Coke

Our offer for cokemaking industry

The coke industry faces challenges such as reducing CO2, SOx, and NOx emissions, fluctuating raw material prices, and adapting to changes in global steel demand.

These challenges necessitate increasing the efficiency of installations and constructing new, costly facilities to reduce environmental impact. PCO Żarów supports the industry by offering proven refractory lining solutions and producing aluminosilicate refractory products. Our bricks and shapes are manufactured according to customer specifications or standards such as DIN 1089-2. We handle both small-scale repair deliveries and large orders involving thousands of tons.
about_headerCoke

What we can do for you

Refractory lining design

  • Thermal calculations using Simu-Therm for selected components of battery mass.
  • Complete design and engineering package for refractory linings of reactors, including: detailed design (general layouts and details, reinforcement drawings, steel workshop drawings, component drawings, material sheets, bill of materials), installation instructions, drying curves and startup instructions, maintenance instructions.
  • Inspection of refractory linings in reactors, regenerative areas, chamber doors, and furnace roofs.
  • As-built documentation for repairs.

Production and supply

  • Chamotte, quartz-chamotte, high-alumina, and insulating materials for regenerative heat exchangers, combustion chambers, chamber doors, and coke battery roofs.
  • Ceramic linings for reactors used in catalytic NH3 decomposition and sulfur recovery units (SRU).
  • Ceramic linings for coke unloading wharfs and settlers.
  • Chamotte, high-alumina, and insulating linings for coke dry quenching (CDQ) installations.
  • Ceramic linings for battery roofs, regenerators, flue gas channels, and chimneys.
  • Refractory concretes and masses, including those for coke battery door linings.

Installation services

  • On-site installation of new firing furnaces, CDQ installations, reactors, ceramic linings for coke wharfs, ceramic gas channels, and chimney linings.
  • Repairs and reconstructions (demolition and removal of ceramic scrap, ongoing repairs of chambers, heaters, batteries, and reactor linings).
  • Supply of all necessary supplementary materials.
  • Project planning and management.

Furnaces and high-temperature industrial equipment

Our offer for:

Coke oven battery

A coke battery is a complex furnace system where coal is subjected to pyrolysis at temperatures exceeding 1200 °C. Refractory materials serve both structural and technological functions here, being exposed to extreme thermal, erosive, and corrosive conditions. Our offering includes a complete material solution for the coke battery structure.

Scope of offer: Lining design Refractory products supply Lining installation services
Coke oven battery
1 Coke oven battery roof

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.

2 Coke oven door

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.

3 Flue gas channels and chimney

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.

4 Regenerators filling (beneath coking chambers)

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.

5 Regenerator chamber closures (insulating mirror walls)

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.

6 Battery hearth

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.

What can we help with?

If you would like to receive free advice or inquire about the selection of refractory linings, leave us your contact details, and we will call you!

Send an inquiry
Problem:

Deformations and dimensional deviations of shapes prevent quick and airtight assembly of the structure.

Problem:

Limited availability of refractory materials due to the large format and complexity of shape models.

Challenge:

The need to use materials with low secondary shrinkage to maintain the tightness of the lining.

Our offer for:

Coke wharf

The coke wharf and settler are integral components of a traditional coke plant using the wet quenching method. Their functions include draining excess water from the coking coal, cooling the hot coke before further transport, and helping to control the amount of coke falling onto the conveyor belt.

Scope of offer: Lining design Refractory products supply Lining installation services
Coke wharf
1 Coke wharf

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.

What can we help with?

If you would like to receive free advice or inquire about the selection of refractory linings, leave us your contact details, and we will call you!

Send an inquiry
Problem:

Coke getting stuck during discharge, caused by wear and tear in the lining.

Problem:

Coke getting stuck during discharge due to the rough surface of the chute ramp.

Problem:

Year-round operation in environmental conditions (frost resistance of the refractory lining).

Our offer for:

Coke Dry Quenching

Coke pushed from the coke oven chambers must be cooled to enable safe transport and further processing. This stage of the process can be carried out through a coke dry quenching installation. In this installation, the coke is cooled by contact with a circulating inert gas, usually nitrogen, instead of traditional wet quenching with water. This method not only protects the environment by reducing dust emissions but also provides energy benefits through the recovery of heat from the hot coke. The refractory materials used in the lining of this installation must exhibit good resistance to mechanical impacts (abrasion, impact) and thermal shocks.

Scope of offer: Lining design Refractory products supply Lining installation services
Coke Dry Quenching
1 Quenching Chamber (Pre-chamber)

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.

2 Cooling Chamber

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.

3 Dust Collector

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.

What can we help with?

If you would like to receive free advice or inquire about the selection of refractory linings, leave us your contact details, and we will call you!

Send an inquiry
Problem:

Continuous flow of hot gases and dust leads to erosion of the refractory lining surface.

Problem:

Cyclic temperature changes cause the formation of microcracks and material degradation.

Challenge:

Coke combustion products may contain chemicals that react with refractory materials, accelerating their wear.

Our offer for:

Reactor for the catalytic decomposition of ammonia and sulfur production using the Claus process

A reactor for the catalytic decomposition of ammonia and sulfur production using the Claus process is a critical component in the sulfur recovery process from waste gases and plays a vital role in reducing harmful emissions to the atmosphere. Due to the complex operational conditions, the refractory lining in this reactor faces several significant challenges.

Scope of offer: Lining design Refractory products supply Lining installation services
Reactor for the catalytic decomposition of ammonia and sulfur production using the Claus process
1 Burner

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.

2 Cylindrical Reactor Section

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.

3 Ceramic Bed

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.

4 Sieve Floor

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.

5 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.

What can we help with?

If you would like to receive free advice or inquire about the selection of refractory linings, leave us your contact details, and we will call you!

Send an inquiry
Problem:

Under certain operating conditions, sulfuric acid condensation may occur, leading to chemical corrosion of the refractory lining.

Problem:

Improper or insufficient insulation of the steel reactor casing can cause overheating of the shell.

Problem:

Difficulty finding a specialized/experienced installation company.

Why choose PCO?

We Produce Any Shape

We can create even the most complex shapes in a variety of formats. PCO has its own mechanical workshop equipped with CNC machines, where we prepare the necessary molds for order fulfillment. Additionally, once created, the molds will be stored with us (free of charge) and used for your future repair orders.

Dimensional Consistency Regardless of Production Series Size

We understand how crucial dimensional accuracy is in ceramics. Large dimensional deviations can result in additional installation costs, work delays, or even project halts. Our years of experience and advanced forming technologies allow us to produce the most demanding products with precision.

Experienced Bricklaying Team

Building a refractory structure requires specialized experience, skills, and equipment, which are becoming increasingly rare in the market. That's why the PCO group, through its service company, provides support to our clients in the installation and repair of refractory linings for coke oven batteries. This allows you to purchase both installation services and the necessary ceramic materials from a single source.

Selected Products and Services for the Coke Industry

SITONEX

SITONEX

Product We developed the SITONEX material as a solution to the issues related to the expansion of the coke battery lining.
Why? SITONEX is a quartz-chamotte material that differs from traditional chamotte products due to a special silica additive. This additive undergoes transformations during use, increasing its volume, which compensates for the shrinkage of the aluminosilicate material. As a result, the material features secondary expansion (a positive value of the linear dimensional change constant), which ensures stable product geometry and thus durable sealing of the refractory lining. SITONEX products have properties in accordance with the E65-1 grade as per DIN 1089-2.
Checker Bricks

Checker Bricks

Product Complex, multi-hole ceramic shapes used in the aluminosilicate filling of the coke battery regenerator.
Why? These bricks perform an important technological function: their multi-hole structure increases the heat exchange surface between the material they are made of and the medium flowing through the regenerator at any given time. A key factor for high efficiency is the creation of thin walls (10-13 mm) between the brick holes and maintaining precise dimensions. Inaccurate manufacturing could increase the flow resistance of the medium, thus reducing the efficiency of the entire process.
ABRAL ŻRMK

ABRAL ŻRMK

Product ABRAL ŻRMK™ is a modern, corundum-zirconium ceramic material with enhanced mechanical and thermal strength.
Why? We developed it specifically for lining the hot coke chutes in coke plant installations. ABRAL ŻRMK™ is produced using technology based on fused aggregates bonded with special chemical binders. As a result, our material has high durability. This product is a good alternative to fused basalt, which is much more susceptible to impact and thermal shocks. Compared to cast iron plates or traditional chamotte materials, it achieves a significantly longer service life due to its higher wear resistance.

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