A comprehensive engineering analysis was performed on a coke oven battery roof and heating walls in a $200 M construction litigation.
Premature grouting of the roof was a major consideration in evaluating the structural integrity and projected life expectancy of the battery. O’Donnell Consulting (OCE) made extensive use of finite element engineering analysis to calculate temperatures, deflections, strains, and stresses using time-dependent creep analysis methods to evaluate the long term integrity of the roof and heating walls.
When in operation, coke oven batteries normally undergo time-dependent deformations, and creep, due to static and cyclic thermo-mechanical loads. Using finite element analysis methods, evaluations were carried out for a 25-year operating period.
OCE performed analyses of the refractory material properties to determine input for engineering analysis. The boundary conditions are used to model the type and direction of constraints on the battery. Three dimensional, non-linear models were developed to quantify the stability of the heating walls and evaluate the wall stresses. These models were subjected to cyclic pressure and thermal loading conditions, due to charging.
The effects of operating conditions on the as-built battery with construction imperfections were evaluated to determine the battery displacements and stresses vs. time. The finite element results showed that the battery oven walls would not deflect enough to induce instability. The construction imperfections had no meaningful effect on the structural integrity, robustness, or longevity of the battery. Such studies are quite useful in planning battery maintenance efforts.
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