refractory repair strategies for battery life extension condition monitoring: comit preventative...
TRANSCRIPT
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Refractory Repair Strategies for Battery Life Extension
•Condition monitoring: COMIT•Preventative maintenance
•Remedial repairs
Ernie Goffi, Senior Vice PresidentFosbel Inc.
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Condition Monitoring:
COMIT (Coke Oven Management Information
Technology)
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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
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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
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COMIT Dashboard: Plant Overview
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Battery Status: Plan View
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Wall History: Table of Repairs & Inspections
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Activity Entry: Down to a specific location
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Wall Diagram
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Priority Report for Repairs & Inspections
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Histogram of Condition Ranking
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Current Inspection Histogram
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Weekly Report of Fosbel Activities
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Historical Chart of Condition Trends
Coal blend problem – Jan. to March 2005
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KPI chart of Fosbel performance onsite
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Life Chart: Sept 2002
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Life Chart: March 2006
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Priority Chart for all 5 dimensions of Condition Monitoring
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Cost Analysis: Production Yields
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Flue Rankings Chart
0 is best, 5 > 250°C deviation
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Thermograph of battery heating: by temperature
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Thermograph without temps
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Thermograph showing ranks
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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.
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MICOWALLModular Interlocking Coke Oven
Wall Technology
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MICOWALL (Modular Interlocking Coke Oven Wall)
Coke Oven Repair Technology
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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
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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
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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
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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
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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
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Coke Ovens Modular Wall Design
Isometric Layout of Modular End Wall
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Typical Heating Flue Course
Coke Ovens Modular Wall Design
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Coke Ovens Modular Wall Design
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1st Course Layout
Coke Ovens Modular Wall Design
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Oven Roof Brick
Coke Ovens Modular Wall Design
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Bridging Course above Horizontal Flue
Coke Ovens Modular Wall Design
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Horizontal Flue Course
Coke Ovens Modular Wall Design
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MICOWALL Construction
View of heating flue @ Tier 6
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Brick Construction @ Tier 11
MICOWALL Construction
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MICOWALL Construction
Completed Endflue
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MICOWALL Utilizing Conventional Silica
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MICOWALL Utilizing Conventional Silica
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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