COMA <strong>Coke</strong> Conference March 2012
Typical Project Schedule<br />
• Engineering & fabrication 20-24 weeks<br />
– Depending on delivery Silika<br />
• Site preparation 4-6 weeks<br />
• Demolition (3-wall block) 6-8 days<br />
• Wall re-built & heat-up 26-29 days<br />
– Wall placement in one day<br />
<strong>Oven</strong>s ~32-37 days out of service, which is a<br />
reduction of 15 days (Fused Silika) to 45 days<br />
(Silika).<br />
COMA <strong>Coke</strong> Conference March 2012
Cost Comparison<br />
• Total Cost for Fastwall is comparable with<br />
traditional repair methods.<br />
– Incl. Tools, Special Equipment & Refractory<br />
Materials.<br />
– On the basis of a 15 wall project.<br />
• Additional cost/time for additional<br />
regenerator repairs and supply of steel<br />
components are not in comparison.<br />
COMA <strong>Coke</strong> Conference March 2012
Repair cost for 1 block of 3 walls,<br />
based on order for 5 blocks<br />
3,000,000.00<br />
2,500,000.00<br />
2,000,000.00<br />
Traditional Silika<br />
1,500,000.00<br />
Smart Demo & Modular Fused SIlika<br />
1,000,000.00<br />
500,000.00<br />
<strong>FastWall</strong> Silika<br />
0.00<br />
Total Repair Cost<br />
COMA <strong>Coke</strong> Conference March 2012
Validation <strong>Coke</strong> Deficits<br />
• <strong>Coke</strong> Production (MT)<br />
• Validation<br />
– Sale of <strong>Coke</strong> versus Variable Cost <strong>Coke</strong> Production<br />
• Cost = (Coal + Energy) -/- Byproducts<br />
– Assumed price difference: US$ 200,-- MT Dry <strong>Coke</strong><br />
– International benchmarking<br />
COMA <strong>Coke</strong> Conference March 2012
<strong>Coke</strong> Deficit on a 3-wall repair<br />
1,600,000.00<br />
1,400,000.00<br />
1,200,000.00<br />
1,000,000.00<br />
800,000.00<br />
600,000.00<br />
400,000.00<br />
200,000.00<br />
0.00<br />
<strong>Coke</strong> Deficit<br />
90 days<br />
49 days<br />
35 days<br />
Traditional Silika<br />
Smart Demo & Modular<br />
Fused SIlika<br />
Fastwall Silika<br />
COMA <strong>Coke</strong> Conference March 2012
Total Repair Cost for 3 walls<br />
€4,500,000.00<br />
€4,000,000.00<br />
€3,500,000.00<br />
Total Cost Repair €<br />
€3,000,000.00<br />
€2,500,000.00<br />
€2,000,000.00<br />
€1,500,000.00<br />
€1,000,000.00<br />
<strong>Coke</strong> Deficit Repair<br />
Period €<br />
Cost to Customer<br />
€500,000.00<br />
€0.00<br />
Traditional Silika<br />
Smart Demo &<br />
Modular Fused<br />
SIlika<br />
<strong>FastWall</strong> Silika<br />
COMA <strong>Coke</strong> Conference March 2012
Summary<br />
• Patented Fast Wall <strong>System</strong> is a breakthrough<br />
in Repair Techniques for <strong>Coke</strong> batteries;<br />
• Huge improvement of labor conditions and<br />
safety for contractors’ personnel & production<br />
crew;<br />
• Repair duration reduces up to 30%, total cost<br />
are ≤ traditional systems;<br />
• Fastwall could become a standard system for<br />
Battery repairs in <strong>Coke</strong>making!!<br />
COMA <strong>Coke</strong> Conference March 2012
Health, Safety & Environment<br />
International Developments Environmental Laws &<br />
Regulations<br />
• Heat exposure<br />
• Dust exposure (coal & coke, quartz dust during<br />
demolition, etc.)<br />
• Labor regulations for working times<br />
• Work procedures on <strong>Coke</strong> Batteries<br />
• Reduce labor crew during repairs<br />
Demands & Expectations are in line with the Fast<br />
Wall system!<br />
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COMA <strong>Coke</strong> Conference March 2012
Conclusion<br />
• It is possible to reduce the time for a 3-wall<br />
replacement to 35 days and to minimize typical<br />
delays/interruptions during a repair.<br />
• It is possible to optimize mechanical demolition<br />
and installation thereby significantly improving<br />
labor conditions.<br />
• Large benefits for:<br />
– Health & Safety (labor conditions)<br />
– Plant Safety (less interaction of contractor and<br />
production).<br />
– Total Repair Cost (Cost to Customer)<br />
– <strong>Oven</strong> availability<br />
COMA <strong>Coke</strong> Conference March 2012
For further information and discussions on the subject<br />
focused on your own Batteries & Repair Program:<br />
HeatTeQ Refractory Services b.v.<br />
Robijnstraat 94<br />
1812RB Alkmaar<br />
The Netherlands<br />
Tel. +31 72 7000056<br />
E-mail:<br />
Web:<br />
info@heatteq.com<br />
www.heatteq.com<br />
COMA <strong>Coke</strong> Conference March 2012
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