Repair or replacement of the roof of the coke oven
Patent Information
- Authority / Receiving Office
- JP · JP
- Patent Type
- Applications
- Current Assignee / Owner
- PAUL WURTH SA
- Filing Date
- 2023-07-12
- Publication Date
- 2026-07-02
Smart Images
Figure 00000000_0000_ABST
Abstract
Description
Technical Field
[0001] The present invention generally relates to the maintenance of existing coke oven batteries, and more particularly to an efficient method for replacing or repairing the roof of a coke oven battery during the continuous operation of the coke oven battery.
Background Art
[0002] Coke oven batteries are mainly used to produce coke by heating coal to a temperature of about 1300 ° C in an airless environment. Such coke oven batteries usually include a plurality of aligned coking chambers, hereinafter referred to as "ovens", separated from each other by heating walls and covered by a vault (round ceiling), hereinafter also referred to as the ceiling in this specification, and a battery roof. The heating walls and the coking chambers extend from one side of the coke oven battery to the other side. A normal installation may include more than 100 coking chambers (rooms), each room having a height from 3.5 to about 8 m, a length from about 12 m to 16 m and a width from about 0.4 m to 0.5 m. At each end side of the coking chamber, there is provided a coke oven door that enables airtight closure until the door of the furnace is removed at the end of each coking cycle and the hot coke is discharged from the chamber with the aid of a pusher ram attached to a pusher machine.
[0003] Such coke oven batteries can have a lifespan of 30 to in some cases more than 50 years, but such long-term operation requires appropriate maintenance and repair not only to counter normal wear and tear, but also to take into account nuisance regulations widely associated with visible emissions related to, for example, gas, dust, and raw coke oven gas generated during coal distillation.
[0004] One of the particularly exposed parts of a coke oven battery is the roof, especially the roof for a top charging coke oven battery, where coal is supplied through a group of charging holes, usually three to five per coking chamber. In practice, in a top charging configuration, a heavy charging car usually moves on rails mounted on the roof and sequentially supplies the coking chambers according to the requirements of the coking cycle. In stamp charged ovens, the supply is through the side doors of the coke oven, but they generally include charging gas transfer vehicles that move in a similar manner on the rails of the roof of the coke oven battery. In both top charging batteries and stamping batteries, the roof has large orifices at the top of the coking chambers, on one or both sides of the roof, for collecting and transporting the coke oven gas resulting from the coking operation to the coke oven main gas collector through vertical pipe sections, so-called ascension pipes. The roof also generally includes inspection holes located directly above and in the center of the heating walls of the heating flues provided within the heating walls. Finally, the upper coke oven battery also includes a bracing system including longitudinal and transverse tie rods, which are also generally included / incorporated in the refractory roof portion.
[0005] Several problems occur due to the normal damage suffered by the roof of a coke oven battery, as follows: - Bulging or non-uniformity of the charging holes relative to the top floor level (height) of the battery, resulting in loss of proper sealing between the sleeve of the charging vehicle and the charging holes, thereby making it difficult to load coal, and thus resulting in unnecessary coal dispersion and dust emission during the furnace loading stage; - During the passage of heavy charging vehicles without interruption, due to the pumping effect on the rails caused by their movement, the bricks under the sleepers supporting the rails of the charging vehicles are crushed, and damage that increases dramatically over time occurs if left unattended; - Rails of worn and misaligned charging vehicles, associated with problems of charging vehicle movement; - Deformation and breakage of casting parts (e.g., base rings, charging frames (frames) and covers, and inspection hole frames and their covers), which pose a high risk of causing fugitive visible emissions; - General increase in leakage emissions due to cracks that may appear in the refractory top; - Clinker tiles on the raised furnace roof due to the presence of carbon penetrating through thermal expansion and expansion joints; - Heating loss / reduction in thermal efficiency; and - Abnormal distortion of the reinforcement structure and the possibility of breakage of tie rods.
[0006] Due to the very long expected life of the coke oven battery, depending on operating factors, maintenance procedures, and ambient conditions such as the presence of heavy rain (tropical conditions), it may be necessary to repair or replace some or all of the coke oven roof multiple times. Even for a relatively new coke oven battery, such interventions may be required regularly, for example, after a fixed period of 5 to 10 years.
[0007] Most major maintenance operations must be performed while the coke oven battery is still operating and / or at a high temperature in order to maintain the integrity of the refractories, which would be damaged if the coke oven battery dropped below a specified temperature threshold, since most major maintenance operations are not performed with the coke oven battery completely shut down (which is not a common option). This so-called "hot repair" also means not only working under very high temperature conditions, but also that the operation of components of the coke oven battery not being maintained is not obstructed in any significant way. Further, when taking the coke production chamber out of service, even if it is continuously heated above the specified temperature threshold, the output of the coke oven battery decreases and the operating cost increases in order to avoid refractory disintegration or excessive shrinkage. In fact, the oven chamber in which major roof repairs or replacements are to be carried out must be kept empty with non-negligible production losses of coke and gas depending on the extent of the repair or replacement.
[0008] In view of the above, in order to reduce costs, it is necessary to minimize the timing of repairs or replacements at high temperatures and the number of workers required therefor. The technical solution must be highly reliable and long-lasting, and its implementation should improve safety during disassembly and assembly and limit production losses as much as possible, or enable production to start earlier. SUMMARY OF THE INVENTION PROBLEMS TO BE SOLVED BY THE INVENTION
[0009] Accordingly, an object of the present invention is to provide a method for repairing or replacing the roof of a coke oven battery that can be carried out in a "hot state", i.e., enabling rapid repair or replacement of a significant number of components or generally the entire roof of the coke oven battery by simply taking a small number of coke production chambers out of service at a time. This method can also reduce the number of workers required to work on the coke oven battery roof at a time and enhance safety during operation. MEANS FOR SOLVING THE PROBLEMS
[0010] In order to achieve the above object, the present invention proposes, in a first aspect, a method for repairing or replacing the roof of an operating coke oven battery. The coke oven battery includes a number of parallel coke-producing chambers separated from each other by heating walls and closed at the top by a ceiling and covered by a roof itself. The roof over each coke-producing chamber includes holes for a first plurality of charging holes or charging gas transfer holes and one or two ascension pipes each provided with a corresponding base ring connected to one or two gas collecting mains. The roof over each heating wall includes a second plurality of inspection holes and a number of rail sleepers configured for support rails for a coke charging vehicle or a charging gas transfer vehicle. According to the present invention, a method applicable to major repairs or high-temperature repairs including the removal of at least a part of the embedded metal parts includes the following steps: I.a) Optionally (depending on the extent of the damage), stop the operation of at least one coke-producing chamber by discharging the hot coke contained therein, and disconnect the base ring(s) from the gas collecting main(s), thus preventing further raw gas from passing between the furnace and the gas collecting main; I.b) Remove (at least) the damaged roof components on the at least one coke-producing chamber and the adjacent heating wall, including one or more charging holes or gas transfer holes, inspection holes, base ring(s), and rail sleepers, and optionally provide temporary support for the rails on the at least one coke-producing chamber and the adjacent heating wall, thereby providing a void space within the roof; I.c) Provide a set of construction modules Each construction module comprises: 1. A first plurality of charging hole or gas transfer hole modules each including one or more refractory precast support blocks for charging holes or gas transfer holes and a charging or gas transfer hole metal frame with a metal cover; 2. A second plurality of inspection hole modules, each including a refractory precast support block for an inspection hole, optionally a refractory precast spacer for an inspection hole, and a metal lid for an inspection hole metal frame; 3. One or two base ring modules, each including one or more refractory precast support blocks for a base ring and a metal base ring; 4. A rail sleeper module, each including one or more refractory precast support blocks for a sleeper, optionally a refractory precast spacer for a sleeper, and a metal sleeper; 5. A finishing module including a third plurality of liner slabs, mortar, and a refractory castable filler material; and the refractory precast support blocks are made of a low-expansion refractory material such as fused silica; including a set of elements; I.d) Depending on the depth required for repair, but not including the ceiling, place the first plurality of charging holes or gas transfer hole modules, and / or the second plurality of inspection hole modules, and / or the base ring modules and / or the rail sleeper modules at their respective predetermined locations within the roof space, and connect adjacent refractory precast blocks with mortar as required; I.e) Partially fill the voids within the roof remaining after steps I.b) and I.d) with a liner slab (selected between silica and insulation material depending on the depth of the area to be filled), the liner slab being made of bricks, blocks, and / or castables, and fill the remaining part of the voids within the roof by pouring and / or casting a refractory castable material; I.f) If removed previously, reconnect the base ring(s) to the main gas recovery pipe(s), operate at least one coking chamber of the repaired or replaced roof, attach the rails to the sleepers, and if previously installed, remove the temporary support of the rails provided in step I.b), and I.g) If necessary or desired, repeat steps I.a) to I.f) for at least one further coke production chamber.
[0011] The second aspect provides a kit of parts comprising a set of structural modules, said set of structural modules each comprising a first plurality of charging or gas transfer hole modules each comprising a hollow metal charging or gas transfer hole with one or more precast charging hole or gas transfer hole support blocks and a metal lid, a second plurality of inspection hole modules each comprising a metal inspection hole with a precast inspection hole support block and a metal lid, one or two base ring modules each comprising one or more precast base ring support blocks and a metal base ring, a rail sleeper module each comprising one or more precast sleeper support blocks, a hollow metal sleeper and a filler, and a finishing module comprising a third plurality of liner slabs, mortar and a refractory castable filler material, wherein said precast support blocks are made of a low expansion refractory material such as fused silica.
[0012] In a third aspect, the invention discloses the use of the kit of parts of the second aspect in the repair or replacement of the roof of an operating coke oven battery.
[0013] For existing coke oven batteries, due to their long life and the time-consuming maintenance required to achieve long-term operation, especially under such harsh conditions, each coke oven battery or even sections within the same coke oven battery can be different from one another, and the actual configuration or actual damage at a particular location may be different from what is found there, even if they are in close proximity. In particular, in the conventional structure of coke oven batteries, there are usually relatively small quantities of bricks of various shapes. Therefore, maintenance interventions involving the repair or replacement of parts of a coke oven battery require a high degree of flexibility with respect to the situation faced by repair workers at a particular location. This is particularly true with respect to the actual degree of damage within each section along the roof structure.
[0014] As already mentioned at the beginning, the roof of the coke oven battery is exposed to significant disasters both inside and outside the coke oven battery, particularly important components (key features) such as charging holes or gas transfer holes, inspection holes, base rings, rail sleepers, or the underlying support structure.
[0015] Therefore, by carrying out repairs or replacements, some or all of these problems can clearly be overcome, but if the methods and materials used do not provide a durable solution, that is, a quality sufficient to guarantee long-term use without prematurely failing the provided materials and structures, but only enable quick repairs or replacements, it will have the opposite effect.
[0016] The inventors have the following, a. Refractory precast support blocks made of low-expansion refractory materials. One material that particularly meets this requirement is a fused silica precast block (hydraulically bonded) in the dry form with a minimum SiO2 content of 95% by weight and a maximum linear thermal expansion of ±0.20%; and / or b. Mortar for connecting adjacent precast blocks. The mortar is preferably refractory clay mortar. One material that particularly meets this requirement is refractory clay mortar with a minimum Al2O3 content of 30% by weight and a maximum linear thermal expansion of 3%; and / or c. Liner slabs selected between silica and insulation shaped material depending on the depth of the space to be filled. The properties of the materials may vary depending on the conditions to be endured. d. Refractory castable materials, also called fillers, that fill all the empty volumes remaining after placing materials a, b, and / or c. One material that particularly meets this requirement is alumina-silica medium cement castable with an Al2O3 content range of 50 wt% to 60 wt%, an SiO2 content range of 30 wt% to 40 wt%, and a maximum linear thermal expansion of 1%. Another compatible material is silica castable with a minimum SiO2 content of 95 wt% and a maximum linear thermal expansion of ±0.20%; By using a combination including; It has been discovered that the number of bricks or blocks of different shapes can be strictly minimized, not only significantly shortening the time required to properly lay and assemble all these bricks and blocks, but also enabling the formation of a very robust and durable roof structure within a very short period. In addition, by using low thermal expansion materials, the resulting roof structure has high dimensional stability, negligible expansibility during heating, excellent fire resistance, good compressive strength, and appropriate thermal shock resistance. In some embodiments, it is particularly preferred that the refractory precast support blocks made of low expansion refractory materials are made of the same material as the refractory castable material (filler). In further embodiments, it is preferred that the refractory precast support blocks and the liner slabs are made of the same material as the refractory castable material (filler). The expression "low expansion refractory material" means a refractory material having a linear thermal expansion of up to 5%, preferably up to 3.5%, and most preferably up to 2%.
[0017] Furthermore, in the present method, all elements of the structural module can be easily realized initially at the refractory work site and do not need to have very strict and precise dimensional tolerances. Then, they do not need to be accurately dimensioned, shaped, and laid around bricks or blocks, nor do they require complicated and time-consuming preparation work, and can be simply and accurately placed at the intended location. In fact, from the perspective of elevation, especially in terms of height, the elements of the structural module can be absolutely essential for allowing appropriate telescopic movements of the charging machine after the filling and / or casting of the filler. It is only necessary that they are correctly positioned at the intended location and position relative to each other and to the unreplaced portions so that one refractory unit with all important configurations is formed at the correct location by the roof structure. This relative positioning can be predicted at the design stage and can be finally adjusted slightly using the liner slab.
[0018] In the context of the present invention, the term "ceiling" of the coke production chamber generally means the lowermost layer of refractory bricks or the lowermost layer of refractory blocks above the coke production chamber, the lower side of which closes the upper coke production chamber, generally rests on the upper part of the adjacent heating wall, and is in direct contact with the high-temperature environment of the coke production chamber. The term "roof" of the coke oven battery generally refers to the position directly above the ceiling up to the uppermost finishing surface in contact with the atmosphere and is related to the components resting on the ceiling.
[0019] Since the ceiling or at least parts of the ceiling of the coke production chamber(s) directly below the repair site may be damaged or in need of replacement, a method for repairing or replacing the roof of an operating coke oven battery preferably provides for such a situation. In fact, as already explained above, the actual state of the ceiling and the roof at a specific location is generally unknown and can only become apparent when the overlying structure is removed. Therefore, it is advantageous that a method for repairing or replacing the roof of an operating coke oven battery further includes the following steps: I.b1) Remove at least the damaged ceiling parts on the at least one coke production chamber and the adjacent heating walls, where the step is performed during or after step I.b) and before step I.c), and I.c1) Provide precast replacement parts made of a low-expansion refractory material such as fused silica and place the precast replacement parts in the location of the removed ceiling parts, where the step is performed after step I.b1) or I.c) and before step I.d).
[0020] After removing the roof parts on a certain coke production chamber, if it is determined that the ceiling parts are damaged, it is necessary to evaluate the degree of damage. Usually, it is not possible to remove the entire ceiling of that coke production chamber. Therefore, in practice, if it is clear that the ceiling is damaged in one place, it may be advantageous to combine steps I.b) and I.b1), that is, to execute step I.b1) during step I.b). Of course, the decision to execute these additional steps I.b1) and I.c1) may be different for one coke production chamber and the next, or after (partially) removing the roof, when inspecting the ceiling of the first coke production chamber, it may be determined that the actual state of the ceiling of other coke production chambers is different, and it is recommended to execute steps I.b1) and I.c1) for all (further) coke production chambers.
[0021] In the method according to the first aspect of the present invention, after the arrangement of the structural modules, that is, before step I.e), the remaining roof voids can be relatively quite large, and thus require a fairly large amount of filler, which is then solidified. Therefore, as per the measures described at the previous point I.e), it may be advantageous to pour the filler and at least partially fill the volume of the roof remaining after the arrangement of the structural modules before casting.
[0022] During the operation of a coke oven battery, several important components included in the roof: in particular the charging hole frame, and / or the gas transfer holes, and the rail sleepers, and the structures on which they rest, are subjected to particularly heavy and repetitive stresses and wear. By providing a hollow structure open to at least those elements made of these metals, the cast filler can penetrate and solidify in these structures, thereby providing better contact and much more robust fixation of each important component in the roof structure, and it has been found that this improves durability. The hollow structure in this context is a hollow shape that allows for the injection / pouring of a fluid filler and the leakage of air during injection / pouring, and preferably provides an undercut retaining structure and / or an inlet for the fluid filler. In particular, the metal charging or gas transfer holes preferably include a ring-shaped hollow volume open at the bottom, including at least one lower edge forming a casting undercut. The rail sleepers can be made of steel in the form of a hollow crossbeam or a crossbeam having a hollow portion, the hollow of which is open at each end and / or side. Since the rail sleepers are generally arranged on the heating wall, they also include one or more integrated inspection holes with metal covers. When considered necessary or useful, other retaining features, such as laterally extending metal fins or metal brackets extending laterally and / or downward, can be provided alternatively or additionally.
[0023] Advantageously, each rail sleeper module further includes an adjustable rail spacer configured to adjust the position of the rail during rail installation. Such an adjustable rail spacer is configured to be mounted on top of the rail sleeper so that its horizontal position can be adapted to facilitate alignment of the rails. The adjustable rail spacer typically includes slots that allow for vertical and horizontal adjustment of the rail spacer itself, and when properly seated in place, they are fixed to the rail sleeper, for example, with nuts and bolts. This is particularly important when there are inspection holes in the rail sleeper, i.e., when the sleepers must be positioned so that the inspection holes are correctly placed.
[0024] In the present invention, the support block often serves as a kind of cutoff form to prevent the cast fluid filler from leaking out of the roof volume, thereby potentially clogging the flue in the heating wall or flowing out to generally unintended locations. In some cases, it may also be necessary or advantageous to provide one or more dedicated casting aids placed in appropriate locations. Such casting aids generally have a simple shape, such as a tube shape, disposed inside the charging or charging gas transfer hole or the base ring. These additional casting aids are only temporarily installed and can be reused after the filler has cured or left in place. In the latter case, the casting aids are preferably made of a material that disintegrates at the operating temperature of the coke production chamber after the start of use.
[0025] Note that the process of repairing or replacing parts of an operating coke oven battery is significantly different from the process of assembling a new coke oven battery. In fact, in so-called "hot repairs" (repairs during operation of the coke oven battery), the roof is generally exposed to a temperature of at least 200°C, and the coke production chamber can be exposed to a temperature of up to 950°C during repair. Thus, the walls, ceiling, and roof of the coke production chamber undergo significant thermal expansion, and newly added replacement parts (bricks, support blocks, metal frames, etc.) begin to expand as soon as the temperature rises after being placed in their corresponding locations. Therefore, the thermal expansion of these parts occurs during hot repairs and needs to be considered throughout the procedure. In contrast, the assembly of a new coke oven battery is usually carried out at ambient temperature, and it is only necessary to handle future thermal expansion in advance, that is, by leaving gaps between different structural elements. Ignoring the effects of thermal expansion can cause cracks to form in the roof of the coke production chamber, which can then spread and ultimately cause leaks. Sufficient heating and expansion of the newly added materials generally occur within the time required for their installation, but it may be advantageous to provide a step of waiting for the modules placed in step I.d) and / or the liner slabs placed in step I.e) to exceed a predetermined temperature threshold, thereby enabling the modules and / or liner slabs to withstand thermal expansion before casting refractory castable materials. The temperature threshold can be determined in advance based on the coefficient of thermal expansion of each module or set to a specific value such as 200°C or 250°C.
[0026] After the modules arranged in step I.d) and / or the liner slabs arranged in step I.e) have withstood thermal expansion, by casting a refractory castable material, each module can be molded into the exact geometric arrangement (geometry) of the void / hollow volume defined by the refractory castable material in the expanded state, i.e., during the operation of the coke oven battery. In other words, the proposed method significantly reduces the formation of cracks in the replaced part of the coke production chamber during the operation of the coke oven battery, despite the difference in the coefficient of thermal expansion between different module components (e.g., between the metal frame, refractory precast support blocks, and castable materials).
Brief Description of the Drawings
[0027] Preferred embodiments of the invention will now be described by way of example with reference to the accompanying drawings:
Figure 1
Figure 2
Figure 3
Figure 4
[0028] Further details and advantages of the present invention will become apparent from the following detailed description of several non-limiting embodiments with reference to the accompanying drawings. Description of Preferred Embodiments
[0029] Figures 1 to 4 show cross-sectional views in the horizontal and vertical directions of advantageous embodiments of four important components integrated within a repaired or replaced coke oven battery roof according to the present invention.
[0030] Figure 1 is a cross-sectional view of a preferred configuration module of a charging hole 10 (or a similar design for a charging gas transfer hole) above a coke production chamber after repair or replacement of the roof of a coke oven battery. In particular, a precast charging hole or charging gas transfer hole support block 30 rests on the ceiling 60, and a hollow charging or gas transfer hole metal frame 20 (comprising one or more undercuts 21 and / or one or more casting anchors 22) with a metal lid 25 is preferably arranged at the top of the roof such that its upper surface is essentially flush with the top of the floor corresponding to the top (finished) surface of the clinker tile or brick 50 as shown in the illustration. The hollow metal charging or gas transfer hole 20 has already been positioned at the correct height and location, for example, by brackets (not shown), before the filler 40 is injected into the hollow structure of the frame 20 and the void volume of the roof. Alternatively, the hollow structure such as the frame 20 can be pre-filled with a refractory castable material and subsequently placed on the roof before the refractory castable material hardens. This void volume has already been reduced by providing a precast filler slab 45 as described in point I.e).
[0031] Figure 2 is a cross-sectional view of an embodiment of a structural module of a hollow metal rail sleeper 120 with an adjustable rail spacer 125 and a rail assembly 110 attached thereto after repair or replacement of the roof of a coke oven battery. During repair or replacement, the hollow metal rail sleeper 120 is preferably placed on one or more precast rail sleeper support blocks 130, which themselves are either on a ceiling 160 above a heating wall or at least partially directly on the heating wall. After their placement, a filler 140 is cast around and within the hollow portion of the metal rail sleeper 120 and solidifies. Since the hollow metal rail sleeper 120 is placed above a heating wall that includes a flue 170 for high-temperature gases required for the coke production process, both the precast rail sleeper support block 130 and the hollow metal rail sleeper are provided with integral inspection holes 210, 180 that are centered above the flue 170, and a lid 181 for each inspection hole 180 of the hollow rail sleeper is provided. The rail assembly 110 can be fixed to the metal rail sleeper using an adjustable rail spacer 125. The adjustable rail spacer 125 is preferably adjustable in both the vertical and horizontal directions and, once correctly positioned in place, is fixed to the rail sleeper 120, for example, with nuts and bolts. Thereby, first, the rail sleeper 120 including the inspection hole 180 can be correctly positioned with respect to the center of the flue below in the heating wall, and then the adjustable rail spacer 125 can be correctly positioned at the required position of the rail assembly 110. The design shown in Figure 2 is for reference only.
[0032] Figure 3 is a longitudinal sectional view of an embodiment of the inspection hole 210 using a structural module including one or more metal inspection holes 220, precast inspection hole support blocks 230, and metal lids 225 for the inspection holes, together with a filler 240, after repair or replacement of the roof of a coke oven battery. The metal inspection holes 220 are preferably placed on or within one or more precast inspection hole support blocks 230. The metal inspection holes 220 and the precast inspection hole support blocks 230 are arranged in concentric positions above the flue 270, and a lid 225 for each inspection hole 210 is provided.
[0033] Figure 4 is a longitudinal cross-sectional view of an embodiment of the riser hole 310 using a base ring structure module of a riser tube including one or more precast base ring support blocks 330, a metal base ring 320, and a cast-in filler 340. Figure 4 also shows the lateral tie rods 395 and the protective shaped metal enclosure 390 after repair or replacement of the roof of the coke oven battery. The one or more precast base ring support blocks 330 are arranged to cover up to the level of the ceiling and a metal base ring 320 provided with casting anchors 322 (for example, fins or brackets), and this metal base ring 320 may also include a hollow portion similar to the hollow loading or gas transfer hole metal frame 20 of Figure 1, and is centered at the center of the base ring 310 and arranged at a predetermined position with respect to the top surface of the roof regardless of the presence or absence of the undercut 21. Here too, the metal base ring 320 may have been arranged at the correct height and location using, for example, brackets (not shown) before casting the filler 340 into the void volume of the roof. Figure 4 also shows a component of the reinforcement structure of the coke oven battery, namely, the lateral tie rods 395 within the metal formed protective enclosure 390. The metal formed protective enclosure 390 not only enables the movement / dilatation of the tie rods, but also protects the tie rods from heat and can help evaluate and monitor the stress and forces exerted on the tie rods 395.
Explanation of Reference Numerals
[0034] 10 Charging hole or gas transfer hole (frame) 20 Hollow metal charging or gas transfer hole (frame) 21 Undercut 22 Casting anchor 25 Metal lid of metal charging or gas transfer hole 30 Precast charging hole or gas transfer hole support block 40 Cast-in filler 45 Liner slab selected between silica and heat insulating material 50 Clicker tile or brick 60 Ceiling 110 Rail assembly 120 Metal hollow rail tie 125 Adjustable rail spacer 130 Precast rail tie support block 135 Rail tie spacer 140 Injected filler 160 Ceiling (on the heating wall) 170 Flue of the heating wall 180 Inspection hole of the hollow rail tie 181 Cover of the inspection hole 210 Inspection hole 220 Metal inspection hole 225 Metal cover of the inspection hole 230 Precast inspection hole support block 240 Cast-in filler 270 Flue of the heating wall 310 Base ring 320 Metal base ring 322 Casting anchor 330 Precast base ring support block 340 Cast-in filler 390 Metal forming protective coating 395 Lateral tie rod
Claims
1. The coke oven battery includes a number of parallel coke-producing chambers, separated by heating walls and delimited at the top by a ceiling, and covered by a roof itself. A method for repairing or replacing the roof of an operating coke oven battery, wherein the roof includes, for each coke production chamber, a first plurality of charging holes or gas transfer holes above the coke production chamber, a second plurality of inspection holes above the separation heating wall, one or two base rings of a riser pipe connected to one or two gas recovery main pipes, and rail sleepers configured for support rails of a coke charging vehicle or charging gas transfer vehicle, the method being: I. a) If necessary, stop the operation of at least one coke production chamber by discharging the high-temperature coke contained therein, and disconnect the base rings(s) from the gas recovery main pipes(s). I. b) Remove the damaged roof components on the at least one coke production chamber and adjacent heating wall, including one or more charging holes or gas transfer holes, inspection holes, base rings, and rail sleepers, and optionally provide temporary support for the rails on the at least one coke production chamber and adjacent heating wall. I. c) Provide a set of structural modules, Each structural module is: (1) A first plurality of charging or gas transfer port modules, each comprising one or more fire-resistant precast support blocks for charging or gas transfer ports and a charging or gas transfer port metal frame equipped with a metal cover, (2) A second set of inspection hole modules, each including a fire-resistant precast support block for the inspection hole and an inspection hole metal frame with a metal cover; (3) One or two base ring modules, each including one or more fire-resistant precast support blocks and metal base rings for base rings; (4) Rail sleeper modules, each including one or more fire-resistant precast support blocks for sleepers, and metal sleepers, (5) A finishing module comprising a third plurality of liner slabs, mortar and fire-resistant castable filler material, The aforementioned fire-resistant precast support block includes a set of elements made of low-expansion fire-resistant material; I. d) Arrange the first set of multiple charging or gas transfer hole modules, and / or the second set of multiple inspection hole modules, and / or the base ring modules and / or rail sleeper modules in their respective designated locations within the roof space, and, where necessary, connect adjacent fire-resistant precast blocks with mortar; I. e) Partially fill the remaining voids in the roof after steps I. b) and I. d) with liner slabs, and fill the remaining voids in the roof by pouring and / or casting of fire-resistant castable material; I. f) If they have been removed beforehand, connect the base rings to the gas recovery main pipes, operate at least one coke production chamber on the repaired or replaced roof, attach the rails to the sleepers, and if they have been installed beforehand, remove the temporary supports for the rails provided in step I. b), and I. g) If necessary or desired, repeat steps I. a) to I. f) for at least one more coke production chamber. Each step includes I. d1) Wait for the modules positioned in step I. d) and / or the liner slabs positioned in step I. e) to exceed a predetermined temperature threshold, thereby allowing the modules and / or liner slabs to withstand thermal expansion before casting the refractory castable material; Furthermore, repairs and replacements must be carried out while the roof of the coke forming chamber is exposed to at least 200°C. method.
2. I. b1) Remove at least one damaged ceiling component from the coke-making chamber and the adjacent heating wall, where the step is performed during or after step I. b) and before step I. c), and I. c1) Provide a precast ceiling component made of low-expansion fire-resistant material and place the precast ceiling component in the location of the removed ceiling component, wherein the step is performed after step I. b1) or I. c) and before step I. d). The method according to claim 1, further comprising the step.
3. a. The refractory precast support block made of low-expansion refractory material is a fused silica precast support block; and / or b. The mortar is Al ２ O ３ A refractory clay mortar having a minimum content of 30% by weight and / or a maximum linear thermal expansion of 3%; and / or c. The liner slab is made of a material selected between silica and thermal insulation molding material, depending on the depth of the space to be filled; d. The method according to claim 1, wherein the use of the refractory castable material to fill any remaining void after materials a, b, and c have been placed is either alumina-silica medium cement castable or fused silica castable.
4. The method according to claim 3, wherein the refractory precast support block made of a low-expansion refractory material is a fused silica precast support block having a minimum SiO2 content of 95% by weight and / or a maximum linear thermal expansion of ±0.20%.
5. The method according to claim 3, wherein the alumina-silica medium cement castable has an Al₂O₃ content range of 50% to 60% by weight, and / or an SiO₂ content range of 30% to 40% by weight, and / or a maximum linear thermal expansion of 1%.
6. The method according to claim 3, wherein the fused silica castable has a minimum SiO2 content of 95% by weight and / or a maximum linear thermal expansion of ±0.20%.
7. The method according to any one of claims 1 to 3, wherein the refractory precast support block made of a low-expansion refractory material is made of the same material as the refractory castable material; or the refractory precast support block and liner slab are made of the same material as the refractory castable material.
8. The method according to any one of claims 1 to 3, wherein each rail sleeper module further includes an adjustable rail spacer configured for adjusting the position of the rail during rail installation.
9. The method according to any one of claims 1 to 3, wherein each rail sleeper includes one or more inspection holes equipped with metal covers.
10. The method according to claim 1, wherein the temperature threshold is 200°C.
11. The method according to any one of claims 1 to 3, wherein the charging or gas transfer hole metal frame(s) and / or the metal sleeper(s) are provided with open hollow structures configured to allow cast and / or molded refractory castable filler material to permeate and solidify these structures.
12. The method according to claim 11, wherein the hollow structure of the charging or gas transfer hole metal frame(s) and / or the metal sleeper(s) is provided with an air escape route and / or an undercut holding structure and / or an inlet for castable refractory filler material during casting, and the charging or gas transfer hole metal frame(s) and / or the metal sleeper(s) is further provided with laterally extending metal fins and / or laterally or downwardly extending metal brackets.
13. (1) A set of structural modules comprising: (1) a first set of multiple charging or gas transfer hole modules, each comprising a charging or gas transfer hole metal frame with one or more refractory precast support blocks and a metal cover for the charging or gas transfer hole; (2) a second set of multiple inspection hole modules, each comprising a refractory precast support block and a metal cover for the inspection hole; (3) one or two base ring modules, each comprising one or more refractory precast support blocks and a metal base ring for the base ring; (4) a rail sleeper module, each comprising one or more refractory precast support blocks and a metal sleeper for the sleeper; and (5) a third set of finishing modules comprising liner slabs, mortar and refractory castable filler material; wherein the refractory precast support blocks are made of low-expansion refractory material. The charging or gas transfer port metal frames (multiple) and / or metal sleepers (multiple) are provided with open hollow structures configured to allow cast and / or molded refractory castable filler material to permeate and solidify within these structures. A kit of parts.
14. a. The refractory precast support block made of low-expansion refractory material is a fused silica precast support block; and / or b. The mortar is Al ２ O ３ A refractory clay mortar having a minimum content of 30% by weight and / or a maximum linear thermal expansion of 3%; and / or c. The liner slab is made of a material selected between silica and thermal insulation molding material, depending on the depth of the space to be filled: d. The kit of parts according to claim 13, wherein the use of the refractory castable material to fill any remaining void after materials a, b, and c have been placed is either alumina-silica medium cement castable or fused silica castable.
15. The kit of components according to claim 13, wherein the refractory precast support block made of a low-expansion refractory material is a fused silica precast support block having a minimum SiO2 content of 95% by weight and / or a maximum linear thermal expansion of ±0.20%.
16. A kit of components according to claim 13, wherein the alumina-silica medium cement castable has an Al₂O₃ content range of 50% to 60% by weight, and / or an SiO₂ content range of 30% to 40% by weight, and / or a maximum linear thermal expansion of 1%.
17. A kit of components according to claim 13, wherein the fused silica castable has a minimum SiO₂ content of 95% by weight and / or a maximum linear thermal expansion of ±0.20%.
18. The kit of parts according to claim 13 or 14, further comprising an adjustable rail spacer configured to adjust the position of the rail to which each rail sleeper module is fixed.
19. A kit of parts according to claim 13 or 14, wherein each rail sleeper includes one or more inspection holes with metal covers.
20. Use of the parts kit according to claim 13 or 14 in repairing or replacing the roof of a coke oven battery in operation.