JP2949138B2 - Coke oven repair module - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates generally to repair modules for use in repairing coke ovens, and more particularly in repairing heated walls extending between coking chambers in a group of coke ovens.

[0002]

2. Description of the Related Art Coke is produced by heating pulverized coal in an air-free environment for a period of time. Usually coke is produced in a coke oven group comprising a plurality of side-by-side coking chambers separated from one another by heated walls. The side of the coke oven group from which coke is discharged is called the coke side, the other side is called the extruder side,
The heating wall and the coking chamber extend from one side to the other. In a typical installation, the group could have 40 to 100 or more coking chambers side by side, each chamber being 3 to 6 meters in height, typically 14 meters in length, and about 1/2 in width. Meters. The width of each chamber is tapered slightly so that the coked coal in the chamber can be extruded from the chamber, and the width of the chamber on the extruder side is 3 inches less than the width on the coke side. Each heating wall is usually made from several horizontal layers of horizontally extending silica brick, which are assembled around a vertically extending flue in the heating wall, the flue being heated and Repeat the exhaust air condition. There can be eight bricks in each layer of each flue. Therefore, in a heated wall with 20 layers and 28 flue, 44
There can be more than 00 silica bricks, each brick being located at a specific location.

[0003] The coking chamber is usually between 2100 degrees Fahrenheit and 2500 degrees Fahrenheit.
Maintained at a temperature of degrees. Coal to be coked is placed (or charged) into the coking chamber through a charging port at the top of each coking chamber. During the charging and subsequent coking times, which can be 24 hours in length, the coke oven door closes the end of the coking chamber. Gas containing a hydrocarbon, such as steam, ammonia and sulfur dioxide and NO _x and methane while the coking process is performed is released from the coal. These gases are usually collected for processing into various chemicals. Gas released from the coal first passes through a standpipe extending from the roof of the coke ovens, and the gas is received in a collection main. Usually there is one standpipe in each coking chamber. Gases released from the coal during coking cause the standpipe and collection mains of the coking chamber to be at or above atmospheric pressure.

[0004] At the completion of the coking cycle, the coke oven door is removed from both ends of the coking chamber, and the coked coal is passed through the coking chamber by an extruder which exerts a total force through the coking chamber. And the coke goes across the coke guide and into the cooling car. When the door is opened, the pressure in the coking chamber is immediately released, and condensed gas or liquid flows from the collecting mains back through the standpipe onto the silica brick to delaminate their surfaces. In addition, cold air entering after the coking process is completed also has a negative effect on the surface of the silica brick. This is because the surface of the silica brick has little resistance to thermal shock. Anyway after some cycles it can be seen that the surface of the silica brick is damaged, especially at the end of the heating wall adjacent to the standpipe.

[0005] In the past, these heated walls were usually first repaired by applying silica cement on the vertical surfaces of the damaged heated wall. However, eventually, the ends of the damaged heating wall need to be totally rebuilt. Reconstruction of the heated wall is a very time consuming and expensive scheme, as each heated wall contains many specific location bricks. Typically, reconstruction of one heated wall end is performed by a group of five people in a couple of weeks.

[0006]

SUMMARY OF THE INVENTION It is an object of the present invention to provide a repair molding module for use in repairing a heated wall between coking chambers. The repair module is formed in one piece from a moldable refractory material having a high degree of dimensional stability, the structure being a substantially box-like structure with a vertically extending flue in it, Is adapted to conform to the original shape of the end of the heating wall, and the other end is adapted to interfit with the existing brickwork.

[0007] Erasing the whole sentence and leaving it as missing

[0008] Erasing the whole sentence and setting the missing number

[0009]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring to FIG. 1, a portion of a coke oven group is shown, generally indicated at 10. The coke oven group configuration shown is sometimes referred to as a by-product coke oven. Because the volatiles released during the coking process are collected at the mains for further processing to some of the thousands of different by-products that can be derived from the coke oven volatiles Because it is collected on 12. The coke oven group includes a plurality of coking chambers 14 (FIGS. 2-4), each coking chamber extending from the extruder side 16 (FIG. 4) to the coke side 18 over the entire length of the coke oven group. . Each coking chamber 14 may be 45 feet long and may be 3 to 6 meters in height, but is typically 5 meters. The coking chamber is made slightly tapered, with a width on the extruder side of, for example, 16 inches and a width on the coke side of 19 inches. During coking, chamber 14 is closed by coke oven door 20 (FIG. 4). The coking chambers 14 are separated from each other by heated walls, generally indicated at 22. Each heating wall is usually formed from layers next to a silica brick, with each layer having hundreds of bricks.
Each heating wall is provided with a plurality of flues 24 for alternately performing a normal heating cycle and an exhaust air cycle. Coking room
The floor of the heating wall 22 as well as 14 is supported by columnar walls 26 (FIG. 3). The space between the columnar walls is used for reconstruction purposes and is usually filled with lattice bricks 28. The heated air and gas are introduced into the flue through a nozzle 29 at the bottom of the flue and ignited. The combustion gas heats the heating wall to a temperature typically in the range of 2100 to 2500 degrees Fahrenheit.

In a normal cycle of operation of the coking chamber, coal is introduced into the chamber through a charge or opening 30 (FIG. 2) and is leveled. There the chamber is sealed and the coal in the chamber is heated for a sustained period of time, usually 24 hours, to release volatiles from the coal. Upon completion of the coking cycle for a particular coking chamber, the door 20 is moved by a door mechanism 31, and an extruder (not shown) enters the coking chamber from the extruder side to remove coke in the coking chamber. Pushed from the chamber, the coke is discharged across a coke guide 32 onto a quench car 34. As the door is moved, the cool air will rush into the coking chamber and rapidly cool the brick surface. Further, the liquid from inside the collection main pipe 12 is sucked from the main pipe through the stand pipe 36 connected to the coking chamber, and the liquid is also eventually discharged from the silica brick of the heating wall close to the discharged coking chamber. Can be delaminated.

It should be noted in this respect that the above-described structure of the coke ovens and the method of operation thereof are well known in the art. A group of by-product coke ovens of the type shown somewhat schematically herein is more fully described in DE 511,320.

An ongoing problem in operating co-product coke ovens is the progressive deterioration of the heating walls between the coke oven chambers. In the past, the repair of the heating wall was first started by first shutting off the flow of air and gas to the heating wall to prevent combustion in the flue, and the two sides of the heating wall being repaired in two coking chambers To isolate the area to be repaired by placing a septum 38 (FIG. 4)
It was the practice to place 40 on the surface of the adjacent heated wall.

Although this general type of repair has been satisfactory in some situations, sometimes the end of the heated wall needs to be rebuilt. This is achieved by dismantling the brickwork of that portion of the heated wall to be repaired, replacing damaged bricks, and rebuilding the heated wall.
Due to the large number of bricks used in the heated wall, this is a very time consuming process and usually takes two to three weeks to complete.

Recently, a new silica-based mixture has been developed and is described in US Pat. No. 4,506,025. This material was developed for use as a replacement for silica brick.

Even though this material has high dimensional stability and high thermal shock resistance in the temperature range that can be provided by bricks in coke ovens, a number of bricks that would have to be utilized are: It must be understood that it will still require a long repair time. further,
FIG. 14 if coke oven shows bottom layer of brick in heated wall
If made with the usual design as shown in the above, the surface of many adjacent bricks would need to be very carefully mortared.

In accordance with the present invention, a new forming module is formed from a material of the type described in the aforementioned US Pat. No. 4,506,025, wherein the forming module of the present invention moves from one side of the heated wall to the other. It surrounds at least one extending flue and preferably surrounds three flues as shown in FIG. Thus, according to the present invention,
A new mold repair module is provided for use in repairing heated walls between coke oven chambers. Bottom module 50, lower center module 52, upper center module 54
(FIG. 13), and a variety of different modules such as the upper module 56 are provided. Each of the various modules 50 to 56 generally has first and second opposed side walls 58, 60 (FIG. 11) and is a square with parallel pipes, the side walls being approximately equal to the width of the heating wall. They are separated from each other by a distance. In addition, the module has first and second opposite ends that extend generally vertically and terminate at surfaces 62,64. The first end is adapted to be disposed at one end of the heating wall and has a vertical end surface 62 that matches the vertical end surface of the heating wall to be repaired. The second end is a centrally located protrusion adapted to interfit with the old brickwork in the best manner shown in FIG.
64.1. Each module further has upper and lower generally horizontal surfaces 66, 68, respectively. The lower horizontal surface 68 of the bottom module 50 is generally planar and is adapted to lie on the upper horizontal surface of the columnar wall 26. The upper horizontal surface of the bottom module and the upper horizontal surface 68 of the lower center module 52 and the upper center module 54 have laterally spaced, vertically extending V-shapes, best shown in FIGS. A mold groove 70 is provided. Each V-shaped groove 70 is adapted to receive a corresponding V-shaped protrusion 72 (FIG. 9) on the lower surface of an adjacent module 52, 54 or 56. Further, a vertically extending hole is provided in the interlocking adjacent module,
The vertically extending holes can receive mating rods 74 formed of the same material as the module itself. These mating rods will also properly align them with each other when the modules are assembled in a heated wall in a manner that will be described more fully below.

Each module of the preferred embodiment shown in the drawings is three flue long. Its length is a normal length, the length needed to be rebuilt in a normal coke oven group adjacent to the end of the heating wall. Thus, the module is about 76 inches long, 24 inches wide, 12 inches high and weighs about 1700-18
00 pounds. The bottom module will be located on the horizontal surface of the column and around the nozzle 29. It is necessary to provide a bottom module 50 with a cleaning port 76 (FIG. 7) to prevent the nozzles from becoming blocked with mortar as the modules are stacked one on top of the other and hardened with mortar. Extends on both sides of the module. In a preferred embodiment, the lower central module is provided with three flue 24 and the flue adjacent to the first end (left side of FIG. 7) is not provided with an air port forming structure 78, The second and third flues are provided with air port forming structures of the same material and are balanced and integrated with the module. Air port forming structures are well known in the prior art, but are usually formed from refractory clay or the like, and can be separated and completely separate from the silica brick making the heated wall. It should be noted. The purpose of the air port formation is to provide additional air above the flue substrate for combustion purposes to uniformly heat the flue throughout its vertical length. Therefore, rich fuel gas is supplied to the lowermost nozzle 29 through the fuel gas line 80, and air is supplied to the lowermost nozzle 29 through the separation air line 82, but all fuel supplied to the lowermost nozzle is supplied. There is insufficient air to be consumed. However, the air supplied by the air port forming structure 78 will allow the fuel provided to the nozzle to be consumed completely further up the flue, and therefore the overall vertical of the heating wall. Allows for relatively uniform heating of the area. The upper central module 54 differs from the lower central module merely by omitting the air port formation in the second and third flue. The uppermost module 56 (FIG. 13) is provided with a transverse passage 84 that allows fuel in the heated flue to be drawn down the adjacent flue. For example, referring to FIG. 13, if the left stack 24.1 is in the combustion cycle, then the right stack 24.2 is in the exhaust cycle, and the gas from the stack 24.1 will be in the upper module.
It will pass through transverse passage 84 in 56 and descend down the exhaust flue 24.2. This combustion / exhaust cycle is inverted periodically, for example every 30 minutes, to provide more uniform heating of the brickwork in the heating wall, and features of this design are usually due to the coke ovens of the type described. It will be.

By using the repair module of the present invention, there is almost no air passage for the escape of volatile by-products from the coking process into the flue, and this passage is limited to only the horizontal surfaces between the modules. The horizontal surface of which is provided with a V-groove to prevent volatile by-products from the coal from flowing into the flue. If such by-products are to flow, they can cause erosion and / or burning of bricks in these areas, since volatile by-products become flammable when in an oxygen environment. Should be recognized. Therefore, rather than allowing all volatile by-products to leak through the module or brickwork into the flue, it is desirable to discharge through the standpipe 32 at the top of the coking oven. Further comparing FIG. 7 with FIG. 14, it can be seen that hardening the module of the invention with mortar would be much easier than hardening the brickwork of the prior art.

To make the module of the present invention, a form is mounted on a vibrating table and filled to a suitable level with a slurry of a moldable refractory material. The slurry is then shaken to remove any foam and ensure proper mixing. After the slurry material is first prepared, the material is removed from the mold and placed in a furnace that is fired at progressively higher temperatures for a period of time. Therefore, the temperature of the furnace is from ambient temperature to 950 ° C, 1
Increased by about 50 ° C per hour. It has been found that a very satisfactory product can be obtained by slowly raising the temperature during the pre-baking of the module. The product is very thermally stable during the normal operating temperature of the coke ovens.

In accordance with the principles of the present invention, a method for repairing a damaged end of a heated wall utilizing a forming module of the present invention will include the following steps.
However, although the preferred sequence of steps is set forth below, it should be appreciated that the sequence may be varied somewhat by individual contractor preferences. For convenience of description of the method, it is assumed that the bricks surrounding the last three flue of the heating wall adjacent to the coke side of the coke oven group are to be repaired. First, the coke oven door on the coke side of the group of two coke oven chambers adjacent to the heated wall to be repaired is removed. The frame for the coke oven door will also be removed. To facilitate work in this area, bulkheads 38 are erected in each coke oven chamber adjacent to the heated wall to be repaired, extending from floor to ceiling and between the walls of each chamber. After erecting the bulkhead, the side walls of the heated wall immediately adjacent to the heated wall to be repaired are also covered with insulation. Next, the backstay 88 (FIG. 4) adjacent to the end of the heated wall to be repaired is cut off and removed adjacent to the floor level and above the area to be repaired. Incidentally, at the end of each heating wall, there is provided a backstay arranged on the outer surface of the coke oven group, and the base of the backstay is fitted to the base of the coke oven group, and a backstay for each heating wall is provided. It should be noted that the upper portions of the backstays are secured together by a securing rod (not shown). After the backstay has been removed, the roof must be hung over the area where the heated wall is to be removed. To achieve this, the top layer of silica brick is removed very carefully.
Then, as best shown in FIGS. 3 and 5, a plurality of support beams 90 are located at the top of the group. Threaded rod
92 passes through a hole provided in the center of each support beam 90.
The threaded rod passes through an inspection port 94 in the old brickwork. A nut 96 is located at the upper end of each threaded rod 92 to limit downward movement of the rod. Nut 98 and washer 100 after rod is properly positioned
Are mounted on the lowermost end of each rod as shown in FIG. Retainer plate with keyhole 104
Since 102 is positioned for each rod 94 and its plate is positioned with respect to rod 94 and washer 100, the plate can first be passed over the washer, and FIGS. As can be best appreciated by reference, the plate is moved to a nod which can be supported by a washer. Nuts 96 and 98 are then properly tightened and retainer plate 102 is pressed against the ceiling. Additional struts (not shown) may be provided to extend from both sides of the top of the old heating wall to the adjacent heating wall.

After the roof has been properly suspended, the remnants of the old brickwork are removed in the area of the heated wall to be repaired. The bottom gas nozzle is then plugged in a conventional manner to prevent any mortar from entering the gas nozzle. .

At this time, it is also necessary to properly prepare the old brickwork located adjacent to the new module. For this end, the old brickwork is stacked at least to the height of the module to be inserted, and the old brickwork is cut appropriately to receive the projecting central part 64.1, best shown in FIG. To The entire face of the old brickwork can just be properly prepared at this point, but more usually only a sufficient amount of old brickwork will need to properly accommodate the next module To be properly prepared. This makes it easy to mortar the modules mounted on the old brickwork.

After the floor area is properly prepared and the overall planar surface is mortared, the bottom shaping repair module is inserted. For example, this bottom repair module typically has three spaced vertical flue channels extending upward from a lower horizontal surface, the flue channels being separated from each other by a distance equal to the distance between the gas nozzles. Is being discussed. As mentioned above, the bottom module is provided with a side cleaning port. The top surface of the bottom module is provided with a layer of mortar, and the lower center module is located on the bottom module. Each module is quite large and heavy, so the positioning is usually
The module is driven by a forklift truck that lifts the module to the desired height,
The groove 70 can be slid to a final position that will receive the V-shaped protrusion 72 of the uppermost module.
After the appropriate number of lower central modules have been properly positioned, it is necessary to continue creating the heated wall by merely attaching the upper central module one after the other. When finally raised to the appropriate height, the top or traversing module 56 is positioned in place. When all modules of the invention have been installed, re-installing the top layer of brickwork that has been left for this purpose;
It is only necessary that the parts be mortared in place.

When the mortar compaction is complete, reach into the lowest module through the cleaning port and also remove any mortar that has fallen on the top of the plug mounted on the gas port; It is necessary to remove the gas plug. Re-attaching the backstay removed prior to installing the repair module, installing the removed door frame prior to repairing the heated wall, removing bulkheads and separating side walls. It is only necessary to re-install the coke oven door that was removed prior to repair of the heated wall.

While the preferred form of the invention as well as the preferred method of attachment have been shown and discussed above, it should be recognized that other modifications may occur to those skilled in the art. Therefore, applicant does not intend to be limited to the specific details shown and described above.

[Brief description of the drawings]

FIG. 1 is a perspective view of a coke side of a coke oven group.

FIG. 2 is a partial cross-sectional view schematically taken along line 2-2 of FIG.

FIG. 3 schematically along line 3-3 in FIG. 1, showing two side-by-side coking chambers, a heated wall for both sides of the chamber, and a central heated wall removed for repair purposes. Vertical sectional view.

FIG. 4 is a sectional view schematically taken along line 4-4 of FIG. 3;

FIG. 5 is a sectional view schematically taken along line 5-5 in FIG. 3;

FIG. 6 is a schematic view taken along line 6-6 of FIG. 3;

FIG. 7 is a perspective view particularly showing one end of the reconstructed heating wall.

FIG. 8 is a cross-sectional view taken generally along line 8-8 in FIG. 7;

FIG. 9 is a cross-sectional view taken generally along the line 9-9 in FIG. 7;

FIG. 10 is a cross-sectional view taken generally along line 10-10 in FIG. 7;

FIG. 11 is a plan view of one of the repair modules shown in FIG. 7;

FIG. 12 is similar to FIG. 11, but showing the repair module at the top.

FIG. 13 is a cross-sectional view schematically taken along line 13-13 of FIG.

FIG. 14 illustrates a single layer of silica brick that is used to form a portion of a heated wall, which is of the prior art, but is replaced by the forming module of the present invention.

[Explanation of symbols]

10 ... coke oven group, 14 ... coking chamber, 16 ... extruder side, 18 ... coke side, 20 ... coke oven door, 22 ... heating wall, 24 ... flue, 29 ... nozzle, 36 ... stand pipe, 38 ...
Partition wall, 40… Separation wall, 50… Bottom module, 52… Lower center module, 54… Upper center module, 56… Top module, 58,60… Side wall, 62,64… Vertical surface, 66,68… Horizontal surface, 76 ... cleaning port, 78 ... air port configuration, 84 ... crossing passage, 88 ... backstay.

──────────────────────────────────────────────────続 き Continued on the front page (58) Field surveyed (Int.Cl. ⁶ , DB name) C10B 29/06 C10B 5/04 C10B 29/02

Claims (1)

(57) [Claims] 1. A repair forming module for use in repairing heated walls between coking chambers in a coke oven group, wherein each heated wall extends vertically at an interval and includes fuel gas. It has a plurality of flue which can be used alternately to burn or exhaust air, each flue has a gas nozzle at its bottom, said molding module has high dimensional stability And a first and a second refractory material formed from a moldable refractory material having a high thermal shock resistance in the range of 0 ° to 2700 ° F. and having a width substantially equal to the width of the heating wall. Two opposing side walls and first and second opposing ends extending substantially vertically, said first end being adapted and repaired to be one end of a heating wall. Having a vertical end surface shaped to match the vertical end surface of the heated wall, The second end is adapted to be positioned in an interdigitated relationship within an adjacent old brickwork of the heated wall and further provided with substantially parallel upper and lower surfaces having parallel pipes. A single rectangular structure having a plurality of vertical smoke extending upwardly from the substantially horizontal lower surface and spaced apart from each other at a spacing equal to the spacing between the gas nozzles. Molding module for repair, a unitary structure with roads.