Improved Coke Plant Hydraulic Cylinder Duty Cycle

A coke plant was spending in excess of $500,000 / year in hydraulic cylinder repair and had been previously trying to reduce their repair costs by pursuing vendors with a low-cost repair philosophy.  Additionally, the combination of high heat and coke dust created an environment that is one of the most challenging in any industry. 

As cylinders were brought to us for remanufacturing the failure mode was determined. Original design parameters were compared with existing application realities. The equipment was then observed in operation and production and maintenance personnel were consulted. Upgrades in materials and design for both seals and hard components were agreed upon and implemented. 

Results: 

During our trial period the company noted two things:  

1. Our remanufacture costs were approximately 30% more than previous vendors.
2. Our remanufactured units were lasting longer. A lot longer.  

Cylinders duty cycles were increased by as much as 10x’s. At the end of the first full year, savings in excess of $250,000 in remanufacture costs alone were realized. When the removal and replacement costs and downtime costs were considered, the savings were significantly higher.