Method and apparatus for repairing coke oven

Abstract

Provided is a method for repairing a coke oven that includes: a confirmation step in which a three-dimensional measurement device is used to observe, from an oven mouth, concavity and convexity of an oven wall of a neighboring non-replacement target combustion chamber that is adjacent to one side surface of one replacement target combustion chamber or a plurality of continuous replacement target combustion chambers, and concavity and convexity of an oven wall of a neighboring non-replacement target combustion chamber that is adjacent to the other side surface of the one replacement target combustion chamber or plurality of continuous replacement target combustion chambers, thereby confirming that bulging amounts of the oven walls of the neighboring non-replacement target combustion chambers are each smaller than a given value; a replacement step in which when the bulging amounts of the oven walls of the neighboring non-replacement target combustion chambers have each been confirmed to be smaller than the given value in the confirmation step, a portion of an oven wall of the one replacement target combustion chamber or plurality of continuous replacement target combustion chambers, which requires repair, is dismantled, followed by newly stacking oven wall bricks and binder bricks in the dismantled area; and a step of using a previously formed oven wall refractory aggregate and a previously formed ceiling part refractory aggregate as a newly stacked oven wall and ceiling part in the replacement target combustion chamber.

Description

Technical Field

[0001] The present invention relates to a method and device for repairing a coke oven, in which a coke oven is repaired in a hot condition by replacing the oven wall bricks composing the oven wall that separates a carbonization chamber and a combustion chamber.Background Art

[0002] In general, as shown in FIG. 13, a chamber-type coke oven is configured in such a manner that formed on the upper part of a regenerative chamber 53 is an oven battery as an assembly composed of a given number of alternately arranged carbonization chambers 51 and combustion chambers 52. A plurality of charging holes 54 are opened on the ceiling part of each carbonization chamber 51. These charging holes 54 are provided to charge coal delivered by a charging car 55 running over the coke oven into the carbonization chamber 51. The coal charged from the charging holes 54 into the carbonization chamber 51 undergoes carbonization upon receiving heat from the combustion chamber 52 and turns into red-hot coke before being pushed out from the carbonization chamber 51 by a pusher machine 56. Next, the red-hot coke that has been pushed out from the carbonization chamber 51 by the pusher machine 56 is received by a quenching car 58 through a guide car 57, and this quenching car 58 then transports the red-hot coke to a red-hot coke quenching facility (not shown).

[0003] The carbonization chambers 51, combustion chambers 52, and regenerative chamber 53 are built with many bricks; as shown in FIG.14, multiple flues (vertical flues) 59 are formed inside the combustion chambers 52 in such a way that they are formed along a direction (oven longitudinal direction) that is orthogonal to a direction along which the carbonization chambers 51 and combustion chambers 52 are arranged. Further, the carbonization chamber 51 has an oven mouth into which a pusher ram 56a (see FIG.13) of the pusher machine 56 is inserted, and an oven mouth from which the red-hot coke is pushed out. Buckstays 60 (see FIG.14) made of an H-shaped steel or the like are erected in the vicinity of these oven mouths for the purpose of preventing deformation and collapse of the oven walls.

[0004] In such a coke oven, the wall-forming bricks forming the walls of the combustion chambers 52 may wear significantly. In this regard, conventionally, coke oven repair was performed in a hot condition by replacing significantly worn wall-forming bricks with new bricks (e.g., see Patent Literature 1). Further, as a repairing method conducted by performing replacing, there are known various kinds of methods (see Patent Literatures 2 to 8).Citation ListPatent Literature

[0005] Patent Literature 1: Japanese Patent No.5347614 Patent Literature 2: JP-A-2022-110682 Patent Literature 3: Japanese Patent No.6587951 Patent Literature 4: Japanese Patent No.6280453 Patent Literature 5: Japanese Patent No.6482484 Patent Literature 6: Japanese Patent No.6502435 Patent Literature 7: Japanese Patent No.6502436 Patent Literature 8: JP-A-2017-137447 Summary of InventionTechnical Problem

[0006] However, the following problems were observed when the combustion chamber bricks of the coke oven were replaced in such a manner that bricks of several flues from the oven mouth were partially replaced, or all the bricks were replaced (through replacing), in a hot condition. That is, in these cases, there was observed a phenomenon where the neighboring combustion chambers adjacent to the combustion chamber that has been repaired and the remaining bricks of an unrepaired portion that has remained without being dismantled would bulge toward the carbonization chamber side after repair. With the bricks of the combustion chamber bulging toward the carbonization chamber side, there occurs a problem that when using a pusher machine to discharge the carbonized coke in the carbonization chamber, the pusher ram will stop as a result of coming into contact with the bulging bricks, which leads to an extrusion clogging trouble where the coke fails to be discharged out of the coke oven.

[0007] It is an object of the present invention to provide a method and device for repairing a coke oven, which are capable of solving the above problem so that when repairing, in a hot condition, the bricks composing the wall of a combustion chamber in a coke oven, extrusion clogging will not occur as the neighboring non-replacement target combustion chambers that do not require repair and are adjacent to the replacement target combustion chamber that is to be replaced for repair and the remaining bricks of an unrepaired portion that has remained without being dismantled will not exhibit oven wall bulge toward the carbonization chamber side after repair.Solution to Problem

[0008] The method of the present invention for repairing a coke oven is a method of repairing a coke oven by replacing, in a hot condition, bricks of one combustion chamber that compose the coke oven or bricks of a plurality of continuous combustion chambers that compose the coke oven with two or more oven wall bricks and binder bricks along an oven longitudinal direction from an oven mouth. This method includes: a confirmation step in which a three-dimensional measurement device is used to observe, from the oven mouth, concavity and convexity of an oven wall of a neighboring non-replacement target combustion chamber that is adjacent to one side surface of one replacement target combustion chamber or a plurality of continuous replacement target combustion chambers, and concavity and convexity of an oven wall of a neighboring non-replacement target combustion chamber that is adjacent to the other side surface of the one replacement target combustion chamber or plurality of continuous replacement target combustion chambers, thereby confirming that bulging amounts of the oven walls of the neighboring non-replacement target combustion chambers are each smaller than a given value; a replacement step in which when the bulging amounts of the oven walls of the neighboring non-replacement target combustion chambers have each been confirmed to be smaller than the given value in the confirmation step, a portion of an oven wall of the one replacement target combustion chamber or plurality of continuous replacement target combustion chambers, which requires repair, is dismantled, followed by newly stacking oven wall bricks and binder bricks in the dismantled area; and a step of using a previously formed oven wall refractory aggregate and a previously formed ceiling part refractory aggregate as a newly stacked oven wall and ceiling part in the replacement target combustion chamber.

[0009] Further, as for the method of the present invention for repairing a coke oven, which is configured in the above manner, it is considered that more preferable solutions can be brought when: (1) the given value of the bulging amount is a value capable of ensuring an extrusion clogging rate that does not hinder a normal operation, the extrusion clogging rate being calculated by the following formula (1): Extrusion clogging rate % = 5 × 10 − 8 × d 5 wherein d (mm) represents the bulging amount, (2) the ensured extrusion clogging rate that does not hinder a normal operation is 5%, and the given value of the bulging amount is 40 mm by calculating d from the formula (1), (3) the method further includes: a repair range determination step in which before dismantling a portion of the replacement target combustion chamber that requires repair, a three-dimensional measurement device is used to observe the concavity and convexity of the oven walls from the oven mouth to determine a range of oven wall bricks and binder bricks that requires repair; and a dismantling step in which the convexity of the oven walls that has been determined in the repair range determination step is further checked through a flue hole, whereafter binder bricks ranging from those that have been determined as sound to those close to the oven mouth are dismantled, (4) with part of an oven wall of a combustion chamber being previously opened, a gas hole and an air hole in the existing combustion chamber are lidded with a curing member or lidded by being filled with a heat insulation material from a flue hole that is provided at an upper part of the oven wall of the combustion chamber, whereby falling scraps can be restricted from mixing into a regenerative chamber at the time of dismantling the replacement target combustion chamber, (5) repair operation is performed with respect to a pair of neighboring combustion chambers integrally formed by stacking integral type or two-split type precast blocks in a hollow cavity of bricks formed at a ceiling part of the pair of neighboring combustion chambers, (6) the method further includes: a step of installing a heat insulation panel by placing the heat insulation panel on a conveying carriage and then performing pulling with a traction wire so as to introduce the heat insulation panel into a given carbonization chamber and stop, or by pushing out the heat insulation panel with a pusher machine before stopping, prior to dismantling a portion of the replacement target combustion chamber that requires repair, (7) the method further includes: a step of using a carrier of heavy machinery for dismantling when dismantling a portion of the replacement target combustion chamber that requires repair, (8) the method further includes: a step of using a carrier that traverses over the coke oven to transport and import the oven wall refractory aggregate and the ceiling part refractory aggregate, (9) the method further includes: a step of performing positioning in a horizontal direction with a laser light when horizontally arranging the oven wall refractory aggregate and ceiling part refractory aggregate; and a step of installing a spacer for achieving a constant mortar joint thickness, (10) the method further includes: a step of installing the ceiling part refractory aggregate and then pouring a castable refractory into a gap surrounding the ceiling part refractory aggregate so as to fill the same, when newly forming a replacing ceiling part, and (11) integrally formed blocks that are integrally formed by a monolithic refractory are previously prepared by dividing a wall body composing the combustion chamber into a plurality of blocks, the wall body is then dismantled and taken out of the coke oven, followed by carrying the integrally formed blocks into the coke oven and arranging them in such a manner that an end portion of each integrally formed block is to be abutted against two orthogonal surfaces that are provided at an end portion of the existing wall body, thereby rebuilding the wall body.

[0010] Further, as for a device of the present invention for repairing a coke oven, which is used in the above coke oven repairing method, it is considered that more preferable solutions can be brought when: (1) the device includes: slide gates that are provided on an oven top portion of the coke oven, are capable of moving in a traverse direction such that an opening portion occurring when dismantling the oven top portion of the coke oven can be opened at the time of dismantling the coke oven and closed when the coke oven dismantling operation is stopped, and are provided with a safety handrail therearound, (2) the device includes: a heat insulation structural body with several kinds of heat insulation materials being placed on top of one another in an iron frame and being fixed and integrated therein, the heat insulation structural body being installed between a replacement target combustion chamber and its neighboring non-replacement target combustion chamber for the purpose of retaining the heat of the neighboring non-replacement target combustion chamber adjacent to the replacement target combustion chamber and thus heat-insulating a space for replacing operation in the replacement target combustion chamber, when dismantling the coke oven, (3) the device includes: a slide-type scaffold that is provided for realizing fall prevention of an operator and securing the operator's foothold during operation, the slide-type scaffold being detachable from outside the coke oven and being configured to allow two or more said slide-type scaffolds to be coupled and connected to one another, and (4) the device includes: a ceiling restraining beam that is formed by welding and fixing a beam and a heat insulation structural body with a heat insulation material being abutted against existing bricks, the ceiling restraining beam being configured to heat-insulate and prevent the collapse of existing bricks of a neighboring non-replacement target combustion chamber adjacent to a replacement target combustion chamber that is to repaired, when dismantling a ceiling part of said replacement target combustion chamber. Advantageous Effects of Invention

[0011] According to the method and device of the present invention for repairing a coke oven, before dismantling the bricks of a replacement target combustion chamber as a target of repair, by observing the condition of the walls of the neighboring non-replacement target combustion chambers, a proper range of oven wall bricks and binder bricks that is to be repaired can be determined, thereby making it possible to solve the problem that the walls of the neighboring non-replacement target combustion chambers will bulge toward the carbonization chamber after repair.Brief Description of Drawings

[0012] [FIG.1A] is a drawing showing how repair takes place when there is no bulge on the oven walls of neighboring non-replacement target combustion chambers. [FIG.1B] is another drawing showing how repair takes place when there is no bulge on the oven walls of the neighboring non-replacement target combustion chambers. [FIG.1C] is yet another drawing showing how repair takes place when there is no bulge on the oven walls of the neighboring non-replacement target combustion chambers. [FIG.2A] is a drawing showing how repair takes place when there is bulge on the oven walls of the neighboring non-replacement target combustion chambers. [FIG.2B] is another drawing showing how repair takes place when there is bulge on the oven walls of the neighboring non-replacement target combustion chambers. [FIG.2C] is yet another drawing showing how repair takes place when there is bulge on the oven walls of the neighboring non-replacement target combustion chambers. [FIG.3] is a set of drawings in which FIGs.3(a) and (b) are each a drawing showing an example of a slide gate, which serves as a preferable embodiment in the method of the present invention for repairing a coke oven. [FIG.4] is a set of drawings in which FIGs.4(a) and (b) are each a drawing showing an example of a heat insulation structural body, which serves as a preferable embodiment in a coke oven repairing device used in the method of the present invention for repairing a coke oven. [FIG.5] is a drawing showing an example of previous gas hole curing, which serves as a preferable embodiment in the method of the present invention for repairing a coke oven. [FIG.6] is a set of drawings in which FIGs.6(a) and (b) are each a drawing showing an example of an in-oven slide scaffold, which serves as a preferable embodiment in the coke oven repairing device used in the method of the present invention for repairing a coke oven. [FIG.7] is a drawing showing an example of a ceiling restraining beam, which serves as a preferable embodiment in the coke oven repairing device used in the method of the present invention for repairing a coke oven. [FIG.8] is a drawing showing an example of a crossover MCB, which serves as a preferable embodiment in the method of the present invention for repairing a coke oven. [FIG.9] is a drawing showing a working state of Example 1. [FIG. 10] is a drawing showing a working state of Example 2. [FIG. 11] is a drawing showing a working state of Example 3. [FIG.12] is a graph showing a correlation between an extrusion clogging rate and a bulging amount under a fully charged condition of 30 t of coal. [FIG.13] is a drawing showing an example of a known coke oven. [FIG.14] is a drawing showing the known coke oven from above. Description of Embodiments

[0013] An embodiment of the present invention is described in detail hereunder. Here, the following embodiment is a set of examples of a device and / or method embodying the technical concept of the present invention and is not to limit the configuration of the present invention to those shown below. That is, various modifications can be made to the technical concept of the present invention within the technical scope described in the claims.<Overview of the present invention>

[0014] The present invention relates to a method and device for repairing a coke oven and was achieved based on the following findings. Conventionally, in a method for repairing a coke oven, there has been a problem that when repairing a replacement target combustion chamber that is to be repaired, the oven walls of neighboring non-replacement target combustion chambers that are adjacent to the replacement target combustion chamber will each bulge toward the carbonization chamber side. Further, with the neighboring non-replacement target combustion chambers bulging significantly, there has also been a problem that a heat insulation panel(s) cannot be installed properly, whereby the temperature of the neighboring non-replacement target combustion chamber will decrease such that it will bulge into the carbonization chamber. In order to solve these problems, before repairing a replacement target combustion chamber, the condition of the oven walls of the neighboring non-replacement target combustion chambers is observed, and the condition is then deemed as sound when the oven walls of the neighboring non-replacement target combustion chambers meet certain conditions. It was found that by repairing a replacement target combustion chamber under a condition where the neighboring non-replacement target combustion chambers have been deemed as sound, the oven walls of the neighboring non-replacement target combustion chambers would not bulge toward the carbonization chamber side after repair.

[0015] Here, in the present invention, the neighboring non-replacement target combustion chambers that are adjacent to a replacement target combustion chamber(s) refer to a neighboring non-replacement target combustion chamber that is adjacent to one side surface of one replacement target combustion chamber or a plurality of continuous replacement target combustion chambers, and a neighboring non-replacement target combustion chamber that is adjacent to the other side surface of such one replacement target combustion chamber or plurality of continuous replacement target combustion chambers. However, in the following description, the method of the present invention for repairing a coke oven is described on the premise that there is one replacement target combustion chamber. In addition, it is needless to say that the following description likewise applies to a plurality of continuous replacement target combustion chambers.

[0016] FIGs.1A to 1C are each a drawing showing how repair takes place when there is no bulge on the oven walls of the neighboring non-replacement target combustion chambers. In the beginning, as shown in FIG.1A, a three-dimensional measurement device is used to observe the concavity and convexity of the oven wall of a neighboring non-replacement target combustion chamber that is adjacent to one side surface of the replacement target combustion chamber to be repaired, and the concavity and convexity of the oven wall of a neighboring non-replacement target combustion chamber that is adjacent to the other side surface of such replacement target combustion chamber, whereby it is confirmed that the bulge of the oven walls of the neighboring non-replacement target combustion chambers is smaller than a given value. Next, as shown in FIG.1B, a heat insulation panel is arranged on surfaces of the neighboring non-replacement target combustion chambers that face the replacement target combustion chamber to be repaired, and a portion of the replacement target combustion chamber that is to be replaced is dismantled. Later, as shown in FIG.1C, the dismantled portion of the replacement target combustion chamber is replaced so as to repair the replacement target combustion chamber that is to be repaired. At that time, as for the neighboring combustion chambers for which their oven wall bulge has been confirmed to be smaller than the given value as shown in FIG.1A, none of them exhibits oven wall bulge as shown in FIG.1C.

[0017] FIGs.2A to 2C are each a drawing showing how repair takes place when there is a bulge on the oven walls of the neighboring non-replacement target combustion chambers. In the beginning, as shown in FIG.2A, a three-dimensional measurement device is used to observe the concavity and convexity of the oven wall of a neighboring non-replacement target combustion chamber that is adjacent to one side surface of the replacement target combustion chamber to be repaired, and the concavity and convexity of the oven wall of a neighboring non-replacement target combustion chamber that is adjacent to the other side surface of such replacement target combustion chamber. FIG.2A shows an example where it was observed that the oven wall of a neighboring non-replacement target combustion chamber adjacent to the upper side of the replacement target combustion chamber bulged by an amount as large as or larger than the given value, and that the oven wall of a neighboring non-replacement target combustion chamber adjacent to the lower side of the replacement target combustion chamber bulged by an amount smaller than the given value. Next, as shown in FIG.2B, a heat insulation panel is arranged on surfaces of the neighboring non-replacement target combustion chambers that face the replacement target combustion chamber to be repaired, and a portion of the replacement target combustion chamber that is to be replaced is dismantled. At that time, as for the oven wall of the neighboring non-replacement target combustion chamber on the upper side, that is bulging by an amount as large as or larger than the given value, the bulging part becomes a hindrance when installing the heat insulation panel. Later, as shown in FIG.2C, the dismantled portion of the replacement target combustion chamber is replaced so as to repair the replacement target combustion chamber that is to be repaired. There, as for the neighboring non-replacement target combustion chamber on the upper side for which its oven wall bulge has been confirmed to be as large as or larger than the given value as shown in FIG.2A, the bulging amount thereof after the replacement is larger than before the replacement as shown in FIG.2C. Meanwhile, as for the neighboring non-replacement target combustion chamber on the lower side for which its oven wall bulge has been confirmed to be smaller than the given value as shown in FIG.2A, the bulging amount thereof does not change before and after the replacement as shown in FIG.2C.

[0018] The method of the present invention for repairing a coke oven, which was achieved based on the above findings, is a method of repairing a coke oven by replacing, in a hot condition, the bricks of one combustion chamber that compose the coke oven or the bricks of a plurality of continuous combustion chambers that compose the coke oven with two or more oven wall bricks and binder bricks along the oven longitudinal direction from the oven mouth. This method is characterized by including a confirmation step and a replacement step. The confirmation step is a step in which a three-dimensional measurement device is used to observe, from the oven mouth, the concavity and convexity of the oven wall of a neighboring non-replacement target combustion chamber that is adjacent to one side surface of one replacement target combustion chamber or a plurality of continuous replacement target combustion chambers, and the concavity and convexity of the oven wall of a neighboring non-replacement target combustion chamber that is adjacent to the other side surface of such one replacement target combustion chamber or plurality of continuous replacement target combustion chambers, thereby confirming that the bulging amounts of the oven walls of these neighboring non-replacement target combustion chambers are each smaller than the given value. The replacement step is a step in which when the bulging amounts of the oven walls of the neighboring non-replacement target combustion chambers have each been confirmed to be smaller than the given value in the confirmation step, a portion(s) of the oven wall(s) of the one replacement target combustion chamber or the plurality of continuous replacement target combustion chambers, which require repair, is dismantled, followed by newly stacking oven wall bricks and binder bricks in the dismantled area.

[0019] According to the above method of the present invention for repairing a coke oven, when repairing, in a hot condition, the bricks composing the oven wall of a combustion chamber of the coke oven, neither the oven wall of the neighboring non-replacement target combustion chamber that is adjacent to the one side surface nor the oven wall of the neighboring non-replacement target combustion chamber that is adjacent to the other side surface will bulge toward the carbonization chamber side after repair.

[0020] In addition, the method of the present invention for repairing a coke oven further includes a step of using a previously formed oven wall refractory aggregate and a previously formed ceiling part refractory aggregate as a newly stacked oven wall and ceiling part in the replacement target combustion chamber, as described in Patent Literature 4 (publication of Japanese Patent No.6280453). According to this embodiment, with the method of the present invention for repairing a coke oven, there can be provided a repairing method capable of improving efficiency in repair operations. Here, the refractory aggregate mentioned above refers to, for example, a refractory brick block body and a sintered or non-sintered castable block.

[0021] Further, as a preferable embodiment, the method of the present invention for repairing a coke oven includes a repair range determination step and a dismantling step. The repair range determination step is a step in which before dismantling a portion of the replacement target combustion chamber that requires repair, a three-dimensional measurement device is used to observe the concavity and convexity of the oven wall from the oven mouth to determine a range of oven wall bricks and binder bricks that requires repair. The dismantling step is a step in which the convexity of the oven wall that has been determined in the repair range determination step is further checked through the flue hole, whereafter binder bricks ranging from those that have been determined as sound to those close to the oven mouth are dismantled.

[0022] According to the above preferable embodiment of the method of the present invention for repairing a coke oven, when repairing, in a hot condition, the bricks composing the oven wall of a combustion chamber of the coke oven, the remaining bricks of an unrepaired portion in the replacement target combustion chamber to be repaired, which have remained without being dismantled, will not bulge toward the carbonization chamber side after repair.<Preferable embodiments in method and device of the present invention for repairing coke oven>(1) Preferable embodiment in repairing device (slide gate):

[0023] FIGs.3(a) and (b) are each a drawing showing an example of a slide gate(s), which serves as a preferable embodiment in the method of the present invention for repairing a coke oven. FIGs.3(a) and (b) are top views showing a combustion chamber from above; a symbol "1" indicates a charging car rail for a charging car that charges coal into the combustion chamber, symbols "2-1" and "2-2" indicate movable slide gates for opening and closing an opening portion 3 on the coke oven, a symbol "4" indicates a slide gate rail for moving the slide gates 2-1 and 2-2, and a symbol "5" indicates a safety handrail provided at each slide gate.

[0024] The opening portion 3 mentioned in this embodiment is formed by, for example, collapse of the ceiling part of the replacement target combustion chamber that is to be repaired. The slide gates 2-1 and 2-2 are provided at a repair target portion having the opening portion 3 of the ceiling part of the replacement target combustion chamber that is to be repaired, and are removed after repair. The slide gates 2-1 and 2-2 are capable of moving in a traverse direction along the slide gate rail 4. By allowing the slide gates 2-1 and 2-2 to move in opposite directions from each other, the opening portion 3 can be closed when the operation is stopped as shown in FIG.3(a) and opened at the time of operation as shown in FIG.3(b). As shown in FIG.3(b), the safety handrail 5 is provided for the purpose of preventing people and objects from falling while the opening portion 3 remains opened.

[0025] Often, when dismantling the oven top portion of a coke oven, the opening portion 3 will occur on the coke oven such that people and objects may fall from such opening portion 3. In the method of the present invention for repairing a coke oven, by installing the slide gates 2-1 and 2-2 of this embodiment, fall (people, objects) from the opening portion 3 can be favorably prevented.(2) Preferable embodiment in repairing device (heat insulation structural body):

[0026] FIGs.4(a) and (b) are each a drawing showing an example of a heat insulation structural body, which serves as a preferable embodiment in a coke oven repairing device used in the method of the present invention for repairing a coke oven. In FIGs.4(a) and (b), a heat insulation structural body 11 of this embodiment is a heat insulation structural body with several kinds of heat insulation materials 13-1 and 13-2 being placed on top of one another in an iron frame(s) 12 and being fixed and integrated therein.

[0027] As shown by its cross-sectional surface in FIG.4(b), the heat insulation structural body 11 is composed of a pair of iron frames 12, a pair of biosoluble heat insulation materials 13-1 provided between the iron frames 12, and a high-performance heat insulation material 13-2 sandwiched between the biosoluble heat insulation materials 13-1. The high-performance heat insulation material 13-2 has a thermal conductivity of up to 0.003 W / mk, which is about 1 / 10 of the thermal conductivity of the biosoluble heat insulation materials 13-1. By using the high-performance heat insulation material 13-2, the thickness of the heat insulation structural body 11 can be reduced. Further, the high-performance heat insulation material 13-2 itself is brittle. Thus, by sandwiching the high-performance heat insulation material 13-2 with the pair of biosoluble heat insulation materials 13-1, the high-performance heat insulation material 13-2 can be favorably fixed. The heat insulation structural body 11 is provided only at a portion of the replacement target combustion chamber that is to be dismantled.

[0028] The heat insulation structural body 11 of this embodiment is to be installed between a replacement target combustion chamber and its neighboring non-replacement target combustion chamber for the purpose of retaining the heat of the neighboring non-replacement target combustion chamber adjacent to the replacement target combustion chamber and thus heat-insulating a space for replacing operation in the replacement target combustion chamber, when dismantling the coke oven. In the coke oven repairing device used in the method of the present invention for repairing a coke oven, by arranging the heat insulation structural body 11 of this embodiment on a surface facing the replacement target combustion chamber that is to be repaired outside the neighboring non-replacement target combustion chamber, the heat of the existing oven wall (neighboring combustion chamber) can be retained whereby the space for brick replacing operation can be favorably heat-insulated.(3) Preferable embodiment in repairing method (previous gas hole curing):

[0029] FIG.5 is a drawing showing an example of previous gas hole curing, which serves as a preferable embodiment in the method of the present invention for repairing a coke oven. FIG.5 is a top view showing the lower part of a combustion chamber from above; provided on the bottom part of the combustion chamber are a M gas (mixed gas of blast furnace gas and coke gas) hole 21, a C gas (coke gas) hole 22, and an air hole 23. In this embodiment, it is preferred that these gas holes be previously cured before repair.

[0030] That is, with part of the oven wall of the combustion chamber being previously opened, the gas holes and air hole in the existing combustion chamber are lidded with a curing member. As one example of performing curing with a lid, there is a method where, before repair, the oven wall bricks in the lower part of the combustion chamber to be repaired are dismantled, followed by installing a heat insulation material (iron sheet and cloth) in the bottom part of the combustion chamber. As another example of performing curing with a lid, there is a method where, before repair, the heat insulation material is to be put into the combustion chamber from the flue hole provided at the upper part of the replacement target combustion chamber that is to be repaired, to the extent that the inner side is filled. The curing of the gas holes may simply be performed only on a portion corresponding to a portion of the replacement target combustion chamber that is to be dismantled.

[0031] In the method of the present invention for repairing a coke oven, by performing the previous gas hole curing of this embodiment, as far as the combustion chamber to be repaired is concerned, scraps falling at the time of dismantling can be restricted from mixing into the regenerative chamber. In this way, the necessity of removing by suction the falling scraps that have entered the regenerative chamber can be favorably reduced, as has been necessary in the conventional setting.(4) Preferable embodiment in repairing device (in-oven slide scaffold):

[0032] FIGs.6(a) and (b) are each a drawing showing an example of an in-oven slide scaffold, which serves as a preferable embodiment in a coke oven repairing device used in the method of the present invention for repairing a coke oven. In FIGs.6(a) and (b), a symbol "31" indicates a coke oven, and a symbol "32" indicates an in-oven slide scaffold installed in the coke oven. The in-oven slide scaffold 32 of this embodiment is provided for realizing fall prevention of an operator 33 and securing the operator's foothold during operation, the in-oven slide scaffold 32 being a slide-type scaffold that is detachable from outside the coke oven 31 and is configured to allow two or more such in-oven slide scaffolds 32 to be coupled and connected to one another.

[0033] The in-oven slide scaffold 32 of this embodiment is such that it is to be installed in the carbonization chamber of the coke oven 31 from the oven mouth side, whereby a foothold is established inside the carbonization chamber, which allows the in-oven slide scaffold 32 to be used for securing a foothold of the operator. The in-oven slide scaffold(s) 32 can be extended by being coupled while being slid in the in-oven direction, and can also be stacked by being coupled in the oven height direction. In the case of the coke oven repairing device used in the method of the present invention for repairing a coke oven, by using the in-oven slide scaffold of this embodiment, an operator in charge of the repair operation can be favorably prevented from falling, and the operator's foothold during operation can be favorably secured.(5) Preferable embodiment in repairing device (ceiling restraining beam):

[0034] FIG.7 is a drawing showing an example of a ceiling restraining beam, which serves as a preferable embodiment in a coke oven repairing device used in the method of the present invention for repairing a coke oven. In FIG.7, a ceiling restraining beam 41 is configured in such a manner that a heat insulation structural body 44 integrated by fixing a heat insulation material 42 with an iron frame 43 is abutted against an existing ceiling part 45 of the coke oven, and a beam 46 is welded and fixed to the iron frame 43. The ceiling restraining beam 41 may simply be formed only at a portion corresponding to a portion of the replacement target combustion chamber that is to be dismantled.

[0035] In the case of the coke oven repairing device used in the method of the present invention for repairing a coke oven, by using the ceiling restraining beam of this embodiment, heat insulation and collapse prevention of the existing bricks can be favorably realized after dismantling the ceiling part of the combustion chamber to be repaired.(6) Preferable embodiment in repairing method (crossover MCB):

[0036] FIG.8 is a drawing showing an example of a crossover MCB (Module Castable Blocks), which serves as a preferable embodiment in the method of the present invention for repairing a coke oven. In FIG.8, there is shown a configuration in which a passage for discharging a combustion exhaust gas is established between neighboring combustion chambers. In this embodiment, the configuration is formed and stacked with integral type or two-split type large-scale precast blocks including a hollow cavity of bricks (portions indicated by arrows in FIG.8).

[0037] In a coke oven having the crossover MCB of this embodiment, a pair of combustion chambers is treated as one combustion chamber. Thus, in this embodiment, the repair operation is not performed with respect to each induvial combustion chamber, but performed with respect to a pair of combustion chambers integrally formed by stacking integral type or two-split type precast blocks in the hollow cavity of the bricks formed at the ceiling part of neighboring combustion chambers. In this way, even in a coke oven having a crossover MCB, the method of the present invention for repairing a coke oven can be favorably applied.<Known techniques favorably applicable to the method of the present invention for repairing a coke oven>

[0038] With regard to the above method of the present invention for repairing a coke oven, more preferable embodiments include a coke oven repairing method and coke oven repairing device employing the following exemplified known techniques that have already been disclosed in patent publications and patent application publications.

[0039] In the case of the method of the present invention for repairing a coke oven, it is preferred that the method include a step of installing a heat insulation panel by placing the heat insulation panel on a conveying carriage and then performing pulling with a traction wire so as to introduce the heat insulation panel into a given carbonization chamber and stop, or by pushing out the heat insulation panel with a pusher machine before stopping, prior to dismantling a portion of the replacement target combustion chamber that requires repair, as described in Patent Literature 2 (JP-A-No.2022-110682). According to this embodiment, with the method of the present invention for repairing a coke oven, when repairing a combustion chamber wall ranging from the pusher machine side of the coke oven to the quenching car side thereof over the entire length, a heat insulation wall for protecting the operator(s) can be installed in the coke oven in an inexpensive manner and a short period of time.

[0040] It is preferred that the method of the present invention for repairing a coke oven include a step of using a carrier of heavy machinery for dismantling when dismantling a portion of the replacement target combustion chamber that requires repair, as described in Patent Literature 3 (publication of Japanese Patent No.6587951). According to this embodiment, with the method of the present invention for repairing a coke oven, a heavy machinery for dismantling can be easily transported to a site where the wall body and ceiling of a combustion chamber of a coke oven are to be dismantled. As a result, the dismantling operation can be performed efficiently and safely, whereby shortening of work periods and reduction of work cost are made possible.

[0041] It is preferred that the method of the present invention for repairing a coke oven include a step of using a carrier that traverses over the coke oven to transport the oven wall refractory aggregate and the ceiling part refractory aggregate, as described in Patent Literature 5 (publication of Japanese Patent No.6482484). According to this embodiment, with the method of the present invention for repairing a coke oven, module blocks for rebuilding the wall body and ceiling of a combustion chamber of a coke oven can be efficiently transported to a site for repair work, and such module blocks and castable blocks can be easily and safely imported into the coke oven.

[0042] It is preferred that the method of the present invention for repairing a coke oven include a step of performing positioning in a horizontal direction with a laser light when horizontally arranging the oven wall refractory aggregate and ceiling part refractory aggregate; and a step of installing a spacer for achieving a constant mortar joint thickness, as described in Patent Literature 6 (publication of Japanese Patent No.6502435). According to this embodiment, with the method of the present invention for repairing a coke oven, wall bodies built by stacking module blocks can be prevented from deforming and collapsing.

[0043] It is preferred that the method of the present invention for repairing a coke oven include a step of installing a ceiling part refractory aggregate and then pouring a castable refractory into a gap surrounding the ceiling part refractory aggregate so as to fill the same, when newly forming a replacing ceiling part, as described in Patent Literature 7 (publication of Japanese Patent No.6502436). According to this embodiment, with the method of the present invention for repairing a coke oven, the ceilings of the carbonization chambers and combustion chambers in a coke oven can be repaired in an efficient manner and in a short period of time.

[0044] It is preferred that the method of the present invention for repairing a coke oven be performed in the following manner as described in Patent Literature 8 (JP-A- 2017-137447). That is, integrally formed blocks that are integrally formed by a monolithic refractory are previously prepared by dividing a wall body composing a combustion chamber into a plurality of blocks, the wall body is then dismantled and taken out of the coke oven, followed by carrying the integrally formed blocks into the coke oven and arranging them in such a manner that an end portion of each integrally formed block is to be abutted against two orthogonal surfaces that are provided at an end portion of the existing wall body, thereby rebuilding the wall body. According to this embodiment, with the method of the present invention for repairing a coke oven, the repair work of a combustion chamber in a coke oven can be carried out efficiently, which leads to shortening of work periods, a reduction in workload, an improvement in safety as well as an improvement in durability after repair.<Embodiments with preferable given values in the present invention>

[0045] Preferable given values in the present invention are determined as follows. Coke that has undergone carbonization is discharged into a quenching car from inside the coke oven via a pusher ram. At that time, due to equipment troubles or the like of the pusher ram, extrusion clogging may occur. One reason for that is because the movement of the pusher ram is interfered with due to the bulge of the combustion chamber bricks, which leads to extrusion clogging.

[0046] In the present invention, based on a correlation between the bulging amount of the bricks and an extrusion clogging rate, there is derived an embodiment with a favorable given value in terms of an upper limit of the bulging amount at which extrusion clogging will not occur. Specifically, the extrusion clogging rate and bulging amount were actually calculated in the case of a coke oven fully charged and filled with 30 t of coal. The following Table 1 shows data of the extrusion clogging rate and bulging amount that were calculated when the amount of coal charged was 30 t. Further, FIG.12 is a graph plotting a correlation between the extrusion clogging rate and bulging amount based on the data shown in Table 1. [Table 1]No.Extrusion clogging rate (%)Bulging amount (mm)No.Extrusion clogging rate (%)Bulging amount (mm)10514230205153383051664240101784650151810476151924707152025608110212665911522285610115233057111202433581222525335913227263360

[0047] From the results shown in Table 1 and FIG.12, the following formula (1) was obtained via regression analysis. Extrusion clogging rate % = 5 × 10 − 8 × d 5

[0048] Here, d (mm) represents the bulging amount.

[0049] Thus, it can be understood that the preferable given value in the present invention is a value capable of ensuring an extrusion clogging rate that does not hinder a normal operation, the extrusion clogging rate being calculated by the formula (1).

[0050] Here, in a normal coke oven operation, since it is considered that operation can be carried out with almost no problem when the extrusion clogging rate is <5%, it is considered that there will be no trouble of extrusion clogging so long as the bulging amount d is that satisfying formula (1)<5%. Here, the range of d is calculated from the formula (1) as follows. Extrusion clogging rate % = 5 × 10 − 8 × d 5 < 5 ⇔ d < 5 ÷ 5 × 10 − 8 1 / 5 = 40 mm ← 10 8 / 5 = 39.8

[0051] As is clear from this result, the preferable given value of the bulging amount is 40 mm, and an example of its specific range is less than 40 mm.Examples<Example 1>

[0052] As shown in FIG.9, with regard to a combustion chamber (replacement target combustion chamber) that was to be repaired and composed a coke oven, and two combustion chambers (neighboring non-replacement target combustion chambers) that were adjacent to the combustion chamber to be repaired and likewise composed the coke oven, concavity and convexity measurement was carried out, via a laser scanner, with respect to oven walls at given sites of oven mouth bricks of the neighboring combustion chambers (neighboring non-replacement target combustion chambers) before and after replacing the combustion chamber (replacement target combustion chamber) that was to be repaired. Further, before replacing the combustion chamber that was to be repaired (replacement target combustion chamber), the presence or non-presence of cracks was observed via observation from flue holes. The results are shown in the following Table 2. [Table 2]Concavity and convexity measurement on oven wall by laser scannerCracks observed from flue holeConcavity and convexity measurement on oven wall by laser scannerBefore replacingAfter replacingOven mouth brick 3Oven mouth brick 4Oven mouth brick 3Oven mouth brick 4Present Invention 1+5mm+5mmNot observed+10mm+10mmPresent Invention 2+10mm+10mmNot observed+15mm+15mmComparative Example 1+40mm+15mmObserved+60mm+25mm(+ indicates bulge, - indicates depression)

[0053] As is clear from the results shown in Table 2, when an oven mouth bulging amount of the neighboring combustion chambers (neighboring non-replacement target combustion chambers) before replacing was +40 mm, the bulge intensified after replacing. Thus, it was made clear that the oven mouth bulging amount of the neighboring combustion chambers (neighboring non-replacement target combustion chambers) before replacing needed to be less than +40 mm. Further, it was also made clear that when such bulging amount was ≤15 mm, there was not much change after replacing (range of measurement error). In addition, it can be understood that there is a correlation between the intensity of the oven mouth bulging amount and the presence or non-presence of brick cracks from within the flue holes.<Example 2>

[0054] As shown in FIG.10, with regard to an example in which oven mouth bulge prevention bricks were arranged between a combustion chamber (replacement target combustion chamber) that was to be repaired and composed a coke oven and two combustion chambers (neighboring non-replacement target combustion chambers) that were adjacent to the combustion chamber to be repaired and likewise composed the coke oven, concavity and convexity measurement was carried out, via a laser scanner, with respect to oven walls at given sites of oven mouth bricks of the neighboring combustion chambers (neighboring non-replacement target combustion chambers) before and after replacing the combustion chamber (replacement target combustion chamber) that was to be repaired. Further, before replacing the combustion chamber that was to be repaired (replacement target combustion chamber), the presence or non-presence of cracks was observed via observation from flue holes. The results are shown in the following Table 3. [Table 3]Concavity and convexity measurement on oven wall by laser scannerCracks observed from flue holeInstallation of bulge prevention brick at oven mouth positionConcavity and convexity measurement on oven wall by laser scannerBefore replacingAfter replacingOven mouth brick 3Oven mouth brick 4Oven mouth brick 3Oven mouth brick 4Present Invention 3+10mm+15mmNot observedInstalled+10mm+15mmPresent Invention 4+35mm+30mmNot observedInstalled+38mm+32mmComparative Example 2+40mm+25mmObservedInstalled+47mm+27mm(+ indicates bulge, - indicates depression)

[0055] As is clear from the results shown in Table 3, bulge after replacing was able to be restricted by installing the bulge prevention bricks at the oven mouth. However, it can be understood that when the bulging amount was as large as +40 mm, it was difficult to restrict the bulge from intensifying even with the use of the bulge prevention bricks.<Example 3>

[0056] As shown in FIG.11, there was studied a case where part of a combustion chamber (replacement target combustion chamber) that was to be repaired was left when performing repair. With regard to an example in which oven mouth bulge prevention bricks were arranged between a combustion chamber (replacement target combustion chamber) that was to be partially repaired and composed a coke oven, and two combustion chambers (neighboring non-replacement target combustion chambers) that were adjacent to the combustion chamber (replacement target combustion chamber) to be repaired and likewise composed the coke oven, concavity and convexity measurement was carried out, via a laser scanner, with respect to oven walls at given sites of oven mouth bricks of the neighboring combustion chambers (neighboring non-replacement target combustion chambers) before and after replacing the combustion chamber (replacement target combustion chamber) that was to be repaired. Further, before replacing the combustion chamber that was to be repaired (replacement target combustion chamber), the presence or non-presence of cracks was observed via observation from flue holes. The results are shown in the following Table 4. [Table 4]Concavity and convexity measurement on oven wall by laser scannerObservation from flue hole (presence or non-presence of cracks)Bulge prevention brick installed / not installedConcavity and convexity measurement on oven wall by laser scannerBefore replacingAfter replacingOven mouth brick 3Oven mouth brick 4Old brick 1Old brick 2Oven mouthRemaining combustion chamberOven mouthRemaining combustion chamberOven mouth brick 3Oven mouth brick 4Old brick 1Old brick 2Present Invention 5+ 5mm+ 5mm+ 5mm+ 5mmNot observedNot observedNot installedNot installed+ 10mm+ 10mm+ 10mm+ 10mmPresent Invention 6+ 10mm+ 10mm+ 10mm+ 10mmNot observedNot observedNot installedInstalled+ 15mm+ 15mm+ 10mm+ 10mmPresent Invention 7+ 10mm+ 15mm+ 15mm+ 15mmNot observedNot observedInstalledInstalled+ 10mm+ 15mm±0mm±0mmComparative Example 3+ 5mm+ 5mm+ 10mm+ 10mmNot observedObservedNot installedNot installed+ 10mm+ 10mm+ 40mm+ 50mmComparative Example 4+ 10mm+ 10mm+ 10mm+ 10mmNot observedObservedNot installedInstalled+ 15mm+ 15mm+ 30mm+ 30mmComparative Example 5+ 10mm+ 10mm+ 15mm+ 15mmNot observedObservedNot installedInstalled+ 15mm+ 15mm+ 40mm+ 35mm(+ indicates bulge, - indicates depression)

[0057] As is clear from the results shown in Table 4, when there were cracks in the combustion chamber (old bricks) that was left, there was observed bulge after performing replacing (even when there was observed no bulge on the oven wall of such particular part). Further, the above results indicate that bulge restriction was difficult regardless of whether or not the bulge prevention bricks were installed.Industrial Applicability

[0058] With the method and device of the present invention for repairing a coke oven, before dismantling the bricks of a replacement target combustion chamber as a repair target, a proper range of oven wall bricks and binder bricks that is to be repaired can be determined by observing the condition of the walls of neighboring combustion chambers (neighboring non-replacement target combustion chambers). Thus, the present invention is industrially useful because it is capable of solving the problem that the walls of the neighboring combustion chambers (neighboring non-replacement target combustion chambers) will bulge toward the carbonization chamber side after repair.Reference Signs List

[0059] 1 Charging car rail 2-1, 2-2 Slide gate 3 Opening portion 4 Slide gate rail 5 Safety handrail 11 Heat insulation structural body 12 Iron frame 13-1 Biosoluble heat insulation material 13-2 High-performance heat insulation material 21 M gas (mixed gas of blast furnace gas and coke gas) hole 22 C gas (coke gas) hole 23 Air hole 31 Coke oven 32 In-oven slide scaffold 33 Operator 41 Ceiling restraining beam 42 Heat insulation material 43 Iron frame 44 Heat insulation structural body 45 Ceiling part 46 Beam 51 Carbonization chamber 52 Combustion chamber 53 Regenerative chamber 54 Charging hole 55 Charging car 56 Pusher machine 56a Pusher ram 57 Guide car 58 Quenching car 59 Flue (vertical flue) 60 Buckstay

Examples

examples

[0052]As shown in FIG.9, with regard to a combustion chamber (replacement target combustion chamber) that was to be repaired and composed a coke oven, and two combustion chambers (neighboring non-replacement target combustion chambers) that were adjacent to the combustion chamber to be repaired and likewise composed the coke oven, concavity and convexity measurement was carried out, via a laser scanner, with respect to oven walls at given sites of oven mouth bricks of the neighboring combustion chambers (neighboring non-replacement target combustion chambers) before and after replacing the combustion chamber (replacement target combustion chamber) that was to be repaired. Further, before replacing the combustion chamber that was to be repaired (replacement target combustion chamber), the presence or non-presence of cracks was observed via observation from flue holes. The results are shown in the following Table 2.

[Table 2]

Concavity and convexity measurement on oven wall by laser sc...

Technical Field

[0001] The present invention relates to a method and device for repairing a coke oven, in which a coke oven is repaired in a hot condition by replacing the oven wall bricks composing the oven wall that separates a carbonization chamber and a combustion chamber.Background Art

[0002] In general, as shown in FIG. 13, a chamber-type coke oven is configured in such a manner that formed on the upper part of a regenerative chamber 53 is an oven battery as an assembly composed of a given number of alternately arranged carbonization chambers 51 and combustion chambers 52. A plurality of charging holes 54 are opened on the ceiling part of each carbonization chamber 51. These charging holes 54 are provided to charge coal delivered by a charging car 55 running over the coke oven into the carbonization chamber 51. The coal charged from the charging holes 54 into the carbonization chamber 51 undergoes carbonization upon receiving heat from the combustion chamber 52 and turns into red-hot coke before being pushed out from the carbonization chamber 51 by a pusher machine 56. Next, the red-hot coke that has been pushed out from the carbonization chamber 51 by the pusher machine 56 is received by a quenching car 58 through a guide car 57, and this quenching car 58 then transports the red-hot coke to a red-hot coke quenching facility (not shown).

[0003] The carbonization chambers 51, combustion chambers 52, and regenerative chamber 53 are built with many bricks; as shown in FIG.14, multiple flues (vertical flues) 59 are formed inside the combustion chambers 52 in such a way that they are formed along a direction (oven longitudinal direction) that is orthogonal to a direction along which the carbonization chambers 51 and combustion chambers 52 are arranged. Further, the carbonization chamber 51 has an oven mouth into which a pusher ram 56a (see FIG.13) of the pusher machine 56 is inserted, and an oven mouth from which the red-hot coke is pushed out. Buckstays 60 (see FIG.14) made of an H-shaped steel or the like are erected in the vicinity of these oven mouths for the purpose of preventing deformation and collapse of the oven walls.

[0004] In such a coke oven, the wall-forming bricks forming the walls of the combustion chambers 52 may wear significantly. In this regard, conventionally, coke oven repair was performed in a hot condition by replacing significantly worn wall-forming bricks with new bricks (e.g., see Patent Literature 1). Further, as a repairing method conducted by performing replacing, there are known various kinds of methods (see Patent Literatures 2 to 8).Citation ListPatent Literature

[0005] Patent Literature 1: Japanese Patent No.5347614 Patent Literature 2: JP-A-2022-110682 Patent Literature 3: Japanese Patent No.6587951 Patent Literature 4: Japanese Patent No.6280453 Patent Literature 5: Japanese Patent No.6482484 Patent Literature 6: Japanese Patent No.6502435 Patent Literature 7: Japanese Patent No.6502436 Patent Literature 8: JP-A-2017-137447 Summary of InventionTechnical Problem

[0006] However, the following problems were observed when the combustion chamber bricks of the coke oven were replaced in such a manner that bricks of several flues from the oven mouth were partially replaced, or all the bricks were replaced (through replacing), in a hot condition. That is, in these cases, there was observed a phenomenon where the neighboring combustion chambers adjacent to the combustion chamber that has been repaired and the remaining bricks of an unrepaired portion that has remained without being dismantled would bulge toward the carbonization chamber side after repair. With the bricks of the combustion chamber bulging toward the carbonization chamber side, there occurs a problem that when using a pusher machine to discharge the carbonized coke in the carbonization chamber, the pusher ram will stop as a result of coming into contact with the bulging bricks, which leads to an extrusion clogging trouble where the coke fails to be discharged out of the coke oven.

[0007] It is an object of the present invention to provide a method and device for repairing a coke oven, which are capable of solving the above problem so that when repairing, in a hot condition, the bricks composing the wall of a combustion chamber in a coke oven, extrusion clogging will not occur as the neighboring non-replacement target combustion chambers that do not require repair and are adjacent to the replacement target combustion chamber that is to be replaced for repair and the remaining bricks of an unrepaired portion that has remained without being dismantled will not exhibit oven wall bulge toward the carbonization chamber side after repair.Solution to Problem

[0008] The method of the present invention for repairing a coke oven is a method of repairing a coke oven by replacing, in a hot condition, bricks of one combustion chamber that compose the coke oven or bricks of a plurality of continuous combustion chambers that compose the coke oven with two or more oven wall bricks and binder bricks along an oven longitudinal direction from an oven mouth. This method includes: a confirmation step in which a three-dimensional measurement device is used to observe, from the oven mouth, concavity and convexity of an oven wall of a neighboring non-replacement target combustion chamber that is adjacent to one side surface of one replacement target combustion chamber or a plurality of continuous replacement target combustion chambers, and concavity and convexity of an oven wall of a neighboring non-replacement target combustion chamber that is adjacent to the other side surface of the one replacement target combustion chamber or plurality of continuous replacement target combustion chambers, thereby confirming that bulging amounts of the oven walls of the neighboring non-replacement target combustion chambers are each smaller than a given value; a replacement step in which when the bulging amounts of the oven walls of the neighboring non-replacement target combustion chambers have each been confirmed to be smaller than the given value in the confirmation step, a portion of an oven wall of the one replacement target combustion chamber or plurality of continuous replacement target combustion chambers, which requires repair, is dismantled, followed by newly stacking oven wall bricks and binder bricks in the dismantled area; and a step of using a previously formed oven wall refractory aggregate and a previously formed ceiling part refractory aggregate as a newly stacked oven wall and ceiling part in the replacement target combustion chamber.

[0009] Further, as for the method of the present invention for repairing a coke oven, which is configured in the above manner, it is considered that more preferable solutions can be brought when: (1) the given value of the bulging amount is a value capable of ensuring an extrusion clogging rate that does not hinder a normal operation, the extrusion clogging rate being calculated by the following formula (1): Extrusion clogging rate % = 5 × 10 − 8 × d 5 wherein d (mm) represents the bulging amount, (2) the ensured extrusion clogging rate that does not hinder a normal operation is 5%, and the given value of the bulging amount is 40 mm by calculating d from the formula (1), (3) the method further includes: a repair range determination step in which before dismantling a portion of the replacement target combustion chamber that requires repair, a three-dimensional measurement device is used to observe the concavity and convexity of the oven walls from the oven mouth to determine a range of oven wall bricks and binder bricks that requires repair; and a dismantling step in which the convexity of the oven walls that has been determined in the repair range determination step is further checked through a flue hole, whereafter binder bricks ranging from those that have been determined as sound to those close to the oven mouth are dismantled, (4) with part of an oven wall of a combustion chamber being previously opened, a gas hole and an air hole in the existing combustion chamber are lidded with a curing member or lidded by being filled with a heat insulation material from a flue hole that is provided at an upper part of the oven wall of the combustion chamber, whereby falling scraps can be restricted from mixing into a regenerative chamber at the time of dismantling the replacement target combustion chamber, (5) repair operation is performed with respect to a pair of neighboring combustion chambers integrally formed by stacking integral type or two-split type precast blocks in a hollow cavity of bricks formed at a ceiling part of the pair of neighboring combustion chambers, (6) the method further includes: a step of installing a heat insulation panel by placing the heat insulation panel on a conveying carriage and then performing pulling with a traction wire so as to introduce the heat insulation panel into a given carbonization chamber and stop, or by pushing out the heat insulation panel with a pusher machine before stopping, prior to dismantling a portion of the replacement target combustion chamber that requires repair, (7) the method further includes: a step of using a carrier of heavy machinery for dismantling when dismantling a portion of the replacement target combustion chamber that requires repair, (8) the method further includes: a step of using a carrier that traverses over the coke oven to transport and import the oven wall refractory aggregate and the ceiling part refractory aggregate, (9) the method further includes: a step of performing positioning in a horizontal direction with a laser light when horizontally arranging the oven wall refractory aggregate and ceiling part refractory aggregate; and a step of installing a spacer for achieving a constant mortar joint thickness, (10) the method further includes: a step of installing the ceiling part refractory aggregate and then pouring a castable refractory into a gap surrounding the ceiling part refractory aggregate so as to fill the same, when newly forming a replacing ceiling part, and (11) integrally formed blocks that are integrally formed by a monolithic refractory are previously prepared by dividing a wall body composing the combustion chamber into a plurality of blocks, the wall body is then dismantled and taken out of the coke oven, followed by carrying the integrally formed blocks into the coke oven and arranging them in such a manner that an end portion of each integrally formed block is to be abutted against two orthogonal surfaces that are provided at an end portion of the existing wall body, thereby rebuilding the wall body.

[0010] Further, as for a device of the present invention for repairing a coke oven, which is used in the above coke oven repairing method, it is considered that more preferable solutions can be brought when: (1) the device includes: slide gates that are provided on an oven top portion of the coke oven, are capable of moving in a traverse direction such that an opening portion occurring when dismantling the oven top portion of the coke oven can be opened at the time of dismantling the coke oven and closed when the coke oven dismantling operation is stopped, and are provided with a safety handrail therearound, (2) the device includes: a heat insulation structural body with several kinds of heat insulation materials being placed on top of one another in an iron frame and being fixed and integrated therein, the heat insulation structural body being installed between a replacement target combustion chamber and its neighboring non-replacement target combustion chamber for the purpose of retaining the heat of the neighboring non-replacement target combustion chamber adjacent to the replacement target combustion chamber and thus heat-insulating a space for replacing operation in the replacement target combustion chamber, when dismantling the coke oven, (3) the device includes: a slide-type scaffold that is provided for realizing fall prevention of an operator and securing the operator's foothold during operation, the slide-type scaffold being detachable from outside the coke oven and being configured to allow two or more said slide-type scaffolds to be coupled and connected to one another, and (4) the device includes: a ceiling restraining beam that is formed by welding and fixing a beam and a heat insulation structural body with a heat insulation material being abutted against existing bricks, the ceiling restraining beam being configured to heat-insulate and prevent the collapse of existing bricks of a neighboring non-replacement target combustion chamber adjacent to a replacement target combustion chamber that is to repaired, when dismantling a ceiling part of said replacement target combustion chamber. Advantageous Effects of Invention

[0011] According to the method and device of the present invention for repairing a coke oven, before dismantling the bricks of a replacement target combustion chamber as a target of repair, by observing the condition of the walls of the neighboring non-replacement target combustion chambers, a proper range of oven wall bricks and binder bricks that is to be repaired can be determined, thereby making it possible to solve the problem that the walls of the neighboring non-replacement target combustion chambers will bulge toward the carbonization chamber after repair.Brief Description of Drawings

[0012] [FIG.1A] is a drawing showing how repair takes place when there is no bulge on the oven walls of neighboring non-replacement target combustion chambers. [FIG.1B] is another drawing showing how repair takes place when there is no bulge on the oven walls of the neighboring non-replacement target combustion chambers. [FIG.1C] is yet another drawing showing how repair takes place when there is no bulge on the oven walls of the neighboring non-replacement target combustion chambers. [FIG.2A] is a drawing showing how repair takes place when there is bulge on the oven walls of the neighboring non-replacement target combustion chambers. [FIG.2B] is another drawing showing how repair takes place when there is bulge on the oven walls of the neighboring non-replacement target combustion chambers. [FIG.2C] is yet another drawing showing how repair takes place when there is bulge on the oven walls of the neighboring non-replacement target combustion chambers. [FIG.3] is a set of drawings in which FIGs.3(a) and (b) are each a drawing showing an example of a slide gate, which serves as a preferable embodiment in the method of the present invention for repairing a coke oven. [FIG.4] is a set of drawings in which FIGs.4(a) and (b) are each a drawing showing an example of a heat insulation structural body, which serves as a preferable embodiment in a coke oven repairing device used in the method of the present invention for repairing a coke oven. [FIG.5] is a drawing showing an example of previous gas hole curing, which serves as a preferable embodiment in the method of the present invention for repairing a coke oven. [FIG.6] is a set of drawings in which FIGs.6(a) and (b) are each a drawing showing an example of an in-oven slide scaffold, which serves as a preferable embodiment in the coke oven repairing device used in the method of the present invention for repairing a coke oven. [FIG.7] is a drawing showing an example of a ceiling restraining beam, which serves as a preferable embodiment in the coke oven repairing device used in the method of the present invention for repairing a coke oven. [FIG.8] is a drawing showing an example of a crossover MCB, which serves as a preferable embodiment in the method of the present invention for repairing a coke oven. [FIG.9] is a drawing showing a working state of Example 1. [FIG. 10] is a drawing showing a working state of Example 2. [FIG. 11] is a drawing showing a working state of Example 3. [FIG.12] is a graph showing a correlation between an extrusion clogging rate and a bulging amount under a fully charged condition of 30 t of coal. [FIG.13] is a drawing showing an example of a known coke oven. [FIG.14] is a drawing showing the known coke oven from above. Description of Embodiments

[0013] An embodiment of the present invention is described in detail hereunder. Here, the following embodiment is a set of examples of a device and / or method embodying the technical concept of the present invention and is not to limit the configuration of the present invention to those shown below. That is, various modifications can be made to the technical concept of the present invention within the technical scope described in the claims.<Overview of the present invention>

[0014] The present invention relates to a method and device for repairing a coke oven and was achieved based on the following findings. Conventionally, in a method for repairing a coke oven, there has been a problem that when repairing a replacement target combustion chamber that is to be repaired, the oven walls of neighboring non-replacement target combustion chambers that are adjacent to the replacement target combustion chamber will each bulge toward the carbonization chamber side. Further, with the neighboring non-replacement target combustion chambers bulging significantly, there has also been a problem that a heat insulation panel(s) cannot be installed properly, whereby the temperature of the neighboring non-replacement target combustion chamber will decrease such that it will bulge into the carbonization chamber. In order to solve these problems, before repairing a replacement target combustion chamber, the condition of the oven walls of the neighboring non-replacement target combustion chambers is observed, and the condition is then deemed as sound when the oven walls of the neighboring non-replacement target combustion chambers meet certain conditions. It was found that by repairing a replacement target combustion chamber under a condition where the neighboring non-replacement target combustion chambers have been deemed as sound, the oven walls of the neighboring non-replacement target combustion chambers would not bulge toward the carbonization chamber side after repair.

[0015] Here, in the present invention, the neighboring non-replacement target combustion chambers that are adjacent to a replacement target combustion chamber(s) refer to a neighboring non-replacement target combustion chamber that is adjacent to one side surface of one replacement target combustion chamber or a plurality of continuous replacement target combustion chambers, and a neighboring non-replacement target combustion chamber that is adjacent to the other side surface of such one replacement target combustion chamber or plurality of continuous replacement target combustion chambers. However, in the following description, the method of the present invention for repairing a coke oven is described on the premise that there is one replacement target combustion chamber. In addition, it is needless to say that the following description likewise applies to a plurality of continuous replacement target combustion chambers.

[0016] FIGs.1A to 1C are each a drawing showing how repair takes place when there is no bulge on the oven walls of the neighboring non-replacement target combustion chambers. In the beginning, as shown in FIG.1A, a three-dimensional measurement device is used to observe the concavity and convexity of the oven wall of a neighboring non-replacement target combustion chamber that is adjacent to one side surface of the replacement target combustion chamber to be repaired, and the concavity and convexity of the oven wall of a neighboring non-replacement target combustion chamber that is adjacent to the other side surface of such replacement target combustion chamber, whereby it is confirmed that the bulge of the oven walls of the neighboring non-replacement target combustion chambers is smaller than a given value. Next, as shown in FIG.1B, a heat insulation panel is arranged on surfaces of the neighboring non-replacement target combustion chambers that face the replacement target combustion chamber to be repaired, and a portion of the replacement target combustion chamber that is to be replaced is dismantled. Later, as shown in FIG.1C, the dismantled portion of the replacement target combustion chamber is replaced so as to repair the replacement target combustion chamber that is to be repaired. At that time, as for the neighboring combustion chambers for which their oven wall bulge has been confirmed to be smaller than the given value as shown in FIG.1A, none of them exhibits oven wall bulge as shown in FIG.1C.

[0017] FIGs.2A to 2C are each a drawing showing how repair takes place when there is a bulge on the oven walls of the neighboring non-replacement target combustion chambers. In the beginning, as shown in FIG.2A, a three-dimensional measurement device is used to observe the concavity and convexity of the oven wall of a neighboring non-replacement target combustion chamber that is adjacent to one side surface of the replacement target combustion chamber to be repaired, and the concavity and convexity of the oven wall of a neighboring non-replacement target combustion chamber that is adjacent to the other side surface of such replacement target combustion chamber. FIG.2A shows an example where it was observed that the oven wall of a neighboring non-replacement target combustion chamber adjacent to the upper side of the replacement target combustion chamber bulged by an amount as large as or larger than the given value, and that the oven wall of a neighboring non-replacement target combustion chamber adjacent to the lower side of the replacement target combustion chamber bulged by an amount smaller than the given value. Next, as shown in FIG.2B, a heat insulation panel is arranged on surfaces of the neighboring non-replacement target combustion chambers that face the replacement target combustion chamber to be repaired, and a portion of the replacement target combustion chamber that is to be replaced is dismantled. At that time, as for the oven wall of the neighboring non-replacement target combustion chamber on the upper side, that is bulging by an amount as large as or larger than the given value, the bulging part becomes a hindrance when installing the heat insulation panel. Later, as shown in FIG.2C, the dismantled portion of the replacement target combustion chamber is replaced so as to repair the replacement target combustion chamber that is to be repaired. There, as for the neighboring non-replacement target combustion chamber on the upper side for which its oven wall bulge has been confirmed to be as large as or larger than the given value as shown in FIG.2A, the bulging amount thereof after the replacement is larger than before the replacement as shown in FIG.2C. Meanwhile, as for the neighboring non-replacement target combustion chamber on the lower side for which its oven wall bulge has been confirmed to be smaller than the given value as shown in FIG.2A, the bulging amount thereof does not change before and after the replacement as shown in FIG.2C.

[0018] The method of the present invention for repairing a coke oven, which was achieved based on the above findings, is a method of repairing a coke oven by replacing, in a hot condition, the bricks of one combustion chamber that compose the coke oven or the bricks of a plurality of continuous combustion chambers that compose the coke oven with two or more oven wall bricks and binder bricks along the oven longitudinal direction from the oven mouth. This method is characterized by including a confirmation step and a replacement step. The confirmation step is a step in which a three-dimensional measurement device is used to observe, from the oven mouth, the concavity and convexity of the oven wall of a neighboring non-replacement target combustion chamber that is adjacent to one side surface of one replacement target combustion chamber or a plurality of continuous replacement target combustion chambers, and the concavity and convexity of the oven wall of a neighboring non-replacement target combustion chamber that is adjacent to the other side surface of such one replacement target combustion chamber or plurality of continuous replacement target combustion chambers, thereby confirming that the bulging amounts of the oven walls of these neighboring non-replacement target combustion chambers are each smaller than the given value. The replacement step is a step in which when the bulging amounts of the oven walls of the neighboring non-replacement target combustion chambers have each been confirmed to be smaller than the given value in the confirmation step, a portion(s) of the oven wall(s) of the one replacement target combustion chamber or the plurality of continuous replacement target combustion chambers, which require repair, is dismantled, followed by newly stacking oven wall bricks and binder bricks in the dismantled area.

[0019] According to the above method of the present invention for repairing a coke oven, when repairing, in a hot condition, the bricks composing the oven wall of a combustion chamber of the coke oven, neither the oven wall of the neighboring non-replacement target combustion chamber that is adjacent to the one side surface nor the oven wall of the neighboring non-replacement target combustion chamber that is adjacent to the other side surface will bulge toward the carbonization chamber side after repair.

[0020] In addition, the method of the present invention for repairing a coke oven further includes a step of using a previously formed oven wall refractory aggregate and a previously formed ceiling part refractory aggregate as a newly stacked oven wall and ceiling part in the replacement target combustion chamber, as described in Patent Literature 4 (publication of Japanese Patent No.6280453). According to this embodiment, with the method of the present invention for repairing a coke oven, there can be provided a repairing method capable of improving efficiency in repair operations. Here, the refractory aggregate mentioned above refers to, for example, a refractory brick block body and a sintered or non-sintered castable block.

[0021] Further, as a preferable embodiment, the method of the present invention for repairing a coke oven includes a repair range determination step and a dismantling step. The repair range determination step is a step in which before dismantling a portion of the replacement target combustion chamber that requires repair, a three-dimensional measurement device is used to observe the concavity and convexity of the oven wall from the oven mouth to determine a range of oven wall bricks and binder bricks that requires repair. The dismantling step is a step in which the convexity of the oven wall that has been determined in the repair range determination step is further checked through the flue hole, whereafter binder bricks ranging from those that have been determined as sound to those close to the oven mouth are dismantled.

[0022] According to the above preferable embodiment of the method of the present invention for repairing a coke oven, when repairing, in a hot condition, the bricks composing the oven wall of a combustion chamber of the coke oven, the remaining bricks of an unrepaired portion in the replacement target combustion chamber to be repaired, which have remained without being dismantled, will not bulge toward the carbonization chamber side after repair.<Preferable embodiments in method and device of the present invention for repairing coke oven>(1) Preferable embodiment in repairing device (slide gate):

[0023] FIGs.3(a) and (b) are each a drawing showing an example of a slide gate(s), which serves as a preferable embodiment in the method of the present invention for repairing a coke oven. FIGs.3(a) and (b) are top views showing a combustion chamber from above; a symbol "1" indicates a charging car rail for a charging car that charges coal into the combustion chamber, symbols "2-1" and "2-2" indicate movable slide gates for opening and closing an opening portion 3 on the coke oven, a symbol "4" indicates a slide gate rail for moving the slide gates 2-1 and 2-2, and a symbol "5" indicates a safety handrail provided at each slide gate.

[0024] The opening portion 3 mentioned in this embodiment is formed by, for example, collapse of the ceiling part of the replacement target combustion chamber that is to be repaired. The slide gates 2-1 and 2-2 are provided at a repair target portion having the opening portion 3 of the ceiling part of the replacement target combustion chamber that is to be repaired, and are removed after repair. The slide gates 2-1 and 2-2 are capable of moving in a traverse direction along the slide gate rail 4. By allowing the slide gates 2-1 and 2-2 to move in opposite directions from each other, the opening portion 3 can be closed when the operation is stopped as shown in FIG.3(a) and opened at the time of operation as shown in FIG.3(b). As shown in FIG.3(b), the safety handrail 5 is provided for the purpose of preventing people and objects from falling while the opening portion 3 remains opened.

[0025] Often, when dismantling the oven top portion of a coke oven, the opening portion 3 will occur on the coke oven such that people and objects may fall from such opening portion 3. In the method of the present invention for repairing a coke oven, by installing the slide gates 2-1 and 2-2 of this embodiment, fall (people, objects) from the opening portion 3 can be favorably prevented.(2) Preferable embodiment in repairing device (heat insulation structural body):

[0026] FIGs.4(a) and (b) are each a drawing showing an example of a heat insulation structural body, which serves as a preferable embodiment in a coke oven repairing device used in the method of the present invention for repairing a coke oven. In FIGs.4(a) and (b), a heat insulation structural body 11 of this embodiment is a heat insulation structural body with several kinds of heat insulation materials 13-1 and 13-2 being placed on top of one another in an iron frame(s) 12 and being fixed and integrated therein.

[0027] As shown by its cross-sectional surface in FIG.4(b), the heat insulation structural body 11 is composed of a pair of iron frames 12, a pair of biosoluble heat insulation materials 13-1 provided between the iron frames 12, and a high-performance heat insulation material 13-2 sandwiched between the biosoluble heat insulation materials 13-1. The high-performance heat insulation material 13-2 has a thermal conductivity of up to 0.003 W / mk, which is about 1 / 10 of the thermal conductivity of the biosoluble heat insulation materials 13-1. By using the high-performance heat insulation material 13-2, the thickness of the heat insulation structural body 11 can be reduced. Further, the high-performance heat insulation material 13-2 itself is brittle. Thus, by sandwiching the high-performance heat insulation material 13-2 with the pair of biosoluble heat insulation materials 13-1, the high-performance heat insulation material 13-2 can be favorably fixed. The heat insulation structural body 11 is provided only at a portion of the replacement target combustion chamber that is to be dismantled.

[0028] The heat insulation structural body 11 of this embodiment is to be installed between a replacement target combustion chamber and its neighboring non-replacement target combustion chamber for the purpose of retaining the heat of the neighboring non-replacement target combustion chamber adjacent to the replacement target combustion chamber and thus heat-insulating a space for replacing operation in the replacement target combustion chamber, when dismantling the coke oven. In the coke oven repairing device used in the method of the present invention for repairing a coke oven, by arranging the heat insulation structural body 11 of this embodiment on a surface facing the replacement target combustion chamber that is to be repaired outside the neighboring non-replacement target combustion chamber, the heat of the existing oven wall (neighboring combustion chamber) can be retained whereby the space for brick replacing operation can be favorably heat-insulated.(3) Preferable embodiment in repairing method (previous gas hole curing):

[0029] FIG.5 is a drawing showing an example of previous gas hole curing, which serves as a preferable embodiment in the method of the present invention for repairing a coke oven. FIG.5 is a top view showing the lower part of a combustion chamber from above; provided on the bottom part of the combustion chamber are a M gas (mixed gas of blast furnace gas and coke gas) hole 21, a C gas (coke gas) hole 22, and an air hole 23. In this embodiment, it is preferred that these gas holes be previously cured before repair.

[0030] That is, with part of the oven wall of the combustion chamber being previously opened, the gas holes and air hole in the existing combustion chamber are lidded with a curing member. As one example of performing curing with a lid, there is a method where, before repair, the oven wall bricks in the lower part of the combustion chamber to be repaired are dismantled, followed by installing a heat insulation material (iron sheet and cloth) in the bottom part of the combustion chamber. As another example of performing curing with a lid, there is a method where, before repair, the heat insulation material is to be put into the combustion chamber from the flue hole provided at the upper part of the replacement target combustion chamber that is to be repaired, to the extent that the inner side is filled. The curing of the gas holes may simply be performed only on a portion corresponding to a portion of the replacement target combustion chamber that is to be dismantled.

[0031] In the method of the present invention for repairing a coke oven, by performing the previous gas hole curing of this embodiment, as far as the combustion chamber to be repaired is concerned, scraps falling at the time of dismantling can be restricted from mixing into the regenerative chamber. In this way, the necessity of removing by suction the falling scraps that have entered the regenerative chamber can be favorably reduced, as has been necessary in the conventional setting.(4) Preferable embodiment in repairing device (in-oven slide scaffold):

[0032] FIGs.6(a) and (b) are each a drawing showing an example of an in-oven slide scaffold, which serves as a preferable embodiment in a coke oven repairing device used in the method of the present invention for repairing a coke oven. In FIGs.6(a) and (b), a symbol "31" indicates a coke oven, and a symbol "32" indicates an in-oven slide scaffold installed in the coke oven. The in-oven slide scaffold 32 of this embodiment is provided for realizing fall prevention of an operator 33 and securing the operator's foothold during operation, the in-oven slide scaffold 32 being a slide-type scaffold that is detachable from outside the coke oven 31 and is configured to allow two or more such in-oven slide scaffolds 32 to be coupled and connected to one another.

[0033] The in-oven slide scaffold 32 of this embodiment is such that it is to be installed in the carbonization chamber of the coke oven 31 from the oven mouth side, whereby a foothold is established inside the carbonization chamber, which allows the in-oven slide scaffold 32 to be used for securing a foothold of the operator. The in-oven slide scaffold(s) 32 can be extended by being coupled while being slid in the in-oven direction, and can also be stacked by being coupled in the oven height direction. In the case of the coke oven repairing device used in the method of the present invention for repairing a coke oven, by using the in-oven slide scaffold of this embodiment, an operator in charge of the repair operation can be favorably prevented from falling, and the operator's foothold during operation can be favorably secured.(5) Preferable embodiment in repairing device (ceiling restraining beam):

[0034] FIG.7 is a drawing showing an example of a ceiling restraining beam, which serves as a preferable embodiment in a coke oven repairing device used in the method of the present invention for repairing a coke oven. In FIG.7, a ceiling restraining beam 41 is configured in such a manner that a heat insulation structural body 44 integrated by fixing a heat insulation material 42 with an iron frame 43 is abutted against an existing ceiling part 45 of the coke oven, and a beam 46 is welded and fixed to the iron frame 43. The ceiling restraining beam 41 may simply be formed only at a portion corresponding to a portion of the replacement target combustion chamber that is to be dismantled.

[0035] In the case of the coke oven repairing device used in the method of the present invention for repairing a coke oven, by using the ceiling restraining beam of this embodiment, heat insulation and collapse prevention of the existing bricks can be favorably realized after dismantling the ceiling part of the combustion chamber to be repaired.(6) Preferable embodiment in repairing method (crossover MCB):

[0036] FIG.8 is a drawing showing an example of a crossover MCB (Module Castable Blocks), which serves as a preferable embodiment in the method of the present invention for repairing a coke oven. In FIG.8, there is shown a configuration in which a passage for discharging a combustion exhaust gas is established between neighboring combustion chambers. In this embodiment, the configuration is formed and stacked with integral type or two-split type large-scale precast blocks including a hollow cavity of bricks (portions indicated by arrows in FIG.8).

[0037] In a coke oven having the crossover MCB of this embodiment, a pair of combustion chambers is treated as one combustion chamber. Thus, in this embodiment, the repair operation is not performed with respect to each induvial combustion chamber, but performed with respect to a pair of combustion chambers integrally formed by stacking integral type or two-split type precast blocks in the hollow cavity of the bricks formed at the ceiling part of neighboring combustion chambers. In this way, even in a coke oven having a crossover MCB, the method of the present invention for repairing a coke oven can be favorably applied.<Known techniques favorably applicable to the method of the present invention for repairing a coke oven>

[0038] With regard to the above method of the present invention for repairing a coke oven, more preferable embodiments include a coke oven repairing method and coke oven repairing device employing the following exemplified known techniques that have already been disclosed in patent publications and patent application publications.

[0039] In the case of the method of the present invention for repairing a coke oven, it is preferred that the method include a step of installing a heat insulation panel by placing the heat insulation panel on a conveying carriage and then performing pulling with a traction wire so as to introduce the heat insulation panel into a given carbonization chamber and stop, or by pushing out the heat insulation panel with a pusher machine before stopping, prior to dismantling a portion of the replacement target combustion chamber that requires repair, as described in Patent Literature 2 (JP-A-No.2022-110682). According to this embodiment, with the method of the present invention for repairing a coke oven, when repairing a combustion chamber wall ranging from the pusher machine side of the coke oven to the quenching car side thereof over the entire length, a heat insulation wall for protecting the operator(s) can be installed in the coke oven in an inexpensive manner and a short period of time.

[0040] It is preferred that the method of the present invention for repairing a coke oven include a step of using a carrier of heavy machinery for dismantling when dismantling a portion of the replacement target combustion chamber that requires repair, as described in Patent Literature 3 (publication of Japanese Patent No.6587951). According to this embodiment, with the method of the present invention for repairing a coke oven, a heavy machinery for dismantling can be easily transported to a site where the wall body and ceiling of a combustion chamber of a coke oven are to be dismantled. As a result, the dismantling operation can be performed efficiently and safely, whereby shortening of work periods and reduction of work cost are made possible.

[0041] It is preferred that the method of the present invention for repairing a coke oven include a step of using a carrier that traverses over the coke oven to transport the oven wall refractory aggregate and the ceiling part refractory aggregate, as described in Patent Literature 5 (publication of Japanese Patent No.6482484). According to this embodiment, with the method of the present invention for repairing a coke oven, module blocks for rebuilding the wall body and ceiling of a combustion chamber of a coke oven can be efficiently transported to a site for repair work, and such module blocks and castable blocks can be easily and safely imported into the coke oven.

[0042] It is preferred that the method of the present invention for repairing a coke oven include a step of performing positioning in a horizontal direction with a laser light when horizontally arranging the oven wall refractory aggregate and ceiling part refractory aggregate; and a step of installing a spacer for achieving a constant mortar joint thickness, as described in Patent Literature 6 (publication of Japanese Patent No.6502435). According to this embodiment, with the method of the present invention for repairing a coke oven, wall bodies built by stacking module blocks can be prevented from deforming and collapsing.

[0043] It is preferred that the method of the present invention for repairing a coke oven include a step of installing a ceiling part refractory aggregate and then pouring a castable refractory into a gap surrounding the ceiling part refractory aggregate so as to fill the same, when newly forming a replacing ceiling part, as described in Patent Literature 7 (publication of Japanese Patent No.6502436). According to this embodiment, with the method of the present invention for repairing a coke oven, the ceilings of the carbonization chambers and combustion chambers in a coke oven can be repaired in an efficient manner and in a short period of time.

[0044] It is preferred that the method of the present invention for repairing a coke oven be performed in the following manner as described in Patent Literature 8 (JP-A- 2017-137447). That is, integrally formed blocks that are integrally formed by a monolithic refractory are previously prepared by dividing a wall body composing a combustion chamber into a plurality of blocks, the wall body is then dismantled and taken out of the coke oven, followed by carrying the integrally formed blocks into the coke oven and arranging them in such a manner that an end portion of each integrally formed block is to be abutted against two orthogonal surfaces that are provided at an end portion of the existing wall body, thereby rebuilding the wall body. According to this embodiment, with the method of the present invention for repairing a coke oven, the repair work of a combustion chamber in a coke oven can be carried out efficiently, which leads to shortening of work periods, a reduction in workload, an improvement in safety as well as an improvement in durability after repair.<Embodiments with preferable given values in the present invention>

[0045] Preferable given values in the present invention are determined as follows. Coke that has undergone carbonization is discharged into a quenching car from inside the coke oven via a pusher ram. At that time, due to equipment troubles or the like of the pusher ram, extrusion clogging may occur. One reason for that is because the movement of the pusher ram is interfered with due to the bulge of the combustion chamber bricks, which leads to extrusion clogging.

[0046] In the present invention, based on a correlation between the bulging amount of the bricks and an extrusion clogging rate, there is derived an embodiment with a favorable given value in terms of an upper limit of the bulging amount at which extrusion clogging will not occur. Specifically, the extrusion clogging rate and bulging amount were actually calculated in the case of a coke oven fully charged and filled with 30 t of coal. The following Table 1 shows data of the extrusion clogging rate and bulging amount that were calculated when the amount of coal charged was 30 t. Further, FIG.12 is a graph plotting a correlation between the extrusion clogging rate and bulging amount based on the data shown in Table 1. [Table 1]No.Extrusion clogging rate (%)Bulging amount (mm)No.Extrusion clogging rate (%)Bulging amount (mm)10514230205153383051664240101784650151810476151924707152025608110212665911522285610115233057111202433581222525335913227263360

[0047] From the results shown in Table 1 and FIG.12, the following formula (1) was obtained via regression analysis. Extrusion clogging rate % = 5 × 10 − 8 × d 5

[0048] Here, d (mm) represents the bulging amount.

[0049] Thus, it can be understood that the preferable given value in the present invention is a value capable of ensuring an extrusion clogging rate that does not hinder a normal operation, the extrusion clogging rate being calculated by the formula (1).

[0050] Here, in a normal coke oven operation, since it is considered that operation can be carried out with almost no problem when the extrusion clogging rate is <5%, it is considered that there will be no trouble of extrusion clogging so long as the bulging amount d is that satisfying formula (1)<5%. Here, the range of d is calculated from the formula (1) as follows. Extrusion clogging rate % = 5 × 10 − 8 × d 5 < 5 ⇔ d < 5 ÷ 5 × 10 − 8 1 / 5 = 40 mm ← 10 8 / 5 = 39.8

[0051] As is clear from this result, the preferable given value of the bulging amount is 40 mm, and an example of its specific range is less than 40 mm.Examples<Example 1>

[0052] As shown in FIG.9, with regard to a combustion chamber (replacement target combustion chamber) that was to be repaired and composed a coke oven, and two combustion chambers (neighboring non-replacement target combustion chambers) that were adjacent to the combustion chamber to be repaired and likewise composed the coke oven, concavity and convexity measurement was carried out, via a laser scanner, with respect to oven walls at given sites of oven mouth bricks of the neighboring combustion chambers (neighboring non-replacement target combustion chambers) before and after replacing the combustion chamber (replacement target combustion chamber) that was to be repaired. Further, before replacing the combustion chamber that was to be repaired (replacement target combustion chamber), the presence or non-presence of cracks was observed via observation from flue holes. The results are shown in the following Table 2. [Table 2]Concavity and convexity measurement on oven wall by laser scannerCracks observed from flue holeConcavity and convexity measurement on oven wall by laser scannerBefore replacingAfter replacingOven mouth brick 3Oven mouth brick 4Oven mouth brick 3Oven mouth brick 4Present Invention 1+5mm+5mmNot observed+10mm+10mmPresent Invention 2+10mm+10mmNot observed+15mm+15mmComparative Example 1+40mm+15mmObserved+60mm+25mm(+ indicates bulge, - indicates depression)

[0053] As is clear from the results shown in Table 2, when an oven mouth bulging amount of the neighboring combustion chambers (neighboring non-replacement target combustion chambers) before replacing was +40 mm, the bulge intensified after replacing. Thus, it was made clear that the oven mouth bulging amount of the neighboring combustion chambers (neighboring non-replacement target combustion chambers) before replacing needed to be less than +40 mm. Further, it was also made clear that when such bulging amount was ≤15 mm, there was not much change after replacing (range of measurement error). In addition, it can be understood that there is a correlation between the intensity of the oven mouth bulging amount and the presence or non-presence of brick cracks from within the flue holes.<Example 2>

[0054] As shown in FIG.10, with regard to an example in which oven mouth bulge prevention bricks were arranged between a combustion chamber (replacement target combustion chamber) that was to be repaired and composed a coke oven and two combustion chambers (neighboring non-replacement target combustion chambers) that were adjacent to the combustion chamber to be repaired and likewise composed the coke oven, concavity and convexity measurement was carried out, via a laser scanner, with respect to oven walls at given sites of oven mouth bricks of the neighboring combustion chambers (neighboring non-replacement target combustion chambers) before and after replacing the combustion chamber (replacement target combustion chamber) that was to be repaired. Further, before replacing the combustion chamber that was to be repaired (replacement target combustion chamber), the presence or non-presence of cracks was observed via observation from flue holes. The results are shown in the following Table 3. [Table 3]Concavity and convexity measurement on oven wall by laser scannerCracks observed from flue holeInstallation of bulge prevention brick at oven mouth positionConcavity and convexity measurement on oven wall by laser scannerBefore replacingAfter replacingOven mouth brick 3Oven mouth brick 4Oven mouth brick 3Oven mouth brick 4Present Invention 3+10mm+15mmNot observedInstalled+10mm+15mmPresent Invention 4+35mm+30mmNot observedInstalled+38mm+32mmComparative Example 2+40mm+25mmObservedInstalled+47mm+27mm(+ indicates bulge, - indicates depression)

[0055] As is clear from the results shown in Table 3, bulge after replacing was able to be restricted by installing the bulge prevention bricks at the oven mouth. However, it can be understood that when the bulging amount was as large as +40 mm, it was difficult to restrict the bulge from intensifying even with the use of the bulge prevention bricks.<Example 3>

[0056] As shown in FIG.11, there was studied a case where part of a combustion chamber (replacement target combustion chamber) that was to be repaired was left when performing repair. With regard to an example in which oven mouth bulge prevention bricks were arranged between a combustion chamber (replacement target combustion chamber) that was to be partially repaired and composed a coke oven, and two combustion chambers (neighboring non-replacement target combustion chambers) that were adjacent to the combustion chamber (replacement target combustion chamber) to be repaired and likewise composed the coke oven, concavity and convexity measurement was carried out, via a laser scanner, with respect to oven walls at given sites of oven mouth bricks of the neighboring combustion chambers (neighboring non-replacement target combustion chambers) before and after replacing the combustion chamber (replacement target combustion chamber) that was to be repaired. Further, before replacing the combustion chamber that was to be repaired (replacement target combustion chamber), the presence or non-presence of cracks was observed via observation from flue holes. The results are shown in the following Table 4. [Table 4]Concavity and convexity measurement on oven wall by laser scannerObservation from flue hole (presence or non-presence of cracks)Bulge prevention brick installed / not installedConcavity and convexity measurement on oven wall by laser scannerBefore replacingAfter replacingOven mouth brick 3Oven mouth brick 4Old brick 1Old brick 2Oven mouthRemaining combustion chamberOven mouthRemaining combustion chamberOven mouth brick 3Oven mouth brick 4Old brick 1Old brick 2Present Invention 5+ 5mm+ 5mm+ 5mm+ 5mmNot observedNot observedNot installedNot installed+ 10mm+ 10mm+ 10mm+ 10mmPresent Invention 6+ 10mm+ 10mm+ 10mm+ 10mmNot observedNot observedNot installedInstalled+ 15mm+ 15mm+ 10mm+ 10mmPresent Invention 7+ 10mm+ 15mm+ 15mm+ 15mmNot observedNot observedInstalledInstalled+ 10mm+ 15mm±0mm±0mmComparative Example 3+ 5mm+ 5mm+ 10mm+ 10mmNot observedObservedNot installedNot installed+ 10mm+ 10mm+ 40mm+ 50mmComparative Example 4+ 10mm+ 10mm+ 10mm+ 10mmNot observedObservedNot installedInstalled+ 15mm+ 15mm+ 30mm+ 30mmComparative Example 5+ 10mm+ 10mm+ 15mm+ 15mmNot observedObservedNot installedInstalled+ 15mm+ 15mm+ 40mm+ 35mm(+ indicates bulge, - indicates depression)

[0057] As is clear from the results shown in Table 4, when there were cracks in the combustion chamber (old bricks) that was left, there was observed bulge after performing replacing (even when there was observed no bulge on the oven wall of such particular part). Further, the above results indicate that bulge restriction was difficult regardless of whether or not the bulge prevention bricks were installed.Industrial Applicability

[0058] With the method and device of the present invention for repairing a coke oven, before dismantling the bricks of a replacement target combustion chamber as a repair target, a proper range of oven wall bricks and binder bricks that is to be repaired can be determined by observing the condition of the walls of neighboring combustion chambers (neighboring non-replacement target combustion chambers). Thus, the present invention is industrially useful because it is capable of solving the problem that the walls of the neighboring combustion chambers (neighboring non-replacement target combustion chambers) will bulge toward the carbonization chamber side after repair.Reference Signs List

[0059] 1 Charging car rail 2-1, 2-2 Slide gate 3 Opening portion 4 Slide gate rail 5 Safety handrail 11 Heat insulation structural body 12 Iron frame 13-1 Biosoluble heat insulation material 13-2 High-performance heat insulation material 21 M gas (mixed gas of blast furnace gas and coke gas) hole 22 C gas (coke gas) hole 23 Air hole 31 Coke oven 32 In-oven slide scaffold 33 Operator 41 Ceiling restraining beam 42 Heat insulation material 43 Iron frame 44 Heat insulation structural body 45 Ceiling part 46 Beam 51 Carbonization chamber 52 Combustion chamber 53 Regenerative chamber 54 Charging hole 55 Charging car 56 Pusher machine 56a Pusher ram 57 Guide car 58 Quenching car 59 Flue (vertical flue) 60 Buckstay

Examples

examples

[0052]As shown in FIG.9, with regard to a combustion chamber (replacement target combustion chamber) that was to be repaired and composed a coke oven, and two combustion chambers (neighboring non-replacement target combustion chambers) that were adjacent to the combustion chamber to be repaired and likewise composed the coke oven, concavity and convexity measurement was carried out, via a laser scanner, with respect to oven walls at given sites of oven mouth bricks of the neighboring combustion chambers (neighboring non-replacement target combustion chambers) before and after replacing the combustion chamber (replacement target combustion chamber) that was to be repaired. Further, before replacing the combustion chamber that was to be repaired (replacement target combustion chamber), the presence or non-presence of cracks was observed via observation from flue holes. The results are shown in the following Table 2.

[Table 2]

Concavity and convexity measurement on oven wall by laser sc...

Claims

1. A method for repairing a coke oven, which is a method of repairing a coke oven by replacing, in a hot condition, bricks of one combustion chamber that compose the coke oven or bricks of a plurality of continuous combustion chambers that compose the coke oven with two or more oven wall bricks and binder bricks along an oven longitudinal direction from an oven mouth, comprising: a confirmation step in which a three-dimensional measurement device is used to observe, from the oven mouth, concavity and convexity of an oven wall of a neighboring non-replacement target combustion chamber that is adjacent to one side surface of one replacement target combustion chamber or a plurality of continuous replacement target combustion chambers, and concavity and convexity of an oven wall of a neighboring non-replacement target combustion chamber that is adjacent to the other side surface of the one replacement target combustion chamber or plurality of continuous replacement target combustion chambers, thereby confirming that bulging amounts of the oven walls of the neighboring non-replacement target combustion chambers are each smaller than a given value; a replacement step in which when the bulging amounts of the oven walls of the neighboring non-replacement target combustion chambers have each been confirmed to be smaller than the given value in the confirmation step, a portion of an oven wall of the one replacement target combustion chamber or plurality of continuous replacement target combustion chambers, which requires repair, is dismantled, followed by newly stacking oven wall bricks and binder bricks in the dismantled area; and a step of using a previously formed oven wall refractory aggregate and a previously formed ceiling part refractory aggregate as a newly stacked oven wall and ceiling part in the replacement target combustion chamber.

2. The method for repairing a coke oven according to claim 1, wherein the given value of the bulging amount is a value capable of ensuring an extrusion clogging rate that does not hinder a normal operation, the extrusion clogging rate being calculated by the following formula (1): Extrusion clogging rate % = 5 × 10 − 8 × d 5 wherein d (mm) represents the bulging amount.

3. The method for repairing a coke oven according to claim 2, wherein the ensured extrusion clogging rate that does not hinder a normal operation is 5%, and the given value of the bulging amount is 40 mm by calculating d from the formula (1).

4. The method for repairing a coke oven according to claim 1, further comprising: a repair range determination step in which before dismantling a portion of the replacement target combustion chamber that requires repair, a three-dimensional measurement device is used to observe the concavity and convexity of the oven walls from the oven mouth to determine a range of oven wall bricks and binder bricks that requires repair; and a dismantling step in which the convexity of the oven walls that has been determined in the repair range determination step is further checked through a flue hole, whereafter binder bricks ranging from those that have been determined as sound to those close to the oven mouth are dismantled.

5. A device for repairing a coke oven, which is used in the repairing method according to any one of claims 1 to 4, comprising: slide gates that are provided on an oven top portion of the coke oven, are capable of moving in a traverse direction such that an opening portion occurring when dismantling the oven top portion of the coke oven can be opened at the time of dismantling the coke oven and closed when the coke oven dismantling operation is stopped, and are provided with a safety handrail therearound.

6. A device for repairing a coke oven, which is used in the repairing method according to any one of claims 1 to 4, comprising: a heat insulation structural body with several kinds of heat insulation materials being placed on top of one another in an iron frame and being fixed and integrated therein, the heat insulation structural body being installed between a replacement target combustion chamber and its neighboring non-replacement target combustion chamber for the purpose of retaining the heat of the neighboring non-replacement target combustion chamber adjacent to the replacement target combustion chamber and thus heat-insulating a space for replacing operation in the replacement target combustion chamber, when dismantling the coke oven.

7. The method for repairing a coke oven according to any one of claims 1 to 4, wherein with part of an oven wall of a combustion chamber being previously opened, a gas hole and an air hole in the existing combustion chamber are lidded with a curing member or lidded by being filled with a heat insulation material from a flue hole that is provided at an upper part of the oven wall of the combustion chamber, whereby falling scraps can be restricted from mixing into a regenerative chamber at the time of dismantling the replacement target combustion chamber.

8. A device for repairing a coke oven, which is used in the repairing method according to any one of claims 1 to 4, comprising: a slide-type scaffold that is provided for realizing fall prevention of an operator and securing the operator's foothold during operation, the slide-type scaffold being detachable from outside the coke oven and being configured to allow two or more said slide-type scaffolds to be coupled and connected to one another.

9. A device for repairing a coke oven, which is used in the repairing method according to any one of claims 1 to 4, comprising: a ceiling restraining beam that is formed by welding and fixing a beam and a heat insulation structural body with a heat insulation material being abutted against existing bricks, the ceiling restraining beam being configured to heat-insulate and prevent the collapse of existing bricks of a neighboring non-replacement target combustion chamber adjacent to a replacement target combustion chamber that is to repaired, when dismantling a ceiling part of said replacement target combustion chamber.

10. The method for repairing a coke oven according to any one of claims 1 to 4, wherein repair operation is performed with respect to a pair of neighboring combustion chambers integrally formed by stacking integral type or two-split type precast blocks in a hollow cavity of bricks formed at a ceiling part of the pair of neighboring combustion chambers.

11. The method for repairing a coke oven according to any one of claims 1 to 4, further comprising: a step of installing a heat insulation panel by placing the heat insulation panel on a conveying carriage and then performing pulling with a traction wire so as to introduce the heat insulation panel into a given carbonization chamber and stop, or by pushing out the heat insulation panel with a pusher machine before stopping, prior to dismantling a portion of the replacement target combustion chamber that requires repair.

12. The method for repairing a coke oven according to any one of claims 1 to 4, further comprising: a step of using a carrier of heavy machinery for dismantling when dismantling a portion of the replacement target combustion chamber that requires repair.

13. The method for repairing a coke oven according to any one of claims 1 to 4, further comprising: a step of using a carrier that traverses over the coke oven to transport and import the oven wall refractory aggregate and the ceiling part refractory aggregate.

14. The method for repairing a coke oven according to any one of claims 1 to 4, further comprising: a step of performing positioning in a horizontal direction with a laser light when horizontally arranging the oven wall refractory aggregate and ceiling part refractory aggregate; and a step of installing a spacer for achieving a constant mortar joint thickness.

15. The method for repairing a coke oven according to any one of claims 1 to 4, further comprising: a step of installing the ceiling part refractory aggregate and then pouring a castable refractory into a gap surrounding the ceiling part refractory aggregate so as to fill the same, when newly forming a replacing ceiling part.

16. The method for repairing a coke oven according to any one of claims 1 to 4, wherein integrally formed blocks that are integrally formed by a monolithic refractory are previously prepared by dividing a wall body composing the combustion chamber into a plurality of blocks, the wall body is then dismantled and taken out of the coke oven, followed by carrying the integrally formed blocks into the coke oven and arranging them in such a manner that an end portion of each integrally formed block is to be abutted against two orthogonal surfaces that are provided at an end portion of the existing wall body, thereby rebuilding the wall body.

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