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SBS Industrial Solutions GmbH>KALCERAM-K wear-resistant tiles for coke wharfs

KALCERAM-K wear-resistant coating for coke ramps

KALCERAM-K — is a specially developed ceramic for coke ramps. The material has special sliding properties, thermal and acid resistance and is thus an ideal solution in the extreme coke ramps environment.

Material comparisons

Test phase

Comparisons were made of 6 different materials after 6 months of testing at the Coke Plant in Ukraine.

Comparisons show unsatisfactory sliding properties of „D“ material, coke does not come off well even with a large ramp inclination angle, stronger washout, cracks are observed.

The KALCERAM-K material is distinguished by increased hardness and strength, this material is more resistant to chemical stress in the aggressive environment of the coke ramp as well.

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These material properties guarantee a particularly long service life, which has been proven for decades at leading European enterprises.

 

Comparisons of 6 different materials after 6 months of testing

Materials A, B, C, E did not withstand the load (severe damage).

Coke plant in Ukraine

Initial situation at the coke ramp (summer 2016)

6 months after the installation of KALCERAM-K (May 2017)

Further improvements were developed and implemented after the trial period in 2018 to improve durability.

By the end of 2020 this material has been in operation for more than 4 years without replacement.

This confirms the high quality of the material to meet the stated requirements when operating on coke ramps.

KALCERAM-K installed on KALFIX E10 (January 2019)

  • The coke comes off the ramp completely;
  • No abrasions, chips or cracks were found;
  • A decrease in operating costs up to 80% in annual terms;
  • Improving the coke quality due to a decrease in coke dust and an increase in turnover when working with metallurgical plants.
Results
  • The cost of ramp re-lining is reduced by 40-50%
  • Coke quality improvement due to dust amount reducing the and increasing turnover with metallurgical plants
  • Reduction of ramp relining cycles due to CERAM-R durability
CERAM-R tiles installation
  • Thin KALCERAM-K tiles 40mm thick are laid on the ramp slab using special KALFIX mortar
  • The base of the tile should be flat and hard without cracks, moisture
  • If the tiles are not laid in KALFIX, we cannot take over responsibility for how it will show itself in further operation.

Benefits

  • Tightness
  • Reduced mechanical stress
  • Even load distribution on the tiles
  • Longer service life

We do not recommend placing tiles in an arbitrary manner on a sandy substrate.

Coke ramp plate, top edge
  • High-chromium wear-resistant corner of the top edge made of KALMETALL C155

Benefits

  • Fastening system versatility
  • Protection of the first row of tiles from mechanical shock
Coke ramp plate, bottom edge
  • The proposed solution is from KALMETALL C155 

Benefits:

  • Corners can be replaced
  • Easy installation
  • Support / prevention of the lining “sliding”
  • Ready-made modules / molds for the corner plates production
Column Lining
  • Columns are lined with PROTECT material along the entire perimeter of the column (up to a height of 1 meter)
  • PROTECT — is a high-strength, wear-resistant concrete with application temperatures up to 1200 °С
  • The recommended layer thickness is ~ 25-30mm

Benefits

  • High resistance to chemical and abrasive wear, high shock resistance
References

KALCERAM-K has been successfully used for many years in the following coke plants:

  • Arcelor Mittal (Sidmar), Gent, Belgium
  • HKM, Duisburg, Germany
  • Thyssen, Duisburg, Germany
  • Dillinger Huette, Dillingen, Germany
  • Voestаlpine, Linz, Austria
  • PJSC Zaporizhcoke (Metinvest), Zaporizhje, Ukraine
  • PJSC Dneprodzerzhinsky Coke Plant (Kamenskoe, Ukraine)
  • PJSC Yuzkoks (Kamenskoe, Ukraine)
  • PJSC Avdeevsky Coke Plant (Avdievka, Ukraine)
  • PJSC MK Azovstal (Mariupol, Ukraine)
  • Arcelor Mittal, Krivij Rih, Ukraine (test area, tiles only)

 

AM Gent
  • The example of KALCERAM-K, ArcelorMittal Gent (Belgium)
ТК Duisburg, German
  • The example Thyssen Krupp, Duisburg Germany