Latest Developments in Coke Oven Health Diagnostics and Battery Life Extension Strategies...
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Transcript of Latest Developments in Coke Oven Health Diagnostics and Battery Life Extension Strategies...
Latest Developments in Coke Oven Health Diagnostics and Battery Life Extension
StrategiesInternational Conclave for Iron & Steel Making
- Raipur, 7th February, 2015
K.G.VenkatesanFosbel India Pvt. Ltd.
4 Key Elements of Condition Monitoring
Predictive Life of Coke Oven Battery
QUALITY STABILITY
Flue Temperature
Surveys
Battery Expansion
Survey
STRUCTURAL STABILITY
Emissions Survey
ENVIRONMENTAL STABILITY
Battery Condition COMIT
PRODUCTION STABILITY
Background & Philosophy
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•Refractory consumption in steel in the 1970’s was over 25kgs per tonne liquid steel. Today world’s best is just below 5kgs.
•Most product groups and repair strategies are now well known but the strategic application of these is often overlooked.
•The refractory industry has mostly mature product technologies and innovation in service based technologies is the next quantum improvement.
•The implementation of Condition Monitoring with iterative feedback mechanisms is essential for asset preservation.
•Refractory installers must look to software based tools and even robotics to extend and preserve campaign life performance.
Established Refractory Inspection SystemsOwner Method Freq Type Meas. PurposeJapan (NSC) Visual Ann + PM Cracks Life PredictionArcelor (NSC) Visual Ann + PM Cracks Life PredictionEurope(OSC) Visual Ann + RM Exper. Rebuild focusCOMIT(Fosbel) Visual Mon + PM Rank Prev + Life + Op Sec.Comments:• Japan & Arcelor
– Process has no measure for deep oven condition.– Counting cracked bricks does not account for movement or prior repair– No day to day repair prioritisation capability– Life Prediction curve is not modifiable to match battery design and ops.
• Europe– Subjective basis only, no measures of relative condition– Based on rebuild requirements, no provision for PM strategies– Report is out of date before it is fully assessed by customer– No facility to predict operational security risks.
4 Key Elements of Best Practice
Battery Diagnostics
(COMIT)
Total Operational
Control
Remedial Battery Repairs
Total Operating
Costs Contained
Preventative Maintenance
Battery Deterioration Factors
Battery deterioration can be classified into two factors:
CAUSAL• Battery heating stability• Operating Temperature• Operating Practices• Coal Properties• Operational Reliability
(PRI)• Battery Design• Mechanical Maintenance
CONSEQUENTIAL• Refractory Condition• Ram or Pushing Force• Flue Leakage• Battery expansion• Stickers
Some consequential factors can also be part of an ongoing causal chain.
Coke Oven Walls
Heating
Leakag
e
Pushing
Structura
l
Coals
Causal Wheel to Battery Life
Key Consequential Indicator
“The refractory condition is the indicator of all trauma and
operating practices past and present in the coke oven battery.”
Refractory Condition:
What is COMIT™?
What is COMIT™?
• Coke Oven Management Information Technology
• A comprehensive coke oven condition monitoring program
• Web-based application that provides a variety of reporting options with the ability to drill down to see the underlying details
• Translates day-to-day condition monitoring data into meaningful output
• Provides insights into battery deterioration and improvement trends
• Enables more effective and proactive coke battery maintenance
• Provides visibility across multiple battery and plant locations
• Adaptable for many battery designs and operating condition, including Non-Recovery/Heat Recovery batteries
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Elements of COMIT™
COMIT™ is structured in a modular format:
• Wall Analysis and Prioritization (using Fosbel assessment data)• Ranking
• Inspections
• Life of Repair
• Risk Analysis
• Operational Data Collection & Reporting (using customer-provided data)• Temperature• Pushing Amps• Battery Expansion• Door Repairs• Stack Emissions
• Battery Analysis and Reporting
• Life Prediction13
COMIT™ Condition Assessment
COMIT™ identifies and assesses oven refractory condition in two ways:
1. Before repair: Visual rankings performed by Fosbel technicians are
used to assess refractory damage.
2. After repair: Oven status is verified using calculations based on Fosbel
repair material volume to provide the most accurate view of current
oven condition.
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COMIT™ Assessment Ranking Criteria
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Estimated Time before repair
(months) Rank
Recommended inspection frequency
(weeks) CBM stage Typical condition
120+ 0.0 104 New, undamaged. Recent thru-wall rebuild.
48-120 0.5 52
Condition Monitoring Recent end-flue rebuild.
24-48 1.0 26 Future CBM repairs expected
18-24 1.5 20 Imminent CBM repairs forecast
12-18 2.0 10 Minor damage - regular CBM
6-12 2.5 6 Medium damage - frequent CBM
3-6 3.0 4
Preventative Maintenance
High damage - intense CBM
2-3 3.5 2 Major damage - brick patch
1-2 4.0 1 Extensive damage - end flue forecast
0-1 4.5 Every push Extensive damage - end flue planned
0 5.0 -
Remedial Maintenance
Out of service
Examples of COMIT™ Output
COMIT™ Dashboard: Plant OverviewEnables Visibility Across Multiple Batteries
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COMIT™ Battery Status: Battery Condition with Drill Down Interactivity
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COMIT™ provides drill down interactivity, e.g. in battery status view shown above, user can click on one oven to drill down to see individual oven data.
COMIT™ Visual Rankings:Enables Identification of Problem Areas
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For this customer, a spike in the visual rankings in COMIT™ was identified (see Feb & Mar 2005 in graph above). This brought to light
an issue that was rectified with a change in coal blend.
Additional COMIT™ Modules: Temperature Enables overall view of battery temperatures
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Example above: Thermograph of Oven Crosswalls without temperature values. Maps actual temperatures on oven diagram using color-coding.
Additional COMIT™ Modules: Battery ExpansionEnables better visibility and more proactive maintenance
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Above: Battery Expansion Deflection Profile Diagram illustrates profile of individual oven buckstay
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COMIT Summary
• A day to day condition monitoring system that predicts operational security risks.
• Ensures production is maintained through elimination of oven failures.
• More functional for daily monitoring of oven repair priority than an Annual Diagnosis
• Most importantly feeds directly into battery life prediction monitoring.
• Enables continuous monitoring of battery life trends.
• Only software that will quantify life of repairs including ceramic welding.
Elements of Condition Monitoring
Flue Temperature
Surveys
Refractory Condition
Survey
Battery Expansion & Bracing
Survey
Flue Leakage, Fugitive &
Stack Emission Survey
Coke Oven Battery Life Determined
HEATING SECURITY
STRUCTURAL SECURITY
ENVIRONMENTAL SECURITY
OPERATIONAL SECURITY
COMITTM can track all of these Elements
Ram Pushing
Force
PRODUCTION SECURITY
Battery Life Projection Model
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