Coke Oven
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Repairs
Ceramic Welding Technology
Ceramic Welding was developed in the 1970s/80s. It is a proven method for hot repairs of industrial furnaces under operating temperatures. A mixture of ceramic and metallic particles is projected with oxygen onto the hot refractory ceramic surface and melts on impact both the projected powder, as well as the surface, thus creating a bond, equivalent to metallic welding.
The Ceramic Welding method allows furnace repairs without having to cool down the surface. In fact, the battery can keep on producing while an individual oven is repaired. In contrast to a gunning repair, Ceramic Welding provides long lasting repair results, which are measured in years not months.
DOMINION NovoCOS provides this technology for Coke Ovens batteries. DOMINION NovoCOS uses state of the art equipment which is audited and certified for technical functionality and safety by TÜV inspection.
Our technology and variable length lances enable us to complete Ceramic Welding repairs as deep as the center of the Coke Oven if necessary, we worked already with 12 m long water-cooled lances, not losing any welding quality due to our advanced technology and application by professional DN technicians.
DOMINION NovoCOS works to the highest standards of Health & Safety, meeting or exceeding all requirements relating to working practices.
Repair inside a “top-charging” oven
Which Coke Oven types and refractory-defects can be repaired?
DOMINION NovoCOS has the expertise and the Know-How to repair all types of different coke ovens as well as all types of refractory defects inside a coke oven.
That means in practice, DN repairs all refractory defects inside “top-charging”-, “stamp-charging”-, but also “heat recovery” ovens around the world.
The previous photo show the repairs inside a “top-charging” oven, whereas below you see a repair at a “heat-recovery” oven.
Defect inside a “heat-recovery” oven
Tunnel repair inside a heat-recovery oven
Special door-frame welding / sealing inside a “top-charging” oven
Partial rebricking using fused silica modules:
Where the damage to the coke oven walls is already so severe that there are holes in the wall, brick-shaped modules made from fused silica grain are utilized. These are fixed in place by Ceramic Welding which is also used to fill any remaining gaps.
The fused silica material will not display the thermal expansion seen with fired silica brick which is why there are no heat- up problems, which is why they are known in the cokemaking industry as zero expansion bricks.
Special Brickwork Technology
Partial rebricking using fused silica modules:
Where the damage to the coke oven walls is already so severe that there are holes in the wall, brick-shaped modules made from fused silica grain are utilized. These are fixed in place by Ceramic Welding which is also used to fill any remaining gaps.
The fused silica material will not display the thermal expansion seen with fired silica brick which is why there are no heat- up problems, which is why they are known in the cokemaking industry as zero expansion bricks.
Additional Repair Services
DOMINION NovoCOS offers a full-service package, including all refractory and mechanical repair and maintenance activities in addition to the Ceramic Welding and brickwork technologies.
These additional services include:
- Gunning of heating walls and charging holes
- Dusting
- Repair of regenerators
- Repair of coking chamber floor
- Cleaning of regenerators, sole-channel and flues
- Special channel cleaning by using drilling equipment developed by DN
- Monitoring of emissions
- Stand-pipe repairs and replacement
- Jamb joint repairs with different technologies
- Standpipe repairs, sealing and replacement
- Exchange of frame and other mechanical parts
