Rautaruukki Oyi, Coke Battery Inspection, Mechanical & Refractories

HeatTeQ Refractories Services BV was given the order to perform a Battery Inspection on Ruukki Steel's Coke Batteries at the Rautaruukki Plant. Ruukki Steel's objective is to secure trouble free Coke production for the next twenty five years, with the highest availability of Coke ovens to the most practical achievable levels. Over the years, HeatTeQ and its employees have built up a vast experience in Coke Battery Assessments, following repair recommendations and implementations. There are three Key Aspects affecting availability of Production Capacity;

  • Operational procedures;
  • Regular refractory maintenance program;
  • Refractory repair program and material applications.

Facts & figures

Project: Coke Battery Inspection, Mechanical & Refractories
Client: Ruukki Metals, Raahe, Finland
No. of Ovens: 70 (2 Batteries of 35 ovens each)
Duration: 6 weeks
Execution year: 2013

Manhours: 1.048
Battery Height: 7 meter
Partners: Fully executed with own personnel
Coke Battery Design: Twin Flue, Gyprokos

During the inspection a geodetic survey was performed. If the geodetic survey is repeated with regular intervals, the wear and growth of the battery can be monitored.

An inspection project basically consists of 4 phases: preparation, inspection, analyses and reporting. The final report will be a tool for Ruukki Metals OY to assess the condition of their batteries and to determine the scope and time frame of their repair program.

The next steps for a battery Repair Program are:

  • determine detail scope of work. This will also entail a detail inspection on the regenerator and regenerator wall. The engineering package for wall refractory
  • replacement will be based on the findings during the regenerator inspection.
  • Determine areas for design improvements to State-of -the-art.
  • Prepare enquiry documents for any design improvements required for the repair program.
  • Determine the right choice of material.

As part of the Report, a detail evaluation was made between traditional wall repairs and the alternative repair technique HeatTeQ is offering to the market, in co-operation with Vanocur Llc from Buffalo, USA. The fused silica modular shape system is a great alternative for the conventional silica repair systems. The biggest advantage is the huge time savings during the repair period. Due to the non – expanding characteristics of fused silica and the large modular shapes, the repair period can be reduced from 30-60%, depending on battery design and total scope of work. However, the higher cost of fused silica materials must be leveled out with the advantages of the shorter repair period, which are production savings of Coke.