1. Refractory Repair Strategies for Battery Life Extension
Condition monitoring: COMIT
Preventative maintenance
Remedial repairs
Ernie Goffi, Senior Vice President
Fosbel Inc.

2. Condition Monitoring: COMIT (Coke Oven Management Information Technology)

3. 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

4. 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

5. COMIT Dashboard: Plant Overview

6. Battery Status: Plan View

7. Wall History: Table of Repairs & Inspections

8. Activity Entry: Down to a specific location

9. Wall Diagram

10. Priority Report for Repairs & Inspections

11. Histogram of Condition Ranking

12. Current Inspection Histogram

13. Weekly Report of Fosbel Activities

14. Historical Chart of Condition Trends
Coal blend problem – Jan. to March 2005

15. KPI chart of Fosbel performance onsite

16. Life Chart: Sept 2002

17. Life Chart: March 2006

18. Priority Chart for all 5 dimensions of Condition Monitoring

19. Cost Analysis: Production Yields

20. Flue Rankings Chart
0 is best, 5 > 250°C deviation

21. Thermograph of battery heating: by temperature

22. Thermograph without temps

23. Thermograph showing ranks

24. COMIT Case Study: Tata Iron & Steel Company, India
In 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.

25. MICOWALL Modular Interlocking Coke Oven Wall Technology

26. MICOWALL (Modular Interlocking Coke Oven Wall) Coke Oven Repair Technology

27. 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

28. 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

29. 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

30. 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

31. 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

32. Coke Ovens Modular Wall Design
Isometric Layout of Modular End Wall

33. Coke Ovens Modular Wall Design
Typical Heating Flue Course

34. Coke Ovens Modular Wall Design

35. Coke Ovens Modular Wall Design
1st Course Layout

36. Coke Ovens Modular Wall Design
Oven Roof Brick

37. Coke Ovens Modular Wall Design
Bridging Course above Horizontal Flue

38. Coke Ovens Modular Wall Design
Horizontal Flue Course

39. MICOWALL Construction
View of heating Tier 6

40. MICOWALL Construction
Brick Tier 11

41. MICOWALL Construction
Completed Endflue

42. MICOWALL Utilizing Conventional Silica

43. MICOWALL Utilizing Conventional Silica

44. Fosbel, Inc.
640 N. Rocky River Drive, Berea, Oh 44017
Telephone: 440/ Fax: 440/
Internet:
Fosbel, Inc.
20600 Sheldon Road, Brook Park, OH 44142
Telephone: Fax:
Internet: