Custom Coke Oven Refractory Solutions for Coke Batteries

Name: China Functional Refractories For Coke Ovens Manufacturers Suppliers Factory - Luming New Materials
Brand: Luming
SKU: 307706283

Tel/WhatsApp:0086-18905335290

Email:luming@lm-kiln.com

We provide one-stop refractory solutions for industrial kilns, from customized refractory design and material selection to the production of refractory bricks, castables, precast refractory blocks, insulation products, and refractory anchors. We also offer installation guidance and kiln dry-out support to help customers improve kiln efficiency, reduce maintenance costs, and maximize refractory service life.

A coke oven is a pyrolysis furnace used in the coking process, which involves heating coal in isolation from air to high temperatures (typically 1000–1100°C), allowing volatile components in the coal to escape, leaving behind high-carbon solid coke. Coke appears gray, hard, and porous, with carbon content mainly above 90%, used in metallurgy, chemical industries, and other fields.

Coke ovens mainly consist of the following parts:

1.Coking Chambers: These are the core components of coke ovens, used for loading coal and conducting carbonization. Modern coke ovens typically have dozens to over a hundred coking chambers arranged side by side.

2.Heating Chambers: Located on both sides of the coking chambers, they provide heat for the carbonization process by burning coke oven gas or external fuels.

3.Regenerators: Utilize waste gas heat to preheat combustion air and gas, improving thermal efficiency.

4.Flue System: Collects and transports combustion waste gases.

5.Coal Charging and Coke Discharging Equipment: Including coal charging cars, coke pushing machines, coke guide cars, and other mechanical equipment.

Our company is a specialized enterprise dedicated to the research, development, and production of high-quality sintered refractory materials for coke ovens.

Glazed Precast Refractory Bricks for Coke Oven Doors

Glazed Precast Refractory Bricks for Coke Oven Doors are a new type of refractory material specifically designed for coke oven doors. These products primarily utilize mullite and cordierite as the principal raw materials.

They are produced through optimized particle grading, the addition of composite micro-powders and additives, vibration casting with water, followed by curing, drying,glazing, high-temperature firing, and rigorous selection processes. They are characterized by Convenient and quick installation, Anti-coking and anti-tar sticking, Excellent structural integrity, Outstanding sealing performance without gas leakage, superior thermal shock resistance, and long service life.

Advantages of Glazed Precast Refractory Bricks for Coke Oven Doors:

Glazed precast refractory bricks for coke oven doors are installed by assembling large precast blocks, providing excellent structural integrity and fast installation. This design eliminates the disadvantages of traditional small brick masonry, such as numerous joints and easy gas leakage. The bricks adopt a surface glazing process, forming a sealed and smooth surface that effectively prevents coal tar from penetrating into the refractory material and causing coke buildup, thereby reducing cleaning workload and maintenance intensity. Manufactured primarily from mullite and cordierite, combined with composite micro-powder technology and special additives, the bricks are vibration-cast to achieve excellent thermal shock stability. They are well suited for the frequent heating and cooling cycles of coke ovens and offer a long service life.

Energy-Saving Refractory Solutions for CDQ Coke Quenching Tanks

With the core principles of energy conservation and consumption reduction, this solution aims to extend the service life of coke bucket linings. Our primary goals are to minimize conductive heat dissipation and reduce coke combustion loss and heat waste caused by air infiltration due to poor sealing. These objectives are achieved through the optimization of refractory materials and structural design.

Our Luming Company adopts a high thermal shock and wear-resistant precast lining approach for the CDQ coke quenching tank. The working layer precast blocks are securely fixed to the tank wall using anchors and bolts, ensuring structural strength, overall integrity, and excellent sealing performance of the refractory lining. The insulation layer utilizes microsphere hollow ball lightweight castable, which significantly enhances thermal insulation and heat preservation effects, substantially lowering the tank shell temperature and reducing heat losses.

According to the dimensions of the coke quenching tank, the total lining thickness is designed to be 100 mm. The dense refractory precast blocks serve as the working layer with a thickness of 60–80 mm, while the insulation castable is poured behind the precast blocks with a thickness of 40–20 mm . The bottom 200–300mm of the inclined section and the bottom gate are integrally cast using high-strength, wear-resistant, and explosion-proof castable. Advantages: Convenient and rapid installation without the need for drying or baking; excellent wear resistance. Installation only requires welding anchors according to the design requirements or welding and drilling for fixing the precast blocks. Service life: ≥ 12 months.

Construction Scheme and Application Performance

To achieve modular assembly of refractory materials in the coke quenching tank, reduce on-site construction quality risks and drying risks associated with refractories, the coke tank refractory system has been converted to assembled precast blocks. These precast blocks are baked at our facility and can be directly used after assembly, thereby significantly improving the replacement efficiency and operational availability of the coke tank refractories.

1.Bottom Gate Area Due to the substantial thickness of the bottom gate, drilling holes for precast block installation is inconvenient. After welding anchors, LM-JMS78 wear-resistant castable is applied via pouring construction, which is convenient and rapid.

2.Cone Section The cone section is assembled using precast blocks with a typical total thickness of 100 mm. First, lay a 20–40 mm lightweight castable layer as the backup insulation. Then, arrange the designed precast blocks sequentially, compact them firmly, and proceed with the next row. At the joints between the cone section and straight section, formwork can be erected for pouring construction to ensure seamless integration. 3.Straight Section The straight section is assembled using precast blocks of material grade LM-JM28 wear-resistant precast refractory. Depending on the height, it is divided into 6–7 layers, with each precast block thickness of 60–80 mm. Each precast block includes pre-embedded anchors and threaded rods. According to the designed rod positions, drill corresponding holes in the tank shell. Extend the threaded rods from the precast blocks through the steel shell, then secure them with nuts and washers. Between the precast blocks and the coke tank steel shell, apply 5–50 mm zirconia-containing ceramic fiber paper or board as a cushion/compressible layer.

4.Coke Tank Rim Weld anchors and secure turtle-shell mesh (hexagonal expanded metal) according to the designed thickness requirements. Use our company's KS-1 wear-resistant plastic refractory for troweling or ramming application. This material requires no baking/drying, offering convenient and rapid construction.

Application Performance

This scheme reduces the outer shell temperature of the coke quenching tank to approximately 200°C, significantly decreasing conductive heat loss and heat loss from coke combustion. At the same time, it minimizes coke burn-off, thereby improving coke quality. Overall thermal losses are reduced by more than 40%. The service life of the refractory lining reaches over 1 year , while effectively protecting the coke tank body and greatly extending the overall equipment lifespan. With a one-time investment, subsequent maintenance is simple - only the refractory components need replacement. Compared to replacing alloy lining plates, this solution offers lower cost, longer service life, and superior energy savings and consumption reduction.

The main products for coke ovens bellow:

Glazed prefabricated parts for coke oven doors and riser linings

Item	LM-GYZ50	LM-GYZ65
AL₂O₃_,% ≥	50	65
MgO , % ≤	3	3
Linear change rate ,1250℃x2h , %, ±	0.2	0.2
Thermal shock resistance, 1100℃ water cooling, Times ≥	40	50
Bulk density g/m³ ≥	2.0	2.4
Compressive strength MPa ≥	45	50
Refractoriness ℃ ≥	1580	1650

Refractory materials for coke bucket:

Item Mark No.		LM-JGM18	LM-JGM23
AL₂O_{3 +}SiO₂ / % ≥		90	90
Linear change rate ,% , 1100℃x3h ±		0.5	0.3
Thermal shock resistance, 1100℃ water cooling, Times ≥		35	30
Bulk Density g/m³ ≥	110℃x24h	1.8	2.3
Compressive strength ,MPa ≥	110℃x24h	30	50
Compressive strength ,MPa ≥	1100℃x3h	50	70
Modulus of Rupture ,MPa ≥	110℃x24h	3	6
Modulus of Rupture ,MPa ≥	1100℃x3h	5	8

Refractory materials for raw gas waste heat recovery units:

Self-flow castable:

Item Mark No.
AL₂O_{3 +}SiO₂ +MgO/ % ≥		90
Bulk Density g/m³ ≥		2.10
Compressive strength ,MPa ≥	110℃x24h	40
	1100℃x3h	60
Modulus of Rupture ,MPa ≥	110℃x24h	6
	1100℃x3h	8
Thermal shock resistance,1100℃,water cooling, Times ≥		30
Linear change rate ,% , 1100℃x3h ±		0.5

Ceramic fiberboard(hydrophobicity):

Item Mark No.
AL₂O₃ % ≥		40
Fe₂O₃% ≤		1.8
Bulk density kg/m³		280±20
Thermal conductivity w/m.k	400℃	0.086
	600℃	0.12

Zero-expansion high-purity silica bricks for rapid repair:

Item Mark No.	LM-GZ99	LM-GZ98	LM-GZ97
SiO₂_,% , ≥	98.5	98.0	97.0
AL₂O₃_,% , ≤	0.2	0.3	0.5
Fe₂O₃ , % , ≤	0.3	0.5	0.8
CaO ,% , ≤	0.1	0.15	0.2
Thermal expansion coefficient,%,1000℃, ≤	0.15	0.20	0.30
Thermal shock resistance,1100℃,water cooling, Times ≥	30	30	30
Bulk density ,g/m³ ≥	1.85	1.80	1.75
Compressive strength, MPa ≥	35	30	25
Apparent porosity, % ≤	18	18	18
0.2MP Refractoriness under load ℃ ≥	1650	1600	1500

Unshaped refractories for Coke Dry Quenching (CDQ) furnaces:

Item Mark No.		Index
Item Mark No.		LM-AS1	LM-AS2
AL₂O_{3 +}SiC ,% ≥		65	65
Bulk density, g/m³^,110℃x24h≥		2.65	2.60
Compressive strength ,MPa ≥	110℃x24h	40	60
Compressive strength ,MPa ≥	1400℃x3h	60	80
Modulus of Rupture,MPa ≥	110℃x24h	4	6
Modulus of Rupture,MPa ≥	1400℃x3h	8	8
Linear change rate , 1400℃x3h, ,% ≤ ±		1.0	1.0
Application area		Cooling Section	Buttress ,Ramp area

why choose us

Our Quality Management

Our company strictly adheres to national and industry standards for refractory materials in design, production, and inspection. We also comply with international standards specified by clients to meet customized requirements.Based on the principles of safety, reliability, and cost-effectiveness, we have established a comprehensive quality management system and inspection and testing system.Our internal quality control standards encompass all critical aspects: Raw material qualification,Production process monitoring, Key control point management, Equipment maintenance & inspection,Full-process quality testing & evaluation, Closed-loop quality feedback & improvement.We implement strict raw material quality control, conducting batch-by-batch inspection with full documentation to ensure consistent material compliance.During the production process, strict quality control is enforced, with every process detail rigorously monitored and inspected. A comprehensive quality management and accountability system is implemented to ensure the overall product quality is flawless.Deploy qualified and experienced project managers and professional construction teams to carry out meticulous construction, ensuring construction quality and progress, and guaranteeing timely completion with high quality and quantity.

Our service:

1.Personalized customization solutions:

Based on client requirements, we conduct multi-dimensional analysis covering: Usage Pain Points,Cost Control, Service Life,Energy Saving & Emission Reduction, Project Timeline,etc;We design configuration plans for different budgets and provide detailed product technical specifications and user instructions to ensure customers have a comprehensive understanding of the product;Provide customers with comprehensive end-to-end solutions including consultation, design, production, construction, after-sales service, maintenance and upkeep.

2.Technical Support & Training:

We Provide 24/7 customer service, ready to accept customer inquiries and feedback at any time.Based on customer needs, we can organize regular or occasional technical training sessions on product usage and maintenance to improve customers' ability to use and maintain the products.

3.High-efficiency supply and logistics solutions:

Flexible production mechanism, with adaptable production scheduling to maximize fulfillment of customer delivery requirements.Tiered Delivery Time Management: We provide customized logistics solutions tailored to client requirements, ensuring on-time arrival to meet diverse delivery needs.

4.Customized Packaging Solutions:

All delivered goods are packaged in strict compliance with the buyer's requirements as well as relevant national and industry standards.Shaped products such as refractory bricks and precast blocks are typically packaged on wooden pallets, wrapped with stretch film for sealing, and secured with plastic-steel strapping.Unshaped refractory materials are packaged in 25-50kg plastic bags, with additional outer protection using bulk bags.Our company provides customized packaging solutions including containers, wooden cases, metal boxes, and moisture-proof marine packaging, fully compliant with both local regulations and corporate requirements in your market.

5.After-sales Service & Continuous Improvement:

We provide complimentary technical consulting services to promptly address any issues encountered during product use.During the warranty period, any quality defects caused by our materials or workmanship will be remedied through free repair, replacement or improvement.During project operation, we systematically collect and analyze user feedback to promptly identify and rectify deficiencies, thereby continuously improving product and service quality while enhancing performance and energy efficiency.Continuously improve the quality management system and production processes to enhance both product and service quality and operational efficiency.