Method and Apparatus for Replacing Coke Oven Wall

Abstract

Methods of replacing a damaged wall of a coke oven having a height h and a length l are provided. In one aspect, the method comprises removing the damaged wall from the coke oven, casting, outside of the oven, a replacement wall section having a length equal to the length l of the damaged coke oven wall and a height equal to the height h of the damaged coke oven wall, and positioning, inside the coke oven, the replacement wall section.

1 . A method of replacing a damaged wall of a coke oven, the damaged coke oven wall having a height h and a length  1 , the method comprising:
 removing the damaged wall from the coke oven,   casting, outside of the oven, a replacement wall section having a length equal to the length l of the damaged coke oven wall and a height equal to the height h of the damaged coke oven wall, and   positioning, inside the coke oven, the replacement wall section.   
   
   
       2 . A method of replacing a damaged wall of a coke oven, the damaged coke oven wall having a height h and a length l, the method comprising:
 removing the damaged wall from the coke oven,   casting, outside of the oven, a plurality of replacement wall sections, each replacement wall section having a length equal to the length l of the damaged coke oven wall and a height equal to a fraction of the height h of the damaged coke oven wall, and   positioning, inside the coke oven, the plurality of replacement wall sections one on top of another, such that the plurality of replacement wall sections has a combined height equal to the height h of the damaged coke oven wall.   
   
   
       3 . The method of  claim 2  wherein the plurality of replacement wall sections comprise a lower half section and an upper half section. 
   
   
       4 . A method of replacing a damaged wall of a coke oven, the damaged coke oven wall having a height h and a length l, the method comprising:
 removing the damaged wall from the coke oven,   casting, outside of the oven, a plurality of replacement wall sections, each replacement wall section having a length equal to a fraction of the length l of the damaged coke oven wall and a height equal to the height h of the damaged coke oven wall, and   positioning, inside the coke oven, the plurality of replacement wall sections end to end, such that the plurality of replacement wall sections has a combined length equal to the length l of the damaged coke oven wall.   
   
   
       5 . The method of  claim 4  wherein the plurality of replacement wall sections comprise a pusher side section, a middle section, and a coke side section. 
   
   
       6 . The method of  claim 5  wherein abutting ones of the pusher side, middle, and coke side sections are formed to have mating, interlocking ends. 
   
   
       7 . The method of any of  claims 1 - 6  wherein the replacement wall sections are cast with air/gas passages and vertical flues therein. 
   
   
       8 . A method of replacing a damaged wall of a coke oven, the method comprising:
 removing the damaged wall from the coke oven,   casting, outside of the oven, a replacement wall section,   providing first and second fixture plates,   sandwiching the replacement wall section between the plates,   lifting the replacement wall section by lifting the plates,   positioning the plates and hence the replacement wall section inside the coke oven, and   removing the plates from the replacement wall section.   
   
   
       9 . The method of  claim 8  further comprising:
 providing a layer of rubber on each of the fixture plates for contacting the replacement wall section so as to avoid damage to the wall section during installation of the wall section in the oven.   
   
   
       10 . The method of  claim 8  further comprising:
 providing rolling trucks secured to the fixture plates for rolling movement of the replacement wall section and plates in the oven during installation of the wall section in the oven.   
   
   
       11 . The method of  claim 10  further comprising:
 interconnecting the rolling trucks and the fixture plates with hydraulic cylinders to facilitate leveling and load distribution of the fixture plates and hence replacement wall section during installation of the replacement wall section in the oven.   
   
   
       12 . The method of  claim 11  further comprising:
 providing a computer and a controller in operable association with the hydraulic cylinders to automate leveling and load distribution of the fixture plates and hence replacement wall section during installation of the replacement wall section in the oven.   
   
   
       13 . The method of  claim 8  further comprising:
 casting holes through the replacement wall section, and   compressing the replacement wall section between the fixture plates by compression pins which pass through the holes in the wall section and connect the fixture plates.   
   
   
       14 . The method of  claim 8  wherein the replacement wall section is installed in the oven through an open end of the oven. 
   
   
       15 . The method of  claim 8  wherein the replacement wall section is installed in the oven through an open roof of the oven. 
   
   
       16 . The method of  claim 8  further comprising:
 casting mortar joints in at least one of upper and lower surfaces of the replacement wall section.   
   
   
       17 . The method of  claim 8  further comprising:
 providing a vertically movable leveling bed adjacent the coke oven, and   at least partially supporting the replacement wall section and fixture plates with the leveling bed as the replacement wall section is installed in the oven.   
   
   
       18 . The method of  claim 17  further comprising:
 providing a frame, and   interconnecting the leveling bed and the frame with hydraulic cylinders to facilitate vertical movement of the leveling bed during installation of the replacement wall section in the oven.   
   
   
       19 . The method of  claim 18  further comprising:
 providing a computer and a controller in operable association with the hydraulic cylinders to automate vertical movement of the leveling bed during installation of the replacement wall section in the oven.   
   
   
       20 . A fixture for installing a replacement wall section into a coke oven, said fixture comprising:
 a pair of plates for sandwiching the replacement wall section therebetween,   rolling trucks for rolling movement of the replacement wall section and said plates during installation of the wall section in the oven,   hydraulic cylinders interconnecting said plates and trucks, and   a computer/controller in operable association with said hydraulic cylinders to automate leveling and load distribution of said fixture plates and hence the wall section during installation of the wall section in the oven.   
   
   
       21 . The fixture of  claim 20  further including a layer of rubber on each of said fixture plates for contacting the wall section so as to avoid damage to the wall section during installation of the wall section in the oven. 
   
   
       22 . The fixture of  claim 20  further comprising angle clips removably secured to bottoms of said plates to add support for the wall section during installation of the wall section in the oven. 
   
   
       23 . The fixture of  claim 22  further comprising a layer of rubber on an upward facing surface of each of said clips for contacting a bottom of the wall section so as to avoid damage to the wall section during installation of the wall section in the oven. 
   
   
       24 . The fixture of  claim 20  further comprising a plurality of compression pin assemblies for securing said plates to the wall section, each said compression pin assembly comprising:
 a two-piece outer sleeve, and   a two-piece inner pin, one portion of said two-piece inner pin having a male threaded portion on one end which fits in a complimentary female threaded portion of the other portion of said two-piece inner pin,   Bellville washers on the other end of said one portion of said two-piece inner pin, said other end of said one portion of said two-piece inner pin being threaded, and   a nut on said other end of said one portion of said two-piece inner pin.   
   
   
       25 . The fixture of  claim 20  wherein said pair of plates side plates, and further comprising a pair of end plates removably secured to ends of said pair of side plates. 
   
   
       26 . The fixture of  claim 25  further comprising a layer of rubber on each of said side plates and each of said end plates for contacting the wall section so as to avoid damage to the wall section during installation of the wall section in the oven. 
   
   
       27 . A method of repairing a damaged wall of a coke oven, the coke oven wall having a floor to ceiling height h and a pusher side to coke side length l, the method comprising:
 removing a damaged portion of the wall of the coke oven, the damaged wall portion having a height equal to the height h of the coke oven wall and a length equal to a fraction of the length l of the coke oven wall,   casting, outside of the oven, a replacement wall section, the replacement wall section having a height equal to the height h of the coke oven wall and a length equal to the fraction of the length l of the coke oven wall, and   positioning the replacement wall section inside the coke oven.   
   
   
       28 . The method of  claim 27  further comprising casting at least one vertical flue in the replacement wall section. 
   
   
       29 . The method of  claim 27  wherein the replacement wall section is a pusher side replacement wall section. 
   
   
       30 . The method of  claim 27  wherein the replacement wall section is a coke side replacement wall section. 
   
   
       31 . The method of  claim 27  wherein the fraction is about one-third.