How to repair damaged refractory bricks at the bottom of the carbonization chamber?
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The refractory bricks at the bottom on the coke side of the carbonization chamber have been damaged by the coke pushing rod due to the warping of the grinding plate; any expert who can advise on how to repair them would be greatly appreciated.
We have carried out cold-state repairs here, but not any hot-state repairs yet. I think we should first prepare the bricks that need to be replaced, preheat them to around 800 degrees, and then replace them after emptying the furnace. If the area is not large, it can be repaired with refractory mortar.
What’s your phone number? This kind of situation has also occurred in our factory; we use a heat-based repair material. If you need it, please contact 13805372396
①After the coke is removed, a rake is used to push the remaining coke at the bottom of the furnace back into it, and the hollow areas are cleaned with air； ②Pour the phosphate slurry into the depression and then level it off; if the depression is deep, a small clay brick can be placed there to level it ； ③In cases of severe damage, the old bricks are removed and replaced, with the gaps between the bricks filled with phosphate mortar ； Finally, cover the repair area with an aluminum silicate fiber mat; after burning it empty for 20 minutes, add coal.
Thermal repair can be used. Prepare the bottom bricks for the carbonization chamber in advance (have a few extra pieces), cut them to the desired thickness, dry them and heat them to over 600 degrees. After the coke has been pushed out, clean up any remaining coke as well as any damaged bricks. Use insulating material to transport the dried silicon bricks to the site, where they can then be installed. Note that a pre-made fake furnace door can be placed inside the carbonization chamber.
It can be treated by spraying or grouting.
The method mentioned on the sixth floor is very useful. Our factory has previously carried out thermal repairs on certain furnaces, and recently we rebuilt the carbonization chamber, replacing many of the bricks at the bottom.
Your handling process is too complicated. Our company has dealt with this issue many times; the solution involves using a new type of thermal filler for patching, followed by grouting. It’s simple, convenient, and durable.
It depends on the location of the furnace bottom bricks that need to be replaced. If they are within three vertical flues, it is possible to build a wall around them and then consider replacing the furnace bottom bricks; if they are too far away, cleaning can be carried out first, followed by the application of a high-temperature adhesive, the addition of phosphate mortar, leveling and drying, and finally spraying a slurry.
Our plant uses rammed coke ovens, and the furnace bottom has been repaired multiple times; up to 12 furnace bottom bricks have been replaced. The process is quite simple: a certain number of furnace bottom bricks are prepared and dried and dehydrated for two to three days, after which they are heated to a very high temperature. This approach is chosen because it facilitates handling and transportation, and also because high-temperature silica bricks will crack when exposed to cold air. Prepare tools: a long gray shovel with a deep bowl, such that one scoop is enough to place one brick; long rods and tools that can be used to clean the damaged bricks at the bottom of the furnace. Make sure to remove all the original mortar so that the surface of the next layer of bricks is visible; clean until the innermost intact brick at the bottom of the furnace is reached. Tools for sliding bricks can be used to move them along the bottom of the furnace. The mortar uses silica fire mortar. Prepare personal protective equipment, masks, etc. Bricks are laid one by one, from the inside out. If the innermost brick is out of alignment with the older bricks, it can be removed, realigned, and reinstalled. Act quickly: one spoonful of ash per brick, and use a spatula to remove any excess ash. The last brick should have an expansion gap of 20–30 mm from the protective plate; this gap should be filled tightly with asbestos rope and smoothed out, ensuring it does not rise too high above the grinding plate so as to prevent the furnace door from failing to close properly. The time-changing function of our factory’s product works quite well; it has never stopped working. In other words, thermal repair cannot achieve the standards of a newly built structure.