The Most Comprehensive Construction Steps and Methods for Masonry of Coke Oven Regenerators
01 Laying of the Sliding Layer in Coke Oven Regenerators
1.First, build the foundation platform and adjust and correct the resistance wall. After passing the inspection, prepare to lay the sliding layer.
2.When using river sand to lay the sliding layer, the river sand should be flat, uniform, and of consistent thickness everywhere.
3.A layer of asphalt felt should be laid between the refractory bricks and the river sand sliding layer before masonry.
4.When using thin steel plates as the sliding layer, the following requirements should be observed:
(1) The sliding layer should be laid completely at one time before bricklaying. Before laying, apply yellow drying oil to the bottom of the steel plate.
(2) After the steel plate is laid and inspected to be qualified, apply a thin layer of yellow drying oil on the upper surface of the steel plate, then lay a layer of asphalt felt, and then carry out bricklaying.
(3) Mortar contaminated with oil is strictly prohibited from being recycled.
02 Bricklaying Process for Small Flues and Regenerator Walls in Coke Oven Regenerators
1.Before masonry of the small flues, mark the width sidelines of each wall based on the centerline of the combustion chamber, and mark the height lines of each brick layer on the vertical benchmark, or use the method of measuring and setting out wall by wall in sections for masonry.
2.The first layer of the small flue should be dry-laid for trial to check that the width of the reserved expansion joint is qualified, and then set out the lines to masonry the main wall and furnace head of the small flue.
3.The furnace head position should be masonry several layers of bricks at one time, and a stepped backward (step-back joint) should be made inside the wall to prevent the furnace head from shifting on the sliding layer.
4.During masonry, repeatedly check and verify the horizontal and vertical (verticality) of the masonry according to the centerline to prevent the furnace wall from twisting.
5.The masonry process should be carried out carefully, and the furnace head position should not be collided. When changing shifts, first check and confirm whether the furnace head position has been moved and make adjustments.
6.Check the flatness of the masonry wall surface at any time. After the masonry of the small flue wall is completed, check the brick layer elevation and gradually level it.
03 Masonry Process for Lining Bricks and Grate Bricks in Coke Oven Regenerators
1.First, masonry the central partition wall. After completion and cleaning of the construction area, masonry the lining bricks. The masonry sequence should be from the center to both sides.
2.Lay yellow cardboard when masonry bricks. After the lining bricks are masonry, fix them with wooden supports to ensure that the width of the expansion joint between the lining bricks and the furnace wall does not change during masonry.
3.After the masonry of the lining bricks is completed, clean the bottom and wall surface of the small flue, lay a layer of 10-15 mm clean sawdust on the bottom of the small flue, and then masonry the grate bricks layer by layer from the center to both sides. The refractory mortar extruded from the brick joints should be cleaned up in time.
4.When masonry perforated grate bricks, strictly check the aperture of the grate bricks, and masonry them only after they are qualified. When masonry the grate bricks of the air and gas regenerators, first carry out dry-laying for trial and joint inspection, and then carry out formal masonry.
5.Check the flatness of the leg platform of the grate bricks with a wooden straightedge, and the gap error should meet the construction requirements.
6.After the masonry of the grate bricks is completed, clean the expansion joints and inspect them. After passing the inspection, lay a wooden protective plate on the grate bricks. The gap between the protective plate and the wall should not exceed 15 mm.
04 Masonry Process for Regenerator Wall Bricks in Coke Oven Regenerators
1.Use the matching refractory mortar for the masonry according to the design drawings. When changing the material of the refractory mortar, clean the preparation utensils.
2.According to the elevation mark of the gas pipe bricks, start from the first gas pipe brick at both sides of the furnace head, and then lay the line to masonry the gas pipe bricks in other parts in sequence.
3.During masonry, use a gauge plate to correct the center distance between the gas pipe bricks. The length of the gauge plate should be more than half of the furnace length. The gauge plate should be marked with the vertical centerline of the coke oven, the front line, and the center positions of each gas pipe. The flatness of the masonry should be checked and corrected every two layers of bricks.
4.The refractory mortar in the mortar joints of the gas pipe bricks should be filled full and dense, and the refractory mortar entering the pipe brick holes should be cleaned up. Before the end of each working day, carry out a thorough cleaning of the gas pipe bricks from top to bottom in sequence to ensure that the gas pipe bricks are unobstructed.
5.The masonry position of the gas pipe bricks should be checked at any time during masonry, and the gas pipe bricks should not be collided or twisted during the masonry of the regenerator wall bricks.
6.The central partition wall should be masonry after the main single wall is masonry to a certain height (generally not more than 1.2 meters). During masonry, reserve expansion joints and sliding joints according to the construction design requirements, and lay and fill them full and dense.
7.The elevation between the regenerator main wall and the adjacent single wall, and between the main wall and the adjacent main wall should be checked frequently to keep them consistent.
05 Masonry Process for Checker Bricks in Coke Oven Regenerators
1.After the furnace body masonry is completed, blow and clean the regenerator cover and carry out secondary jointing. Mark the control lines between the central partition wall and the sealing wall on the regenerator wall.
2.Blow clean the checker bricks with compressed air and prepare to masonry the checker bricks.
3.When dry-laying the first layer of checker bricks, check the placement position and stability of the checker bricks, and only after they are qualified can the lower layer of checker bricks be dry-laid.
4.For the checker brick layers above the second layer, dry-lay them in a stepped backward (step-back) manner from the central partition wall to the furnace head.
5.Frequently check the unobstructedness of the grid holes of each layer of checker bricks, and the upper and lower layers of checker bricks should be aligned.
6.Yellow cardboard can be used to maintain the gap width and stability between the checker bricks and the regenerator wall. Non-combustible materials should not be used as padding.
7.After the dry masonry of the checker bricks in each regenerator is completed and inspected to be qualified, start to masonry the regenerator sealing wall.
8.For the regenerator walls and checker bricks of the compartment-type regenerator coke oven, masonry should be carried out in sections alternately. Before dry-laying the checker bricks in each section, first masonry the sealing wall or partition wall of this section and clean the wall joints. During the dry masonry of the checker bricks, pay attention to preventing refractory mortar from falling into the checker bricks of the lower section. After the dry masonry is completed and inspected to be qualified, immediately cover with a protective plate. The protective plate should be set firmly and tightly, close to the regenerator wall surface, to avoid refractory mortar from leaking onto the checker bricks.
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