A system for capturing carbon dioxide from flue gas produced by a coke oven includes a coke oven system and a capture system. The coke oven is configured to process coal to produce coke and a flue gas comprising carbon dioxide. The coke oven includes an induced draft fan positioned downstream of the coke oven. The induced draft fan is configured to provide a vacuum to the coke oven and move the flue gas away from the coke oven. The coke oven system also includes a stack open to atmosphere and downstream of the induced draft fan. The capture system is fluidically coupled to the coke oven system at a point between the coke oven and the stack. The capture system is configured to remove carbon dioxide from the flue gas.
C10B 41/08 - Safety devices, e.g. signalling or controlling devices for use in the discharge of coke for the withdrawal of the distillation gases
B01D 53/14 - Separation of gases or vapoursRecovering vapours of volatile solvents from gasesChemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases or aerosols by absorption
A system for capturing carbon dioxide from flue gas produced by a coke oven includes a coke oven system and a capture system. The coke oven is configured to process coal to produce coke and a flue gas comprising carbon dioxide. The coke oven includes an induced draft fan positioned downstream of the coke oven. The induced draft fan is configured to provide a vacuum to the coke oven and move the flue gas away from the coke oven. The coke oven system also includes a stack open to atmosphere and downstream of the induced draft fan. The capture system is fluidically coupled to the coke oven system at a point between the coke oven and the stack. The capture system is configured to remove carbon dioxide from the flue gas.
B01D 53/14 - Separation of gases or vapoursRecovering vapours of volatile solvents from gasesChemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases or aerosols by absorption
B01D 53/00 - Separation of gases or vapoursRecovering vapours of volatile solvents from gasesChemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases or aerosols
Milling systems and methods for producing materials with a particular particle size distribution are disclosed herein. In some embodiments, a system for providing materials having a particular particle size includes a mill configured to produce grinded materials, a classifier positioned to receive the grinded materials and including a first classifier outlet and a second classifier outlet, and a screen positioned to receive the grinded materials from the second classifier outlet and including a first screen outlet and a second screen outlet. The classifier can be configured to separate the grinded materials based on a first threshold particle size. The screen can be configured to separate the grinded materials based on a second threshold particle size greater than the first threshold particle size.
Milling systems and methods for producing materials with a particular particle size distribution are disclosed herein. In some embodiments, a system for providing materials having a particular particle size includes a mill configured to produce grinded materials, a classifier positioned to receive the grinded materials and including a first classifier outlet and a second classifier outlet, and a screen positioned to receive the grinded materials from the second classifier outlet and including a first screen outlet and a second screen outlet. The classifier can be configured to separate the grinded materials based on a first threshold particle size. The screen can be configured to separate the grinded materials based on a second threshold particle size greater than the first threshold particle size.
B02C 23/14 - Separating or sorting of material, associated with crushing or disintegrating with more than one separator
B07B 13/05 - Grading or sorting solid materials by dry methods, not otherwise provided forSorting articles otherwise than by indirectly controlled devices according to size using material mover cooperating with retainer, deflector or discharger
B07B 1/00 - Sieving, screening, sifting, or sorting solid materials using networks, gratings, grids, or the like
B02C 25/00 - Control arrangements specially adapted for crushing or disintegrating
5.
EMISSIONS RECOVERY SYSTEMS FOR INDUSTRIAL FACILITIES, AND ASSOCIATED ASSEMBLIES AND METHODS
Systems and methods for recovering emissions from industrial facilities are disclosed herein. The systems can include an emissions recovery system for use in an industrial facility comprising ducting, a first vent, and a second vent at an opening. The ducting can have a first end region fluidically coupled to a baghouse, and a second end region, opposite the first. The ducting can be configured to operate under a vacuum. The first vent and the second vent can each be fluidically coupled to the second end region of the ducting. The first vent can be positionable at a first distance from the opening, and the second vent can also be positionable at a second distance from the opening. Each of the first and the second vents can be configured to collect emissions particles released from at least the opening.
Industrial cars for holding high-temperature materials, such as flat push hot cars for transporting hot coke and deposits, and associated systems and methods are disclosed herein. In some embodiments, an industrial car can include an at least partially enclosed hot box with a base and sidewalls, and one or more of the base or sidewalls can be covered by surface plates. The surface plates can be arranged in a floating configuration with gaps therebetween, such that the surface plates can move relative to one another and thermally expand without exerting excessive compressive force against adjacent surface plates. In some embodiments, the hot box can also include a roof with a first non-curved member and a second non-curved member abutting the first non-curved member. In some embodiments, the industrial car can include one or more emission ducts to remove dust and exhaust from within and around the industrial car.
Systems, devices and methods for screening materials or industrial products, such as foundry coke, are disclosed herein. In some embodiments, representative systems and/or devices can include (i) a plurality of screening members each extending along a first axis, wherein the screening members are configured to make contact with a material to be screened, (ii) a plurality of elevating members extending along the first axis, wherein individual elevating member are coupled to a lower portion of corresponding individual screening members, and (iii) a cross support extending along a second axis angled relative to the first axis, wherein the cross support is coupled to a lower portion of at least some of the elevating members.
B07B 13/04 - Grading or sorting solid materials by dry methods, not otherwise provided forSorting articles otherwise than by indirectly controlled devices according to size
8.
SYSTEMS, DEVICES AND METHODS FOR SCREENING INDUSTRIAL PRODUCTS
Systems, devices and methods for screening materials or industrial products, such as foundry coke, are disclosed herein. In some embodiments, representative systems and/or devices can include (i) a plurality of screening members each extending along a first axis, wherein the screening members are configured to make contact with a material to be screened, (ii) a plurality of elevating members extending along the first axis, wherein individual elevating member are coupled to a lower portion of corresponding individual screening members, and (iii) a cross support extending along a second axis angled relative to the first axis, wherein the cross support is coupled to a lower portion of at least some of the elevating members.
Industrial cars for holding high-temperature materials, such as flat push hot cars for transporting hot coke and deposits, and associated systems and methods are disclosed herein. In some embodiments, an industrial car can include an at least partially enclosed hot box with a base and sidewalls, and one or more of the base or sidewalls can be covered by surface plates. The surface plates can be arranged in a floating configuration with gaps therebetween, such that the surface plates can move relative to one another and thermally expand without exerting excessive compressive force against adjacent surface plates. In some embodiments, the hot box can also include a roof with a first non-curved member and a second non-curved member abutting the first non-curved member. In some embodiments, the industrial car can include one or more emission ducts to remove dust and exhaust from within and around the industrial car.
Systems and methods for recovering emissions from industrial facilities are disclosed herein. The systems can include an emissions recovery system for use in an industrial facility comprising ducting, a first vent, and a second vent at an opening. The ducting can have a first end region fluidically coupled to a baghouse, and a second end region, opposite the first. The ducting can be configured to operate under a vacuum. The first vent and the second vent can each be fluidically coupled to the second end region of the ducting. The first vent can be positionable at a first distance from the opening, and the second vent can also be positionable at a second distance from the opening. Each of the first and the second vents can be configured to collect emissions particles released from at least the opening.
Production systems and methods for producing pellets or pellet products, which can be used, e.g., in an electric arc furnace (EAF) to produce metal alloys, are disclosed herein. In some embodiments, a method for forming coke pellets includes (i) blending biomass with a set of materials to form an input blend, (ii) preconditioning the input blend by hydrating the input blend to generate a first plurality of particles, (iii) charging the first plurality of particles into an oven to produce a second plurality of particles via pyrolysis, (iv) post-conditioning the second plurality of particles to produce a third plurality of particles by exposing the second plurality of particles to at least one of an amphipathic binder, a hydrophobic binder, or a hydrophilic binder, and (v) physically altering the third plurality of particles to form coke pellets. The biomass can have a first volatility and the set of materials can have a second volatility lower than the first volatility.
Production systems and methods for producing pellets or pellet products, which can be used, e.g., in an electric arc furnace (EAF) to produce metal alloys, are disclosed herein. In some embodiments, a method for forming coke pellets includes (i) blending biomass with a set of materials to form an input blend, (ii) preconditioning the input blend by hydrating the input blend to generate a first plurality of particles, (iii) charging the first plurality of particles into an oven to produce a second plurality of particles via pyrolysis, (iv) post-conditioning the second plurality of particles to produce a third plurality of particles by exposing the second plurality of particles to a binder, and (v) physically altering the third plurality of particles to form coke pellets. The biomass can have a first volatility and the set of materials can have a second volatility lower than the first volatility.
Loading granulated metallic units (GMUs) into railcars, and associated systems, devices, and methods, are disclosed here. In some embodiments, an apparatus for loading GMUs into a railcar comprises a housing unit, a weigh bin, a weigh bin gate, a hopper, and an articulating chute. GMUs in the weigh bin are discharged via gravity through the weigh bin gate when the weigh bin gate opens. The hopper is configured to guide GMUs received from the weigh bin to the articulating chute. The articulating chute is angled and rotatable about an axis of the hopper such that, when rotated, the end of the chute is closer to the floor of a railcar. In some embodiments, the chute includes telescoping segments.
B65D 88/30 - Hoppers, i.e. containers having funnel-shaped discharge sections specially adapted to facilitate transportation from one utilisation site to another
14.
LOW-SULFUR GRANULATED METALLIC UNITS, AND ASSOCIATED SYSTEMS, DEVICES, AND METHODS
A low-sulfur granulated metallic unit having a mass fraction of sulfur between 0.0001 wt.% and 0.08 wt.% is disclosed herein. Additionally or alternatively, the granulated metallic unit can comprise a mass fraction of phosphorous of at least 0.025 wt.%, a mass fraction of silicon between 0.25 wt.% and 1.5 wt.%, a mass fraction of manganese of at least 0.2 wt.%, a mass fraction of carbon of at least 0.8 wt.%, and/or a mass fraction of iron of at least 94.0 wt.%.
Systems for continuous granulated metallic unit (GMU) production, and associated devices and methods are disclosed herein. In some embodiments, a continuous GMU production system includes a furnace unit, a desulfurization unit, a plurality of granulator units, and a cooling system. The furnace unit can receive input materials such as iron ore and output molten metal. The desulfurization unit can reduce a sulfur content of the molten metallics received from the furnace unit. Each of the plurality of granulator units can include a tundish that can control the flow of molten metallics and a reactor that can granulate the molten metallics to form GMUs. The cooling system can provide cooled water to the reactor. Continuous GMU production systems configured in accordance with embodiments of the present technology can produce GMUs under continuous operations cycles for, e.g., at least 6 hours.
B22F 9/08 - Making metallic powder or suspensions thereofApparatus or devices specially adapted therefor using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying
B22D 5/04 - Machines or plants for pig or like casting with endless casting conveyors
B22F 1/06 - Metallic powder characterised by the shape of the particles
16.
USE OF A BASIC OXYGEN FURNACE TO PRODUCE GRANULATED METALLIC UNITS, AND ASSOCIATED SYSTEMS, DEVICES, AND METHODS
Systems and methods for using a liquid hot metal processing unit to produce granulated metallic units (GMUs) are disclosed herein. In some embodiments of the present technology, a liquid hot metal processing system for producing GMUs comprises a liquid hot metal processing unit including a granulator unit. The granulator unit can include a tilter positioned to receive and tilt a ladle, a controller operably coupled to the tilter to control tilting of the ladle, a tundish positioned to receive the molten metallics from the ladle, and a reactor positioned to receive the molten metallics from the tundish. The reactor can be configured to cool the molten metallics to form granulated metallic units (GMUs).
F27B 1/28 - Arrangements of monitoring devices, of indicators, of alarm devices
B22F 9/08 - Making metallic powder or suspensions thereofApparatus or devices specially adapted therefor using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying
A low-carbon granulated metallic unit having a mass fraction of carbon between 0.1 wt.% and 4.0 wt.% is disclosed herein. Additionally or alternatively, the granulated metallic unit can comprise a mass fraction of phosphorous of at least 0.025 wt.%, a mass fraction of silicon between 0.25 wt.% and 1.5 wt.%, a mass fraction of manganese of at least 0.2 wt.%, a mass fraction of sulfur of at least 0.0001 wt.%, and/or a mass fraction of iron of at least 94.0 wt.%.
B22F 1/06 - Metallic powder characterised by the shape of the particles
B22F 9/08 - Making metallic powder or suspensions thereofApparatus or devices specially adapted therefor using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying
C22C 38/02 - Ferrous alloys, e.g. steel alloys containing silicon
C22C 1/04 - Making non-ferrous alloys by powder metallurgy
18.
TREATING COOLING WATER IN IRON PRODUCTION FACILITIES, AND ASSOCIATED SYSTEMS, DEVICES, AND METHODS
Treating cooling water in industrial production facilities and associated systems, devices, and methods are disclosed herein. The system can comprise a cooling tower with a first and second cell, each having a housing to receive return water and a sump below to maintain supply water configured to directly contact molten metal. The system includes an inlet and an inlet line to provide return water to the cooling tower and an outlet and an outlet line to direct supply water back to the industrial production facility. The inlet, outlet, and cooling tower form a closed-loop network. Additionally, a blowdown line is fluidically coupled to the outlet to divert a portion of the supply water away from the closed-loop network.
Reduced-waste systems and methods for granulated metallic units (GMUs) production are disclosed herein. A representative method can include receiving a first supply of molten iron and producing GMUs by granulating the molten iron poured onto a target material of a reactor. The method can include removing residual fines of the GMUs via a classifier based on a threshold particle size and mixing the residual fines with a second supply of molten iron to produce additional GMUs.
B22F 9/08 - Making metallic powder or suspensions thereofApparatus or devices specially adapted therefor using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying
B22D 5/04 - Machines or plants for pig or like casting with endless casting conveyors
B22D 35/00 - Equipment for conveying molten metal into beds or moulds
B22F 1/06 - Metallic powder characterised by the shape of the particles
20.
PROCESSING GRANULATED METALLIC UNITS WITHIN ELECTRIC ARC FURNACES, AND ASSOCIATED SYSTEMS AND METHODS
Processing granulated metallic units within electric arc furnaces (EAFs) and associated systems, devices, and methods are disclosed herein. A representative method can include receiving granulated metallic units in an EAF, wherein the granulated metallic units comprise no more than 0.05 wt.% of sulfur and at least 50% of particles in the granulated iron material have a particle size of at least 6 millimeters. The method can include applying electrical energy to the granulated iron via electrodes and melting the granulated iron material to form a molten steel product. The method can also include tapping the EAF to remove the molten steel product from the EAF.
B22F 9/08 - Making metallic powder or suspensions thereofApparatus or devices specially adapted therefor using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying
F27B 3/08 - Hearth-type furnaces, e.g. of reverberatory typeElectric arc furnaces heated electrically, e.g. electric arc furnaces, with or without any other source of heat
B22D 5/04 - Machines or plants for pig or like casting with endless casting conveyors
B22F 1/06 - Metallic powder characterised by the shape of the particles
21.
RAILCARS FOR TRANSPORTING GRANULATED METALLIC UNITS, AND ASSOCIATED SYSTEMS, DEVICES, AND METHODS
Railcars for transporting granulated metallic units, and associated systems, devices, and methods are disclosed herein. For example, a reinforced railcar apparatus includes a container envelope and a reinforcement liner. The container envelope includes side walls and end walls extending from a floor of the railcar. The side walls are a first length and the end walls are a second length less than the first length. Top portions of the rigid side walls and end walls define an opening of the container envelope through which granulated metallic units are discharged into the railcar assembly. The railcar assembly includes angled interior walls coupled to the bottom surface and extending from a top portion of the end walls to the bottom surface. The reinforcement liner is disposed over a portion of the bottom surface and the angled interior walls. In some embodiments, the railcar assembly includes an open-topped box layered with impact-absorbing material.
Torpedo cars for use with granulated iron production, and associated systems, devices, and methods are disclosed herein. In some embodiments of the present technology, a torpedo car includes a tilting mechanism, a body rotatably coupled to the tilting mechanism, and a controller operably coupled to the tilting mechanism to control tilting of the body. The body can include (i) an inner surface defining a cavity and a channel, and (ii) an outer surface defining an opening to the cavity and a channel outlet of the channel spaced apart from the opening. The channel can extend between the channel outlet and a channel inlet interfacing the cavity. The inner surface can include a slag dam configured to prevent slag from exiting the opening while the torpedo car tilts. The controller can control the tilting mechanism to control molten metal flow out of the cavity through the channel.
B22D 41/08 - Casting melt-holding vessels, e.g. ladles, tundishes, cups or the like for bottom pouring
B22D 41/12 - Travelling ladles or similar containersCars for ladles
B22D 5/04 - Machines or plants for pig or like casting with endless casting conveyors
B22D 35/00 - Equipment for conveying molten metal into beds or moulds
B22F 9/08 - Making metallic powder or suspensions thereofApparatus or devices specially adapted therefor using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying
23.
LOADING GRANULATED METALLIC UNITS INTO RAILCARS, AND ASSOCIATED SYSTEMS, DEVICES, AND METHODS
Loading granulated metallic units (GMUs) into railcars, and associated systems, devices, and methods, are disclosed here. In some embodiments, an apparatus for loading GMUs into a railcar comprises a housing unit, a weigh bin, a weigh bin gate, a hopper, and an articulating chute. GMUs in the weigh bin are discharged via gravity through the weigh bin gate when the weigh bin gate opens. The hopper is configured to guide GMUs received from the weigh bin to the articulating chute. The articulating chute is angled and rotatable about an axis of the hopper such that, when rotated, the end of the chute is closer to the floor of a railcar. In some embodiments, the chute includes telescoping segments.
Railcars for transporting granulated metallic units, and associated systems, devices, and methods are disclosed herein. For example, a reinforced railcar apparatus includes a container envelope and a reinforcement liner. The container envelope includes side walls and end walls extending from a floor of the railcar. The side walls are a first length and the end walls are a second length less than the first length. Top portions of the rigid side walls and end walls define an opening of the container envelope through which granulated metallic units are discharged into the railcar assembly. The railcar assembly includes angled interior walls coupled to the bottom surface and extending from a top portion of the end walls to the bottom surface. The reinforcement liner is disposed over a portion of the bottom surface and the angled interior walls. In some embodiments, the railcar assembly includes an open-topped box layered with impact-absorbing material.
A low-sulfur granulated metallic unit having a mass fraction of sulfur between 0.0001 wt. % and 0.08 wt. % is disclosed herein. Additionally or alternatively, the granulated metallic unit can comprise a mass fraction of phosphorous of at least 0.025 wt. %, a mass fraction of silicon between 0.25 wt. % and 1.5 wt. %, a mass fraction of manganese of at least 0.2 wt. %, a mass fraction of carbon of at least 0.8 wt. %, and/or a mass fraction of iron of at least 94.0 wt. %.
A low-carbon granulated metallic unit having a mass fraction of carbon between 0.1 wt. % and 4.0 wt. % is disclosed herein. Additionally or alternatively, the granulated metallic unit can comprise a mass fraction of phosphorous of at least 0.025 wt. %, a mass fraction of silicon between 0.25 wt. % and 1.5 wt. %, a mass fraction of manganese of at least 0.2 wt. %, a mass fraction of sulfur of at least 0.0001 wt. %, and/or a mass fraction of iron of at least 94.0 wt. %.
Treating cooling water in industrial production facilities and associated systems, devices, and methods are disclosed herein. The system can comprise a cooling tower with a first and second cell, each having a housing to receive return water and a sump below to maintain supply water configured to directly contact molten metal. The system includes an inlet and an inlet line to provide return water to the cooling tower and an outlet and an outlet line to direct supply water back to the industrial production facility. The inlet, outlet, and cooling tower form a closed-loop network. Additionally, a blowdown line is fluidically coupled to the outlet to divert a portion of the supply water away from the closed-loop network.
C02F 1/52 - Treatment of water, waste water, or sewage by flocculation or precipitation of suspended impurities
C02F 103/16 - Nature of the water, waste water, sewage or sludge to be treated from metallurgical processes, i.e. from the production, refining or treatment of metals, e.g. galvanic wastes
28.
USE OF RESIDUAL IRON WITHIN GRANULATED METALLIC UNIT PRODUCTION FACILITIES, AND ASSOCIATED SYSTEMS, DEVICES, AND METHODS
Reduced-waste systems and methods for granulated metallic units (GMUs) production are disclosed herein. A representative method can include receiving a first supply of molten iron and producing GMUs by granulating the molten iron poured onto a target material of a reactor. The method can include removing residual fines of the GMUs via a classifier based on a threshold particle size and mixing the residual fines with a second supply of molten iron to produce additional GMUs.
B22F 9/08 - Making metallic powder or suspensions thereofApparatus or devices specially adapted therefor using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying
B22F 9/00 - Making metallic powder or suspensions thereofApparatus or devices specially adapted therefor
C21B 13/00 - Making spongy iron or liquid steel, by direct processes
C21C 7/00 - Treating molten ferrous alloys, e.g. steel, not covered by groups
29.
TORPEDO CARS FOR USE WITH GRANULATED METALLIC UNIT PRODUCTION, AND ASSOCIATED SYSTEMS, DEVICES, AND METHODS
Torpedo cars for use with granulated iron production, and associated systems, devices, and methods are disclosed herein. In some embodiments of the present technology, a torpedo car includes a tilting mechanism, a body rotatably coupled to the tilting mechanism, and a controller operably coupled to the tilting mechanism to control tilting of the body. The body can include (i) an inner surface defining a cavity and a channel, and (ii) an outer surface defining an opening to the cavity and a channel outlet of the channel spaced apart from the opening. The channel can extend between the channel outlet and a channel inlet interfacing the cavity. The inner surface can include a slag dam configured to prevent slag from exiting the opening while the torpedo car tilts. The controller can control the tilting mechanism to control molten metal flow out of the cavity through the channel.
B22D 41/12 - Travelling ladles or similar containersCars for ladles
B22F 9/08 - Making metallic powder or suspensions thereofApparatus or devices specially adapted therefor using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying
30.
CONTINUOUS GRANULATED METALLIC UNITS PRODUCTION, AND ASSOCIATED SYSTEMS, DEVICES, AND METHODS
Systems for continuous granulated metallic unit (GMU) production, and associated devices and methods are disclosed herein. In some embodiments, a continuous GMU production system includes a furnace unit, a desulfurization unit, a plurality of granulator units, and a cooling system. The furnace unit can receive input materials such as iron ore and output molten metal. The desulfurization unit can reduce a sulfur content of the molten metallics received from the furnace unit. Each of the plurality of granulator units can include a tundish that can control the flow of molten metallics and a reactor that can granulate the molten metallics to form GMUs. The cooling system can provide cooled water to the reactor. Continuous GMU production systems configured in accordance with embodiments of the present technology can produce GMUs under continuous operations cycles for, e.g., at least 6 hours.
B22F 9/08 - Making metallic powder or suspensions thereofApparatus or devices specially adapted therefor using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying
Systems and methods for using a liquid hot metal processing unit to produce granulated metallic units (GMUs) are disclosed herein. In some embodiments of the present technology, a liquid hot metal processing system for producing GMUs comprises a liquid hot metal processing unit including a granulator unit. The granulator unit can include a tilter positioned to receive and tilt a ladle, a controller operably coupled to the tilter to control tilting of the ladle, a tundish positioned to receive the molten metallics from the ladle, and a reactor positioned to receive the molten metallics from the tundish. The reactor can be configured to cool the molten metallics to form granulated metallic units (GMUs).
B22F 9/04 - Making metallic powder or suspensions thereofApparatus or devices specially adapted therefor using physical processes starting from solid material, e.g. by crushing, grinding or milling
Processing granulated metallic units within electric arc furnaces (EAFs) and associated systems, devices, and methods are disclosed herein. A representative method can include receiving granulated metallic units in an EAF, wherein the granulated metallic units comprise no more than 0.05 wt. % of sulfur and at least 50% of particles in the granulated iron material have a particle size of at least 6 millimeters. The method can include applying electrical energy to the granulated iron via electrodes and melting the granulated iron material to form a molten steel product. The method can also include tapping the EAF to remove the molten steel product from the EAF.
A coke product configured to be used in foundry cupolas to melt iron and produce cast iron products is disclosed herein. In some embodiments, the coke product has a Coke Reactivity Index (CRI) of at least 30% and an ash fusion temperature (AFT) less than 1316° C. Additionally or alternatively, the coke product can comprise a fixed carbon content of at least 80% and/or a volatile matter content of no more than 1.0%.
C10B 57/04 - Other carbonising or coking processesFeatures of destructive distillation processes in general using charges of special composition
C10B 57/06 - Other carbonising or coking processesFeatures of destructive distillation processes in general using charges of special composition containing additives
C10L 1/04 - Liquid carbonaceous fuels essentially based on blends of hydrocarbons
A coke oven includes an oven chamber, an uptake duct in fluid communication with the oven chamber, the uptake duct being configured to receive exhaust gases from the oven chamber, an uptake damper in fluid communication with the uptake duct, the uptake damper being positioned at any one of multiple positions, the uptake damper configured to control an oven draft, an actuator configured to alter the position of the uptake damper between the positions in response to a position instruction, a sensor configured to detect an operating condition of the coke oven, wherein the sensor includes one of a draft sensor, a temperature sensor configured to detect an uptake duct temperature or a sole flue temperature, and an oxygen sensor, and a controller being configured to provide the position instruction to the actuator in response to the operating condition detected by the sensor.
F22B 1/18 - Methods of steam generation characterised by form of heating method by exploitation of the heat content of hot heat carriers the heat carrier being a hot gas, e.g. waste gas such as exhaust gas of internal-combustion engines
A coke product configured to be used in foundry cupolas to melt iron and produce cast iron products is disclosed herein. In some embodiments, the coke product has a Coke Reactivity Index (CRI) of at least 30% and an ash fusion temperature (AFT) less than 1316° C. Additionally or alternatively, the coke product can comprise (i) an ash content of at least 8.0%, (ii) a volatile matter content of no more than 1.0%, (iii) a Coke Strength After Reaction (CSR) of no more than 40%, (iv) a 2-inch drop shatter of at least 90%, and/or (v) a fixed carbon content of at least 85%.
C10B 57/04 - Other carbonising or coking processesFeatures of destructive distillation processes in general using charges of special composition
C10B 57/06 - Other carbonising or coking processesFeatures of destructive distillation processes in general using charges of special composition containing additives
C10L 1/04 - Liquid carbonaceous fuels essentially based on blends of hydrocarbons
Foundry coke products, and associated methods and systems for melting iron in a cupola furnace with the coke products are disclosed herein. A representative method can include receiving a population of coke products and iron in a cupola furnace, and melting the iron in the cupola furnace to form molten iron having a carbon content higher than a carbon content of the received iron. The coke products can comprise (i) an elongate shape including a length:width dimension of at least 1.5:1, (ii) an ash fusion temperature of no more than 2400° F., and/or (iii) a coke reactivity index (CRI) of at least 30%.
A coke oven includes an oven chamber configured to support and heat a coal bed, a castable slab below the oven chamber, and a foundation supporting the heat recovery oven. One or more beams are positioned between the castable slab and the foundation. The beams extend from a first end of the oven chamber to a second end of the oven chamber, forming a plurality of air gaps between the castable slab and the foundation. Heat from the oven chamber is dissipated by the one or more beams.
Mixture products containing charred products and coal or coke, and associated systems, devices and methods are disclosed herein. The charred product components of the mixture products can be made by receiving an input material in an oven, and heating the oven containing the input material to a predetermined temperature of at least 900°F for a predetermined time of no more than 48 hours to produce a charred product. Advantageously, embodiments of the present technology can enable a more efficient mixture product production process. The resulting mixture products can also have higher quality in terms of desired Coke Strength After Reaction (CSR), Coke Reactivity Index (CRI), volatile matter content, ash content, sulfur content, grain size, etc.
Pellet products, and associated systems, devices and methods are disclosed herein. A production system can include a heat processing assembly comprising an oven configured to process an input material at a processing temperature of at least 1,000℉ for a processing period to produce processed materials, and a pelletization assembly configured to pelletize at least some of the processed materials and one or more additives to generate the pellets. In some embodiments, individual pellets include two or more of coke, coke breeze, char, biochar, charcoal fines, biochar fines, or carbon-containing materials, and at least one of a binder or a cross-linker. A production method can include receiving an input material, processing the input material at a processing temperature of at least 1400℉ in an oven for a processing period to produce processed materials, and pelletizing at least some of the processed materials with one or more additives to produce the pellets.
C10L 5/44 - Solid fuels essentially based on materials of non-mineral origin on vegetable substances
C10L 5/46 - Solid fuels essentially based on materials of non-mineral origin on sewage, house, or town refuse
C10L 5/14 - Briquetting processes with the aid of binders, e.g. pretreated binders with organic binders
C10L 9/08 - Treating solid fuels to improve their combustion by heat treatment, e.g. calcining
C10L 9/10 - Treating solid fuels to improve their combustion by using additives
B30B 11/02 - Presses specially adapted for forming shaped articles from material in particulate or plastic state, e.g. briquetting presses or tabletting presses using a ram exerting pressure on the material in a moulding space
B30B 15/34 - Heating or cooling presses or parts thereof
41.
PRODUCTS COMPRISING CHAR AND CARBON, AND ASSOCIATED SYSTEMS, DEVICES, AND METHODS
Mixture products containing charred products and coal or coke, and associated systems, devices and methods are disclosed herein. The charred product components of the mixture products can be made by receiving an input material in an oven, and heating the oven containing the input material to a predetermined temperature of at least 900° F. for a predetermined time of no more than 48 hours to produce a charred product. Advantageously, embodiments of the present technology can enable a more efficient mixture product production process. The resulting mixture products can also have higher quality in terms of desired Coke Strength After Reaction (CSR), Coke Reactivity Index (CRI), volatile matter content, ash content, sulfur content, grain size, etc.
C21C 7/00 - Treating molten ferrous alloys, e.g. steel, not covered by groups
C10B 5/02 - Coke ovens with horizontal chambers with vertical heating flues
C10B 53/02 - Destructive distillation, specially adapted for particular solid raw materials or solid raw materials in special form of cellulose-containing material
C10B 57/06 - Other carbonising or coking processesFeatures of destructive distillation processes in general using charges of special composition containing additives
C10B 57/16 - Features of high-temperature carbonising processes
42.
PELLETIZED PRODUCTS AND ASSOCIATED SYSTEMS, DEVICES, AND METHODS
Pellet products, and associated systems, devices and methods are disclosed herein. A production system can include a heat processing assembly comprising an oven configured to process an input material at a processing temperature of at least 1,000° F. for a processing period to produce processed materials, and a pelletization assembly configured to pelletize at least some of the processed materials and one or more additives to generate the pellets. In some embodiments, individual pellets include two or more of coke, coke breeze, char, biochar, charcoal fines, biochar fines, or carbon-containing materials, and at least one of a binder or a cross-linker. A production method can include receiving an input material, processing the input material at a processing temperature of at least 1400° F. in an oven for a processing period to produce processed materials, and pelletizing at least some of the processed materials with one or more additives to produce the pellets.
Coal blends used to produce foundry coke products are disclosed herein. Coal blends can include first coals having a first volatile matter mass fraction less than or equal to a first threshold, and second coals having a second volatile mass fraction greater than or equal to a second threshold that is less than the second threshold. The coal blend can have an ash fusion temperature less than 2600 °F and an aggregated volatile matter mass fraction between 15% and 25%.
Methods and systems for coking coal blends to produce foundry coke products are disclosed herein. Methods for producing coke products can include charging a coal blend into a coke oven; and heating the charged coal blend such that a crown temperature of the coke oven is greater than a lower bound coking temperature. The pyrolysis duration begins when the crown temperature of the oven is greater than the lower bound coking temperature, and ends when the crown temperature of the oven is less than the lower bound coking temperature.
Coal blends used to produce foundry coke products are disclosed herein. Coal blends can include first coals having a first volatile matter mass fraction less than or equal to a first threshold, and second coals having a second volatile mass fraction greater than or equal to a second threshold that is less than the second threshold. The coal blend can have an ash fusion temperature less than 2600° F. and an aggregated volatile matter mass fraction between 15% and 25%.
C10B 57/06 - Other carbonising or coking processesFeatures of destructive distillation processes in general using charges of special composition containing additives
C10B 5/02 - Coke ovens with horizontal chambers with vertical heating flues
C10B 21/10 - Regulating or controlling the combustion
C10B 41/00 - Safety devices, e.g. signalling or controlling devices for use in the discharge of coke
C10B 53/00 - Destructive distillation, specially adapted for particular solid raw materials or solid raw materials in special form
C10B 57/04 - Other carbonising or coking processesFeatures of destructive distillation processes in general using charges of special composition
C10B 57/16 - Features of high-temperature carbonising processes
C10L 5/04 - Raw material to be usedPretreatment thereof
C10L 5/44 - Solid fuels essentially based on materials of non-mineral origin on vegetable substances
C10L 5/48 - Solid fuels essentially based on materials of non-mineral origin on industrial residues or waste materials
Methods and systems for coking coal blends to produce foundry coke products are disclosed herein. Methods for producing coke products can include charging a coal blend into a coke oven; and heating the charged coal blend such that a crown temperature of the coke oven is greater than a lower bound coking temperature. The pyrolysis duration begins when the crown temperature of the oven is greater than the lower bound coking temperature, and ends when the crown temperature of the oven is less than the lower bound coking temperature.
C10B 5/02 - Coke ovens with horizontal chambers with vertical heating flues
C10B 21/10 - Regulating or controlling the combustion
C10B 41/00 - Safety devices, e.g. signalling or controlling devices for use in the discharge of coke
C10B 53/00 - Destructive distillation, specially adapted for particular solid raw materials or solid raw materials in special form
C10B 57/04 - Other carbonising or coking processesFeatures of destructive distillation processes in general using charges of special composition
C10B 57/06 - Other carbonising or coking processesFeatures of destructive distillation processes in general using charges of special composition containing additives
C10B 57/16 - Features of high-temperature carbonising processes
C10L 5/04 - Raw material to be usedPretreatment thereof
C10L 5/44 - Solid fuels essentially based on materials of non-mineral origin on vegetable substances
C10L 5/48 - Solid fuels essentially based on materials of non-mineral origin on industrial residues or waste materials
Systems and methods for removing carbonaceous clinker material from a coke oven are described. A coke oven can be provided including an oven floor, coke, and clinker material deposited on the oven floor. After a temperature of the coke oven has reached a first temperature (e.g., after heating coal in the oven to produce coke), the method includes increasing the temperature of the coke oven to a second temperature that is higher than the first temperature for a predetermined amount of time. After the predetermined amount of time, the temperature is reduced to a third temperature that is lower than the first temperature.
High quality coke products made in horizontal ovens such as heat recovery, non-recovery or Thompson ovens from an optimized coal blend. The coke products have unique properties such as an oblong shape and improved Coke Strength after Reaction (CSR) and Coke Reactivity Index (CRI) properties.
High quality coke products made in horizontal ovens such as heat recovery, non-recovery or Thompson ovens from an optimized coal blend. The coke products have unique properties such as an oblong shape and improved Coke Strength after Reaction (CSR) and Coke Reactivity Index (CRI) properties.
Systems and methods of preventing an event occurrence or mitigating effects of an event occurrence in an industrial facility are disclosed herein. In some embodiments, a first input is received from a first sensor and, based at least in part on the first input, an initial action is automatically generated. In response to the initial action, a second input is received from a second sensor and, based at least in part of the received first and second inputs, a likelihood of an event occurrence is determined. Based at least in part of the determined likelihood, a remedial action configured to prevent the occurrence of the event occurrence is automatically generated. In some embodiments, the remedial action is generated in real-time and can be directed to a process condition, environmental condition, or secondary source.
G01N 33/00 - Investigating or analysing materials by specific methods not covered by groups
G05B 19/418 - Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM]
G08B 3/10 - Audible signalling systemsAudible personal calling systems using electric transmissionAudible signalling systemsAudible personal calling systems using electromagnetic transmission
G08B 5/36 - Visible signalling systems, e.g. personal calling systems, remote indication of seats occupied using electric transmissionVisible signalling systems, e.g. personal calling systems, remote indication of seats occupied using electromagnetic transmission using visible light sources
Systems and apparatuses for cooling flue gases emitted from an industrial facility, such as a coke oven in a coke manufacturing plant. A representative system includes a heat recovery steam generator (HRSG) having a steam generation system that converts liquid feedwater into steam by absorbing heat from the flue gases. The steam generation system includes a plurality of tubes that carry the liquid water feedwater and the steam. Some or all of the tubes include steel and a non-corrosive material cladded to the steel that helps to reduce corrosion caused by the high temperature flue gases and extremely corrosive contaminants within the flue gas that can corrode steel.
F22B 1/18 - Methods of steam generation characterised by form of heating method by exploitation of the heat content of hot heat carriers the heat carrier being a hot gas, e.g. waste gas such as exhaust gas of internal-combustion engines
F01K 23/10 - Plants characterised by more than one engine delivering power external to the plant, the engines being driven by different fluids the engine cycles being thermally coupled combustion heat from one cycle heating the fluid in another cycle with exhaust fluid of one cycle heating the fluid in another cycle
E04F 13/14 - Coverings or linings, e.g. for walls or ceilings composed of covering or lining elementsSub-structures thereforFastening means therefor composed of a plurality of similar covering or lining elements of stone or stone-like materials, e.g. ceramicsCoverings or linings, e.g. for walls or ceilings composed of covering or lining elementsSub-structures thereforFastening means therefor composed of a plurality of similar covering or lining elements of glass
04 - Industrial oils and greases; lubricants; fuels
40 - Treatment of materials; recycling, air and water treatment,
39 - Transport, packaging, storage and travel services
Goods & Services
Coke, fuels, solid fuels and coal Electricity generation; energy generation services; energy recycling services, namely, capturing and conversion of wasted energy into electricity and useful steam; generation of power through operation of power generation equipment and facilities; production of energy; production of solid fuel; refinement of fuel materials; custom manufacture of coke fuels and carbon based solid fuels Distribution and transmission of electricity; distribution of energy
04 - Industrial oils and greases; lubricants; fuels
40 - Treatment of materials; recycling, air and water treatment,
39 - Transport, packaging, storage and travel services
Goods & Services
Coke, fuels, solid fuels and coal Electricity generation; energy generation services; energy recycling services, namely, capturing and conversion of wasted energy into electricity and useful steam; generation of power through operation of power generation equipment and facilities; production of energy; production of solid fuel; refinement of fuel materials; custom manufacture of coke fuels and carbon based solid fuels Distribution and transmission of electricity; distribution of energy
56.
FOUNDRY COKE PRODUCTS, AND ASSOCIATED SYSTEMS, DEVICES, AND METHODS
A coke product configured to be used in foundry cupolas to melt iron and produce cast iron products is disclosed herein. In some embodiments, the coke product has a Coke Reactivity Index (CRI) of at least 30% and an ash fusion temperature (AFT) less than 1316 °C. Additionally or alternatively, the coke product can comprise (i) an ash content of at least 8.0%, (ii) a volatile matter content of no more than 1.0%, (iii) a Coke Strength After Reaction (CSR) of no more than 40%, (iv) a 2-inch drop shatter of at least 90%, and//or (v) a fixed carbon content of at least 85%.
A coke product configured to be used in foundry cupolas to melt iron and produce cast iron products is disclosed herein. In some embodiments, the coke product has a Coke Reactivity Index (CRI) of at least 30% and an ash fusion temperature (AFT) less than 1316 °C. Additionally or alternatively, the coke product can comprise (i) an ash content of at least 8.0%, (ii) a volatile matter content of no more than 1.0%, (iii) a Coke Strength After Reaction (CSR) of no more than 40%, (iv) a 2-inch drop shatter of at least 90%, and//or (v) a fixed carbon content of at least 85%.
Foundry coke products, and associated methods and systems for melting iron in a cupola furnace with the coke products are disclosed herein. A representative method can include receiving a population of coke products and iron in a cupola furnace, and melting the iron in the cupola furnace to form molten iron having a carbon content higher than a carbon content of the received iron. The coke products can comprise (i) an elongate shape including a length:width dimension of at least 1.5:1, (ii) an ash fusion temperature of no more than 2400° F., and/or (iii) a coke reactivity index (CRI) of at least 30%.
A coke product configured to be used in foundry cupolas to melt iron and produce cast iron products is disclosed herein. In some embodiments, the coke product has a Coke Reactivity Index (CRI) of at least 30% and an ash fusion temperature (AFT) less than 1316° C. Additionally or alternatively, the coke product can comprise (i) an ash content of at least 8.0%, (ii) a volatile matter content of no more than 1.0%, (iii) a Coke Strength After Reaction (CSR) of no more than 40%, (iv) a 2-inch drop shatter of at least 90%, and//or (v) a fixed carbon content of at least 85%.
Systems and apparatuses for neutralizing acidic compounds in flue gases emitted from a heat recovery coke oven. A representative system includes a spray dry absorber having a barrel that includes a plurality of wall plates that form sidewalls of the barrel. The wall plates include a steel plate and a corrosion resistant alloy cladded to the steel plate and the wall plates are oriented such that the corrosion resistant alloy faces toward and is in fluid communication with an interior area of the barrel. The alloy is resistant to corrosion caused by the acidic compounds in the flue gas and can prevent the steel plate from being corroded by these acidic compounds.
Coke products configured to be combusted in a cupola furnace are disclosed herein. The coke products can include foundry coke products having a hydraulic diameter of at least 3.5", egg coke products having a hydraulic diameter of 1.5?3.5", and breeze coke products having a hydraulic diameter of 0.5?1.5". Individual foundry coke products can comprise an oblong shape including a length of at least 4", a width of at least 1.5", and a length:width ratio of at least 2.0. In some embodiments, the length of individual coke products can be between 6?12" and the width can be at least 2.5". Additionally, the foundry coke products can have a Coke Reactivity Index (CRI)of at least 40%.The coke products can be made from a blend of coal and breeze coke products in horizontal ovens, such as horizontal heat recovery or horizontal non-recovery ovens.
Coke products configured to be combusted in a cupola furnace are disclosed herein. The coke products can include foundry coke products having a hydraulic diameter of at least 3.5″, egg coke products having a hydraulic diameter of 1.5-3.5″, and breeze coke products having a hydraulic diameter of 0.5-1.5″. Individual foundry coke products can comprise an oblong shape including a length of at least 4″, a width of at least 1.5″, and a length:width ratio of at least 2.0. In some embodiments, the length of individual coke products can be between 6-12″ and the width can be at least 2.5″. Additionally, the foundry coke products can have a Coke Reactivity Index (CRI) of at least 40%. The coke products can be made from a blend of coal and breeze coke products in horizontal ovens, such as horizontal heat recovery or horizontal non-recovery ovens.
Coke products configured to be combusted in a cupola furnace are disclosed herein. The coke products can include foundry coke products having a hydraulic diameter of at least 3.5", egg coke products having a hydraulic diameter of 1.5–3.5", and breeze coke products having a hydraulic diameter of 0.5–1.5". Individual foundry coke products can comprise an oblong shape including a length of at least 4", a width of at least 1.5", and a length:width ratio of at least 2.0. In some embodiments, the length of individual coke products can be between 6–12" and the width can be at least 2.5". Additionally, the foundry coke products can have a Coke Reactivity Index (CRI)of at least 40%.The coke products can be made from a blend of coal and breeze coke products in horizontal ovens, such as horizontal heat recovery or horizontal non-recovery ovens.
A coke plant includes multiple coke ovens where each coke oven is adapted to produce exhaust gases, a common tunnel fluidly connected to the plurality of coke ovens and configured to receive the exhaust gases from each of the coke ovens, multiple standard heat recovery steam generators fluidly connected to the common tunnel where the ratio of coke ovens to standard heat recovery steam generators is at least 20:1, and a redundant heat recovery steam generator fluidly connected to the common tunnel where any one of the plurality of standard heat recovery steam generators and the redundant heat recovery steam generator is adapted to receive the exhaust gases from the plurality of ovens and extract heat from the exhaust gases and where the standard heat recovery steam generators and the redundant heat recovery steam generator are all connected in parallel with each other.
C10B 5/02 - Coke ovens with horizontal chambers with vertical heating flues
C23D 5/08 - Applying enamels non-uniformly over the surface
B23P 6/04 - Repairing fractures or cracked metal parts or products, e.g. castings
C10B 41/00 - Safety devices, e.g. signalling or controlling devices for use in the discharge of coke
G01M 3/20 - Investigating fluid tightness of structures by using fluid or vacuum by detecting the presence of fluid at the leakage point using special tracer materials, e.g. dye, fluorescent material, radioactive material
The present technology relates to systems and methods for reducing leaks in a system for coking coal. For example, some embodiments provide systems and method for treating a cracked or leaking surface in a system for coking coal. In particular, the present technology includes systems having one or more substances configured to reduce an airflow through one or more cracks by creating an at least partially impermeable patch. The present technology further includes methods for treating surfaces having one or more cracks to reduce an airflow through the one or more cracks.
C23D 5/08 - Applying enamels non-uniformly over the surface
G01M 3/20 - Investigating fluid tightness of structures by using fluid or vacuum by detecting the presence of fluid at the leakage point using special tracer materials, e.g. dye, fluorescent material, radioactive material
C10B 29/02 - Brickwork, e.g. casings, linings, walls
A coke oven includes an oven chamber configured to support and heat a coal bed, a castable slab below the oven chamber, and a foundation supporting the heat recovery oven. One or more beams are positioned between the castable slab and the foundation. The beams extend from a first end of the oven chamber to a second end of the oven chamber, forming a plurality of air gaps between the castable slab and the foundation. Heat from the oven chamber is dissipated by the one or more beams.
The present technology is generally directed to systems and methods for removing mercury from emissions. More specifically, some embodiments are directed to systems and methods for removing mercury from exhaust gas in a flue gas desulfurization system. In one embodiment, a method of removing mercury from exhaust gas in a flue gas desulfurization system includes inletting the gas into a housing and conditioning an additive. In some embodiments, conditioning the additive comprises hydrating powder-activated carbon. The method further includes introducing the conditioned additive into the housing and capturing mercury from the gas.
B01D 53/02 - Separation of gases or vapoursRecovering vapours of volatile solvents from gasesChemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases or aerosols by adsorption, e.g. preparative gas chromatography
B01D 53/64 - Heavy metals or compounds thereof, e.g. mercury
A system and method for repairing a coke oven having an oven chamber formed from ceramic bricks. A representative system includes a insulated enclosure insertable into the oven chamber and includes removable insulated panels that define an interior area for workers to work in. The insulated enclosure is movable between an expanded configuration and a compact configuration and moving the enclosure to the expanded configuration will decrease the distance between the insulated enclosure and the walls of the oven chamber. Removing the panels exposes the ceramic bricks and allows workers within the interior area to access and the bricks and repair the oven chamber while the oven chamber is still hot. A loading apparatus lifts and inserts the insulated enclosure into the oven chamber. The insulated enclosure can be coupled to additional insulated enclosures to form an elongated interior area.
The present technology is generally directed to vent stack lids and associated systems and methods. In particular, several embodiments are directed to vent stack lids having improved sealing properties in a coke processing system. In a particular embodiment, a vent stack lid comprises a first lid portion proximate to and at least partially spaced apart from a second lid portion. The vent stack lid further comprises a first sealing portion coupled to the first lid portion and a second sealing portion coupled to the second lid portion. In several embodiments, the second sealing portion at least partially overlaps the first sealing portion over the space between the first and second lid portions. In further embodiments, at least one of the first or second sealing portions includes layers of tadpole seals, spring seals, rigid refractory material, and/or flexible refractory blanket.
B23P 19/04 - Machines for simply fitting together or separating metal parts or objects, or metal and non-metal parts, whether or not involving some deformationTools or devices therefor so far as not provided for in other classes for assembling or disassembling parts
A coke oven can include an oven body, a foundation, and a plurality of beams separating the oven body from the foundation, A buckstay applies force to the oven body to maintain compression on the oven body during thermal cycling of the coke oven. The coke oven further comprises a spring-loaded compression device, which can include a restraining device, an anchor coupled to the restraining device, and a spring coupled to the restraining device. The anchor can be attached to one or more of the beams, the foundation of the oven, or to a similar compression device on an opposite side of the oven. The spring applies force between the restraining device and the one or more beams or foundation to compress the buckstay against the oven. The force applied by the spring can maintain structural stability of the coke oven over a plurality of thermal cycles.
Systems and methods for removing carbonaceous clinker material from a coke oven are described. A coke oven can be provided including an oven floor, coke, and clinker material deposited on the oven floor. After a temperature of the coke oven has reached a first temperature (e.g., after heating coal in the oven to produce coke), the method includes increasing the temperature of the coke oven to a second temperature that is higher than the first temperature for a predetermined amount of time. After the predetermined amount of time, the temperature is reduced to a third temperature that is lower than the first temperature.
The present technology is generally directed to providing beds of coking material to charge a coking oven. In various embodiments, a quantity of first particulate material, having a first particulate size and bulk density, is combined with a second particulate material, having a second particulate size and bulk density, to define a multi-modal bed of coking material. The multi-modal bed of coking material exhibits an optimized bulk density that is greater than an ideal bulk density predicted by a linear combination of the bulk densities of the individual materials.
C10B 57/04 - Other carbonising or coking processesFeatures of destructive distillation processes in general using charges of special composition
C10B 57/06 - Other carbonising or coking processesFeatures of destructive distillation processes in general using charges of special composition containing additives
C10L 5/04 - Raw material to be usedPretreatment thereof
The present technology describes methods and systems for an improved quench tower. Some embodiments improve the quench towers ability to recover particulate matter, steam, and emissions that escape from the base of the quench tower. Some embodiments improve the draft and draft distribution of the quench tower. Some embodiments include one or more sheds to enlarge the physical or effective perimeter of the quench tower to reduce the amount of particulate matter, emissions, and steam loss during the quenching process. Some embodiments include an improved quench baffle formed of a plurality of single-turn or multi-turn chevrons adapted to prevent particulate matter from escaping the quench tower. Some embodiments include an improved quench baffle spray nozzle used to wet the baffles, suppress dust, and/or clean baffles. Some embodiments include a quench nozzle that can fire in discrete stages during the quenching process.
A coke plant includes multiple coke ovens where each coke oven is adapted to produce exhaust gases, a common tunnel fluidly connected to the plurality of coke ovens and configured to receive the exhaust gases from each of the coke ovens, multiple standard heat recovery steam generators fluidly connected to the common tunnel where the ratio of coke ovens to standard heat recovery steam generators is at least 20:1, and a redundant heat recovery steam generator fluidly connected to the common tunnel where any one of the plurality of standard heat recovery steam generators and the redundant heat recovery steam generator is adapted to receive the exhaust gases from the plurality of ovens and extract heat from the exhaust gases and where the standard heat recovery steam generators and the redundant heat recovery steam generator are all connected in parallel with each other.
C23D 5/08 - Applying enamels non-uniformly over the surface
C10B 5/02 - Coke ovens with horizontal chambers with vertical heating flues
B23P 6/04 - Repairing fractures or cracked metal parts or products, e.g. castings
C10B 41/00 - Safety devices, e.g. signalling or controlling devices for use in the discharge of coke
G01M 3/20 - Investigating fluid tightness of structures by using fluid or vacuum by detecting the presence of fluid at the leakage point using special tracer materials, e.g. dye, fluorescent material, radioactive material
The present technology is generally directed to horizontal heat recovery and non-heat recovery coke ovens having monolith components. In some embodiments, an HHR coke oven includes a monolith component that spans the width of the oven between opposing oven sidewalls. The monolith expands upon heating and contracts upon cooling as a single structure. In further embodiments, the monolith component comprises a thermally-volume-stable material. The monolith component may be a crown, a wall, a floor, a sole flue or combination of some or all of the oven components to create a monolith structure. In further embodiments, the component is formed as several monolith segments spanning between supports such as oven sidewalls. The monolith component and thermally-volume-stable features can be used in combination or alone. These designs can allow the oven to be turned down below traditionally feasible temperatures while maintaining the structural integrity of the oven.
A duct intersection comprising a first duct portion and a second duct portion extending laterally from a side of the first duct portion. At least one flow modifier is mounted inside one of the first and second duct portions. The flow modifier is a contoured duct liner and/or the flow modifier includes at least one turning vane. The duct intersection may also include a transition portion extending between the first and second duct portions, wherein the transition portion has a length extending along a side of the first duct portion and a depth extending away from the side of the first duct portion, wherein the length is greater than a diameter of the second duct portion.
High quality coke products made in horizontal ovens such as heat recovery, non-recovery or Thompson ovens from an optimized coal blend. The coke products have unique properties such as an oblong shape and improved Coke Strength after Reaction (CSR) and Coke Reactivity Index (CRI) properties.
High quality coke products made in horizontal ovens such as heat recovery, non-recovery or Thompson ovens from an optimized coal blend. The coke products have unique properties such as an oblong shape and improved Coke Strength after Reaction (CSR) and Coke Reactivity Index (CRI) properties.
C10B 53/02 - Destructive distillation, specially adapted for particular solid raw materials or solid raw materials in special form of cellulose-containing material
C10B 57/00 - Other carbonising or coking processesFeatures of destructive distillation processes in general
C10B 57/02 - Multi-step carbonising or coking processes
High quality coke products made in horizontal ovens such as heat recovery, non-recovery or Thompson ovens from an optimized coal blend. The coke products have unique properties such as an oblong shape and improved Coke Strength after Reaction (CSR) and Coke Reactivity Index (CRI) properties.
Systems and methods for an overall oven health optimization system and method are disclosed. The oven health optimization system computes one or more metrics to measure/compare oven health performance data, computes oven life indicator values, generates one or more oven health performance plans, and so on, based on oven operation and/or inspection data parameters.
Systems and methods for an overall oven health optimization system and method are disclosed. The oven health optimization system computes one or more metrics to measure/compare oven health performance data, computes oven life indicator values, generates one or more oven health performance plans, and so on, based on oven operation and/or inspection data parameters.
The present technology is generally directed to systems and methods for optimizing the burn profiles for coke ovens, such as horizontal heat recovery ovens. In various embodiments the burn profile is at least partially optimized by controlling air distribution in the coke oven. In some embodiments, the air distribution is controlled according to temperature readings in the coke oven. In particular embodiments, the system monitors the crown temperature of the coke oven. After the crown reaches a particular temperature range the flow of volatile matter is transferred to the sole flue to increase sole flue temperatures throughout the coking cycle. Embodiments of the present technology include an air distribution system having a plurality of crown air inlets positioned above the oven floor.
A coke oven includes an oven chamber, an uptake duct in fluid communication with the oven chamber, the uptake duct being configured to receive exhaust gases from the oven chamber, an uptake damper in fluid communication with the uptake duct, the uptake damper being positioned at any one of multiple positions, the uptake damper configured to control an oven draft, an actuator configured to alter the position of the uptake damper between the positions in response to a position instruction, a sensor configured to detect an operating condition of the coke oven, wherein the sensor includes one of a draft sensor, a temperature sensor configured to detect an uptake duct temperature or a sole flue temperature, and an oxygen sensor, and a controller being configured to provide the position instruction to the actuator in response to the operating condition detected by the sensor.
F22B 1/18 - Methods of steam generation characterised by form of heating method by exploitation of the heat content of hot heat carriers the heat carrier being a hot gas, e.g. waste gas such as exhaust gas of internal-combustion engines
C10B 5/04 - Coke ovens with horizontal chambers with vertical heating flues with cross-over inter-connections
C10B 21/20 - Methods of heating ovens of the chamber oven type
C10B 27/00 - Arrangements for withdrawal of the distillation gases
The present technology is generally directed to integrated control of coke ovens in a coke plant in order to optimize coking rate, product recovery, byproducts and/or unit lime consumption Optimization objectives are achieved through controlling certain variables (called control variables) by manipulating available handles (called manipulated variables) subject to constraints and system disturbances that affect the controlled variables.
The present technology describes various embodiments of methods and systems for improved coke quenching. More specifically, some embodiments are directed to methods and systems for improving the coke quenching process by partially cracking coke before it is quenched. In one embodiment, coke is partially cracked when placed in horizontal communication with one or more uneven surfaces. In another embodiment, a coke loaf is partially broken when dropped a vertical distance that is less than the height of the coke loaf. In another embodiment, a mass of coke is partially broken when first placed in vertical communication with one or more uneven surfaces and then placed in horizontal communication with the same or different one or more uneven surfaces. In some embodiments, the one or more uneven surfaces may be mounted to a coke oven, train car, hot car, quench car, or combined hot car/quench car.
A coke plant includes multiple coke ovens where each coke oven is adapted to produce exhaust gases, a common tunnel fluidly connected to the plurality of coke ovens and configured to receive the exhaust gases from each of the coke ovens, multiple standard heat recovery steam generators fluidly connected to the common tunnel where the ratio of coke ovens to standard heat recovery steam generators is at least 20:1, and a redundant heat recovery steam generator fluidly connected to the common tunnel where any one of the plurality of standard heat recovery steam generators and the redundant heat recovery steam generator is adapted to receive the exhaust gases from the plurality of ovens and extract heat from the exhaust gases and where the standard heat recovery steam generators and the redundant heat recovery steam generator are all connected in parallel with each other.
F22B 1/18 - Methods of steam generation characterised by form of heating method by exploitation of the heat content of hot heat carriers the heat carrier being a hot gas, e.g. waste gas such as exhaust gas of internal-combustion engines
C10B 5/12 - Coke ovens with horizontal chambers with heat-exchange devices with regenerators
C10B 41/00 - Safety devices, e.g. signalling or controlling devices for use in the discharge of coke
C10B 5/02 - Coke ovens with horizontal chambers with vertical heating flues
C10B 5/06 - Coke ovens with horizontal chambers with horizontal heating flues
C10B 5/08 - Coke ovens with horizontal chambers with horizontal and vertical heating flues
C10B 49/02 - Destructive distillation of solid carbonaceous materials by direct heating with heat-carrying agents including the partial combustion of the solid material to be treated with hot gases or vapours, e.g. hot gases obtained by partial combustion of the charge
A system and method for repairing a coke oven having an oven chamber formed from ceramic bricks. A representative system includes a insulated enclosure insertable into the oven chamber and includes removable insulated panels that define an interior area for workers to work in. The insulated enclosure is movable between an expanded configuration and a compact configuration and moving the enclosure to the expanded configuration will decrease the distance between the insulated enclosure and the walls of the oven chamber. Removing the panels exposes the ceramic bricks and allows workers within the interior area to access and the bricks and repair the oven chamber while the oven chamber is still hot. A loading apparatus lifts and inserts the insulated enclosure into the oven chamber. The insulated enclosure can be coupled to additional insulated enclosures to form an elongated interior area.
The present technology describes various embodiments of systems and methods for maintaining a flat push hot car. In some embodiments, the flat push hot car includes an at least partially enclosed hot box having an interior portion, an exterior portion, a base, and a plurality of sidewalls extending upward from the base. The hot box can be coupled to or integrated with a fluid distribution system. The fluid distribution system can include a spray manifold having one or more inlets configured to release a fluid directed toward the sidewalls of the interior portion so as to provide regional cooling to the hot box.
The present technology is generally directed to methods of decarbonizing coking ovens, and associated systems and devices. In some embodiments, a method of operating and decarbonizing a coking oven can include inserting a charge of coal into the coking oven and heating the coal. The method can further include removing at least a portion of the charge, leaving behind coking deposits in the coking oven. At least a portion of the deposits can be continuously removed from the coking oven. For example, in some embodiments, at least a portion of the deposits can be removed each time a new charge of coal is inserted in the coking oven.
Systems and methods of dynamically charging coal in coke ovens related to the operation and output of coke plants including methods of automatically charging a coke oven using a charging ram in communication with a control system to increase the coke output and coke quality from coke plants. In some embodiments, the control system is capable of moving the charging ram in a horizontal first direction, a horizontal second direction and a vertical third direction while charging coal into the oven. In some embodiments, the coal charging system also includes a scanning system configured to scan an oven floor to generate an oven floor profile and/or oven capacity. The scanning system used in combination with the control system allows for dynamic leveling of the charging ram throughout the charging process. In some embodiments, the charging ram includes stiffener plates and support members to increase the mechanical strength of the charging ram and decrease the sag of the charging ram at a distal end.
Systems and apparatuses for cooling flue gases emitted from an industrial facility, such as a coke oven in a coke manufacturing plant. A representative system includes a heat recovery steam generator (HRSG) having a steam generation system that converts liquid feedwater into steam by absorbing heat from the flue gases. The steam generation system includes a plurality of tubes that carry the liquid water feedwater and the steam. Some or all of the tubes include steel and a non-corrosive material cladded to the steel that helps to reduce corrosion caused by the high temperature flue gases and extremely corrosive contaminants within the flue gas that can corrode steel.
F01K 25/14 - Plants or engines characterised by use of special working fluids, not otherwise provided forPlants operating in closed cycles and not otherwise provided for using special vapours using industrial or other waste gases
F22B 1/18 - Methods of steam generation characterised by form of heating method by exploitation of the heat content of hot heat carriers the heat carrier being a hot gas, e.g. waste gas such as exhaust gas of internal-combustion engines
F22B 37/04 - Component parts or details of steam boilers applicable to more than one kind or type of steam boiler and characterised by material, e.g. use of special steel alloy
F22G 5/04 - Controlling superheat temperature by regulating flue gas flow, e.g. by proportioning or diverting
92.
IMPROVED SYSTEMS AND METHODS FOR UTILIZING FLUE GAS
Systems and apparatuses for cooling flue gases emitted from an industrial facility, such as a coke oven in a coke manufacturing plant. A representative system includes a heat recovery steam generator (HRSG) having a steam generation system that converts liquid feedwater into steam by absorbing heat from the flue gases. The steam generation system includes a plurality of tubes that carry the liquid water feedwater and the steam. Some or all of the tubes include steel and a non-corrosive material cladded to the steel that helps to reduce corrosion caused by the high temperature flue gases and extremely corrosive contaminants within the flue gas that can corrode steel.
F22B 1/18 - Methods of steam generation characterised by form of heating method by exploitation of the heat content of hot heat carriers the heat carrier being a hot gas, e.g. waste gas such as exhaust gas of internal-combustion engines
F01K 25/14 - Plants or engines characterised by use of special working fluids, not otherwise provided forPlants operating in closed cycles and not otherwise provided for using special vapours using industrial or other waste gases
F22G 5/04 - Controlling superheat temperature by regulating flue gas flow, e.g. by proportioning or diverting
F22B 37/04 - Component parts or details of steam boilers applicable to more than one kind or type of steam boiler and characterised by material, e.g. use of special steel alloy
93.
METHODS AND SYSTEMS FOR PROVIDING CORROSION RESISTANT SURFACES IN CONTAMINANT TREATMENT SYSTEMS
Systems and apparatuses for neutralizing acidic compounds in flue gases emitted from a heat recovery coke oven. A representative system includes a spray dry absorber having a barrel that includes a plurality of wall plates that form sidewalls of the barrel. The wall plates include a steel plate and a corrosion resistant alloy cladded to the steel plate and the wall plates are oriented such that the corrosion resistant alloy faces toward and is in fluid communication with an interior area of the barrel. The alloy is resistant to corrosion caused by the acidic compounds in the flue gas and can prevent the steel plate from being corroded by these acidic compounds.
Systems and apparatuses for neutralizing acidic compounds in flue gases emitted from a heat recovery coke oven. A representative system includes a spray dry absorber having a barrel that includes a plurality of wall plates that form sidewalls of the barrel. The wall plates include a steel plate and a corrosion resistant alloy cladded to the steel plate and the wall plates are oriented such that the corrosion resistant alloy faces toward and is in fluid communication with an interior area of the barrel. The alloy is resistant to corrosion caused by the acidic compounds in the flue gas and can prevent the steel plate from being corroded by these acidic compounds.
B01D 53/14 - Separation of gases or vapoursRecovering vapours of volatile solvents from gasesChemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases or aerosols by absorption
A coke plant includes multiple coke ovens where each coke oven is adapted to produce exhaust gases, a common tunnel fluidly connected to the plurality of coke ovens and configured to receive the exhaust gases from each of the coke ovens, multiple standard heat recovery steam generators fluidly connected to the common tunnel where the ratio of coke ovens to standard heat recovery steam generators is at least 20:1, and a redundant heat recovery steam generator fluidly connected to the common tunnel where any one of the plurality of standard heat recovery steam generators and the redundant heat recovery steam generator is adapted to receive the exhaust gases from the plurality of ovens and extract heat from the exhaust gases and where the standard heat recovery steam generators and the redundant heat recovery steam generator are all connected in parallel with each other.
A coke oven includes an oven chamber configured to support and heat a coal bed, a castable slab below the oven chamber, and a foundation supporting the heat recovery oven. One or more beams are positioned between the castable slab and the foundation. The beams extend from a first end of the oven chamber to a second end of the oven chamber, forming a plurality of air gaps between the castable slab and the foundation. Heat from the oven chamber is dissipated by the one or more beams.
Systems and apparatuses for controlling oven draft within a coke oven. A representative system includes an uptake damper coupled to an uptake duct that receives exhaust gases from the coke oven and provides the exhaust gases to a common tunnel for further processing. The uptake damper includes a damper plate pivotably coupled to a refractory surface of the uptake duct and an actuator assembly coupled to the damper plate. The damper plate is positioned completely within the uptake duct and the actuator assembly moves the damper plate between a plurality of different configurations by causing the damper plate to rotate relative to the uptake duct. Moving the uptake damper between the different configurations changes the flow rate and pressure of the exhaust gases through the uptake duct, which affects an oven draft within the coke oven.
Systems and methods for particle leak detection generally include a separation or collection device configured to filter particulate from a stream and a detection device downstream of the separation or collection device. The detection device can be positioned to detect particulate that passes the separation or collection device and can include a probe configured to detect the solid particles. The particle leak detection systems can be configured to be disposed on moveable systems, such as moveable systems in coke oven operations.
Systems and apparatuses for cooling flue gases emitted from an industrial facility, such as a coke oven in a coke manufacturing plant. A representative system includes a heat recovery steam generator (HRSG) having a steam generation system that converts liquid feedwater into steam by absorbing heat from the flue gases. The steam generation system includes a plurality of tubes that carry the liquid water feedwater and the steam. Some or all of the tubes include steel and a non-corrosive material cladded to the steel that helps to reduce corrosion caused by the high temperature flue gases and extremely corrosive contaminants within the flue gas that can corrode steel.
F22B 1/18 - Methods of steam generation characterised by form of heating method by exploitation of the heat content of hot heat carriers the heat carrier being a hot gas, e.g. waste gas such as exhaust gas of internal-combustion engines
F01K 23/10 - Plants characterised by more than one engine delivering power external to the plant, the engines being driven by different fluids the engine cycles being thermally coupled combustion heat from one cycle heating the fluid in another cycle with exhaust fluid of one cycle heating the fluid in another cycle
E04F 13/14 - Coverings or linings, e.g. for walls or ceilings composed of covering or lining elementsSub-structures thereforFastening means therefor composed of a plurality of similar covering or lining elements of stone or stone-like materials, e.g. ceramicsCoverings or linings, e.g. for walls or ceilings composed of covering or lining elementsSub-structures thereforFastening means therefor composed of a plurality of similar covering or lining elements of glass
F27D 17/00 - Arrangements for using waste heatArrangements for using, or disposing of, waste gases
100.
Methods and systems for providing corrosion resistant surfaces in contaminant treatment systems
Systems and apparatuses for neutralizing acidic compounds in flue gases emitted from a heat recovery coke oven. A representative system includes a spray dry absorber having a barrel that includes a plurality of wall plates that form sidewalls of the barrel. The wall plates include a steel plate and a corrosion resistant alloy cladded to the steel plate and the wall plates are oriented such that the corrosion resistant alloy faces toward and is in fluid communication with an interior area of the barrel. The alloy is resistant to corrosion caused by the acidic compounds in the flue gas and can prevent the steel plate from being corroded by these acidic compounds.
