refractory repair strategies for battery life extension condition monitoring: comit preventative...
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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