TATA Steel IJmuiden through wall repairs

The project consisted of replacement of 6 Oven Walls, a block of 3 walls on battery 4 and 3 walls on battery 2. The walls were mechanically demolished and build with Fused Silica modular blocks. The mechanical demolition system was developed in cooperation with Schot Vertical Transport, based in Alkmaar and Wesco Machine Manufacturing, based in IJmuiden. The mechanical demolition consisted of the following elements:

  • A self-propelled demolition platform (Jaap #1) which is placed on the charge car rail. Jaap #1 is equipped with a generator, used for the platform lighting and propulsion as well as a dust water spraying system.
  • A Komatsu demolition excavator, modified with an pressurized cabin to meet Plant Health and Safety requirements and special adapted tools to increase the reach of the excavator down to the regenerator deck.
  • 400T mobile crane to place and remove demolition containers, water and fuel. The 400t crane is also required to remove Jaap #1 and the Komatsu excavator in case of an emergency.

Facts & figures

Project: TATA Steel IJmuiden through wall repairs
Client: TATA Steel IJmuiden, Coke Plant #2
No. of Batteries: 4
Design: Carl Still
Duration: 6 Months incl. preparation and Christmas break

Execution year: 2011/2012
Manhours: 35.000
Oven Height: 6,5 metres
Partners: Ovenbouw Holland and Schot Verticaal Transport
Scope: 2 x 3 throughwalls, from oven sole through the oven deck

The mechanical demolition of 6 coke oven walls was a big success and is the new standard of demolition for through-wall repairs. The temparature of the adjacent walls is maintained by the installation of 2 insulation curtains, immediately after the ovens are taken out of production. The adjacent walls are set to 950 - 1.000˚C, the adjacent ovens are in operation at a double coking time.

The mechanical installation of modular Fused Silica blocks is a fast installation system which requires less manpower thus reduces the exposure of people to the hot and dusty work environment. By using big blocks instead of small silica brick we reduce the number of joints by over 90%. Joints are typically the place where the problems in a coke oven wall starts. Spalling of brick, Coke Oven Gas leakage, etc. is less problematic if the number of joints is reduced. Using Fused Silica also reduces the project duration by its 'zero' expansion abilities. No temperature curve needs to be followed during the heat up of the walls. To bring Fused Silica up to operating temperature requires no more than 24 hrs, whereby traditional silica requires a heat-up period of 14-21 days. The mechanical installation of modular Fused Silica blocks is a fast system which requires less manpower thus reduces the exposure of people to the hot and dusty work environment.