Patent Application
20240400902
The present invention relates to coke ovens, and more particularly, to a cross over duct that connects flues of different heating walls to regulate the temperature and exhaust gases therein.
Coke is typically produced by heating coal in a coke oven battery. This battery may have anywhere from 40 to over 100 side-by-side coking chambers or ovens separated from each other by heating walls. Gas is burned within the walls to heat the coal arranged in the ovens. The floor bricks of each oven rest upon corbels. Below the corbels is an area called the regenerator. The regenerator is filled with bricks that have a relatively large amount of surface area per volume, generally due to slots formed in the bricks. In the regenerator, exhaust waste heat is used to pre-heat incoming air as well as cool the exhaust waste heat prior to discharge. The slotted bricks are called checker bricks, and they facilitate the heat transfer from the exhaust waste heat to the combustion materials. The regenerator supports the corbels. In turn, the corbels support the coke oven floor bricks and the heating walls. The heating walls, floor bricks, and corbels have traditionally been made of silica brick.
Coal is crushed and blended prior to being charged in a coke oven. A larry car charges the individual oven with the blended coal. In the coke oven, the coal is heated to 1,800° F. for up to 18 hours-thus the importance of the regenerator to conserve heat. During that time, the volatiles of the coal are driven into the offgas (removed), and a pure carbon form called “coke” remains.
However, current coke oven battery designs only circulate and/or vent exhaust gases within the specific flue of the heating wall. Specifically, exhaust gases are forced out of the flue, down through the corbel, and into the regenerator. Such designs do not allow for optimal air flow within the heating wall, specifically the flue, and lead to undesirable heating characteristics (i.e., loss of heat, increased fluid pressure within the flue, etc.).
Thus, there is a long felt need for a cross over duct that connects the flues of two different heating walls of a coke oven and improves air and gas flow therein.
There is another long felt need for a cross over duct that connects the flues of two different heating walls of a coke oven thereby decreasing and/or eliminating: excessive loss of heat therein; excessive fluid, and/or gas, pressure therein; and potential leak points created at seams between components of the flues-preserving the structural integrity of the flues over a longer period of time and saving potential repair costs.
There is a further long felt need for a cross over duct that connects the flues of two different heating walls of a coke oven, improves air and gas flow therein, provides for an oven ceiling of a coke oven therebelow, and at least partially provides for a portion of a coke oven battery top.
The present invention is generally arranged in a coke oven having a first heating wall and a second heating wall, where the present invention generally comprises a cross over duct arranged to fluidly connect the first heating wall and the second heating wall of the coke oven. The cross over duct may further comprise a passageway in communication with the first heating wall and the second heating wall.
In some embodiments, the present invention may generally comprise a coke oven battery, the coke oven battery including an oven floor, a first heating wall including a first flue, a second heating wall including a second flue, the second heating wall spaced apart from the first heating wall forming a coke oven therebetween, and a cross over duct, the cross over duct comprising a passageway having a passageway disposed therein, a first aperture open to the passageway, and a second aperture open to the passageway, where the first aperture is in communication with the first flue and the second aperture is in communication with the second flue. The cross over duct may further comprise a first section having a channel disposed therein, the first aperture disposed within the first section, the first aperture open to the channel and a third aperture open to the channel, and a second section having a channel disposed therein, the second aperture disposed within the second section, the second aperture open to the channel of the second section and a fourth aperture open to the channel of the second section, wherein the first channel of the first section and the second channel of the second section form the passageway.
In other embodiments, the present invention may be generally arranged in a coke oven having a first heating wall and a second heating wall, where the present invention may generally comprise a cross over duct arranged to fluidly connect the first heating wall and the second heating wall, the cross over duct comprising a first section having an external surface and an internal surface, the first section having a channel disposed therein, the channel terminated by a first aperture disposed on the internal surface and a second aperture disposed on the internal surface, and a second section having an external surface and an internal surface, the second section having a channel disposed therein, the channel terminated by a first aperture disposed on the internal surface and a second aperture disposed on the internal surface, where the channel of the first section and the channel of the second section form a passageway, the passageway in fluid communication with the first heating wall and the second heating wall.
These and other objects, features, and advantages of the present invention will become readily apparent upon a review of the following detailed description of the invention, in view of the drawings and appended claims.
Various embodiments are disclosed, by way of example only, with reference to the accompanying schematic drawings in which corresponding reference symbols indicate corresponding parts, in which:
At the outset, it should be appreciated that like drawing numbers on different drawing views identify identical, or functionally similar, structural elements. It is to be understood that the claims are not limited to the disclosed aspects.
Furthermore, it is understood that this disclosure is not limited to the particular methodology, materials and modifications described and as such may, of course, vary. It is also understood that the terminology used herein is for the purpose of describing particular aspects only and is not intended to limit the scope of the claims.
Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood to one of ordinary skill in the art to which this invention pertains. It should be understood that any methods, devices or materials similar or equivalent to those described herein can be used in the practice or testing of the example embodiments.
It should be appreciated that the term “substantially” is synonymous with terms such as “nearly,” “very nearly,” “about,” “approximately,” “around,” “bordering on,” “close to,” “essentially,” “in the neighborhood of,” “in the vicinity of,” etc., and such terms may be used interchangeably as appearing in the specification and claims. It should be appreciated that the term “proximate” is synonymous with terms such as “nearby,” “close,” “adjacent,” “neighboring,” “immediate,” “adjoining,” etc., and such terms may be used interchangeably as appearing in the specification and claims. The term “approximately” is intended to mean values within ten percent of the specified value.
It should be understood that use of “or” in the present application is with respect to a “non-exclusive” arrangement, unless stated otherwise. For example, when saying that “item x is A or B,” it is understood that this can mean one of the following: (1) item x is only one or the other of A and B; (2) item x is both A and B. Alternately stated, the word “or” is not used to define an “exclusive or” arrangement. For example, an “exclusive or” arrangement for the statement “item x is A or B” would require that x can be only one of A and B. Furthermore, as used herein, “and/or” is intended to mean a grammatical conjunction used to indicate that one or more of the elements or conditions recited may be included or occur. For example, a device comprising a first element, a second element and/or a third element, is intended to be construed as any one of the following structural arrangements: a device comprising a first element; a device comprising a second element; a device comprising a third element; a device comprising a first element and a second element; a device comprising a first element and a third element; a device comprising a first element, a second element and a third element; or, a device comprising a second element and a third element.
Moreover, as used herein, the phrases “comprises at least one of” and “comprising at least one of” in combination with a system or element is intended to mean that the system or element includes one or more of the elements listed after the phrase. For example, a device comprising at least one of: a first element; a second element; and, a third element, is intended to be construed as any one of the following structural arrangements: a device comprising a first element; a device comprising a second element; a device comprising a third element; a device comprising a first element and a second element; a device comprising a first element and a third element; a device comprising a first element, a second element and a third element; or, a device comprising a second element and a third element. A similar interpretation is intended when the phrase “used in at least one of:” is used herein.
As used herein, “vent” is meant to mean an opening that allows fluid to pass out of or into a confined space, such as a duct. The term “fluid” includes gas.
As also used herein, “fluid communication”, “communication”, and/or substantial equivalents thereof, is meant to mean two or more components are connected such that a substance, e.g., gases, fluid, etc., can flow between and/or within the two components. “Fluid communication”, “communication”, and/or equivalents thereof, is also intend to include heat transfer between two or more components.
Referring now to the figures, the following description should be taken in consideration of
Regenerator 20 comprises a plurality of piers or pillars 22, which are spaced apart to form regenerator regions 24. In some embodiments, each of pillars 22 comprises a plurality of bricks or blocks. Pillars 20 support corbels 40. In some embodiments, each of corbels 40 comprises a plurality of blocks. In some embodiments, corbels 40 comprise a plurality of blocks arranged in a plurality of tiers.
Corbels 40 are arranged on top of pillars 20 and support the oven section of coke oven battery 10. Specifically, corbels 40 support floor 28, heating walls 30A-D, and coal placed in ovens 34, allow air to flow between flues 32A-D and regenerator 20, and/or allow gas to be injected into flues 32A-D. For example, gas or fuel is injected into corbels 40 horizontally via through-bore 42 and flows vertically through holes 46 and into flues 32A-D. Air flows up through holes 48 and into flues 32A-D where it mixes with the fuel and combusts to heat heating walls 30A-D, respectively, thus cooking coal 300 arranged in ovens 34 transforming it into coke (Coal 300 shown in the drawing is merely representative. In practice, the coal is crushed and blended prior to being charged in the coke oven.) Exhaust gasses are created from such combustion, these hot exhaust gases may flow down through holes 48 and into regenerator regions 24, thereby preheating the incoming gas and/or air. Preheating gas and/or air as it flows into flues prior to combustion is desirable because it produces more efficient vaporization and higher combustion efficiency than cold fuel. In some embodiments, coke oven battery 10 further comprises shut-off means (not illustrated) operatively arranged to selectively shut off the gas flow through one or more holes 42. The shut-off means (e.g., valves) allow the operator to control the temperature in each flue 32A-D and thus ovens 34. In some embodiments, and as shown, coke oven battery 10 further comprises one or more cross over ducts 100 operatively arranged to facilitate the transfer of gases between the flues of the heating walls, as will be described in greater detail, infra.
Floor 28 is arranged on and/or engaged with corbels 40. Floor 28 is operatively arranged to support coal 300 in ovens 34. In some embodiments, floor 28 comprises a plurality of blocks. In some embodiments, floor 28 comprises a plurality of blocks arranged in a plurality of tiers. Heating walls 30A-D are arranged on corbels 40 and/or floor 28 and comprise flues 32A-D arranged therein, respectively. (Heating walls 30A-D are comprised of bricks, blocks and/or modules.) Flues 32A-D are in fluid communication with holes 46 and holes 48. Oven ceiling or ceilings 36 are arranged proximate the, or on, top of heating walls 30A-D. Thus, ovens 34 are formed by floor 28, heating walls 30A-D, and oven ceiling 36. Battery top 38, or ceiling, is typically arranged on top of heating walls 30 (typically a separate component of coke oven battery, but integral with cross over duct 100, as shown in
Generally, cross over duct 100 (and cross over duct 200) provide for a transfer of gases, heat, fuel, etc., between two heating walls of coke oven battery 10—generally depicted as arrows A1 and A2, illustrating the aforementioned transfer between heating walls 30A and 30B, specifically flues 32A and 32B, i.e., cross over duct 100 fluidly connects two heating walls. It should be noted that these heating walls are typically isolated, i.e., not in fluid communication.
The following description should be taken in view of
Cross over duct 100 may comprise two sections, 110 and 150, which collectively form cross over duct 100. Section 110 has channel 120 therein, terminated by apertures 111 and 112. Section 150 has channel 160 therein, terminated by apertures 151 and 152. When section 110 is connected to section 150, aperture 112 of section 110 joins aperture 152 of section 150 to form a fluid connection between channel 120 and channel 160. When channel 120 and channel 160 are in fluid connection, passageway 107 is formed.
Section 110 and section 150 may be connected via any suitable means, for example, adhesives, mortar, interference or press fit, bolts, rods, etc., to form duct 100.
Although duct 100 is generally illustrated as having sections 110 and 150, collectively forming duct 100, it should be appreciated that duct 100 may be alternatively configured as a singular piece.
It should be appreciated that distal end 102 of cross over duct 100 also provides for oven ceiling 36 of oven 34 (as shown in
In some configurations of cross over duct 100, proximal surface 101 may include at least one aperture disposed therein, where that aperture is in fluid communication with passageway 107—providing for an inspection access to passageway 107 from proximal surface 101 (or battery top 38). In other configurations, cross over duct 100 may include at least aperture disposed within proximal surface 101 and within section 110, where that aperture is in fluid communication with channel 120—providing for an inspection access to channel 120 from proximal surface 101 (or battery top 38) within section 110 of duct 100. In further configurations, cross over duct 100 may include at least aperture disposed within proximal surface 101 and within section 150, where that aperture is in fluid communication with channel 160—providing for an inspection access to channel 160 from proximal surface 101 (or battery top 38) within section 150 of duct 100. This inspection access, or aperture, could be configured with a seal, shelf to removably accept an inspection plate, or the like, to close off the access to passageway 107, channel 110, and/or channel 150.
The following description should be taken in consideration of the aforementioned figures,
Channel 120 of section 110 generally comprises three sections: distal section 120a, medial section 120b, and proximal section 120c. In some configurations, distal section 120a and proximal section 120c have a substantially linear configuration whereas medial section 120b has a substantially curvilinear configuration. Channel 160 of section 150 generally comprises three sections: distal section 160a, medial section 160b, and proximal section 160c. In some configurations, distal section 160a and proximal section 160c have a substantially linear configuration whereas medial section 160b has a substantially curvilinear configuration. This configuration of channels 120 and 150 (or passageway 107 when sections 110 and 150 are connected) is preferably to encourage efficient and proper flow of gases, heat, waste, particulate matter, or a combination thereof.
In order to create a more secure fit between section 110 and section 150, section 110 includes protruding section 130 and section 150 includes recessed section 170. When joined, combined, connection, protruding section 130 is arranged to be substantially seated, or at least partially within, recessed section 170 of section 150. This arrangement also decreases and/or eliminates excessive movement in directions D1 through D4. Additionally, this arrangement also prevents the creation of a straight joint, or seam, when sections 110 and 150 are connected—25 thereby decreasing the potential for leak points within the seam over an extended operational period.
Sections 110 and 150 may be connected via any suitable means, for example, adhesives, mortar, interference or press fit, bolts, rods, etc., to form cross over duct 100.
As best shown in
The following description should be taken in view of the aforementioned figures,
Duct 200 includes all of the components of duct 100, with the exception of apertures 111 and 151 of sections 110 and 150, respectively. Section 110 of duct 200 includes apertures 111a and 111b, and section 150 of duct 200 includes apertures 151a and 151b. Aperture 111a and 111b are separated by bifurcating section 202 and apertures 151a and 151b are separated by bifurcating section 204. Aperture 111a includes lips 210 and 211, which extend from an internal surface of aperture 111a. Aperture 111b includes lips 212 and 213, which extend from an internal surface of aperture 111b. Aperture 151a includes lips 214 and 215, which extend from an internal surface of aperture 151a. Aperture 151b includes lips 216 and 217, which extend from an internal surface of aperture 151b. Apertures 111a and 111b are in fluid communication with channel 120 of first section 110 of duct 200. Apertures 151a and 151b are in fluid communication with channel 160 of second section 150 of duct 200. The respective pair of lips corresponding to apertures 111a, 111b, 151a and 151b, allow for a plate, brick, block to be placed thereon. As shown in
Thus, cross over duct 200 forms three purposes: as generally illustrated by duct 100 in
It should be appreciated that the cross over duct of the present invention must be composed of a material composition that can withstand at least 1,800° F. without deformation or deterioration. It should be further appreciated that the cross over duct of the present invention is composed of a material composition that can withstand the aforementioned temperature minimum during daily operation of the coke oven battery for a minimum of 20 years.
It will be appreciated that various aspects of the disclosure above and other features and functions, or alternatives thereof, may be desirably combined into many other different systems or applications. Various presently unforeseen or unanticipated alternatives, modifications, variations, or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the following claims.
This application claims the benefit under Articles 4 and 8 of the Stockholm Act of the Paris Convention for the Protection of Industrial Property of U.S. Provisional Patent Application No. 63/262,568, filed on Oct. 15, 2021, which application is hereby incorporated by reference herein in its entirety.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/US2022/078138 | 10/14/2022 | WO |
| Number | Date | Country | |
|---|---|---|---|
| 63262568 | Oct 2021 | US |
