Coke oven repairing method

Abstract

Provided is a method for 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; and 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.

Description

Technical Field

[0001] The present invention relates to a method 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.7, 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.8, 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.7) of the pusher machine 56 is inserted, and an oven mouth from which the red-hot coke is pushed out. Buckstays 60 (see FIG.8) made of a 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 6).Citation ListPatent Literature

[0005] Patent Literature 1: Japanese Patent No.5347614 Patent Literature 2: Japanese Patent No.6183800 Patent Literature 3: Japanese Patent No.5991478 Patent Literature 4: Japanese Patent No.6753389 Patent Literature 5: Japanese Patent No.5365040 Patent Literature 6: JP-A- 2019-108510 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 for repairing a coke oven, which is 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; and 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.

[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) the method further includes, when a charging car rail is included in the range of oven wall bricks and binder bricks that requires repair, a step of reinforcing the rail by providing a gap between a lower surface of a support base for the charging car rail and a ceiling part, the gap being a type of gap to which a load of a charging car is not directly applied, (5) the method further includes: a step of maintaining oven wall temperatures at 400°C or higher, the oven wall temperatures being an oven wall temperature of a neighboring non-replacement target combustion chamber that is adjacent to the replacement target combustion chamber, and an oven wall temperature of an unrepaired portion in the replacement target combustion chamber where binder bricks have been confirmed to be sound, (6) the method further includes: a first new brick stacking step of stacking 1 flue's worth of oven wall bricks and binder bricks as first new bricks with respect to a surface that is exposed as a result of dismantling oven wall bricks and binder bricks as remaining bricks of an unrepaired portion that has remained after dismantling; a heat insulation material attaching step of attaching a heat insulation material to an exposed surface of the 1 flue's worth of oven wall bricks and binder bricks as the first new bricks that have been stacked in the first new brick stacking step; and a second new brick stacking step of stacking oven wall bricks and binder bricks as second new bricks while removing the heat insulation material from below, in a remaining repair range, (7) the method further includes: a step of replacing the oven wall bricks by forming a vertically penetrating joint in a boundary portion between a replaced and repaired oven wall part and an unrepaired oven wall part; a step of raising the temperature of the oven after placing, in a carbonization chamber, an unrepaired side bulge prevention member in such a manner that the unrepaired side bulge prevention member is to be bridged at least between the oven wall bricks of the unrepaired part and an oven wall surface facing said oven wall bricks across the space of the carbonization chamber, and a repaired side bulge prevention member in such a manner that the repaired side bulge prevention member is to be bridged at least between the oven wall bricks of the replaced and repaired oven wall part and an oven wall surface facing said oven wall bricks across the space of the carbonization chamber, in the boundary portion and in a vicinity region thereof; and a step of thermal spraying a thermal spray material into the joint as a gap in the boundary portion between the bricks of the replaced and repaired part and the bricks of the unrepaired part after raising the temperature, and (8) the method further includes: a first bulge prevention member installation step of installing a first bulge prevention member in a second carbonization chamber established between a first neighboring non-replacement target combustion chamber that is adjacent to a repair and replacement target combustion chamber in an oven width direction and a second neighboring non-replacement target combustion chamber located therebeyond, the first bulge prevention member being specifically installed in a position including at least a position corresponding to the first binder brick from the oven mouth among multiple binder bricks forming the first neighboring non-replacement target combustion chamber so that the width of the second carbonization chamber in said position can be maintained constant; a repair step of dismantling and replacing the oven wall bricks and binder bricks of a part of the replacement target combustion chamber that is to be repaired; a second bulge prevention member installation step of installing a second bulge prevention member in a first carbonization chamber established between the replaced replacement target combustion chamber and the first neighboring non-replacement target combustion chamber, the second bulge prevention member being specifically installed in a position including at least a position corresponding to the first binder brick from the oven mouth among multiple binder bricks forming the replacement target combustion chamber so that the width of the first carbonization chamber in said position can be maintained constant; and a temperature raising step of raising the temperature of the replaced replacement target combustion chamber. Advantageous Effects of Invention

[0010] According to the method 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

[0011] [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 drawing showing a working state of Example 1. [FIG.4] is a drawing showing a working state of Example 2. [FIG.5] is a drawing showing a working state of Example 3. [FIG.6] 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.7] is a drawing showing an example of a known coke oven. [FIG.8] is a drawing showing the known coke oven from above. Description of Embodiments

[0012] An embodiment of the present invention is described in detail hereunder. Here, the following embodiment is a set of examples of a 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>

[0013] The present invention relates to a method 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.

[0014] 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.

[0015] 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.

[0016] 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.

[0017] 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.

[0018] 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.

[0019] 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.

[0020] 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.<Known techniques favorably applicable to the method of the present invention for repairing a coke oven>

[0021] With regard to the above method of the present invention for repairing a coke oven, more preferable embodiments include a coke oven repairing method employing the following exemplified known techniques that have already been disclosed in patent publications and patent application publications.

[0022] In the case of the method of the present invention for repairing a coke oven, as described in Patent Literature 2 (Japanese Patent No.6183800), when a charging car rail is included in a range of oven wall bricks and binder bricks that requires repair, it is preferred that the method include a step of reinforcing such rail by providing a gap between the lower surface of a support base for such charging car rail and the ceiling part, the gap being a type of gap to which the load of the charging car is not directly applied. According to this embodiment, with the method of the present invention for repairing a coke oven, damages (damage and deformation of ceiling part bricks and joints) in the ceiling part on which the charging car rail support base is mounted can be precisely suppressed.

[0023] In the case of the method of the present invention for repairing a coke oven, as described in Patent Literature 3 (Japanese Patent No.5991478), it is preferred that the method include a step of maintaining oven wall temperatures at 400°C or higher, the oven wall temperatures being the oven wall temperature of a neighboring non-replacement target combustion chamber that is adjacent to a replacement target combustion chamber, and the oven wall temperature of an unrepaired portion in the replacement target combustion chamber where binder bricks have been confirmed to be sound. According to this embodiment, with the method of the present invention for repairing a coke oven, there can be provided a partial replacement and repair method of a coke oven, that is capable of improving work efficiency and mostly or entirely removing the risks of bulging and falling.

[0024] In the case of the method of the present invention for repairing a coke oven, as described in Patent Literature 4 (Japanese Patent No.6753389), it is preferred that the method include a first new brick stacking step of stacking 1 flue's worth of oven wall bricks and binder bricks as the first new bricks with respect to a surface that is exposed as a result of dismantling the oven wall bricks and binder bricks as the remaining bricks of an unrepaired portion that has remained after dismantling; a heat insulation material attaching step of attaching a heat insulation material to an exposed surface of the 1 flue's worth of oven wall bricks and binder bricks as the first new bricks that have been stacked in the first new brick stacking step; and a second new brick stacking step of stacking oven wall bricks and binder bricks as the second new bricks while removing the heat insulation material from below, in the remaining repair range. According to this embodiment, with the method of the present invention for repairing a coke oven, even in the upper portion of the remaining bricks of the unrepaired portion of a combustion chamber to be repaired, a heat dissipation amount from the surface exposed as a result of dismantling bricks will be reduced, whereby it is possible to restrict temperature fall ranging from the upper portion of the remaining bricks to the lower portion thereof.

[0025] In the case of the method of the present invention for repairing a coke oven, as described in Patent Literature 5 (Japanese Patent No.5365040), it is preferred that the method include a step of replacing oven wall bricks by forming a vertically penetrating joint in a boundary portion between a replaced and repaired oven wall part and an unrepaired oven wall part; a step of raising the temperature of the oven after placing, in the carbonization chamber, an unrepaired side bulge prevention member in such a manner that the unrepaired side bulge prevention member is to be bridged at least between the oven wall bricks of the unrepaired part and an oven wall surface facing such oven wall bricks across the space of the carbonization chamber, and a repaired side bulge prevention member in such a manner that the repaired side bulge prevention member is to be bridged at least between the oven wall bricks of the replaced and repaired oven wall part and an oven wall surface facing such oven wall bricks across the space of the carbonization chamber, in the boundary portion and in the vicinity region thereof; and a step of thermal spraying a thermal spray material into the joint as a gap in the boundary portion between the bricks of the replaced and repaired part and the bricks of the unrepaired part after raising the temperature. According to this embodiment, with the method of the present invention for repairing a coke oven, it is possible to minimize the bulge in the boundary portion between the repaired part and the unrepaired part when reheating the oven wall bricks of a coke oven, thereby making it possible to restrict deformation of oven wall bricks when performing repair in a hot condition.

[0026] In the case of the method of the present invention for repairing a coke oven, as described in Patent Literature 6 (JP-A- 2019-108510), it is preferred that the method include a first bulge prevention member installation step of installing a first bulge prevention member in a second carbonization chamber established between a first neighboring non-replacement target combustion chamber that is adjacent to a repair and replacement target combustion chamber in an oven width direction and a second neighboring non-replacement target combustion chamber located therebeyond, the first bulge prevention member being specifically installed in a position including at least a position corresponding to the first binder brick from the oven mouth among multiple binder bricks forming the first neighboring non-replacement target combustion chamber so that the width of the second carbonization chamber in that position can be maintained constant; a repair step of dismantling and replacing the oven wall bricks and binder bricks of a part of the replacement target combustion chamber that is to be repaired; a second bulge prevention member installation step of installing a second bulge prevention member in a first carbonization chamber established between the replaced replacement target combustion chamber and the first neighboring non-replacement target combustion chamber, the second bulge prevention member being specifically installed in a position including at least a position corresponding to the first binder brick from the oven mouth among multiple binder bricks forming the replacement target combustion chamber so that the width of the first carbonization chamber in that position can be maintained constant; and a temperature raising step of raising the temperature of the replaced replacement target combustion chamber. According to this embodiment, with the method of the present invention for repairing a coke oven, it is possible to properly prevent the bulge of the oven wall bricks of a replacement target combustion chamber that is to be repaired when repairing the oven wall bricks and partition bricks in the vicinity of the oven mouth of the combustion chamber, and the bulge of the oven wall bricks of the first neighboring non-replacement target combustion chamber that is adjacent to such replacement target combustion chamber.<Embodiments with preferable given values in the present invention>

[0027] Preferable given values in the present invention are determined as follows.

[0028] 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.

[0029] 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.6 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

[0030] From the results shown in Table 1 and FIG.6, the following formula (1) was obtained via regression analysis. Extrusion clogging rate % = 5 × 10 − 8 × d 5

[0031] Here, d (mm) represents the bulging amount.

[0032] 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).

[0033] 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

[0034] 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>

[0035] As shown in FIG.3, 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)

[0036] 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>

[0037] As shown in FIG.4, 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)

[0038] 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>

[0039] As shown in FIG.5, 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)

[0040] As is clear from the results shown in Table 4, when there were cracks in the combustion chamber (old bricks) that was left, there were 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

[0041] With the method 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

[0042] 51Carbonization chamber 52Combustion chamber 53Regenerative chamber 54Charging hole 55Charging car 56Pusher machine 56aPusher ram 57Guide car 58Quenching car 59Flue (vertical flue) 60Buckstay

Examples

examples

[0035]As shown in FIG.3, 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...

example 3

[0039]As shown in FIG.5, 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 co...

Technical Field

[0001] The present invention relates to a method 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.7, 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.8, 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.7) of the pusher machine 56 is inserted, and an oven mouth from which the red-hot coke is pushed out. Buckstays 60 (see FIG.8) made of a 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 6).Citation ListPatent Literature

[0005] Patent Literature 1: Japanese Patent No.5347614 Patent Literature 2: Japanese Patent No.6183800 Patent Literature 3: Japanese Patent No.5991478 Patent Literature 4: Japanese Patent No.6753389 Patent Literature 5: Japanese Patent No.5365040 Patent Literature 6: JP-A- 2019-108510 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 for repairing a coke oven, which is 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; and 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.

[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) the method further includes, when a charging car rail is included in the range of oven wall bricks and binder bricks that requires repair, a step of reinforcing the rail by providing a gap between a lower surface of a support base for the charging car rail and a ceiling part, the gap being a type of gap to which a load of a charging car is not directly applied, (5) the method further includes: a step of maintaining oven wall temperatures at 400°C or higher, the oven wall temperatures being an oven wall temperature of a neighboring non-replacement target combustion chamber that is adjacent to the replacement target combustion chamber, and an oven wall temperature of an unrepaired portion in the replacement target combustion chamber where binder bricks have been confirmed to be sound, (6) the method further includes: a first new brick stacking step of stacking 1 flue's worth of oven wall bricks and binder bricks as first new bricks with respect to a surface that is exposed as a result of dismantling oven wall bricks and binder bricks as remaining bricks of an unrepaired portion that has remained after dismantling; a heat insulation material attaching step of attaching a heat insulation material to an exposed surface of the 1 flue's worth of oven wall bricks and binder bricks as the first new bricks that have been stacked in the first new brick stacking step; and a second new brick stacking step of stacking oven wall bricks and binder bricks as second new bricks while removing the heat insulation material from below, in a remaining repair range, (7) the method further includes: a step of replacing the oven wall bricks by forming a vertically penetrating joint in a boundary portion between a replaced and repaired oven wall part and an unrepaired oven wall part; a step of raising the temperature of the oven after placing, in a carbonization chamber, an unrepaired side bulge prevention member in such a manner that the unrepaired side bulge prevention member is to be bridged at least between the oven wall bricks of the unrepaired part and an oven wall surface facing said oven wall bricks across the space of the carbonization chamber, and a repaired side bulge prevention member in such a manner that the repaired side bulge prevention member is to be bridged at least between the oven wall bricks of the replaced and repaired oven wall part and an oven wall surface facing said oven wall bricks across the space of the carbonization chamber, in the boundary portion and in a vicinity region thereof; and a step of thermal spraying a thermal spray material into the joint as a gap in the boundary portion between the bricks of the replaced and repaired part and the bricks of the unrepaired part after raising the temperature, and (8) the method further includes: a first bulge prevention member installation step of installing a first bulge prevention member in a second carbonization chamber established between a first neighboring non-replacement target combustion chamber that is adjacent to a repair and replacement target combustion chamber in an oven width direction and a second neighboring non-replacement target combustion chamber located therebeyond, the first bulge prevention member being specifically installed in a position including at least a position corresponding to the first binder brick from the oven mouth among multiple binder bricks forming the first neighboring non-replacement target combustion chamber so that the width of the second carbonization chamber in said position can be maintained constant; a repair step of dismantling and replacing the oven wall bricks and binder bricks of a part of the replacement target combustion chamber that is to be repaired; a second bulge prevention member installation step of installing a second bulge prevention member in a first carbonization chamber established between the replaced replacement target combustion chamber and the first neighboring non-replacement target combustion chamber, the second bulge prevention member being specifically installed in a position including at least a position corresponding to the first binder brick from the oven mouth among multiple binder bricks forming the replacement target combustion chamber so that the width of the first carbonization chamber in said position can be maintained constant; and a temperature raising step of raising the temperature of the replaced replacement target combustion chamber. Advantageous Effects of Invention

[0010] According to the method 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

[0011] [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 drawing showing a working state of Example 1. [FIG.4] is a drawing showing a working state of Example 2. [FIG.5] is a drawing showing a working state of Example 3. [FIG.6] 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.7] is a drawing showing an example of a known coke oven. [FIG.8] is a drawing showing the known coke oven from above. Description of Embodiments

[0012] An embodiment of the present invention is described in detail hereunder. Here, the following embodiment is a set of examples of a 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>

[0013] The present invention relates to a method 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.

[0014] 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.

[0015] 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.

[0016] 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.

[0017] 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.

[0018] 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.

[0019] 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.

[0020] 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.<Known techniques favorably applicable to the method of the present invention for repairing a coke oven>

[0021] With regard to the above method of the present invention for repairing a coke oven, more preferable embodiments include a coke oven repairing method employing the following exemplified known techniques that have already been disclosed in patent publications and patent application publications.

[0022] In the case of the method of the present invention for repairing a coke oven, as described in Patent Literature 2 (Japanese Patent No.6183800), when a charging car rail is included in a range of oven wall bricks and binder bricks that requires repair, it is preferred that the method include a step of reinforcing such rail by providing a gap between the lower surface of a support base for such charging car rail and the ceiling part, the gap being a type of gap to which the load of the charging car is not directly applied. According to this embodiment, with the method of the present invention for repairing a coke oven, damages (damage and deformation of ceiling part bricks and joints) in the ceiling part on which the charging car rail support base is mounted can be precisely suppressed.

[0023] In the case of the method of the present invention for repairing a coke oven, as described in Patent Literature 3 (Japanese Patent No.5991478), it is preferred that the method include a step of maintaining oven wall temperatures at 400°C or higher, the oven wall temperatures being the oven wall temperature of a neighboring non-replacement target combustion chamber that is adjacent to a replacement target combustion chamber, and the oven wall temperature of an unrepaired portion in the replacement target combustion chamber where binder bricks have been confirmed to be sound. According to this embodiment, with the method of the present invention for repairing a coke oven, there can be provided a partial replacement and repair method of a coke oven, that is capable of improving work efficiency and mostly or entirely removing the risks of bulging and falling.

[0024] In the case of the method of the present invention for repairing a coke oven, as described in Patent Literature 4 (Japanese Patent No.6753389), it is preferred that the method include a first new brick stacking step of stacking 1 flue's worth of oven wall bricks and binder bricks as the first new bricks with respect to a surface that is exposed as a result of dismantling the oven wall bricks and binder bricks as the remaining bricks of an unrepaired portion that has remained after dismantling; a heat insulation material attaching step of attaching a heat insulation material to an exposed surface of the 1 flue's worth of oven wall bricks and binder bricks as the first new bricks that have been stacked in the first new brick stacking step; and a second new brick stacking step of stacking oven wall bricks and binder bricks as the second new bricks while removing the heat insulation material from below, in the remaining repair range. According to this embodiment, with the method of the present invention for repairing a coke oven, even in the upper portion of the remaining bricks of the unrepaired portion of a combustion chamber to be repaired, a heat dissipation amount from the surface exposed as a result of dismantling bricks will be reduced, whereby it is possible to restrict temperature fall ranging from the upper portion of the remaining bricks to the lower portion thereof.

[0025] In the case of the method of the present invention for repairing a coke oven, as described in Patent Literature 5 (Japanese Patent No.5365040), it is preferred that the method include a step of replacing oven wall bricks by forming a vertically penetrating joint in a boundary portion between a replaced and repaired oven wall part and an unrepaired oven wall part; a step of raising the temperature of the oven after placing, in the carbonization chamber, an unrepaired side bulge prevention member in such a manner that the unrepaired side bulge prevention member is to be bridged at least between the oven wall bricks of the unrepaired part and an oven wall surface facing such oven wall bricks across the space of the carbonization chamber, and a repaired side bulge prevention member in such a manner that the repaired side bulge prevention member is to be bridged at least between the oven wall bricks of the replaced and repaired oven wall part and an oven wall surface facing such oven wall bricks across the space of the carbonization chamber, in the boundary portion and in the vicinity region thereof; and a step of thermal spraying a thermal spray material into the joint as a gap in the boundary portion between the bricks of the replaced and repaired part and the bricks of the unrepaired part after raising the temperature. According to this embodiment, with the method of the present invention for repairing a coke oven, it is possible to minimize the bulge in the boundary portion between the repaired part and the unrepaired part when reheating the oven wall bricks of a coke oven, thereby making it possible to restrict deformation of oven wall bricks when performing repair in a hot condition.

[0026] In the case of the method of the present invention for repairing a coke oven, as described in Patent Literature 6 (JP-A- 2019-108510), it is preferred that the method include a first bulge prevention member installation step of installing a first bulge prevention member in a second carbonization chamber established between a first neighboring non-replacement target combustion chamber that is adjacent to a repair and replacement target combustion chamber in an oven width direction and a second neighboring non-replacement target combustion chamber located therebeyond, the first bulge prevention member being specifically installed in a position including at least a position corresponding to the first binder brick from the oven mouth among multiple binder bricks forming the first neighboring non-replacement target combustion chamber so that the width of the second carbonization chamber in that position can be maintained constant; a repair step of dismantling and replacing the oven wall bricks and binder bricks of a part of the replacement target combustion chamber that is to be repaired; a second bulge prevention member installation step of installing a second bulge prevention member in a first carbonization chamber established between the replaced replacement target combustion chamber and the first neighboring non-replacement target combustion chamber, the second bulge prevention member being specifically installed in a position including at least a position corresponding to the first binder brick from the oven mouth among multiple binder bricks forming the replacement target combustion chamber so that the width of the first carbonization chamber in that position can be maintained constant; and a temperature raising step of raising the temperature of the replaced replacement target combustion chamber. According to this embodiment, with the method of the present invention for repairing a coke oven, it is possible to properly prevent the bulge of the oven wall bricks of a replacement target combustion chamber that is to be repaired when repairing the oven wall bricks and partition bricks in the vicinity of the oven mouth of the combustion chamber, and the bulge of the oven wall bricks of the first neighboring non-replacement target combustion chamber that is adjacent to such replacement target combustion chamber.<Embodiments with preferable given values in the present invention>

[0027] Preferable given values in the present invention are determined as follows.

[0028] 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.

[0029] 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.6 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

[0030] From the results shown in Table 1 and FIG.6, the following formula (1) was obtained via regression analysis. Extrusion clogging rate % = 5 × 10 − 8 × d 5

[0031] Here, d (mm) represents the bulging amount.

[0032] 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).

[0033] 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

[0034] 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>

[0035] As shown in FIG.3, 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)

[0036] 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>

[0037] As shown in FIG.4, 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)

[0038] 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>

[0039] As shown in FIG.5, 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)

[0040] As is clear from the results shown in Table 4, when there were cracks in the combustion chamber (old bricks) that was left, there were 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

[0041] With the method 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

[0042] 51Carbonization chamber 52Combustion chamber 53Regenerative chamber 54Charging hole 55Charging car 56Pusher machine 56aPusher ram 57Guide car 58Quenching car 59Flue (vertical flue) 60Buckstay

Examples

examples

[0035]As shown in FIG.3, 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...

example 3

[0039]As shown in FIG.5, 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 co...

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; and 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.

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. The method for repairing a coke oven according to any one of claims 1 to 4, further comprising, when a charging car rail is included in the range of oven wall bricks and binder bricks that requires repair, a step of reinforcing the rail by providing a gap between a lower surface of a support base for the charging car rail and a ceiling part, the gap being a type of gap to which a load of a charging car is not directly applied.

6. The method for repairing a coke oven according to any one of claims 1 to 4, further comprising: a step of maintaining oven wall temperatures at 400°C or higher, the oven wall temperatures being an oven wall temperature of a neighboring non-replacement target combustion chamber that is adjacent to the replacement target combustion chamber, and an oven wall temperature of an unrepaired portion in the replacement target combustion chamber where binder bricks have been confirmed to be sound.

7. The method for repairing a coke oven according to any one of claims 1 to 4, further comprising: a first new brick stacking step of stacking 1 flue's worth of oven wall bricks and binder bricks as first new bricks with respect to a surface that is exposed as a result of dismantling oven wall bricks and binder bricks as remaining bricks of an unrepaired portion that has remained after dismantling; a heat insulation material attaching step of attaching a heat insulation material to an exposed surface of the 1 flue's worth of oven wall bricks and binder bricks as the first new bricks that have been stacked in the first new brick stacking step; and a second new brick stacking step of stacking oven wall bricks and binder bricks as second new bricks while removing the heat insulation material from below, in a remaining repair range.

8. The method for repairing a coke oven according to any one of claims 1 to 4, further comprising: a step of replacing the oven wall bricks by forming a vertically penetrating joint in a boundary portion between a replaced and repaired oven wall part and an unrepaired oven wall part; a step of raising the temperature of the oven after placing, in a carbonization chamber, an unrepaired side bulge prevention member in such a manner that the unrepaired side bulge prevention member is to be bridged at least between the oven wall bricks of the unrepaired part and an oven wall surface facing said oven wall bricks across the space of the carbonization chamber, and a repaired side bulge prevention member in such a manner that the repaired side bulge prevention member is to be bridged at least between the oven wall bricks of the replaced and repaired oven wall part and an oven wall surface facing said oven wall bricks across the space of the carbonization chamber, in the boundary portion and in a vicinity region thereof; and a step of thermal spraying a thermal spray material into the joint as a gap in the boundary portion between the bricks of the replaced and repaired part and the bricks of the unrepaired part after raising the temperature.

9. The method for repairing a coke oven according to any one of claims 1 to 4, further comprising: a first bulge prevention member installation step of installing a first bulge prevention member in a second carbonization chamber established between a first neighboring non-replacement target combustion chamber that is adjacent to a repair and replacement target combustion chamber in an oven width direction and a second neighboring non-replacement target combustion chamber located therebeyond, the first bulge prevention member being specifically installed in a position including at least a position corresponding to the first binder brick from the oven mouth among multiple binder bricks forming the first neighboring non-replacement target combustion chamber so that the width of the second carbonization chamber in said position can be maintained constant; a repair step of dismantling and replacing the oven wall bricks and binder bricks of a part of the replacement target combustion chamber that is to be repaired; a second bulge prevention member installation step of installing a second bulge prevention member in a first carbonization chamber established between the replaced replacement target combustion chamber and the first neighboring non-replacement target combustion chamber, the second bulge prevention member being specifically installed in a position including at least a position corresponding to the first binder brick from the oven mouth among multiple binder bricks forming the replacement target combustion chamber so that the width of the first carbonization chamber in said position can be maintained constant; and a temperature raising step of raising the temperature of the replaced replacement target combustion chamber.

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