Coke plant technologies

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Coke Plant Technologies

Coke Plant Technologies

When it comes to coke plant technologies, thyssenkrupp Uhde is the supplier of choice for new builds and revamps. Since combining the know-how of the former coke oven plant engineering and construction companies Dr. C. Otto, Carl Still, Heinrich Koppers and Didier under its roof, thyssenkrupp Uhde's experienced employees have continuously developed this expertise. We are thus the only company in the world who can offer, supply and commission complete coke oven plants of a wide variety of designs from a single source.

The advantages are obvious

Great flexibility through a broad range of proprietary technologies
A customized solution for every single section of your plant
Latest state of the art
Compliance with the latest environmental standards
Production of high-quality coke for the rest of your value chain or for sale
Improved cost efficiency and environmental compatibility in your coke production
Customer proximity (local presence throughout the world)
Great flexibility in the scope of the work package (from individual services to a turnkey plant)

We offer decades of experience

in the international EPC sector
in implementing plant sections or complete plants
in inspection, maintenance and repair to extend the life cycle of coke oven plants
in expanding or revamping existing plants

Take a look at our extensive list of references (a wealth of projects around the world) and see for yourself.

Single source service solutions along your entire plant life cycle

360° Service - increasing efficiency, conserving resources, reducing emissions

Repairs, inspection and maintenance of coke oven batteries

With 150 years of experience thyssenkrupp Uhde offers the whole scope of services for a straight operation, increase of production, minimization of emissions and to prolong the life time of the batteries:

Inspections of coke oven batteries

Regular inspections of the coke oven batteries are indispensable in order to identify impermissible deformations. We combine our digital and technical competences and use the information to create measurable added value for our customers.

Heating flue/wall inspections

Waste gas measurements/analysis

Inspection of mechanical equipment (wall protection plates, doors, bracing system)

Inspection of coke oven service machines

Thermography

Heating flue/wall inspections

An annual inspection of a coke oven battery is necessary to identify existing problems or defects which will cause problems in the future. To prevent from this, the inspection result will help to determine necessary next steps like maintenance, repair or refurbishment of parts of the battery. This will prolong the life time of the battery and secure the production of coke.

Inspections of the refractory such as:

Inspection of heating walls for cracks, surface damages, deformed areas of brickwork, oven sole and cover bricks

Damaged corbel areas and regenerators walls

Blocked heating flues

Restricted gas flow through the regenerators

Cross-leakages from oven chamber to heating flue

Over expended and grown brickwork at the oven top

High oven top temperatures

Inspections of the mechanical equipment such as:

Misadjustment or inoperative bracing system

Bent/damaged buckstays, supports, tie rods etc.

Any kind of damages to springs, pressure bolts etc.

Malfunctions of the oven closures like oven doors, door frames, charging holes etc.

Malfunctions of the heating system like gas/air boxes, reversing system, gas distribution etc.

Malfunctions of the raw gas system like gas collecting main, stand pipes etc.

Your advantages:

Experienced team with profung knowledge of the entire coking process

Elaboration of maintenance and repair concepts

Future oriented solutions

Cost estimation and return of invest calculation

Drones and 3D scan

Increase the range of your inspection

Whether you are planning a plant extension/revamp or you want to learn more about the current status of your plant and buildings – our (laser-) scanner services will assist you.

We offer drone flights to assess your plant from every angle, executed by our experienced experts who know the plants perfectly. Apart from pure visual examinations our offer ranges from thermodynamic to laser based scans of the plant. The latter one is especially helpful to create 3D models for a variety of purposes (e. g. revamp planning – “are there interfering edges?”)

Your advantages:

Fast and efficient detection of e.g. leakages in heights that are hard to access

Combination of drone and 3D scan with domain expertise

Laserscan

Deformation measurement of mechanical equipment

Using a stationary laser scan or drone, various coke oven sections can be digitally recorded to identify and potential damages :

Location and possible movement of the charging holes, charging car rails and standpipes

Deformation of the gas collecting main

Location and deformation of wall protection plates and buckstays

Deformation of quench car rails

Safe distance to moving plant parts (drone)

Taking digital thermal images with a drone

Your advantages:

Good forecast of essential revamp procedures

Cost efficient solution due to less staff assignment

Increase of economic profitability of coke plant

Remote expert support

Professional support without travelling

With our tools for advanced remote support, our experts can provide you with on-site assistance in real time for immediate trouble shooting and also regular maintenance.

Your added value:

Expert knowledge “remote” on site, worldwide

Fast assistance – tailored to your needs

Easy and cost-efficient

Computer Vision

AI-based defect recognition in coke ovens

On-site support from our experts for your business.

Simplify the inspection of refractory surfaces by:

No further informal inspections required by staff (e.g. door cleaning)

Error detection following a data-driven AI approach

AI-model aiming to learn patterns from a set of pre-processed images

Defining automatically individual defects such as cracks, concrete, graphite, gas leakage by continuous improvement of the model over time

Providing a customer-centric interface

Your advantages:

Identify anomalies in the refractory wall of a coke oven plant by
Systematically capturing images and classifying anomalies

Advising the maintenance team with possible remedial actions

Regular maintenance in coke oven batteries

Due to the usual tear and wear during regular operation, the integrity of the coke battery and the by-product plant can derogate and needs to be adjusted with different measures on a regular basis.

Referring to the refractory brickwork of the battery, leakages due to cracks, leaky joints and damages to the brickwork can occur. Regular maintenance work will prolong the life time of the heating walls until bigger repair works are required.

Often graphite deposits need to be eliminated, doors need to be sealed and means like gunning and ceramic welding can close joints and cracks.

With regard to the mechanical equipment the bracing system shall be adjusted twice a year.
Also steel structures should be inspected to identify defects or probably corrosion.

Based on a regular inspection services thyssenkrupp Uhde offers to prepare maintenance manuals and can execute the works.

Maintenance of the bracing system

Assessment of the integrity of the plant (optionally supported by means like 3-D scans and drone measurement)

Design/material quality improvements

Fabrication and supply of high quality materials in shortest possible time

Highest quality standards

Dismantling and assembly on site

Regular adjustment of the bracing system

- Adjustment the springs to maintain the required anchoring forces

Repairs/ renewals

With increasing age of existing batteries, damages occur due to high temperatures and mechanical stress of the refractory block. Production capacity is effected. thyssenkrupp Uhde is able to prolong the lifetime and to reset the production to the design capacity by using different systems to rehabilitate the refractory installations under the conditions of a producing plant.

thyssenkrupp Uhde is, with its worldwide service teams, in a position to refurbish the refractory block of the damaged heating walls in line with new technologies. Tailor-made integration into the existing plant minimizes production downtimes and extends battery life.

Scope of work

Creation of customized revamp concepts

Reengineering of the existing design

Selection and quality-controlled delivery of materials

Execution of the refurbishment

Management of the entire repair area, including heating management during the refurbishment

Refractory part

Due to the usual tear and wear of the refractory brickwork during regular operation, and very often also due to damage caused by improper operation or the failure to carry out regular maintenance work, the condition of the refractory brickwork deteriorates and the following problems can occur:

Damage to the oven chamber refractory brickwork, such as spalling, cracks, deformed and/or collapsed brickwork, which could cause problems during operation (coking process, machine operation, emissions)

Leaks from the coke oven chamber into the heating flues due to cracks, leaky joints and damage to the brickwork increase emissions and change the heat distribution and combustion

The renewal of heating wall refractories requires special repair techniques and experience in all regards (engineering, material supply, construction work and heating control) as the remaining part of the battery must be kept hot and the new brickwork must be integrated into the existing brickwor

The scope of renewal must be defined based on the condition of the coke oven battery and the location of the main damage, for example:

Full renewal of heating walls (through wall repair)

Renewal of heating wall end flues (end flue repair)

Renewal of regenerator walls and corbel areas during wall repairs

Renewal of the oven top refractories (oven top repair)

Renewal of regenerator internals (re-checkering)

Your advantages:

Prolongation of the life cycle of a battery

Repair during operation of the battery (hot repair)

Minimum production loss

Recovery of the battery performance

Mechanical part

Replacement of buckstays wall protection plates and doorframes

If buckstays, wall protection plates and/or door frames of coke oven batteries are damaged, thyssenkrupp Uhde offers the equipment and qualified personnel to carry out the replacement of these buckstays and door frames. The thyssenkrupp Uhde experts assess the current condition of the buckstays, wall protection plates and door frames, provide a report on the required scope, and offer all exchange work services including dismantling and assembly.

The team consists of engineers, technicians and supervisors based in Germany, as well as in service centers worldwide. Based on many years of experience, thyssenkrupp Uhde offers a complete range of services for the renewal of buckstays and door frames.

Scope of work

Delivery of new buckstays
Delivery of wall protection plates

Delivery of new door frames

Creation of a customized revamp concept

Dismantling of old buckstays and door frames

On-site installation and final assembly of new buckstays and door frames

Your advantages:

Achievement of maximum performance of the battery

Extension of coke battery life
Compliance with environmental regulations

Replacement of buckstays and door frames during
regular production of the battery

Experienced service team

Service in accordance with valid SCC/ OHSAS regulations

Replacement of raw gas system

Evaluation and assessment of the service life of the components (optionally proved by means like 3-D scan, drone thermal measurement)

Implementation of design improvements (EnviBAT® 2.0 etc.) following environmental requirements

Fabrication and supply of high quality materials

Reliable replacement with the shortest possible interruption of production

Your advantages

Increased availability of your plant

Highest technology standard from OEM

Design improvements following environmental requirements

Refurbishment on site: safe - in time – highest quality

Adjustment of heating system

The adjustment of a coke oven battery heating system is an important aspect for the operation. With the adjustment of the heating walls, the draft of the stack or waste gas boxes, the environmental pollution can be reduced to a minimum. Furthermore the steady temperature distribution of the heating walls will ensure a good coke quality and reduce the consumption of gas.

thyssenkrupp revamp teams have specialized engineers and technicians based in Germany as well as worldwide. These teams are experienced with the commissioning of all types of coke oven batteries.

High quality of the product, the full volume of the coke production as well as the compliance with environmental regulations will be achieved with our services.

A heating adjustment is also required in order to execute a “hot repair” safely. It ensures that the remaining brickwork is kept hot and allows the employees to work in a safe environment without being exposed to harmful gas emissions.

Your advantages:

Low emissions

Safe environment

High coke quality and production rate

Low energy consumption- low costs

Spare parts

We are experts when it comes to supplying spare and wear parts for your plant – over the entire lifetime, at the right time and with the right quality. Because the right spare and wear parts are key elements for the availability of your plant.

Easy purchasing of high-quality spare parts

We supply all spare parts and components in OEM quality for your plant. You will receive state-of-the-art technology with guaranteed functionality. In addition, we offer you attractive framework contracts for the procurement of spare and wear parts.

Individual spare parts for enhancing the performance of your plant

With long-term experience as an OEM supplier, we provide innovative spare parts concepts which meet your requirements regarding quality and performance. One part comprises the engineering and manufacturing of individual spare parts in accordance with your requirements. The other part includes the continuous development and enhancement of spare parts and components, in order to increase the availability of your plant.

We also offer spare and wear parts for plants that were engineered and erected by third parties.

Customized wear parts solutions

Our service specialists develop solutions for wear parts according to the individual requirements of your plants and components. They focus especially on innovative solutions aimed at reducing downtimes and at improving plant performance. For this purpose, our expert team assesses your individual production processes and develops a suitable wear part solution for the relevant application, based on OEM expertise and materials engineering.