Coke

The materials used for the roof must have excellent insulating properties and the appropriate density. We have developed ISOLUX insulating materials and higher-density products that stabilize the battery chambers. The final roof layer, resistant to variable conditions and wear, is made of RESIMAX material, which offers high mechanical strength and low water absorption.

Exposed to cyclic temperature changes, the doors must be made from materials resistant to thermal shocks. We have developed KORMAX and PCOCAST materials, based on amorphous silica and cordierite, which enhance the durability of the doors. These materials are produced in the form of shapes, concrete prefabricates, or castable materials for on-site casting.

Both flue gas channels and coke battery chimneys are exposed chemical corrosion caused by the presence of acidic oxides and dust in the flue gases. For those areas we recommend RESIMAX materials with reduced water absorption and increased resistance to acid corrosion.

In the area beneath the coke oven chambers, we use SITONEX quartz-chamotte material, which provides minimal secondary shrinkage, improving the sealing of the regenerator lining. Checker bricks are produced with precisely defined geometry and tolerances, facilitating their installation.

To minimize heat loss through the chamber end closure areas, we use lightweight ISOLUX insulating products with a locking system that improves sealing and reduces heat transfer to the outside.

In the battery hearth area, where sudden temperature changes are most likely, we offer special products with enhanced resistance to thermal shocks (TSR bricks). Our developed material features a high mullite phase content, providing high resistance to temperature fluctuations.

The lining of the coke chute is primarily exposed to elevated temperatures, sudden temperature changes (thermal shocks), strong mechanical impacts, and the erosive effects of falling coke. For these conditions, we have developed the ABRAL ŻRMK corundum-zirconium material.

This area of the installation experiences some of the most challenging conditions in the entire system. These include extremely high temperatures (approximately 900–1000°C) due to the introduction of fresh, hot coke, severe thermal shocks from the cyclic loading of hot material, and intense mechanical stresses caused by the impact of coke during loading. Due to these demanding conditions, we recommend using products from the ANDALUX or SUPERTON series, which are characterized by a high mullite phase content, providing excellent mechanical and thermal resistance. For the insulating layers, we suggest a combination of light and heavy insulation from the ISOLUX series, which effectively minimizes heat loss while withstanding the harsh working conditions.

While the conditions in this part of the installation are somewhat less extreme than in the quenching chamber, they still present several challenges for the refractory lining. Temperatures in this chamber range from 600–800°C, gradually decreasing as the coke cools. The constant flow of inert gases can lead to erosion of refractory materials, and the moving coke imposes abrasive mechanical loads. Shapes and wedges from the ANDALUX and SUPERTON families are well-suited for this section, providing optimal resistance to abrasion and erosion. For the insulating layers, materials from the ISOLUX family are recommended, offering effective thermal insulation and long-lasting durability under demanding conditions.

The role of this part of the installation is to remove and control the amount of dust generated during the coke cooling process. These dust particles can pose environmental hazards and negatively affect the efficiency and longevity of the entire installation. The refractory linings in this section are subjected to stresses such as gas flows containing large amounts of dust and coke particles, uneven temperature distribution with the potential for localized hot spots, and corrosion of materials due to contact with chemical components in the gases and dust. PCO recommends materials from the ANDALUX, SUPERTON, and NORMATON families, which ensure long-lasting and reliable operation due to their high abrasion resistance, low porosity, and excellent resistance to thermal shocks. Additionally, these materials exhibit strong chemical stability, minimizing the risk of material degradation in an aggressive working environment.

The intense heat generated during operation and startup creates thermal stresses in the burner's ceramic parts. The burner material must be resistant to thermal shocks and localized extremely high temperatures.

This section of the reactor is also exposed to high temperatures, although typically lower than in the burner. The primary challenge here is the prolonged exposure to reactive gases. The presence of SO2 and other sulfur compounds can lead to chemical corrosion, weakening the refractory material over time, which may result in the penetration of the insulating layers and thermal disturbances in the reactor’s operation or damage to the steel casing.

The ceramic bed operates at high temperatures and supports the catalyst bed. It is exposed to the direct impact of hot gases and the weight of the catalyst material. The refractory lining must have high stability at elevated temperatures and good chemical resistance to process gases.

The sieve floor must ensure adequate sealing and insulation of the refractory lining while enabling proper installation and operation of corundum tubes from the high-pressure boiler.

In this part, the refractory lining is primarily exposed to high temperatures and potential chemical corrosion from reactive compounds remaining in the gas.