Refractory Repair Strategies for Battery Life Extension

•Condition monitoring: COMIT•Preventative maintenance

•Remedial repairs

Ernie Goffi, Senior Vice PresidentFosbel Inc.

Condition Monitoring:

COMIT (Coke Oven Management Information

Technology)

Coke Oven Maintenance Information Technology (COMIT)

• Based on philosophy wall condition represents battery operating conditions and traumas past and present.

• A non-intrusive Condition Monitoring system for any coke battery design.

• Flexible to account for varying life goals

• Configurable to suit varying battery designs and operating conditions.

• A day-to-day condition monitoring system that predicts operational security risks.

• A battery deterioration or improvement trendline which can be graphically represented.

• Success measurement of PM programs can be graphically represented

Elements of COMIT

COMIT is structured in a modular format:• Weekly Reporting• Operational Data Collection & Reporting• Battery Analysis and Reporting• Wall Analysis and Prioritisation

– Ranking– Inspections Overdue– Life of Repair– Risk Analysis

• Life Prediction

COMIT Dashboard: Plant Overview

Battery Status: Plan View

Wall History: Table of Repairs & Inspections

Activity Entry: Down to a specific location

Wall Diagram

Priority Report for Repairs & Inspections

Histogram of Condition Ranking

Current Inspection Histogram

Weekly Report of Fosbel Activities

Historical Chart of Condition Trends

Coal blend problem – Jan. to March 2005

KPI chart of Fosbel performance onsite

Life Chart: Sept 2002

Life Chart: March 2006

Priority Chart for all 5 dimensions of Condition Monitoring

Cost Analysis: Production Yields

Flue Rankings Chart

0 is best, 5 > 250°C deviation

Thermograph of battery heating: by temperature

Thermograph without temps

Thermograph showing ranks

COMIT Case Study: Tata Iron & Steel Company, IndiaIn less than 2 years of operation at Tisco:

– Battery 7A increased life by 7 years yielding:• 50 ovens x 24/20 x 18t yield x 365 x 7 = 2,759,400t

– Battery 7B increased life by 4 years yielding:• 50 ovens x 24/20 x 18t yield x 365 x 4 = 1,576,800t

– Total coke production increase = 4,336,200– Tangible method of tracking life deterioration

trend in place.– COMIT now networked across the coke plant.

MICOWALLModular Interlocking Coke Oven

Wall Technology

MICOWALL (Modular Interlocking Coke Oven Wall)

Coke Oven Repair Technology

Design Objectives - Cokemaking

• Minimal Production Downtime

• Minimal Impact on Heating

• Maintain Old Silica at Temperature

• Long Life Rehabilitation to Walls

• No Process Safety Interruptions

• Maintain Thermal Design of Flues

Design Objectives - Management

• Reduced Inventory Levels

• Low Installation Costs

• Low Capital Investment

• World’s Best Practice Used

• Cost Effective Repairs

• Safety of People During Repairs

Design Objectives - Installers

• Low Complexity with Fewer Shapes

• Reduced Time Exposure to Heat

• Weight of Blocks within OHS Limits

• No Heat-Up Contractors Required

• Interlocking Integrity Maintained

• New to Old Fits in Expanded Batteries

Design Objectives - Engineering

• Reproducible Design Principles

• Minimal Repetitive Engineering Costs

• Alignment to Existing Ports

• Oven Taper Maintained

• Pressed Shape Preferred over Cast

• Wilputte HF Batteries Resolved

MICOWALL Key Design Outcomes

• Full T&G Bonding and Interlocking

• Fused Silica Optimum Choice

• Pressed Block for Most Shapes

• Same Shapes for C/S & P/S

• Cost Effective Wall Rebuilds

• Thermal Design Fully Maintained

Coke Ovens Modular Wall Design

Isometric Layout of Modular End Wall

Typical Heating Flue Course

Coke Ovens Modular Wall Design

Coke Ovens Modular Wall Design

1st Course Layout

Coke Ovens Modular Wall Design

Oven Roof Brick

Coke Ovens Modular Wall Design

Bridging Course above Horizontal Flue

Coke Ovens Modular Wall Design

Horizontal Flue Course

Coke Ovens Modular Wall Design

MICOWALL Construction

View of heating flue @ Tier 6

Brick Construction @ Tier 11

MICOWALL Construction

MICOWALL Construction

Completed Endflue

MICOWALL Utilizing Conventional Silica

MICOWALL Utilizing Conventional Silica

Fosbel, Inc.

640 N. Rocky River Drive, Berea, Oh 44017Telephone: 440/891-0892 Fax: 440/891-0899Internet: http://www.fosbel.com

Fosbel, Inc.

20600 Sheldon Road, Brook Park, OH 44142Telephone: 216-362-3900 Fax: 216-362-3901Internet: http://www.fosbel.com