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Techniques for routine maintenance of the top of coke oven

Routine maintenance of coke oven equipment is crucial for ensuring the efficiency, safety, and longevity of the entire system. This involves a range of techniques, including regular inspection and cleaning of the oven tops, checking and maintaining the integrity of refractory linings, monitoring and servicing the charging and pushing machinery, and ensuring the proper functioning of gas and air supply systems. Implementing a structured maintenance schedule helps in early detection of potential issues, reduces downtime, and enhances the overall performance of the coke production process


coke oven, coking equipment

Replacing Coal Hole Seat Brick and Iron Ring

When coal hole seat bricks or iron rings break, they must be replaced to prevent smoke and fire. Close the bridge tube flap at coking end, open the riser pipe cover, and inspect the cracks. Use a crowbar to remove the broken pieces, clean out debris, and apply clay mortar. Place new seat bricks, ensuring they are slightly lower than the furnace roof to avoid loosening. Fit the iron ring and fill joints with mortar.

  • Replacing Fire Hole Seat Brick

Replace fire hole seat bricks immediately if damaged. Move adjustment brick, remove iron cover and ring. Insert an iron cup to catch debris, remove broken bricks, and clean ash. Apply clay mortar and place new bricks. Ensure alignment and fill gaps with clay mortar. Remove slag, adjust bricks, and cover the fire hole.

  • Ensuring Furnace Top Surface Tightness

Silica bricks expand, causing gaps and gas leaks. Blow out ash from brick joints with compressed air, fill with clay mortar, and check for leaks. Use a mixture of clay, alumina cement, and quartz sand for better sealing. This prevents gas leakage and enhances structural integrity.

  • Repairing Furnace Roof Surface Tiles

Damaged or uneven roof tiles hinder coal sweeping and trap rainwater. Remove old tiles, clean ash, and lay dry clay mortar. Place new tiles level with the old ones. Use a mixture of clay, alumina cement, and quartz sand to improve strength and durability.

  • Sealing Bridge Pipe Joints

Poorly sealed bridge pipe joints cause smoke. Close the flap, open the riser cover, and remove old filling. Insert asbestos rope soaked in a slurry of clay fire mud and tamp it. Fill remaining space with a mix of asphalt, concentrate powder, and quartz sand.

  • Sealing Riser Tube Root

Clean mud impurities at the root of the riser tube, soak with water, and fill gaps with a mixture of clay fire mud, concentrate powder, and water glass. Alternatively, use clay or plastic for a strong seal without cracks.

  • Repairing Tie Trenches and Covering Bricks

Replace damaged tie bars to prevent masonry loosening. Remove cover bricks, insulation filler, and tie bars. Clean debris, fill gaps with clay mortar, and replace tie bars. Fill the trench with insulation materials, spread dry clay mortar, and lay bricks.

  • Repairing Small Stove

Severely deformed or smoking small stoves require repair. Remove masonry, asbestos rope, and graphite. Fill gaps with asbestos rope soaked in slurry, cover with concentrate powder and clay fire mud, and smooth. Use dry clay mortar for internal masonry and leave gaps for future renovations.

  • Blocking Oven Holes

Waste gas leaks into the combustion chamber through oven holes. Inspect coal loading ports, remove cover, close the bridge tube flap, and repair the plug bricks. Ensure the oven hole is tightly sealed to prevent high temperatures and masonry damage.

  • Fixing Fire Holes

Gas leaks into fire holes during coal loading affect temperature measurement. Insert a steel cup into the fire hole, repair with a trowel or spray gun, and remove the cup. Cover the fire hole and riser tube, and open the bridge tube flap.

  • Building Riser Pipe Lining Bricks

Falling riser linings cause steel shell burns. Remove riser pipe, stop ammonia water supply, and open the riser cover. Lay new lining bricks with expansion joints, ensuring tight horizontal and vertical joints. Use fire clay mixed with clean water for masonry.

  • Cleaning Chutes and Fire Paths

Debris in chutes and fire paths affects airflow. Use iron tools, compressed air, or a vacuum cleaner to remove debris. For serious blockages, use gas or oxygen methods to burn and remove coke. Clean remaining debris with a drill or chain.

  • Replacing Beef Tongue Brick

Preheat new beef tongue bricks to avoid bursting. Remove old bricks and clean the chute. Place new bricks using iron hooks, ensuring proper alignment and tightness. Preheated bricks prevent damage and improve durability.

  • Replacing or Straightening Burner Brick

Blocked or misaligned burner bricks need replacement or adjustment. Preheat burner bricks, insert a drill to remove the old burner, and place a new one with clay mortar. Adjust position using a steel bar for proper alignment.

  • Repairing End Cap Bricks

End cap bricks crack due to cold air exposure. Replace damaged bricks by removing roof masonry and opening the riser cover. Break damaged bricks and lay new preheated siliceous bricks. Continue building the furnace top surface after pushing coke.

By following these detailed procedures, coke oven equipment and coke oven doors can be effectively maintained, ensuring efficient and safe operation.

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