Methods for decarbonizing coking ovens, and associated systems and devices

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.

Heat recovery oven foundation

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 methods for removing mercury from emissions

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.

METHODS AND SYSTEMS FOR IMPROVED COKE QUENCHING

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. 1. A method of producing quenched coke , comprising:disposing an amount of coal into a coke oven located at a first location;heating the amount of coal to produce coke;cracking the coke at a second location, wherein the cracking comprises placing the coke in communication with an uneven surface having a base and one or more raised portions extending from the base; andquenching the coke to form quenched coke.2. The method of claim 1 , wherein the one or more raised portions comprises one or more bumps attached to the base claim 1 , each bump having a rounded portion.3. The method of claim 1 , wherein the one or more raised portions comprises one or more angle ramps attached to the base claim 1 , each angle ramp being attached to the base at an angle that is between 90 and 180 degrees with respect to a front portion and a side portion of the base.4. The method of claim 1 , wherein the one or more raised portions comprises one or more inclined ramps attached to a base claim 1 , each inclined ramp being attached to the base at an angle that is between 90 and 180 degrees with respect ...

Systems and methods for controlling air distribution in a coke oven

The present technology is generally directed to systems and methods for controlling air distribution in a coke oven. In a particular embodiment, a coke oven air distribution system comprises an oven chamber having an oven floor configured to support a coal bed, a plurality of sidewalls extending upward from the oven floor, and an oven crown covering a top portion of the oven chamber. The air distribution system further includes an air inlet positioned above the oven floor and a distributor proximate to the inlet. The inlet is configured to introduce air into the oven chamber and the distributor is configured to at least one of preheat, redirect, or spread air within the oven chamber.

COKE OVEN CHARGING SYSTEM

The present technology is generally directed to coal charging systems used with coke ovens. In some embodiments, a coal charging system includes a charging head having opposing wings that extend outwardly from the charging head, leaving an open pathway through which coal may be directed toward side edges of the coal bed. In other embodiments, an extrusion plate is positioned on a rearward face of the charging head and oriented to engage and compress coal as the coal is charged along a length of the coking oven. In other embodiments, charging plates extend outwardly from inward faces of opposing wings. 1. (canceled)2. (canceled)3. (canceled)4. (canceled)5. (canceled)6. (canceled)7. (canceled)8. (canceled)9. (canceled)10. (canceled)11. (canceled)12. (canceled)13. (canceled)14. (canceled)15. (canceled)16. (canceled)17. (canceled)18. (canceled)19. (canceled)20. (canceled)21. (canceled)22. (canceled)23. (canceled)24. (canceled)25. (canceled)26. (canceled)27. (canceled)28. A coal charging system , the system comprising:an elongated charging frame having a distal end portion, proximal end portion, and opposite sides;a charging head operatively coupled with the distal end portion of the elongated charging frame; the charging head including a planar body residing within a charging head plane and having an upper edge portion, lower edge portion, opposite side portions, a front face, and a rearward face;an extrusion plate operatively coupled with the rearward face of the charging head; the extrusion plate having a coal engagement face that is oriented to face rearwardly and downwardly with respect to the charging head; anda charging conveyor operatively coupled with the elongated charging frame and having a distal end positioned adjacent and in open fluid communication with the coal engagement face of the extrusion plate so that coal is deposited immediately behind the coal engagement face of the extrusion plate.29. The coal charging system of wherein the extrusion plate ...

INTEGRATED COKE PLANT AUTOMATION AND OPTIMIZATION USING ADVANCED CONTROL AND OPTIMIZATION TECHNIQUES

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. 125-. (canceled)26. A coke oven , comprising: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 a plurality of positions including fully opened and fully closed, she uptake damper configured to control an oven draft;a first actuator configured to alter the position of the uptake damper between the plurality of positions in response to a position instruction;a common tunnel in fluid communication with the uptake duct, the common tunnel being configured to receive exhaust gases from the uptake duct;at least one heat recovery steam generator in fluid communication with the common tunnel,the heat recovery steam generator including (i)a heat recovery steam generator damper positioned at any one of a plurality of positions including fully opened and fully closed and (ii) and a second actuator configured to alter the position of the heat recovery steam generator damper;one or more sensors configured to detect an operating condition of the coke oven, wherein the one or more sensors comprises at least one of (i) a draft sensor configured to detect the oven draft, (ii) a temperature sensor configured to detect an oven chamber temperature or a sole flue temperature, or (iii) an oxygen sensor configured to detect an uptake duct oxygen concentration in the uptake duct; anda controller in communication with the actuator and with the ...

COAL BLENDS, FOUNDRY COKE PRODUCTS, AND ASSOCIATED SYSTEMS, DEVICES, AND METHODS

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.

System and method for repairing a coke oven

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.

SPRING-LOADED HEAT RECOVERY OVEN SYSTEM AND METHOD

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.

METHOD AND SYSTEM FOR DYNAMICALLY CHARGING A COKE 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. 1. A coal charging system , the system comprising:a coke oven including a pusher side opening, a coke side opening opposite the pusher side opening, opposite side walls, and an oven floor defined by the pusher side opening, the coke side opening, and the opposite side walls;a charging ram having a proximal end portion, a distal end portion, and opposite sides that define a length of the charging ram, the charging ram being movable at least from the pusher side opening towards the coke side opening;a conveyer system operably coupled to the charging ram and capable of charging coal into the oven, wherein the conveyor system in operation experiences a charging pressure; anda control system in communication with the charging ram, wherein the control system is configured to automatically move the charging ram at least between the pusher side opening and the coke side opening, such that the automatic movement of the charging ram is determined at least in part by the chain pressure ...

SYSTEMS AND METHODS FOR IMPROVING QUENCHED COKE RECOVERY

The present technology is generally directed to systems and methods for improving quenched coke recovery. More specifically, some embodiments are directed to systems and methods utilizing one or more of a screen, barrier, or reflector panel to contain or redirect coke during or after quenching. In a particular embodiment, a quench car system for containing coke includes a quench car having a base, a plurality of sidewalls, and a top portion. The system can further include a permeable barrier covering at least a portion of the top of the quench car, wherein the permeable barrier has a plurality of apertures therethrough. 1. A quench car system for containing coke prepared for quenching at a quenching site , the quench car system comprising:a quench car having a base and a plurality of sidewalls defining an opening, the quench car having a top; anda permeable barrier covering at least a portion of the top of the quench car, the permeable barrier having a plurality of apertures therethrough.2. The quench car system of wherein the permeable barrier is removably coupled to the quench car.3. The quench car system of wherein the permeable barrier extends across the top of the quench car and at least one sidewall.4. The quench car system of wherein the individual apertures have a diameter from about ¼ inch to about ¾ inch.5. The quench car system of wherein the quench car further comprises a containment plate coupled to one or more sidewalls and configured to contain or funnel coke or quench water.6. The quench car system of wherein an individual sidewall comprises a movable gate claim 5 , and wherein the containment plate extends along the gate and is movable between a first position when the gate is open and a second position when the gate is closed.7. The quench car system of wherein two sidewalls meet at a corner claim 5 , and wherein the containment plate is positioned adjacent to the corner and overlaps at least one of the sidewalls.8. The quench car system of wherein ...

Burn profiles for coke operations

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.

Non-perpendicular connections between coke oven uptakes and a hot common tunnel, and associated systems and methods

The present technology is generally directed to non-perpendicular connections between coke oven uptakes and a hot common tunnel, and associated systems and methods. In some embodiments, a coking system includes a coke oven and an uptake duct in fluid communication with the coke oven. The uptake duct has an uptake flow vector of exhaust gas from the coke oven. The system also includes a common tunnel in fluid communication with the uptake duct. The common tunnel has a common flow vector and can be configured to transfer the exhaust gas to a venting system. The uptake flow vector and common flow vector can meet at a non-perpendicular interface to improve mixing between the flow vectors and reduce draft loss in the common tunnel.

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.

Methods and systems for improved coke quenching

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.

Methods and systems for automatically generating a remedial action in an industrial facility

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.

METHODS AND SYSTEMS FOR AUTOMATICALLY GENERATING A REMEDIAL ACTION IN AN INDUSTRIAL FACILITY

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.

Method and system for dynamically charging a coke 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 ...

COKE OVENS HAVING MONOLITH COMPONENT CONSTRUCTION

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. 1. A coke oven chamber , comprising:A monolith sole flue section having a serpentine path therein;a front wall extending vertically upward from the monolith sole flue section and a back wall opposite the front wall;a first sidewall extending vertically upward from the floor between the front wall and the back wall and a second sidewall opposite the first sidewall; anda monolith crown positioned above the monolith sole flue section and spanning from the first sidewall to the second sidewall.2. The coke oven chamber of wherein the monolith crown comprises a plurality of monolith portions spanning from the first sidewall to the second sidewall claim 1 , wherein the plurality of monolith portions are positioned generally adjacent to one another between the front wall and the back wall.3. The coke oven chamber of wherein:at least one of the monolith crown or sidewalls are configured to translate, contract, or expand by an adjustment amount upon heating or cooling the coke oven chamber;the monolith crown comprises a ...

Multi-modal beds of coking material

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.

HEAT RECOVERY OVEN FOUNDATION

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.

REDUCED OUTPUT RATE COKE OVEN OPERATION WITH GAS SHARING PROVIDING EXTENDED PROCESS CYCLE

The present technology is generally directed to systems and methods of controlling or reducing the output rate of a coke oven through gas sharing providing an extended process cycle. In some embodiments, a method of gas sharing between coke ovens to decrease a coke production rate includes operating a plurality of coke ovens to produce coke and heated exhaust gases. In some embodiments, a first coke oven is offset in operation cycle from a second coke oven. The method further includes directing the heated exhaust gases from the first coke oven to the second coke oven while the second coke oven is mid-cycle. The heat transfer allows the second coke oven to extend its cycle while staying above a critical operating temperature. By extending the operational cycle while generally maintaining output per cycle, overall production is decreased. 1. A method of gas sharing between coke ovens to decrease a coke production rate , the method comprising:operating a plurality of coke ovens to produce coke and exhaust gases, wherein each coke oven comprises an uptake damper adapted to control an oven draft in the coke oven, and wherein a first coke oven is offset in operation cycle from a second coke oven;directing the exhaust gases from the first coke oven to a shared gas duct that is in communication with the first coke oven and the second coke oven; andbiasing the draft in the ovens to move the exhaust gas from the first coke oven to the second coke oven via the shared gas duct to transfer heat from the first coke oven to the second coke oven.2. The method of wherein operating a plurality of coke ovens comprises operating the first coke oven and the second coke oven on opposite operating cycles claim 1 , wherein the first coke oven begins an operating cycle when the second coke oven is approximately halfway through an operating cycle.3. The method of wherein directing the exhaust gases from the first coke oven to a shared gas duct comprises directing the exhaust gases from the ...

Exhaust flow modifier, duct intersection incorporating the same, and methods therefor

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.

Systems and methods for removing mercury from emissions

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.

HIGH-QUALITY COKE PRODUCTS

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.

Method and system for optimizing coke plant operation and output

The present technology is generally directed to methods of increasing coke production rates for coke ovens. In some embodiments, a coal charging system includes a false door system with a false door that is vertically oriented to maximize an amount of coal being charged into the oven. A lower extension plate associated with embodiments of the false door is selectively, automatically extended beyond a lower end portion of the false door in order to extend an effective length of the false door. In other embodiments an extension plate may be coupled with an existing false door having an angled front surface to provide the existing false door with a vertically oriented face.

SYSTEM AND METHOD FOR REPAIRING A COKE OVEN

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.

SYSTEM AND METHOD FOR REPAIRING A COKE OVEN

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. 18-. (canceled)9. A method of repairing a coke oven having an oven chamber defined by a floor , a crown , and sidewalls that extend between the floor and the crown and wherein the coke oven comprises a plurality of bricks that form the floor , the crown , and the sidewalls , the method comprising: the insulated enclosure includes a plurality of panels removably coupled to a frame portion,', 'the insulated enclosure is movable between a first configuration and a second configuration,', 'inserting the insulated enclosure into the oven chamber comprises inserting the insulated enclosure into the oven chamber when the insulated enclosure is in the first configuration;, 'inserting a insulated enclosure into the oven chamber, wherein—'}moving the insulated enclosure from the first configuration to the second configuration;detaching at least one of the panels from the frame portion to expose at least one of the floor, the crown, and the sidewalls;repairing at least one of the bricks;reattaching the at least one panel to the frame portion;move the insulated enclosure to the first ...

Coke oven charging system

The present technology is generally directed to coal charging systems used with coke ovens. In some embodiments, a coal charging system includes a charging head having opposing wings that extend outwardly from the charging head, leaving an open pathway through which coal may be directed toward side edges of the coal bed. In other embodiments, an extrusion plate is positioned on a rearward face of the charging head and oriented to engage and compress coal as the coal is charged along a length of the coking oven. In other embodiments, charging plates extend outwardly from inward faces of opposing wings.

METHOD AND SYSTEM FOR OPTIMIZING COKE PLANT OPERATION AND OUTPUT

The present technology is generally directed to methods of increasing coal processing rates for coke ovens. In various embodiments, the present technology is applied to methods of coking relatively small coal charges over relatively short time periods, resulting in an increase in coal processing rate. In some embodiments, a coal charging system includes a charging head having opposing wings that extend outwardly and forwardly from the charging head, leaving an open pathway through which coal may be directed toward side edges of the coal bed. In other embodiments, an extrusion plate is positioned on a rearward face of the charging head and oriented to engage and compress coal as the coal is charged along a length of the coking oven. In other embodiments, a false door system includes a false door that is vertically oriented to maximize an amount of coal being charged into the oven. 1. A method of increasing a coal processing rate of a coke oven , the method comprising:positioning a coal charging system, having an elongated charging frame and a charging head operatively coupled with the distal end portion of the elongated charging frame, at least partially within a coke oven having a maximum coal charge capacity and a maximum coking time associated with the maximum coal charge;charging coal into the coke oven with the coal charging system in a manner that defines a first operational coal charge that is less than the maximum coal charge capacity;coking the first operational coal charge in the coke oven until it is converted into a first coke bed but over a first coking time that is less than the maximum coking time;pushing the first coke bed from the coke oven;charging coal into the coke oven with the coal charging system in a manner that defines a second operational coal charge that is less than the maximum coal charge capacity;coking the second operational coal charge in the coke oven until it is converted into a second coke bed but over a second coking time that is ...

Methods and systems for improved coke quenching

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.

Particulate detection for industrial facilities, and associated systems and methods

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.

Methods and systems for improved quench tower design

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.

System and method for repairing a coke oven

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.

Multi-modal beds of coking material

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.

BURN PROFILES FOR COKE OPERATIONS

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. 115-. (canceled)16. A system for controlling a horizontal heat recovery coke oven burn profile , the method comprising:a horizontal heat recovery coke oven having an oven chamber being at least partially defined by an oven floor, opposing oven doors, opposing sidewalls that extend upwardly from the oven floor between the opposing oven doors, an oven crown positioned above the oven floor, and at least one sole flue, beneath the oven floor, in fluid communication with the oven chamber;a temperature sensor disposed within the oven chamber;at least one air inlet, positioned to place the oven chamber in fluid communication with an environment exterior to the horizontal heat recovery coke oven;at least one uptake channel having an uptake damper in fluid communication with the at least one sole flue; the uptake damper being selectively movable between open and closed positions;the negative pressure draft is reduced over a plurality of flow reducing steps by; anda controller operatively coupled with the uptake damper and adapted to move the uptake damper through a plurality of increasingly flow restrictive positions over the carbonization cycle, based on the plurality of different ...

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.

Horizontal heat recovery coke ovens having monolith crowns

The present technology is generally directed to horizontal heat recovery coke ovens having monolith crowns. In some embodiments, an HHR coke oven includes a monolith crown 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 crown comprises a thermally volume-stable material. In various embodiments, the monolith 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 crown.

Spring-loaded heat recovery oven system and method

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.

MULTI-MODAL BEDS OF COKING MATERIAL

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.

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%.

HEAT RECOVERY OVEN FOUNDATION

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 METHODS FOR IMPROVING QUENCHED COKE RECOVERY

The present technology is generally directed to systems and methods for improving quenched coke recovery. More specifically, some embodiments are directed to systems and methods utilizing one or more of a screen, barrier, or reflector panel to contain or redirect coke during or after quenching. In a particular embodiment, a quench car system for containing coke includes a quench car having a base, a plurality of sidewalls, and a top portion. The system can further include a permeable barrier covering at least a portion of the top of the quench car, wherein the permeable barrier has a plurality of apertures therethrough.

Systems and methods for removing mercury from emissions

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.

High-quality coke products

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.

Foundry coke products and associated processing methods via cupolas

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%.

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.

MULTI-MODAL BEDS OF COKING MATERIAL

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. 1. A method of preparing and coking a multi-modal bed of material , the method comprising:blending a first particulate material, having a first bulk density, with a second particulate material, having a second bulk density, to define a multi-modal bed of coking material having a third bulk density, which is higher than the first bulk density; andprocessing the multi-modal bed of coking material in a coking oven to form a bed of coke, such that the bed of coke exhibits a level of quality that is similar to or exceeds a level of quality of a bed of coke formed by processing a bed of material formed from the first particulate material without the addition of the second particulate material.2. The method of wherein the bed of coke exhibits an average coke size that exceeds an average coke size of a bed of coke formed by processing a bed of material formed from the first particulate material without the addition of the second particulate material.3. The method of wherein the bed of coke exhibits a coke size of approximately 30%>2″ or greater post screening.4. The method of wherein the bed of coke exhibits a coke size of approximately 45%>2″ or greater post screening.5. The method of wherein the bed of coke exhibits a coke size of approximately 60%>2″ or greater post screening.6. The method of wherein the bed of coke exhibits a CSR level that exceeds a CSR level that is not less than a CSR level of a bed of ...

Method and system for dynamically charging a coke 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 ...

Exhaust flow modifier, duct intersection incorporating the same, and methods therefor

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.

Methods for handling coal processing emissions and associated systems and devices

The present technology describes various embodiments of systems and methods for handling emissions. More specifically, some embodiments are directed to systems and methods for collecting heated particulate from a coal processing system. In one embodiment, a method of handling emissions from a coal processing system includes inletting the emissions into a duct. The emissions include heated particulate. The method further includes slowing a speed of the emissions traveling through the duct and disengaging the heated particulate from the emissions without the use of a physical barrier. In some embodiments, the heated particulate is slowed, cooled, and diverted from an emissions pathway into a collection bin.

BURN PROFILES FOR COKE OPERATIONS

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. 128-. (canceled)29. A method of controlling a burn profile of a coke oven , the method comprising:charging a bed of coal into an oven chamber of a coke oven, the oven chamber being at least partially defined by an oven floor, opposing oven doors, opposing sidewalls that extend upwardly from the oven floor between the opposing oven doors, and an oven crown positioned above the oven floor, wherein the oven chamber is in fluid communication with an exterior environment via an air inlet;creating a negative pressure draft on the oven chamber such that air is drawn into the oven chamber through the air inlet, the negative pressure draft causing volatile matter from the coal bed to mix with the air and at least partially combust within the oven chamber and thereby generate heat within the oven chamber;based on a plurality of temperature increases detected in the oven chamber, reducing the flow of air into the oven chamber until the temperature in the oven chamber reaches a predetermined peak temperature; anddirecting the volatile matter from the oven chamber to a sole flue beneath the oven floor, thereby preheating the coke oven for a subsequent coke oven charge.30. The method of claim 29 , ...

Systems and methods for improving quenched coke recovery

The present technology is generally directed to systems and methods for improving quenched coke recovery. More specifically, some embodiments are directed to systems and methods utilizing one or more of a screen, barrier, or reflector panel to contain or redirect coke during or after quenching. In a particular embodiment, a quench car system for containing coke includes a quench car having a base, a plurality of sidewalls, and a top portion. The system can further include a permeable barrier covering at least a portion of the top of the quench car, wherein the permeable barrier has a plurality of apertures therethrough.

METHOD AND SYSTEM FOR OPTIMIZING COKE PLANT OPERATION AND OUTPUT

The present technology is generally directed to methods of increasing coal processing rates for coke ovens. In various embodiments, the present technology is applied to methods of coking relatively small coal charges over relatively short time periods, resulting in an increase in coal processing rate. In some embodiments, a coal charging system includes a charging head having opposing wings that extend outwardly and forwardly from the charging head, leaving an open pathway through which coal may be directed toward side edges of the coal bed. In other embodiments, an extrusion plate is positioned on a rearward face of the charging head and oriented to engage and compress coal as the coal is charged along a length of the coking oven. In other embodiments, a false door system includes a false door that is vertically oriented to maximize an amount of coal being charged into the oven. 1. A method of increasing a coal processing rate of a coke oven , the method comprising:positioning a coal charging system, having an elongated charging frame and a charging head operatively coupled with a distal end portion of the elongated charging frame, at least partially within a coke oven having a maximum designed coal charge capacity, defined as a maximum volume of coal that can be charged into the coke oven according to a width and height of the coke oven multiplied by a maximum bed height, defined by a height of downcomer openings, formed in opposing side walls of the coke oven, above a coke oven floor, and a maximum coking time associated with the maximum designed coal charge, wherein the maximum designed coking time is defined as the amount of time required to fully coke the maximum designed coal charge;charging coal into the coke oven with the coal charging system in a manner that defines a first operational coal charge that is less than the maximum designed coal charge capacity;coking the first operational coal charge in the coke oven until it is converted into a first coke bed ...

SYSTEMS AND METHODS FOR TREATING A SURFACE OF A COKE PLANT

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.

METHODS FOR HANDLING COAL PROCESSING EMISSIONS AND ASSOCIATED SYSTEMS AND DEVICES

The present technology describes various embodiments of systems and methods for handling emissions. More specifically, some embodiments are directed to systems and methods for collecting heated particulate from a coal processing system. In one embodiment, a method of handling emissions from a coal processing system includes inletting the emissions into a duct. The emissions include heated particulate. The method further includes slowing a speed of the emissions traveling through the duct and disengaging the heated particulate from the emissions without the use of a physical barrier. In some embodiments, the heated particulate is slowed, cooled, and diverted from an emissions pathway into a collection bin. 1. A method of handling emissions , comprising:inletting the emissions into a duct, the emissions including heated particulate;slowing a speed of the emissions traveling through the duct; anddisengaging the heated particulate from the emissions without the use of a physical barrier.2. The method of claim 1 , further comprising interfacing the emissions with baffle.3. The method of claim 1 , further comprising collecting the heated particulate in a collection bin.4. The method of wherein inletting the emissions into a duct comprises inletting the emissions via an inlet having a first cross-sectional diameter claim 3 , and wherein collecting the heated particulate in a collection bin comprises collecting the particulate in a collection bin having a second cross-sectional diameter greater than the first cross-sectional diameter.5. The method of claim 1 , further comprising inletting cooling gas into the duct.6. The method of wherein inletting cooling gas into the duct comprises automatically adjusting a modulating damper.7. The method of wherein automatically adjusting the modulating damper comprises automatically adjusting the damper in response to an emissions temperature.8. The method of claim 1 , further comprising controlling a residence time of the emissions in ...

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.

System and method for repairing a coke oven

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.

Decarbonization of coke ovens, and associated systems and methods

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.

METHODS AND SYSTEMS FOR IMPROVED QUENCH TOWER DESIGN

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.

Spring-loaded heat recovery oven system and method

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.

NON-PERPENDICULAR CONNECTIONS BETWEEN COKE OVEN UPTAKES AND A HOT COMMON TUNNEL, AND ASSOCIATED SYSTEMS AND METHODS

The present technology is generally directed to non-perpendicular connections between coke oven uptakes and a hot common tunnel, and associated systems and methods. In some embodiments, a coking system includes a coke oven and an uptake duct in fluid communication with the coke oven. The uptake duct has an uptake flow vector of exhaust gas from the coke oven. The system also includes a common tunnel in fluid communication with the uptake duct. The common tunnel has a common flow vector and can be configured to transfer the exhaust gas to a venting system. The uptake flow vector and common flow vector can meet at a non-perpendicular interface to improve mixing between the flow vectors and reduce draft loss in the common tunnel. 1. A coking system , comprising:a coke oven;an uptake duct in fluid communication with the coke oven and having an uptake flow vector of exhaust gas from the coke oven; anda common tunnel in fluid communication with the uptake duct, the common tunnel having a common flow vector of exhaust gas and configured to transfer the exhaust gas to a venting system, wherein the uptake flow vector and common flow vector meet at a non-perpendicular interface.2. The coking system of wherein at least a portion of the uptake duct is non-perpendicular to the common tunnel.3. The coking system of wherein the non-perpendicular interface comprises at least one of an altitudinal difference or an azimuthal commonality between the uptake flow vector and the common flow vector.4. The coking system of wherein the common tunnel has a common tunnel height claim 1 , an upper portion above a midpoint of the common tunnel height claim 1 , and a lower portion below the midpoint of the common tunnel height claim 1 , and wherein the uptake duct interfaces with the common tunnel in at least one of the upper portion and the lower portion.5. The coking system of wherein the non-perpendicular interface comprises at least one of a baffle claim 1 , gunned surface claim 1 , ...

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.

Burn profiles for coke operations

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.

Reduced output rate coke oven operation with gas sharing providing extended process cycle

The present technology is generally directed to systems and methods of controlling or reducing the output rate of a coke oven through gas sharing providing an extended process cycle. In some embodiments, a method of gas sharing between coke ovens to decrease a coke production rate includes operating a plurality of coke ovens to produce coke and heated exhaust gases. In some embodiments, a first coke oven is offset in operation cycle from a second coke oven. The method further includes directing the heated exhaust gases from the first coke oven to the second coke oven while the second coke oven is mid-cycle. The heat transfer allows the second coke oven to extend its cycle while staying above a critical operating temperature. By extending the operational cycle while generally maintaining output per cycle, overall production is decreased.

SYSTEMS AND METHODS FOR REMOVING MECURY FROM EMISSIONS

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. 124-. (canceled)25. A method of removing mercury from exhaust gas in a flue gas desulfurization system , the method comprising:inletting the gas into a housing;hydrating the additive to increase a moisture content of the additive;introducing the additive, with the increased moisture content, into a dry scrubber associated with the housing; andcapturing mercury from the gas.26. The method of wherein hydrating the additive comprises adding water to the additive.27. The method of claim 26 , further comprising drying previously-hydrated additive claim 26 , which removes excess fluid from the additive but leaves it with an increased moisture content.28. The method of wherein introducing the additive comprises introducing the additive via an atomizer claim 25 , throat claim 25 , or nozzle.29. The method of wherein introducing the additive into the housing comprises automatically modifying a dilution percentage of the additive.30. The method of claim 25 , further comprising sensing at least one of a mercury level claim 25 , temperature or humidity condition.31. The method of wherein introducing the additive comprises automatically introducing the additive in response to the sensed mercury level.321. The method of claim wherein introducing the additive comprises introducing the additive continuously or at a pre-set timing interval.33. A method of ...

EXHAUST FLOW MODIFIER, DUCT INTERSECTION INCORPORATING THE SAME, AND METHODS THEREFOR

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.

Coke oven charging system

The present technology is generally directed to coal charging systems used with coke ovens. In some embodiments, a coal charging system includes a charging head having opposing wings that extend outwardly from the charging head, leaving an open pathway through which coal may be directed toward side edges of the coal bed. In other embodiments, an extrusion plate is positioned on a rearward face of the charging head and oriented to engage and compress coal as the coal is charged along a length of the coking oven. In other embodiments, charging plates extend outwardly from inward faces of opposing wings.

Methods and systems for improved quench tower design

The present technology describes methods and systems for an improved quench tower. Some embodiments improve the quench tower's 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.

OVEN HEALTH OPTIMIZATION SYSTEMS AND METHODS

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. 1. A system for optimizing oven profitability , the system comprising:at least one coke oven for treating coal, wherein the at least one coke oven processes coal to produce coke; at least one hardware processor;', receiving a selection of at least one output parameter that measures oven profitability;', 'selecting a set of performance parameters based on the selected at least one output parameter;', 'wherein the set of operation optimization parameters comprises at least one of coke push grade, soak time, or environmental factors;', 'generating values for a set of operation optimization parameters using values of the set of selected performance parameters,'}, 'selecting a set of inspection parameters based on the selected at least one output parameter; and', 'generating an oven life indicator value, an oven repair plan, or both, using the generated values for the set of operation optimization parameters and values of the selected set of inspection parameters., 'at least one non-transitory memory, coupled to the at least one hardware processor and storing instructions, which when executed by the at least one hardware processor, perform a process, the process comprising], 'at least one oven health optimization system for optimizing profitability of the at least one coke oven, the at least one oven health optimization system comprising2. The system as recited in claim 1 , wherein the at least one output parameter that measures oven profitability comprises:return on investment (ROI) on repair of the at least one coke oven,coke production over time,coking rate,cost to repair the at least one coke oven,cost to ...

METHODS AND SYSTEMS FOR IMPROVED QUENCH TOWER DESIGN

The present technology describes methods and systems for an improved quench tower. Some embodiments improve the quench tower's 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. 151-. (canceled)52. A method for quenching coke in a quench tower , comprising:receiving a train car containing an amount of coke to be quenched, wherein the train car is received through an opening in the quench tower;starting a suppression action to suppress an amount of dust, wherein the suppressing comprises disposing an amount of liquid in the quench tower via one or more quench spray nozzles;starting a quenching action to quench the amount of coke in the train car, wherein starting the quenching action comprises disposing an amount of liquid onto the amount of coke using one or more quench spray nozzles;stopping the suppression action, wherein stopping the suppression action comprises discontinuing disposing an amount of liquid in the quench tower via one or more quench spray nozzles;stopping the quenching action, wherein stopping the quenching action comprises discontinuing disposing an amount of liquid onto the amount of coke using the one or more quench spray nozzles; andtransporting the train car out of the quench tower, wherein the train ...

Coke ovens having monolith component construction

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.

MULTI-MODAL BEDS OF COKING MATERIAL

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. 1. A method of coking beds of material , the method comprising:processing a first bed of carbon-containing material in a coking oven to produce a first volume of coke and a first volume of waste material; andprocessing a second bed of carbon-containing material, comprising the first volume of waste material, in the coking oven to produce a second volume of coke and a second volume of waste material; the second volume of waste material being smaller than the first volume of material.2. The method of wherein the coking oven is a horizontal heat recovery oven.3. The method of wherein the first volume of waste material is an inert carbon material.4. The method of wherein the first volume of waste material is an inert non-carbon-material.5. The method of wherein the first volume of waste material is comprised of breeze.6. The method of wherein the first volume of waste material is comprised of clinker.7. The method of wherein the second bed of carbon-containing material is comprised of a quantity of particulate coking material having a first particulate size; the first volume of waste material having a second particulate size claim 1 , which is smaller than the first particulate size; the particulate coking material being combined with the first volume of waste material to define the second bed of carbon-containing material as a multi-modal bed of material.8. The method of further comprising:milling the first ...

Integrated coke plant automation and optimization using advanced control and optimization techniques

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.

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%.

METHODS FOR DECARBONIZING COKING OVENS, AND ASSOCIATED SYSTEMS AND DEVICES

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. 155-. (canceled)56. A coking system , comprising:a coke oven comprising a plurality of interior surfaces including a floor, a crown, and opposing sidewalls between the floor and the crown;a pushing ram configured to push a charge of coke from the oven; anda decarbonization system reciprocally movable along a length of the coke oven and configured to remove coking deposits from the coke oven, the decarbonization system comprising a scraper operatively coupled to an end portion of the pushing ram, wherein, when the pushing ram is in operation, the scraper extends in a direction substantially parallel to a length axis of the coke oven such that a surface of the scraper faces the floor of the coke oven.57. The system of wherein the scraper comprises at least one rounded or beveled edge proximate at least one of the interior surfaces of the coke oven.58. The system of wherein the scraper includes at least one weight coupled thereto.59. The system of wherein the scraper comprises a first scraping portion and a second scraping portion spaced apart from one another to define a gap claim 56 , the first and second scraping portions being coupled to the pushing ram via respective first and second couplers.60. The system of wherein the first scraping portion is coaxially aligned with the second scraping portion.61. The system of wherein the first and ...

HIGH-QUALITY COKE PRODUCTS

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.

EXHAUST FLOW MODIFIER, DUCT INTERSECTION INCORPORATING THE SAME, AND METHODS THEREFOR

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. 110-. (canceled)11. A contoured duct liner for use in a duct intersection , comprising:a first wall contoured to mate with an inside surface of a duct intersection; anda second wall attached to the first wall, wherein the second wall is contoured to modify the direction of gas flow within the duct intersection.12. The contoured duct liner according to claim 11 , wherein the second wall includes at least one convex surface.13. The contoured duct liner according to claim 11 , wherein the second wall comprises a refractory material.14. A coking facility exhaust system claim 11 , comprising:an emergency stack;a crossover duct extending laterally from a side of the emergency stack; anda contoured duct liner, including a convex surface operative to modify the direction of gas flow proximate an intersection of the emergency stack and crossover duct.15. The coking facility exhaust system according to claim 14 , further comprising a second contoured duct liner disposed on an inside surface of the crossover duct.16. An improved coking facility exhaust system including an emergency stack and a crossover duct extending laterally from a side of the emergency stack claim 14 , the improvement comprising:a contoured duct liner, including a convex surface operative to modify the direction of gas flow proximate an ...

SYSTEMS AND METHODS FOR IMPROVING QUENCHED COKE RECOVERY

The present technology is generally directed to systems and methods for improving quenched coke recovery. More specifically, some embodiments are directed to systems and methods utilizing one or more of a screen, barrier, or reflector panel to contain or redirect coke during or after quenching. In a particular embodiment, a quench car system for containing coke includes a quench car having a base, a plurality of sidewalls, and a top portion. The system can further include a permeable barrier covering at least a portion of the top of the quench car, wherein the permeable barrier has a plurality of apertures therethrough.

Multi-modal beds of coking material

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.

SYSTEMS AND METHODS FOR CONTROLLING AIR DISTRIBUTION IN A COKE OVEN

The present technology is generally directed to systems and methods for controlling air distribution in a coke oven. In a particular embodiment, a coke oven air distribution system comprises an oven chamber having an oven floor configured to support a coal bed, a plurality of sidewalls extending upward from the oven floor, and an oven crown covering a top portion of the oven chamber. The air distribution system further includes an air inlet positioned above the oven floor and a distributor proximate to the inlet. The inlet is configured to introduce air into the oven chamber and the distributor is configured to at least one of preheat, redirect, or spread air within the oven chamber. 1. A coke oven air distribution system , comprising:an oven chamber having an oven floor configured to support a coal bed, a plurality of sidewalls extending upward from the oven floor, and an oven crown covering a top portion of the oven chamber;an air inlet positioned above the oven floor and configured to introduce air into the oven chamber; anda distributor proximate to the inlet and configured to at least one of preheat, redirect, or disperse air within the oven chamber.2. The system of wherein the air inlet comprises an inlet in the oven crown.3. The system of wherein the air inlet comprises an inlet in an individual sidewall.4. The system of wherein the individual sidewall comprises an oven door.5. The system of wherein the distributor comprises a generally cylindrical tube extending into the oven chamber.6. The system of wherein the distributor comprises an impingement plate generally orthogonal to the cylindrical tube.7. The system of wherein the distributor comprises an annulus flow deflecting baffle.8. The system of wherein the distributor comprises an elongated channel having a plurality of apertures therein.9. The system of wherein the elongated channel is elongated in a direction generally parallel to the sidewalls.10. The system of wherein the elongated channel is ...

Burn profiles for coke operations

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.

MULTI-MODAL BEDS OF COKING MATERIAL

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. 150-. (canceled)51. A multi-modal bed of coking material comprising:a first particulate coking material having a first bulk density; anda second particulate coking material having a second bulk density less than the first bulk density,the first particulate coking material being distributed with the second particulate coking material such that the multi-modal bed of coking material comprises a generally uniform distribution of the first particulate material and the second particulate material from a bottom portion of the multi-modal bed of material to an upper portion of the multi-modal bed of material, wherein the multi-modal bed of material includes a third density higher than a density calculated by the weighed sum of the first bulk density and the second bulk density.52. The multi-modal bed of claim 51 , wherein claim 51 , within the multi-modal bed of material claim 51 , the first particulate material is distributed in a manner that defines a plurality of void spaces at least partially filled with the second particulate material.53. The multi-modal bed of claim 51 , wherein the second particulate material comprises less than 10% by weight of the multi-modal bed of material.54. The multi-modal bed of claim 51 , wherein the first particulate coking material comprises a carbon containing material and the second particulate coking material comprises at least one of anthracite claim 51 , breeze claim 51 , ...

COAL BLENDS, FOUNDRY COKE PRODUCTS, AND ASSOCIATED SYSTEMS, DEVICES, AND METHODS

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%.

METHOD AND SYSTEM FOR DYNAMICALLY CHARGING A COKE 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. 129.- (canceled)30. A method for dynamically charging a coal system , the method comprising:positioning a charging ram at an initial charging position of a coke oven, wherein the oven includes a pusher side opening, a coke side opening opposite the pusher side opening, opposite side walls, and an oven floor defined by the pusher side opening, coke side opening, and opposite side walls, and wherein the initial charging position is adjacent to the pusher side opening;charging coal into the oven at the initial charging position via a conveyer system operably coupled to the charging ram, wherein the conveyer system in operation experiences a charging pressure;using a control system, automatically moving the charging ram while simultaneously charging coal into the oven via the conveyer system; andmaintaining the charging pressure within a preset operating range until the oven is charged.31. The method of wherein automatically moving the charging ram includes both automatically ...

BURN PROFILES FOR COKE OPERATIONS

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. 1. A method of controlling a horizontal heat recovery coke oven burn profile , the method comprising:charging a bed of coal into an oven chamber of a horizontal heat recovery coke oven; the oven chamber being at least partially defined by an oven floor, opposing oven doors, opposing sidewalls that extend upwardly from the oven floor between the opposing oven doors, and an oven crown positioned above the oven floor;creating a negative pressure draft on the oven chamber so that air is drawn into the oven chamber through at least one air inlet, positioned to place the oven chamber in fluid communication with an environment exterior to the horizontal heat recovery coke oven;initiating a carbonization cycle of the bed of coal such that volatile matter is released from the coal bed, mixes with the air, and at least partially combusts within the oven chamber, generating heat within the oven chamber;the negative pressure draft drawing volatile matter into at least one sole flue, beneath the oven floor; at least a portion of the volatile matter combusting within the sole flue, generating heat within the sole flue that is at least partially transferred through the oven floor to the bed of coal ...

METHODS AND SYSTEMS FOR IMPROVED COKE QUENCHING

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.

Coke plant tunnel repair and anchor distribution

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.

HORIZONTAL HEAT RECOVERY COKE OVENS HAVING MONOLITH CROWNS

The present technology is generally directed to horizontal heat recovery and non-heat recovery coke ovens having monolith crowns. In some embodiments, an HHR coke oven includes a monolith crown 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 crown comprises a thermally-volume-stable material. The crown may be an oven crown, an upcommer arch, a downcommer arch, a J-piece, a single sole flue arch or multiple sole flue arches, a downcommer cleanout, curvilinear corner sections, and/or combined portions of any of the above sections. In some embodiments, the crown is formed at least in part with a thermally-volume-stable material. In further embodiments, the crown is formed as a monolith (or several monolith segments) spanning between supports such as oven sidewalls. In various embodiments, the monolith 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 crown. 1. A coke oven chamber , comprising:an oven floor;a forward end portion and a rearward end portion opposite the forward end portion;a first sidewall extending vertically upward from the floor between the front wall and the back wall and a second sidewall opposite the first sidewall;a crown positioned above the floor and spanning from the first sidewall to the second sidewall; anda sole flue comprising a thermally-volume-stable material and having a plurality of adjacent runs between the first sidewall and the second sidewall.2. The coke oven chamber of wherein the thermally-volume-stable material comprises fused silica or zirconia.3. The coke oven chamber of wherein the sole flue includes at least one sole flue wall comprised of a plurality of sole flue wall segments.4. The coke oven chamber of wherein the sole flue wall ...

Non-perpendicular connections between coke oven uptakes and a hot common tunnel, and associated systems and methods

The present technology is generally directed to non-perpendicular connections between coke oven uptakes and a hot common tunnel, and associated systems and methods. In some embodiments, a coking system includes a coke oven and an uptake duct in fluid communication with the coke oven. The uptake duct has an uptake flow vector of exhaust gas from the coke oven. The system also includes a common tunnel in fluid communication with the uptake duct. The common tunnel has a common flow vector and can be configured to transfer the exhaust gas to a venting system. The uptake flow vector and common flow vector can meet at a non-perpendicular interface to improve mixing between the flow vectors and reduce draft loss in the common tunnel.

METHODS FOR DECARBONIZING COKING OVENS, AND ASSOCIATED SYSTEMS AND DEVICES

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. 1. A method of decarbonizing a coke oven of coking deposits , the method comprising:processing a charge of coal in the coke oven, wherein the coke oven comprises a plurality of interior surfaces including a floor, a crown, and sidewalls that extend between the floor and the crown;removing the charge from the coke oven; andremoving coking deposits from the coke oven, while removing the charge from the coke oven.2. The method of wherein removing coking deposits from the coke oven comprises scraping at least a portion of the coking deposits with a scraper operatively coupled to a pushing ram.3. The method of wherein removing coking deposits from the coke oven comprises scraping the coking deposits with a scraper having at least one rounded or beveled edge adjacent at least one interior surface of the coke oven.4. The method of wherein removing coking deposits from the coke oven comprises scraping the coking deposits with a scraper having one or more plates that substantially follow a contour of at least one of the interior surfaces of the coke oven during scraping.5. The method of claim 1 , further comprising scoring a surface of the coking deposits.6. The method of wherein removing coking deposits from the coke oven comprises running a scraper along at least one interior surface of the coke oven a single time claim 1 , whereby the scraper is ...

HIGH-QUALITY COKE PRODUCTS

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 REMOVING MERCURY FROM EMISSIONS

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.

COKE PLANT TUNNEL REPAIR AND ANCHOR DISTRIBUTION

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.

Integrated coke plant automation and optimization using advanced control and optimization techniques

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.

COKE PLANT TUNNEL REPAIR AND FLEXIBLE JOINTS

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.

EXHAUST FLOW MODIFIER, DUCT INTERSECTION INCORPORATING THE SAME, AND METHODS THEREFOR

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. 1. A duct intersection , comprising:a first duct portion;a second duct portion extending laterally from a side of the first duct portion; andat least one flow modifier disposed inside one of the first and second duct portions.2. The duct intersection according to claim 1 , wherein the flow modifier is a contoured duct liner.3. The duct intersection according to claim 2 , wherein the contoured duct liner comprises a first contoured wall mated to an inside surface of the duct and a second contoured wall mated to the first contoured wall.4. The duct intersection according to claim 3 , wherein the second contoured wall comprises a refractory material.5. The duct intersection according to claim 2 , wherein the second duct portion tees into the first duct portion.6. The duct intersection according to claim 5 , wherein the contoured duct liner is mounted inside the first duct portion.7. The duct intersection according to claim 5 , wherein the contoured duct liner is mounted inside the second duct portion.8. The duct intersection according to claim 1 , wherein the flow modifier includes at least one turning vane.9. The duct intersection according to claim 1 , wherein the flow modifier comprises molded refractory material.10. The duct intersection according to claim 1 , wherein the second duct portion extends ...

NON-PERPENDICULAR CONNECTIONS BETWEEN COKE OVEN UPTAKES AND A HOT COMMON TUNNEL, AND ASSOCIATED SYSTEMS AND METHODS

The present technology is generally directed to non-perpendicular connections between coke oven uptakes and a hot common tunnel, and associated systems and methods. In some embodiments, a coking system includes a coke oven and an uptake duct in fluid communication with the coke oven. The uptake duct has an uptake flow vector of exhaust gas from the coke oven. The system also includes a common tunnel in fluid communication with the uptake duct. The common tunnel has a common flow vector and can be configured to transfer the exhaust gas to a venting system. The uptake flow vector and common flow vector can meet at a non-perpendicular interface to improve mixing between the flow vectors and reduce draft loss in the common tunnel. 1. (canceled)2. (canceled)3. (canceled)4. (canceled)5. (canceled)6. (canceled)7. (canceled)8. (canceled)9. (canceled)10. (canceled)11. (canceled)12. (canceled)13. (canceled)14. (canceled)15. (canceled)16. (canceled)17. (canceled)18. (canceled)19. (canceled)20. (canceled)21. (canceled)22. (canceled)23. (canceled)24. (canceled)25. A coking system , comprising:a plurality of coke ovens;a plurality of uptake ducts in fluid communication with the plurality of coke ovens; each of the plurality of uptake ducts having an uptake flow vector of exhaust gas from at least one of the plurality of coke ovens; anda common tunnel having a common flow vector of exhaust gas and configured to transfer the exhaust gas to a venting system; the plurality of coke ovens, plurality of uptake ducts, and common tunnel being fluidly coupled with one another to define a negative pressure exhaust system, whereby a draft is induced within the coking system;the plurality of uptake ducts and common tunnel being fluidly coupled with one another at a plurality of interfaces; at least some of the plurality of Interfaces being non-perpendicular, wherein the uptake ducts are disposed at angles with respect to the common tunnel and bias the uptake flow vectors and common flow ...

Systems and methods for treating a surface of a coke plant

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.

METHOD AND SYSTEM FOR OPTIMIZING COKE PLANT OPERATION AND OUTPUT

The present technology is generally directed to methods of increasing coke production rates for coke ovens. In some embodiments, a coal charging system includes a false door system with a false door that is vertically oriented to maximize an amount of coal being charged into the oven. A lower extension plate associated with embodiments of the false door is selectively, automatically extended beyond a lower end portion of the false door in order to extend an effective length of the false door. In other embodiments an extension plate may be coupled with an existing false door having an angled front surface to provide the existing false door with a vertically oriented face. 1. A coal charging system , the system comprising:an elongated charging frame; anda charging head operatively coupled with the distal end portion of the elongated charging frame;an elongated false door frame having a distal end portion, proximal end portion, and opposite sides; anda generally planar false door operatively coupled with the distal end portion of the elongated false door frame; the false door having an upper edge portion, lower edge portion, opposite side portions, a front face, and a rearward face;the front face of the false door residing within a false door plane that is substantially vertical.2. The coal charging system of further comprising:a lower extension plate operatively coupled with the front face of the false door; the lower extension plate being selectively, vertically moveable with respect to the false door between retracted and extended positions; wherein at least one extended position disposes a lower edge portion of the lower extension plate below the lower edge portion of the false door such that an effective height of the false door is increased.3. The coal charging system of further comprising:a linkage arm assembly operatively coupled with the lower extension plate and at least one power cylinder that may be selectively activated to move the lower extension plate ...

COKE OVEN CHARGING SYSTEM

The present technology is generally directed to coal charging systems used with coke ovens. In some embodiments, a coal charging system includes a charging head having opposing wings that extend outwardly from the charging head, leaving an open pathway through which coal may be directed toward side edges of the coal bed. In other embodiments, an extrusion plate is positioned on a rearward face of the charging head and oriented to engage and compress coal as the coal is charged along a length of the coking oven. In other embodiments, charging plates extend outwardly from inward faces of opposing wings. 1. A coal charging system , the system comprising:an elongated charging frame having a distal end portion, proximal end portion, and opposite sides; anda charging head operatively coupled with the distal end portion of the elongated charging frame; the charging head including a planar body residing within a charging head plane and having an upper edge portion, lower edge portion, opposite side portions, a front face, and a rearward face;the charging head further including a pair of opposing wings having free end portions positioned in a spaced-apart relationship from the charging head, defining open spaces that extend from inner faces of the opposing wings through the charging head plane.2. The coal charging system of wherein the opposing wings are positioned to extend forwardly from the charging head plane.3. The coal charging system of wherein the opposing wings are positioned to extend rearwardly from the charging head plane.4. The coal charging system of further comprising:a pair of second opposing wings having free end portions positioned in a spaced-apart relationship from the charging head, defining open spaces that extend from inner faces of the opposing wings through the charging head plane;the second opposing wings extending from the charging head in a direction opposite to a direction in which the other opposing wings extend from the charging head.5. The ...

Systems and methods for treating a surface of a coke plant

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.

Methods and systems for improved quench tower design

The present technology describes methods and systems for an improved quench tower. Some embodiments improve the quench tower's 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.

HORIZONTAL HEAT RECOVERY COKE OVENS HAVING MONOLITH CROWNS

The present technology is generally directed to horizontal heat recovery coke ovens having monolith crowns. In some embodiments, an HHR coke oven includes a monolith crown 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 crown comprises a thermally volume-stable material. In various embodiments, the monolith 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 crown. 1. A coke oven chamber , comprising:a floor;a front wall extending vertically upward from the floor and a back wall opposite the front wall;a first sidewall extending vertically upward from the floor between the front wall and the back wall and a second sidewall opposite the first sidewall; anda monolith crown positioned above the floor and spanning from the first sidewall to the second sidewall.2. The coke oven chamber of wherein the monolith crown comprises a plurality of monolith portions spanning from the first sidewall to the second sidewall claim 1 , wherein the plurality of monolith portions are positioned generally adjacent to one another between the front wall and the back wall.3. The coke oven chamber of wherein: 'the monolith crown comprises a first end portion resting on the first sidewall and a second end portion opposite the first end portion and resting on the second sidewall; and', 'at least one of the monolith crown or sidewalls are configured to translate, contract, or expand by an adjustment amount upon heating or cooling the coke oven chamber;'}the first sidewall and the second sidewall have an interface area greater than the adjustment amount.4. The coke oven chamber of wherein the chamber comprises a coking chamber claim 1 , a sole flue run claim 1 , or a plurality of adjacent sole flue runs.5. ...

PARTICULATE DETECTION FOR INDUSTRIAL FACILITIES, AND ASSOCIATED SYSTEMS AND METHODS

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. 1. A particulate detection system , comprising:a separation or collection device configured to filter particulate from a stream;a detection device downstream of the separation or collection device, wherein the detection device is positioned to detect particulate that passes the separation or collection device, the detection device including a probe configured to detect the solid particles,wherein the detection device is configured to generate an action when a current associated with the detection device is outside a predetermined range.2. The system of wherein the current is a direct current claim 1 , and wherein the probe includes a wireless end portion configured to detect contact with the particulate claim 1 , thereby causing a change in the direct current.3. The system of wherein the current is a direct current claim 1 , and wherein the probe includes a wireless end portion configured to detect a collective charge associated with the particulate claim 1 , thereby causing a change in the direct current.4. The system of wherein the current is an induced current claim 1 , and wherein the probe includes a wireless end portion configured to detect a collective charge associated with the particulate claim 1 , thereby causing a change in the induced current.5. The system of claim 1 , wherein the separation or collection device and the detection device are positioned on a moveable system.6. The system of claim 5 , wherein the moveable system is ...

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. 1. A contaminant treatment system comprising: the barrel comprises one or more wall plates that at least partially form the sidewalls,', 'individual of the one or more of wall plates comprises an alloy that is resistant to corrosion caused by sulfur species, chlorine species, or both, and', 'the individual wall plates are oriented such that the alloy is in fluid communication with the interior area;, 'a barrel having sidewalls that at least partially define an interior area, wherein'}a first means for introducing flue gases having an elevated temperature into the interior area; anda second means for introducing an additive into the interior area, wherein the first and second means are configured to introduce the flue gases and the additive into the interior area such that the flue gases and the additive mix together.2. The contaminant treatment system of claim 1 , wherein the alloy comprises an Inconel alloy claim 1 , an Incoloy alloy claim 1 , a Monel alloy or a Hastelloy alloy.3. The contaminant treatment system of wherein the alloy comprises Alloy 20.4. The contaminant treatment system of claim 1 , wherein the elevated temperature is in the range of from 400° F. to 500° F.5. The contaminant treatment system of wherein the wall plates include a steel portion and wherein the alloy is cladded to the steel ...

OVEN UPTAKES

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. 1. An uptake duct configured to receive exhaust gases , comprising:a channel through which the exhaust gases are configured to pass;a first refractory surface; a damper positioned entirely within the channel, wherein—the damper is movable between a plurality of orientations to change the flow of exhaust gases through the channel; and', 'the damper remains entirely within the channel in each of the plurality of orientations., 'a second refractory surface that opposes the first refractory surface, wherein the first and second refractory surfaces at least partially define the channel;'}2. The uptake duct of claim 1 , wherein the damper is a damper plate having opposing first and second end portions claim 1 , wherein—the second end portion is spaced apart from the first refractory surface by a first distance when the damper plate is in a first of the plurality of orientations, andthe second end portion is spaced apart from the first refractory surface by a second distance less than the first distance when the damper plate is in a second of the plurality of orientations.3. The uptake duct of wherein the damper plate has a plate surface that ...

COKE PLANT TUNNEL REPAIR AND FLEXIBLE JOINTS

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. 1. A flexible seal for positioning between a replacement outer wall portion and a surrounding wall of a tunnel of a high temperature tunnel of a coke manufacturing plant , the flexible seal comprising:a pillow portion overlapping an interface between the replacement outer wall portion and the surrounding wall of the tunnel; a first end connected to the pillow portion; and', 'a second end away from the pillow portion;, 'a fill portion extending radially inward from the pillow portion between the replacement outer wall portion and the surrounding wall of the tunnel, the fill portion comprisinga first bracket contacting a first side of the pillow portion, the first bracket connected to the replacement outer wall portion;a second bracket contacting a second side of the pillow portion opposite the first side of the pillow portion, the second bracket connected to the surrounding wall of the tunnel; anda belt portion overlaying the pillow portion and connected to the first bracket and to the second bracket.2. The flexible seal of claim 1 , wherein the belt portion is connected to the first and second brackets ...

COKE PLANT TUNNEL REPAIR AND ANCHOR DISTRIBUTION

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. 1. A method of repairing a tunnel in a coke plant , the method comprising:removing a first portion of a wall of the tunnel;forming a replacement outer wall portion, the replacement wall portion having a size substantially similar to or larger than the first portion of the wall removed from the wall;connecting a plurality of anchors to the replacement outer wall portion, each anchor comprising a wall-attachment portion and an anchoring portion;connecting the replacement outer wall portion to the tunnel in place of the removed first portion of the wall;depositing a refractory material on an inner portion of the replacement outer wall portion; andsealing a perimeter of the replacement outer wall portion with respect to the tunnel;wherein:the plurality of anchors are distributed in a pattern such that a maximum spacing between the anchors is less than twelve inches.2. The method of claim 1 , wherein an area with highest anchor density is located at an uppermost portion of the replacement outer wall portion as determined when the replacement outer wall portion is connected to the tunnel in place of the ...

GASEOUS TRACER LEAK DETECTION

The present technology provides systems and methods for detecting leaks in a coke plant. In some embodiments, the present technology includes discharging a gaseous tracer adjacent to a surface that at least partially divides a high-pressure system and a low-pressure system. The gaseous tracer can be measured at a location within and/or downstream from the low-pressure system to identify leaks in the structure. 1. A method of detecting a leak in a system for coking coal , the method comprising:discharging a gaseous tracer adjacent to a structure in the system for coking coal, wherein the structure at least partially divides a high-pressure system and a low-pressure system; andafter discharging the gaseous tracer, measuring an amount of the gaseous tracer at a location within and/or downstream from the low-pressure system,wherein measuring a spike in the amount of gaseous tracer at the location within and/or downstream from the low-pressure system indicates there is a leak in the structure.2. The method of claim 1 , wherein the structure is configured to fluidly isolate the high-pressure system and the low-pressure system.3. The method of claim 1 , wherein discharging the gaseous tracer adjacent to the structure comprises discharging the gaseous tracer in the high-pressure system.4. The method of claim 1 , wherein the system for coking coal includes at least one oven and at least one sole flue chamber adjacent to the at least one oven claim 1 , and wherein the at least one oven is the high pressure system claim 1 , the at least one sole flue chamber is the low pressure system claim 1 , and the structure divides the at least one oven and the at least one sole flue chamber.5. The method of claim 1 , the system for coking coal includes at least one oven claim 1 , at least one sole flue chamber adjacent to the at least one oven claim 1 , and at least one tunnel claim 1 , and wherein the high pressure system is an environment external to the at least one oven claim 1 , the ...

DECARBONIZATION OF COKE OVENS AND ASSOCIATED SYSTEMS AND METHODS

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. 1. A method for removing clinker material from a coke oven including an oven floor and clinker material deposited on the oven floor , the method comprising:providing a coke oven including an oven floor, and clinker material deposited on the oven floor;after a temperature of the coke oven is a first temperature,increasing the temperature of the coke oven to a second temperature that is higher than the first temperature for a predetermined amount of time; andafter the predetermined amount of time, reducing the temperature of the coke oven to a third temperature that is lower than the first temperature.2. The method of claim 1 , further comprising applying an oxidizing agent to a portion of the clinker material while the temperature of the oven is the first temperature.3. The method of claim 2 , further comprising providing a lance positioned to direct the oxidizing agent toward the portion of the clinker material.4. The method of claim 3 , further comprising preheating the oxidizing directed toward the clinker material via the lance by coiling the lance to have two or more turns within the coke oven.5. The method of claim 3 , wherein the coke oven includes a crown over the oven floor and an opening in the crown claim 3 , the method further comprising inserting the lance through the opening in the crown.6. The method of claim 2 , wherein the oxidizing ...

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. 1. A heat recovery steam generator (HRSG) configured to receive flue gases , the HRSG comprising:an inlet duct positioned at a first end of the HRSG and configured to receive the flue gases;an outlet duct positioned at a second end of the HRSG, wherein the flue gases are configured to flow through the HRSG by flowing from the inlet duct to the outlet duct; and at least one economizer configured to receive liquid water at a first temperature, wherein the at least one economizer includes a plurality of economizer tubes through which the liquid water flows, wherein the flue gases flowing through the HRSG heat the liquid water within the plurality of economizer tubes from the first temperature to a second temperature greater than the first temperature;', 'at least one evaporator configured to receive the liquid water at the second temperature from the at least one economizer, wherein the at least one evaporator includes a plurality of evaporator tubes through which the liquid water flows, wherein the flue gases flowing through the HRSG heat the liquid water within the plurality of evaporator tubes until the liquid water evaporates into steam, and wherein at least a portion of individual of the plurality of evaporator tubes are cladded with an material that is resistant to corrosion at high temperatures., 'a ...

SPRING-LOADED HEAT RECOVERY OVEN SYSTEM AND METHOD

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. 1. A coke oven , comprising:an oven body;a foundation;a plurality of beams separating the oven body from the foundation;a buckstay applying force to the oven body to maintain compression on the oven body; and a restraining device;', 'an anchor coupled to the restraining device and attachable to one or more of the beams of the plurality of beams; and', 'a spring coupled to the restraining device, the spring applying force between the restraining device and the one or more beams to compress the buckstay against the oven body., 'a spring-loaded compression device including2. The coke oven of claim 1 , further comprising a connecting rod coupling the spring to the restraining device.3. The coke oven of claim 1 , wherein the beam is an I-beam claim 1 , and wherein the anchor passes through a hole in a web of the I-beam.4. The coke oven of claim 1 , wherein the beam is an I-beam claim 1 , and wherein the restraining device passes through a hole in a web of the I-beam.5. The coke oven of claim 1 , wherein the restraining device is on an inside of the buckstay.6. The coke oven of claim 5 , wherein the spring is on an outside of the ...

INTEGRATED COKE PLANT AUTOMATION AND OPTIMIZATION USING ADVANCED CONTROL AND OPTIMIZATION TECHNIQUES

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. 1. A system for integrating control of a coking oven , the system comprising:an oven chamber having controllable air openings; the oven chamber is configured to operate within a temperature profile, wherein the opening and/or closing of the air openings are controllable as manipulated variables to be responsive to optimal set-point temperature profile trajectories in the oven chamber as a controlled variable in the system;an uptake in fluid communication with the oven chamber; the uptake damper controllable as a manipulated variable to be responsive to a change in the temperature profile of the oven as a controlled variable;wherein the controlled variables and the manipulated variables control optimization of a coking rate, an energy efficiency of the system, product yield, and byproducts.2. The system of wherein the oven chamber includes a crown and sole flues and the controlled variable includes controlling temperature in the crown claim 1 , in the sole flues claim 1 , and/or draft in the crown.3. The system of wherein the oven chamber and/or the sole flue includes a push side and a coke side and wherein the controlled variable includes controlling to a temperature differential between the push side and the coke side.4. The system of wherein the air openings are at least one of a sole flue damper claim 1 , door hole damper claim 1 , or top air hole damper in the crown claim 1 , wherein the manipulated variables include opening or closing the uptake claim 1 , sole flue damper claim 1 , door hole damper or top air hole damper in ...

SYSTEMS AND METHODS FOR REMOVING MERCURY FROM EMISSIONS

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.

FOUNDRY COKE PRODUCTS, AND ASSOCIATED SYSTEMS AND METHODS

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. 1. A coke product configured to be combusted in a cupola furnace , the coke product comprising:an oblong shape including a length of at least 4″ and a width of at least 1.5″,wherein the length:width ratio of the coke product is at least 2.0.2. The coke product of claim 1 , wherein the length is between 6-12″.3. The coke product of claim 1 , wherein the width is at least 2.5″.4. The coke product of claim 1 , wherein the length is at least 10″ and the width is at least 2.5″.5. The coke product of claim 1 , wherein the coke product has a hydraulic diameter of at least 3″ claim 1 , and wherein the hydraulic diameter of the coke product is larger than an actual diameter of the coke product.6. The coke product of claim 1 , wherein the coke product has a Coke Reactivity Index (CRI) of at least 40%.7. The coke product of claim 1 , wherein the coke product has a Coke Reactivity Index (CRI) of at least 40% and a Coke Strength after Reaction (CSR) of at least 10%.8. The coke product of claim 1 , wherein the coke product has a Coke Reactivity Index (CRI) between 25-45% and a Coke Strength after Reaction (CSR) of at least 10%.9. The coke product ...

Systems and methods for improving quenched coke recovery

The present technology is generally directed to systems and methods for improving quenched coke recovery. More specifically, some embodiments are directed to systems and methods utilizing one or more of a screen, barrier, or reflector panel to contain or redirect coke during or after quenching. In a particular embodiment, a quench car system for containing coke includes a quench car having a base, a plurality of sidewalls, and a top portion. The system can further include a permeable barrier covering at least a portion of the top of the quench car, wherein the permeable barrier has a plurality of apertures therethrough.

systems and methods for mercury removal from emissions

resumo “sistemas e métodos para a remoção de mercúrio das emissões” a presente tecnologia é, em geral, dirigida aos sistemas e métodos para a remoção de mercúrio das emissões. mais especificamente, algumas formas de reali-zação são dirigidas aos sistemas e métodos para a remoção de mercúrio do gás de escape em um sistema de dessulfurização de gás de combustão. em uma forma de realização, um método para remover mercúrio do gás de escape em um sistema de dessulfurização de gás de combustão inclui inserir o gás em um alojamento e condicionar um aditivo. em algumas formas de realização, o condicionamento do aditivo compreende hidratar pó de carbono ativado. o método ainda inclui introduzir o aditivo condicionado no alojamento e capturar mercúrio do gás. abstract systems and methods for removing mercury from emissions this technology is generally addressed to systems and methods for removing mercury from emissions. more specifically, some embodiments are directed to systems and methods for removing mercury from the exhaust gas in a flue gas desulfurization system. in one embodiment, a method of removing mercury from the exhaust gas in a flue gas desulfurization system includes inserting the gas into a housing and conditioning an additive. in some embodiments, conditioning the additive comprises hydrating activated carbon powder. the method further includes introducing the conditioned additive into the housing and capturing mercury from the gas.

Horizontal heat recovery coke ovens having monolith crowns

The present technology is generally directed to horizontal heat recovery and non-heat recovery coke ovens having monolith crowns. In some embodiments, an HHR coke oven includes a monolith crown 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 crown comprises a thermally-volume-stable material. The crown may be an oven crown, an upcommer arch, a downcommer arch, a J-piece, a single sole flue arch or multiple sole flue arches, a downcommer cleanout, curvilinear corner sections, and/or combined portions of any of the above sections. In some embodiments, the crown is formed at least in part with a thermally-volume-stable material. In further embodiments, the crown is formed as a monolith (or several monolith segments) spanning between supports such as oven sidewalls. In various embodiments, the monolith 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 crown.

Coke oven charging system

Method and system for dynamically charging a coke 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.

System and method for repairing a coke oven

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.

Decarbonizatign of coke ovens, and associated systems and methods

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.

Spring-loaded heat recovery oven system and method

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.

Heat recovery oven foundation

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 METHODS TO TREAT A SURFACE OF A COKERY ROOM

sistemas e métodos para tratar uma superfície de uma coqueria. a presente tecnologia se refere a sistemas e métodos para reduzir vazamentos em um sistema para carvão de coque. por exemplo, algumas modalidades fornecem sistemas e método para tratar uma superfície rachada ou com vazamento em um sistema para carvão de coque. em particular, a presente tecnologia inclui sistemas tendo uma ou mais substâncias configuradas para reduzir um fluxo de ar através de uma ou mais rachaduras criando-se um remendo pelo menos parcialmente impermeável. a presente tecnologia inclui ainda métodos para tratar superfícies tendo uma ou mais rachaduras para reduzir um fluxo de ar através de uma ou mais rachaduras. systems and methods for treating a coke oven surface. the present technology refers to systems and methods for reducing leakage in a coking coal system. for example, some embodiments provide systems and method for treating a cracked or leaking surface in a coking coal system. in particular, the present technology includes systems having one or more substances configured to reduce an airflow through one or more cracks creating an at least partially impermeable patch. the present technology further includes methods for treating surfaces having one or more cracks to reduce airflow through one or more cracks.

Particulate detection system for use in an industrial facility and method for detecting particulate matter in an industrial gas facility

DETECÇÃO DE PARTICULADO PARA INSTALAÇÕES INDUSTRIAIS, E SISTEMAS E MÉTODOS ASSOCIADOS. Os sistemas e os métodos para a detecção de vazamento de partículas, em geral, incluem um dispositivo de separação ou coleta configurado para filtrar o particulado de um fluxo e um dispositivo de detecção a jusante do dispositivo de separação ou coleta. O dispositivo de detecção pode ser posicionado para detectar o particulado que passa pelo dispositivo de separação ou coleta e pode incluir uma sonda configurada para detectar as particulado sólidas. Os sistemas de detecção de vazamento de partículas podem ser configurados para serem dispostos sobre sistemas móveis, como os sistemas móveis em operações de forno de coque. PARTICULATE DETECTION FOR INDUSTRIAL INSTALLATIONS, AND ASSOCIATED SYSTEMS AND METHODS. Systems and methods for detecting particulate leakage generally include a separation or collection device configured to filter particulate matter from a stream and a detection device downstream of the separation or collection device. The detection device may be positioned to detect particulate matter passing through the separation or collection device and may include a probe configured to detect solid particulates. Particle leak detection systems can be configured to be placed on top of mobile systems, such as mobile systems in coke oven operations.

METHODS AND SYSTEMS TO PROVIDE CORROSION RESISTANT SURFACES IN CONTAMINANT TREATMENT SYSTEMS

métodos e sistemas para fornecer superfícies resistentes a corrosão em sistemas de tratamento de contaminantes. sistemas e aparelhos para neutralizar compostos ácidos em gases de combustão emitidos por um forno de coque com recuperação de calor. um sistema representativo inclui um absorvedor de secagem por aspersão tendo um cilindro que inclui uma pluralidade de placas de parede que formam as paredes laterais do cilindro. as placas de parede incluem uma placa de aço e uma liga resistente à corrosão revestida sobre a placa de aço e as placas de parede são orientadas de modo que a liga resistente à corrosão esteja voltada e em comunicação de fluido com uma área interna do cilindro. a liga é resistente à corrosão causada por compostos ácidos no gás de combustão e pode evitar que a placa de aço seja corroída por esses compostos ácidos. methods and systems for providing corrosion resistant surfaces in contaminant treatment systems. systems and apparatus for neutralizing acidic compounds in flue gases emitted by a heat recovery coke oven. a representative system includes a spray-drying absorber having a cylinder that includes a plurality of wall plates that form the side walls of the cylinder. the wall plates include a steel plate and a corrosion resistant alloy coated over the steel plate and the wall plates are oriented so that the corrosion resistant alloy is facing and in fluid communication with an internal area of the cylinder. The alloy is resistant to corrosion caused by acidic compounds in the flue gas and can prevent the steel plate from being corroded by these acidic compounds.

System and method for repairing a coke oven

RESUMEN Un sistema y método para reparar un horno de coque que tiene una cámara de horno formada a partir de ladrillos cerámicos. Un sistema representativo incluye un recinto aislado insertable en la cámara del horno e incluye paneles aislantes extraíbles que definen un área interior para que los trabajadores trabajen. El recinto aislado se puede mover entre una configuración expandida y una configuración compacta, y mover el gabinete a la configuración expandida disminuirá la distancia entre el recinto aislado y las paredes de la cámara del horno. Quitar los paneles expone los ladrillos de cerámica y permite que los trabajadores dentro del área interior accedan a los ladrillos y reparen la cámara del horno mientras la cámara del horno aún está caliente. Un aparato de carga eleva e inserta el recinto aislado en la cámara del horno. El recinto aislado se puede acoplar a recintos aislados adicionales para formar un área interior alargada. SUMMARY A system and method for repairing a coke oven that has a kiln chamber formed from ceramic bricks. A representative system includes an insulated enclosure insertable into the oven chamber and includes removable insulating panels that define an interior area for workers to work. The insulated enclosure can be moved between an expanded configuration and a compact configuration, and moving the cabinet to the expanded configuration will decrease the distance between the insulated enclosure and the oven chamber walls. Removing the panels exposes the ceramic bricks and allows workers inside the interior area to access the bricks and repair the kiln chamber while the kiln 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.

COOLING CAR SYSTEM, COKE COOLING SYSTEM AND ASSOCIATED CAR

SISTEMA E MÉTODOS PARA A RECUPERAÇÃO DE COQUE RESFRIADO. Trata-se de uma tecnologia geralmente direcionada a sistemas para aperfeiçoar a recuperação de coque resfriado. Especificamente, algumas modalidades são direcionadas a sistemas e métodos que utilizam uma ou mais de uma tela, barreira, painel refletor para conter ou redirecionar coque durante ou após o resfriamento. Em uma modalidade especifíco, um sistema de carro de resfriamento para conter coque inclui um carro de resfriamento que tem uma base, uma série de paredes laterais e uma parte superior. O sistema tema pode também incluir uma barreira permeável que cobre uma parte superior do carro de resfriamento, em que a barreira permeável é dotada de uma sérir de aberturas através da mesma. SYSTEM AND METHODS FOR COLD COKE RECOVERY. It is a technology generally directed at systems to improve the recovery of chilled coke. Specifically, some modalities are directed to systems and methods that use one or more of a screen, barrier, reflective panel to contain or redirect coke during or after cooling. In a specific embodiment, a cooling cart system for containing coke includes a cooling cart that has a base, a series of side walls and an upper part. The theme system may also include a permeable barrier that covers an upper part of the cooling car, in which the permeable barrier is provided with a series of openings through it.

Coke oven charging system

The present technology is generally directed to coal charging systems used with coke ovens. In some embodiments, a coal charging system includes a charging head having opposing wings that extend outwardly from the charging head, leaving an open pathway through which coal may be directed toward side edges of the coal bed. In other embodiments, an extrusion plate is positioned on a rearward face of the charging head and oriented to engage and compress coal as the coal is charged along a length of the coking oven. In other embodiments, charging plates extend outwardly from inward faces of opposing wings.

Non-perpendicular connections between coke oven uptakes and a hot common tunnel, and associated systems and methods

The present technology is generally directed to non-perpendicular connections between coke oven uptakes and a hot common tunnel, and associated systems and methods. In some embodiments, a coking system includes a coke oven and an uptake duct in fluid communication with the coke oven. The uptake duct has an uptake flow vector of exhaust gas from the coke oven. The system also includes a common tunnel in fluid communication with the uptake duct. The common tunnel has a common flow vector and can be configured to transfer the exhaust gas to a venting system. The uptake flow vector and common flow vector can meet at a non-perpendicular interface to improve mixing between the flow vectors and reduce draft loss in the common tunnel.

Method and system for optimizing coke plant operation and output

The present technology is generally directed to methods of increasing coke production rates for coke ovens. In some embodiments, a coal charging system includes a false door system with a false door that is vertically oriented to maximize an amount of coal being charged into the oven. A lower extension plate associated with embodiments of the false door is selectively, automatically extended beyond a lower end portion of the false door in order to extend an effective length of the false door. In other embodiments an extension plate may be coupled with an existing false door having an angled front surface to provide the existing false door with a vertically oriented face.

Improved burn temperature profiles for coke operations through various drafts

La presente tecnología se refiere en general a sistemas y métodos para la optimización de perfiles de quema para hornos de coque, tales como hornos de recuperación de calor horizontal. En diversas formas de realización, el perfil de quema se optimiza al menos parcialmente mediante el control de la distribución de aire en el horno de coque. En algunas formas de realización, la distribución de aire se controla de acuerdo con las lecturas de temperatura en el horno de coque. En formas de realización particulares, el sistema controla la temperatura de la copa del horno de coque. Después de que la copa alcance un rango de temperatura particular, el flujo de materia volátil se transfiere a la chimenea única para aumentar las temperaturas de la chimenea única a lo largo del ciclo de coquización. Las formas de realización de la presente tecnología incluyen un sistema de distribución de aire que tiene una pluralidad de entradas de aire de la copa ubicadas por encima del piso del horno. The present technology relates generally to systems and methods for optimizing burn profiles for coke ovens, such as horizontal heat recovery ovens. In various embodiments, the burn profile is at least partially optimized by controlling the air distribution in the coke oven. In some embodiments, the air distribution is controlled according to the temperature readings in the coke oven. In particular embodiments, the system controls the temperature of the coke oven cup. After the cup reaches a particular temperature range, the flow of volatile matter is transferred to the single stack to increase the single stack temperatures throughout the coking cycle. Embodiments of the present technology include an air distribution system having a plurality of cup air inlets located above the oven floor.

Horizontal heat recovery coke ovens having monolith crowns

The present technology is generally directed to horizontal heat recovery coke ovens having monolith crowns. In some embodiments, an HHR coke oven includes a monolith crown 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 crown comprises a thermally volume-stable material. In various embodiments, the monolith 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 crown.

Methods and systems for improved coke quenching

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.

Horizontal heat recovery coke ovens having monolith crowns

The present technology is generally directed to horizontal heat recovery and non-heat recovery coke ovens having monolith crowns. In some embodiments, an HHR coke oven includes a monolith crown 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 crown comprises a thermally-volume-stable material. The crown may be an oven crown, an upcommer arch, a downcommer arch, a J-piece, a single sole flue arch or multiple sole flue arches, a downcommer cleanout, curvilinear corner sections, and/or combined portions of any of the above sections. In some embodiments, the crown is formed at least in part with a thermally-volume-stable material. In further embodiments, the crown is formed as a monolith (or several monolith segments) spanning between supports such as oven sidewalls. In various embodiments, the monolith 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 crown.

Improved burn profiles for coke operations

Decarbonization of coke ovens, and associated systems and methods

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.

Method and system for optimizing coke plant operation and output

The present technology is generally directed to methods of increasing coal processing rates for coke ovens. In various embodiments, the present technology is applied to methods of coking relatively small coal charges over relatively short time periods, resulting in an increase in coal processing rate. In some embodiments, a coal charging system includes a charging head having opposing wings that extend outwardly and forwardly from the charging head, leaving an open pathway through which coal may be directed toward side edges of the coal bed. In other embodiments, an extrusion plate is positioned on a rearward face of the charging head and oriented to engage and compress coal as the coal is charged along a length of the coking oven. In other embodiments, a false door system includes a false door that is vertically oriented to maximize an amount of coal being charged into the oven.

Coke quench tower

Methods and systems for automatically generating a remedial action in an industrial facility

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.

Method and system for dynamically charging a coke 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.

Method and system for optimizing coke plant operation and output

The present technology is generally directed to methods of increasing coke production rates for coke ovens. In some embodiments, a coal charging system includes a false door system with a false door that is vertically oriented to maximize an amount of coal being charged into the oven. A lower extension plate associated with embodiments of the false door is selectively, automatically extended beyond a lower end portion of the false door in order to extend an effective length of the false door. In other embodiments an extension plate may be coupled with an existing false door having an angled front surface to provide the existing false door with a vertically oriented face.

Heat recovery oven foundation

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.

Spring-loaded heat recovery oven system and method

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.

Improved burn profiles for coke operations

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.

Method and system for optimizing coke plant operation and output

The present technology is generally directed to methods of increasing coke production rates for coke ovens. In some embodiments, a coal charging system includes a false door system with a false door that is vertically oriented to maximize an amount of coal being charged into the oven. A lower extension plate associated with embodiments of the false door is selectively, automatically extended beyond a lower end portion of the false door in order to extend an effective length of the false door. In other embodiments an extension plate may be coupled with an existing false door having an angled front surface to provide the existing false door with a vertically oriented face.

Coke oven charging system

The present technology is generally directed to coal charging systems used with coke ovens. In some embodiments, a coal charging system includes a charging head having opposing wings that extend outwardly from the charging head, leaving an open pathway through which coal may be directed toward side edges of the coal bed. In other embodiments, an extrusion plate is positioned on a rearward face of the charging head and oriented to engage and compress coal as the coal is charged along a length of the coking oven. In other embodiments, charging plates extend outwardly from inward faces of opposing wings.

Method and system for optimizing coke plant operation and output

The present technology is generally directed to methods of increasing coke production rates for coke ovens. In some embodiments, a coal charging system includes a false door system with a false door that is vertically oriented to maximize an amount of coal being charged into the oven. A lower extension plate associated with embodiments of the false door is selectively, automatically extended beyond a lower end portion of the false door in order to extend an effective length of the false door. In other embodiments an extension plate may be coupled with an existing false door having an angled front surface to provide the existing false door with a vertically oriented face.

Methods and systems for automatically generating a remedial action in an industrial facility

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.

Method and system for optimizing coke plant operation and output

The present technology is generally directed to methods of increasing coke production rates for coke ovens. In some embodiments, a coal charging system includes a false door system with a false door that is vertically oriented to maximize an amount of coal being charged into the oven. A lower extension plate associated with embodiments of the false door is selectively, automatically extended beyond a lower end portion of the false door in order to extend an effective length of the false door. In other embodiments an extension plate may be coupled with an existing false door having an angled front surface to provide the existing false door with a vertically oriented face.

System and method for repairing a coke oven

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.

Method and system for dynamically charging a coke 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 methods for removing mercury from emissions

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.

Exhaust flow modifier, duct intersection incorporating the same, and methods therefor

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.