The present invention relates to a device for measuring a shape of a wall portion of a coke oven.
The present invention also relates to an installation comprising an oven and such a device, as well as to a method of measuring a shape of a wall portion of a coke oven.
The invention also relates to a method for scanning the entire left and right walls of the oven through an opening of the oven.
Coke ovens are used to produce coke from charcoal in iron and steel industry. They are constituted by alternatively disposing coking chambers and combustion chambers separated by oven walls made of bricks. A coking chamber has a parallelepiped shape, usually between 3.5 and 8 meters high, between 12 and 20 meters deep along a horizontal direction, and between 0.35 and 0.7 meter wide. They usually comprise two opposite doors respectively at both ends along the horizontal direction.
The coking process involves carbonization of coal to high temperatures, above 1000° C., in an oxygen deficient atmosphere in order to concentrate the carbon. Coal is charged from a coal charging hole at a top portion of the coking chamber. Then, a high temperature of 1000° C. or more is applied to the coal inside the coking chamber for approximately 20 hours. Coal is thereby coked (carbonized), and coke cake (hereinafter, referred to as just “coke”) is produced. When the coke is produced, doors disposed at both ends of the coking chamber are opened, the coke is pushed by a pusher from a lateral side of the coking chamber, and the coke is taken out of the coking chamber.
Apart from high temperatures, the coking process also generates a lot of dust, soot and steam.
When coal is transformed into coke, it exerts a high pressure onto the bricks of the oven wall which can then be deformed. These deformations of the oven walls may induce issues for pushing the coke out of the chamber and then increase damages of the oven walls. Moreover, the bricks are exposed to high temperature variations between oven loading and unloading and thermal shocks may occur, which also causes damages to the walls.
All these damages eventually alter the shape of the walls and impact the productivity of the coking plant by inducing issues during coal charging or coke pushing.
Measurements of the wall shape are performed after unloading and before the following loading. The wall temperature is typically in a 900° C. to 1000° C. range.
For this reason, there has been a need for monitoring the conditions of coke ovens, in particular in order to check whether the walls shape is not altered.
In the past, this was performed through visual inspection, but it involved a lot of safety risks for operators and was not very accurate.
Document JP2014-218557 describes using a 3D laser to assess the shape of the chamber wall. The laser is placed on a first location in front of a first door of the coking chamber so as to scan a portion of the left wall of the chamber. Then it is moved to a second location so as to scan a portion of the right wall of the chamber.
Besides, 3D laser scanners have been used in some other technical fields in order to measure three dimensional shapes. However, such scanners have been considered unfit for use within a coking plant, because they cannot withstand the hot, dusty and humid environment nearby running coke ovens.
An object of the invention is to provide a device adapted for measuring a shape of a wall portion of an idle coke oven, and adapted for use nearby a running coke oven.
The present invention provides a device for measuring a shape of a wall portion of a coke oven, the device comprising:
In other embodiments, the device may comprise one or several of the following features, taken in isolation or any technical feasible combination:
The invention also provides an installation comprising a coke oven, and a device for measuring a shape of a wall portion as described above.
The invention further provides a method of measuring a shape of at least part of a chamber of a coke oven, the chamber having a left wall and a right wall opposed along the transverse direction of the oven, the method comprising at least the following steps:
Other features and advantages of the invention will appear upon reading the following description, given by way of example and with reference to the accompanying drawings, in which:
With reference to
The installation 1 comprises a coke oven 5 and a device 10 for measuring a shape of a wall portion 12 of the oven.
The oven 5 extends along a longitudinal direction L, for example approximately horizontal. The oven 5 defines a coking chamber 14 and has at least one door 16 facing the device 10 along the longitudinal direction L.
The door 16 defines an opening of the oven 5 and is intended to be open when the device 10 is running.
As also shown in
For example L1 ranges between 12 and 20 meters.
For example H1 is up to 2 meter.
For example H2 ranges between 3.5 and 8 meters.
For example W1 ranges between 0.35 and 0.7 meter.
The wall 12 is for example substantially vertical and designed to be planar.
The wall portion is advantageously a two-dimensional surface.
The device 10 is adapted for measuring a shape of a portion of the wall 12, in order to advantageously detect whether the shape is locally concave or convex towards the interior of the coking chamber 14.
The device 10 is intended to be positioned outside the oven 5. Since the oven 5 may still have a high level of residual heat, this allows avoiding overly complex and expensive cooling members in the device 10.
As best seen in
The base 22 is advantageously adapted to roll on the ground 18.
The base 22 includes a computer 29, a control unit 30 with one or several control screens, a source of compressed air 32, and a power source 34. The base 22 is advantageously equipped with one or several cooling fans having dust filters.
The base 22 and the spacer 24 are advantageously covered with a protective mat, notably on sides facing the oven 5. For example the mat comprises an aluminized glass fabric or any insulating material.
The power source 34 advantageously allows the device 10 being autonomous in terms of power supply. The power source 34 is for example an inverter. The source of compressed air 32 is for example a cylinder.
The computer 29 is suitable for monitoring the 3D laser scanners 21A, 21B.
Advantageously, the computer 29 includes one or several dedicated software(s) for analyzing the measurements performed by the 3D laser scanners 21A, 21B and for producing a report.
With reference to
When the closing system 40 is in the closed position, the interior of the box 20 is protected against dust, and from water projections from all directions.
The opening 44 in the front face 37 extends along the vertical direction V and along the transverse direction T. For example, the opening 44 has a planar, advantageously rectangular, shape. The opening 44 is advantageously parallel to the transverse direction T and for examples defines an angle α with the vertical direction V ranging between 45° and 80° (
The closing system 40 comprises a cover 46 rotatably mounted on the main part 38 around an axis R (
The closing system 40 advantageously includes a seal in fluoroelastomer installed between the cover 46 and the main part 38. Fluoroelastomer is a fluorocarbon-based synthetic rubber able to withstand a range of temperatures from −20° C. to 200° C.
As a variant, the seal includes a coating adapted for conducting heat towards the rear of the device 10, and for reflecting thermal radiations 4 from the oven 5.
By “adapted to reflect thermal radiations from the oven”, in the present application, it is meant that the 3D laser scanners are protected from the thermal radiations emitted by the oven 5. The axis R is for example approximately parallel to the transverse direction T.
The cover 46 advantageously includes an upper flap 50 (
The cover 46 advantageously includes an external protective panel 52 adapted to reflect thermal radiations 4 coming from the oven 5 when the closing system 40 is in the closed position.
In one embodiment the cover 46 is adapted to be manually moved in order to move the closing system 40 from the closed position to the open position, and vice versa. To that end the cover 46 advantageously comprises handles 54 and fasteners 56, for example hook clamps. In another embodiment the cover 46 is automatically controlled.
The protective panel 52 is for example made of reflective metal, such as stainless steel, polished stainless steel, aluminum or polished aluminum and may contain an insulating material such as ceramic fiber. The external protective panel 52 is advantageously spaced apart from the rest of the cover 46, as best seen on
The main part 38 of the box 20 has a rear face 58 (
In a particular embodiment, two fans 62 are fixed to the rear face 58 and adapted to blow or extract air on the fins 60 to increase the cooling.
The main part 38 also has a bottom wall 64, for example substantially flat, and advantageously forming a connection interface for mechanically connecting the box 20 and the spacer 24. The main part 38 has an upper wall 65.
The main part 38 comprises a beam 68 (
The main part 38 comprises two scanner adapters 72 fixed to the platform 70 and respectively serving as bases for the 3D laser scanners 21A, 21B.
The main part 38 comprises an acquisition module 74 (
The main part 38 advantageously includes a position detector 76 (
The device 10 also includes an internal protective screen 80 adapted to reflect at least 80% of the energy of the thermal radiations 4 coming from the oven 5 substantially radially with respect to the transverse direction T through the opening 44 of the front face 37.
The internal protective screen 80 for example comprises several modules 82 distributed along the transverse direction T, and optionally a transverse module 84 adapted to protect the beam 68 from the thermal radiations 4.
The transverse module 84 is interposed between the beam 68 and the oven 5. The transverse module 84 extends transversely across the opening 44.
Each module 82 is adapted to reflect at least 70% of the energy of the thermal radiations coming from the oven 5.
The modules 82 are advantageously fixed to the lower wall 64 and the upper wall 65 of the main part 38, for example by a few screws respectively, so as to be easily movable by an operator along the transverse direction T in order to define two scanning windows 86A, 86B respectively in front of the 3D laser scanners 21A, 21B, regardless of the position of the latter.
For example, each module 82 has an “L” shape along the transverse direction T. Each module 82 comprises two panels 88 forming the “L”. One of the panels 88 is for example approximately perpendicular to the longitudinal direction L, and the other one is approximately perpendicular to the vertical direction V. The panels 88 are adapted to reflect thermal radiations coming from the oven 5 substantially radially with respect to the transverse direction T through the opening 44.
Advantageously, among the modules 82, a module, for example central along the transverse direction T, is suitable for protecting the position detector 76, and two opposite extremal modules along the transverse direction T are suitable for at least partly protect the gas springs 48.
Advantageously, the modules 82 and the transverse module 84 comprise at least 50% in weight of polished aluminum.
For example the adapters 72 are movable between several positions, for example three, with respect to the platform 70 along the transverse direction T.
Several washers, for example those known as “Delrin washers”, are interposed between the beam 68 and the lower wall 64 in order to limit thermal conduction.
The acquisition module 74 (
The 3D laser scanners 21A, 21B are fixed to the adapters 72 (
The 3D laser scanners 21A, 21B are advantageously protected with reflective adhesive tape stuck to their walls. The adhesive tape is advantageously in aluminized glass fabric, for example the one referenced 363 by the company 3M.
Each of the laser scanners 21A, 21B is for example adapted for emitting and receiving light through the scanning window.
Each of the laser scanners 21A, 21B is configured for moving relative to the box 20 in order to scan the wall portion 12.
The 3D laser scanners 21A, 21B are located at a distance L2 from the coking chamber 14 (
The 3D laser scanners 21A, 21B are adapted to scan the coking chamber 14 in a vertical plane P (
The box 20 and the 3D laser scanners 21A, 21B are configured to scan most of the existing coking ovens. To that end, the box 20 and the 3D laser scanners 21A, 21B are designed in order to allow:
These angles are optimized in order to reduce the scanning time and to allow scanning all the left wall 12A and the right wall 12B.
Such a length allows selecting the spacer 24 from a plurality of spacers having various lengths along the vertical direction V, in order to put the 3D laser scanners 21A, 21B at an adequate height. If H1 was above 1 meter, for example approximately 1.5 meter, a larger spacer or an additional spacer could be used between the base 22 and the box 20.
As a variant of the device 10, there is only one 3D laser scanner in the box 20, such as the laser scanner 21A. In this variant, there is only one scanner adapter 72 fixed to the platform 70 and one nozzle 78. The modules 82 defines only one scanning windows 86A.
A use of the invention will now be described.
It comprises the following steps:
The positions of the 3D laser scanners 21A, 21B are selected depending on the dimensions of the oven 5, particularly the width W1 and the distance L2.
The modules 82, 84 of the internal protective screen 80 are fixed to the rest of the box 20 depending on the position of the 3D laser scanners 21A, 21B with respect to the beam 68 so as to define the scanning windows 86A, 86B (
The step of turning the front face 37 towards the oven 5 includes a substep of bringing the device 10 in front of the oven 5 at the distance L2 as shown in
The optional rotating plate allows aligning the box 20 with respect to the oven 5, so that the wall portion 12 can be scanned. For example, the orientation of the box 20 with respect to the vertical direction V can be monitored.
As long as the closing system 40 is in the closed position, all the elements inside the box 20 are well protected from thermal radiations 4 coming from the oven 5, and dust.
The external protective panel 52 allows leaving the device 10 in front of the oven 5 for some time, for example 5 minutes, without experiencing a temperature increase in the interior of the box 20 that could damage for example the 3D laser scanners 21A, 21B. Also, some heat is evacuated through the rear face 58 of the box 20, due to fins 60. Advantageously, the fans 62 are switched on in order to boost heat exchange through the rear face 58.
Similarly, the protective mats on the base 22 and on the spacer 24 delay the temperature increase of these elements. The cooling fans of the base 22 also contribute to keep the temperature inside the base 22 at an acceptable level, preferably below 40° C.
Due to the on board power source 34 and the source of compressed air 32, the device 10 is autonomous.
In order to perform the scan of the wall portion 12, the cover 46 is open manually. This puts the closing system 40 in the open position shown in
The cover 46 is maintained by the gas springs 48 in the open or closed positions, both being stable.
The position detector 76 (
The 3D laser scanners 21A, 21B are monitored by the computer 29 in order to scan the wall portion 12 through the opening 44 in the front face 37 and deliver signals representative of the shape of the wall portion in a way known in itself. The signals are then interpreted by the computer 29 and converted into data representative of the shape, for example a graph. During scanning, the device 10 is not moved with respect to the oven 5 and the adapters 72 are also in a fixed position.
In a particular embodiment, the entire left wall 12A and the entire right wall 12B are scanned by the 3D laser scanners without moving the device 10 with respect to the oven 5 during scanning.
In order to minimize the temperature increase in the device 10, the duration of the scan is minimized, and preferably kept lower than 3 minutes.
The temperature inside the box 20 is measured by the acquisition module 74 and sent to the computer 29.
The internal protective screen 80, by defining the scanning windows 86A, 86B, confines the laser beams emitted by the 3D laser scanners 21A, 21B in a useful solid angle shown in
The internal protective screen 80 protects the laser scanners 21A, 21B and the gas springs from the thermal radiations 4. The internal protective screen 80 limits the heat flux which enters the box 20 when the closing system 40 is in the open position. The internal protective screen 80 also limits the entry of outside air towards the interior of the box 20.
The flap 50 prevents the largest pieces of dust from entering the slot between the cover 46 and the main part 38 of the box 20.
The results of the scan are interpreted either just after the oven 5 has been scanned, or after all the ovens of a predetermined set have been scanned. Between the scans of two successive ovens, there is usually a waiting time of 8 to 12 minutes.
Due to the base 22, moving the device 10 in front of each oven successively is easy.
Due to the above mentioned features, the device 10 measures a shape of the wall portion 12 of the oven 5, and is particularly fit for use in presence of dust and thermal radiations, as well as nearby a running oven next to the oven 5.
The device 10 is also adapted for measuring a shape of a wall portion of any narrow oven having a great length, for example greater than 5 times the largest transverse dimension of the oven.
Industrial tests of the device 10 were performed confidentially on coke ovens in Dunkirk, France. The device 10 was positioned at 2.5 m from each oven entrance. The scanning phase took about 2.5 minute for each oven and gave very accurate results. Some of these results, obtained with a given oven, are shown in
Curve C1 is the expected width profile of the oven.
Curves C2, C3 and C4 are the measured width profiles respectively at 10%, 50% and 90% of the height of the coking chamber 14 starting from its bottom.
Using these data, it was possible to relate the measured deviations to actual carbon deposit or brick displacements in the oven, and to explain why some of the ovens were easier to load or unload.
Number | Date | Country | Kind |
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PCT/IB2016/001082 | Jun 2016 | IB | international |
Filing Document | Filing Date | Country | Kind |
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PCT/IB2017/053970 | 6/30/2017 | WO | 00 |