Patent Grant
11214739
The present technology is generally directed to dynamic charging in heat recover coke ovens related to the operation and output of coke plants.
Coke is a solid carbon fuel and carbon source used to melt and reduce iron ore in the production of steel. In one process, known as the “Thompson Coking Process,” coke is produced by batch feeding pulverized coal to an oven that is sealed and heated to very high temperatures for approximately forty-eight hours under closely-controlled atmospheric conditions. Coking ovens have been used for many years to convert coal into metallurgical coke. During the coking process, finely crushed coal is heated under controlled temperature conditions to devolatilize the coal and form a fused mass of coke having a predetermined porosity and strength.
Coal particles or a blend of coal particles are charged, or loaded, into the hot ovens, and the coal is heated in the ovens. Due to the high temperature of the ovens during the charging process, the coal feeding process must use conveyers to convey coal particles horizontally into the ovens and provide an elongate bed of coal. The conveyer, which is manually-controlled by an operator, enters the ovens from a pusher side opening and charges coal into oven as it extends toward a coke side opening at the opposite end of the oven. Once the conveyer reaches the opposite end and finishes charging the bed, the conveyer retracts out of the oven from the same side it entered. Once charged, the oven is sealed and heated to form coke.
The manual charging of an oven in this manner commonly results in an uneven coal bed profile. More specifically, opposite ends of the coal bed will often have a different thickness of material, with the coal near the pusher side opening having a significantly greater thickness than the coal near the coke side opening. As a result of the uneven bed profile, the portion of coal at the thin side cokes out much faster and experiences a higher burn loss. The charging of the oven in this manner also commonly leads to inconsistent coke quality and short charging the oven, in which a coal capacity less than the oven's full potential is loaded. The overall effect is reduced coke quality, coke output and revenue for a coke-producing facility.
Non-limiting and non-exhaustive embodiments of the present invention, including the preferred embodiment, are described with reference to the following figures, wherein like reference numerals refer to like parts throughout the various views unless otherwise specified.
The present technology is generally directed to methods of increasing a coal processing rate of coke ovens. One aspect of the present technology is to develop a control system for a charging ram to dynamically charge an oven in order to optimize the oven capacity, coking process, production yield and coke quality. The control system allows each oven to be charged with a more uniform density which results in uniform temperature distribution in the oven and better control of coking cycle time. In some embodiments, a coal charging system includes a charging ram in communication with a control system configured to automatically move the charging ram. The automatic movement of the charging ram can be based on maintaining a steady charging pressure (e.g. chain pressure) while simultaneously charging coal into an oven, or to loading the oven according to an oven profile. Another aspect of the present technology is to develop a dynamic leveler system. In some embodiments, the control system may be configured to automatically adjust the vertical height of the charging ram to maintain an initial charging height or desired height of the charging ram throughout the charging process. Another aspect of the present technology is to develop a scanning system used in conjunction with the control system. In some embodiments, the scanning system is coupled to the charging ram and is positioned to scan the oven floor to determine an oven capacity for coking and/or an oven floor profile. Using the determined oven capacity and/or the oven floor profile, the control system is configured to automatically adjust its vertical position while charging coal into the oven. Yet another aspect of the present technology is to determine the oven floor profile from a pusher ram as the pusher ram removes coke from an oven after it has been coked out. Yet another aspect of the present technology is to strengthen the charging ram to decrease the amount of sag of the distal end of the charging ram. In some embodiments, the charging frame is strengthened using a combination of stiffener plates, RIB support members and rollers.
Specific details of several embodiments of the technology are described below with reference to the Figures. Other details describing well-known structures and systems often associated with pusher systems, charging systems, and coke ovens have not been set forth in the following disclosure to avoid unnecessarily obscuring the description of the various embodiments of the technology. Many of the details, dimensions, angles, spatial orientation and other features shown in the Figures are merely illustrative of particular embodiments of the technology. Accordingly, other embodiments can have other details, dimensions, angles, spatial orientation and features without departing from the spirit or scope of the present technology. A person of ordinary skill in the art, therefore, will accordingly understand that the technology may have other embodiments with additional elements, or the technology may have other embodiments without several of the features shown and described below with reference to the Figures.
Several embodiments of the present technology are directed towards charging the coal in the oven to achieve a constant thickness and constant density of coal in each oven. Other embodiments are directed towards charging the coal in the oven to achieve a maximum amount of coal in each oven. Therefore, the charging procedure is described in detail to better understand how the charging of the oven is improved. Further to the charging procedure described previously, after the PCM 100 pushes the coke out from the oven, the PCM 100 will tram to the right and align the coal charging system with the oven. According to one embodiment, once the alignment is completed, a false door will extend into the oven and the charging ram moves into the oven. A charging delivery device such as a conveyor or charging chain moves forward to deliver coal from a tripper car to a hopper on the PCM and eventually onto the false door. The coal is charged into the oven by the delivery device such as the chain on the charging ram. As coal is charged into the oven, the level of coal and within the oven begin to increase. An operator can monitor and use a sensed charging pressure (e.g. chain pressure) of the charging ram as an indication of the amount of coal being charged into the oven at a given position of the charging ram. As the charging pressure increases, the operator can decrease the charging pressure and/or maintain the charging pressure at a desired pressure by manually moving the charging ram from the pusher side opening of the oven towards the coke side opening of the oven. The coal charging operation is manually controlled by the operator controlling, for example, a joystick in the operator's cab 116.
Each oven 304 includes a pusher side opening 306, a coke side opening 308 opposite the pusher side opening 306, and opposite side walls 310 that together define an oven floor 312. Each oven 304 has an oven ceiling opposite the oven floor 312. The pusher side opening 306 of the oven 304 is the side by which the distal end portion 314 of the charging ram 302 generally enters the oven 304 to charge coal onto the oven floor 312. The plurality of ovens 304 can include any bank of horizontal coke ovens, including, for example, heat-recovery and non-heat-recovery ovens. In some embodiments, the oven floor 312 is generally flat, as is depicted in
In accordance with one embodiment of the disclosure, the coal charging system 300 also includes a rotatably endless conveyer system 330 operably coupled to the charging ram 302 and used to charge coal into the oven 304. The conveyer system 330 includes a chain and fly 332 mechanism coupled to gears 336 that are rotatably mounted to each of the opposite side walls 318 of the charging ram 302. As the conveyer system 330 charges coal into the oven 304, coal begins to build to reach a lower level of the conveyer system 330 and eventually contact the chain 332 of the conveyer system 330. This contact creates a drag force on the conveyer system 330 that results in what may be referred to as a charging pressure (e.g., chain pressure). Charging pressure can be determined by a pressure sensor coupled to the charging ram 302 and used as an implicit identification of how much coal has been charged into the oven at a given position of the charging ram 302.
The coal charging system 300 also includes a control system 340 in communication with the charging ram 302 and used to control movement of the charging ram 302 into and out of the ovens 304. The control system 340 is also used to control and is in communication with the conveyer system 330. The control system 340 allows operators to control aspects of the PCM from a remote location. Many embodiments of the control system 340 and/or technology described below may take the form of computer-executable instructions, including routines executed by a programmable computer. The control system 340 may, for example, also include a combination of supervisory control and data acquisition (SCADA) systems, distributed control systems (DCS), programmable logic controllers (PLC), control devices, and processors configured to process computer-executable instructions. Those skilled in the relevant art will appreciate that the technology can be practiced on computer systems other than those described herein. The technology can be embodied in a special-purpose computer or data processor that is specifically programmed, configured or constructed to perform one or more of the computer-executable instructions described below. Accordingly, the terms “control system” and “computer” as generally used herein refer to any data processor. Information handled by these computers can be presented at any suitable display medium, including a CRT display or LCD.
The technology can also be practiced in distributed environments, where tasks or modules are performed by remote processing devices that are linked through a communications network. In a distributed computing environment, program modules or subroutines may be located in local and remote memory storage devices. Aspects of the technology described below may be stored or distributed on computer-readable media, including magnetic or optically readable or removable computer disks, as well as distributed electronically over networks. Data structures and transmissions of data particular to aspects of the technology are also encompassed within the scope of particular embodiments of the disclosed technology.
In the present application, the control system 340 is configured to automatically move the charging ram 302 (1) in a first direction generally along a z-axis 350 between the coke side opening 308 and the pusher side opening 306 of the oven, (2) in a second direction generally along an x-axis 354 between opposite side walls 310 of the oven 304, and (3) in a third direction generally along a y-axis 352 between the oven floor 312 and the ceiling of the oven 304 located opposite the oven floor 312. The control system 340 may also be configured to automatically move the charging ram 302 in a fourth direction generally rotatable 356 around the z-axis 350, twisting the charging ram 302 in either a clockwise or counter-clockwise direction, such that when the charging ram 302 is twisted, one of the opposite side walls 318 of the charging ram 302 is located higher or lower than the other of the opposite walls 318. In some embodiments, the control system 340 may also be configured to automatically move the charging ram 302 in a fifth direction generally rotatable 358 around the x-axis 354, such that the distal end 314 of the charging ram 302 can be angled upwards away from the oven floor 312, or downwards towards the oven floor 312. In some embodiments, the automatic movement of the charging ram is determined at least in part by the charging pressure experienced by the conveyor system. Details of the control system 340 are described in greater detail below. Moving the charging ram 302 in these directions may be done using a drive system that is operably coupled to the charging ram 302 and in communication with the control system 340. The drive system may include a hydraulic drive, electric drive, screw drive, or other motive drives as known in the art.
At block 404, the method 400 includes charging coal into the oven 304 at the initial charging position via the conveyor system 330. Charging coal into the oven includes loading coal onto the oven floor 312 and building a cake of coal that exerts a charging pressure on the conveyor system 330. In some embodiments, charging pressure may be required to reach a preset locking pressure of over 1700 psi before the locking mechanism releases the charging ram from the initial charging position. In other embodiments, the locking pressure may need to build to 3000 psi or higher before the locking mechanism is released. Notably, the control system can be programmed to automatically release the locking mechanism once the preset locking pressure is reached.
At block 406, the method 400 includes, using a control system 340, automatically moving the charging ram 302 while simultaneously charging coal into the oven 304. Using a control system 340 may include using inputs to the control system 340 to dynamically charge the oven 304. Inputs to the control system 340 may include those described below with reference to
At block 408, the method 400 includes maintaining a charging pressure within a preset operating range until the oven is fully charged. In some embodiments, the preset operating range of the charging pressure will be set between 2000-3500 psi, whereas in other embodiments, the preset operating range will be set to between 2300-2900 psi. In yet other embodiments, the preset operating range will be set even more narrowly to between 2500-2700 psi. Maintaining the charging pressure can include maintaining the charging pressure by holding the charging ram in a given position to build charging pressure, moving the charging ram in a given direction to decrease charging pressure, or varying the rate of speed of the charging ram. In other embodiments, the charging pressure will be maintained at a single set point inputted by the operator.
Once a preset charging pressure is reached, the control system 340 releases the locking mechanism and begins to automatically move the charging ram 302. Each instance the charging ram 302 moves from a first position to a subsequent second different position, charging pressure will decrease and then subsequently increase once the level of coal builds up at the second position. As previously mentioned, the charging pressure is used by the control system 340 as an implicit measure of how much coal is charged into the oven 312 at that particular position of the charging ram 302. In this embodiment, this change in pressure is because the second position, whether towards the coke side opening or one of the opposite side walls, or away from the oven floor, is a location of the oven that has less coal buildup than was present at the first position. This movement is indicated by the step-wise shape of the charging ram position, as shown by step 506. As shown by step 508, a generally steady charging pressure during this charging period is maintained because of the control system's continual adjustment of the charging ram position in response to the charging pressure variation.
The steady charging pressure shown in
Although the charging ram position 520
It is worth noting that the charging pressure is just one measure that can be used to determine the amount of coal that has been charged into the oven 304 at a given position. In practice, any reactionary force, such as pressure or weight, or changing dimension, such as volume or height, that is created as a result of charging the oven 304 can also be used as the measure to determine the amount of charged coal. For example, in other embodiments, electrical signals (e.g., power, voltage, current, etc.), optical signals (e.g., lasers), visual signals (e.g., cameras), or radio waves (e.g., radar) may also be used instead of or in addition to charging pressure.
The scanning system 342 may include any device capable of capturing an image or assigning markers to a location. In some embodiments, the scanning system 342 will include be a camera capable of capturing an 2-D or 3-D image of the oven floor 312. These cameras can include UV cameras, infrared cameras, high-speed cameras, or other cameras including different spectrums known in the art. The scanning system 342 may also include a plurality of lasers or radars that scan the oven 302 and oven floor 312 to determine abnormalities or material resulting in an uneven oven floor 312.
One of the benefits of the scanning system 342 is to create a real-time loading map which can be used to ensure an oven 304 is charged with a constant thickness throughout the oven 304. A constant thickness throughout an oven 304 ensures that coke quality is maximized. Notably, the thickness of a coal bed is measured as the difference from the top of the charged coal to the bottom of the charged coal, and is not necessarily measured from the top of the charged coal to the bottom of the oven floor 312. If, for example, a section of leftover coke remains in an oven 304, the measured thickness for that section is the difference from the top of the carbon material to the bottom of the carbon material positioned immediately above that leftover coke. Accordingly, scanning the oven 304 can allow a coal charging system to locate uneven portions of the oven floor 312 and proactively adjust the loading plan for that oven 304. For example, when loading a section of the oven 304 that has a buildup of material, the control system 340 can proactively adjust the charging ram 302 in the vertical direction 352 in that section to ensure a uniform thickness throughout the oven 304. Another benefit of the scanning system 342 is to create a real-time loading map which can be used to ensure an oven 304 is charged with a varying thickness to maximize the amount of coal charged into the oven. This feature is described below with reference to
As shown in the embodiment of
In some embodiments, the scanning system 342 is configured to scan the oven floor 312 to determine any buildup (i.e. leftover material 360) or unevenness on the oven floor. Each scan by the scanning system 342 can generate an oven capacity, oven floor profile and/or oven profile for that particular oven. In other embodiments, the oven capacity, oven floor profile and/or oven profile may also be determined without the scanning system. For example, the pusher ram 102, which pushes coke from the oven 304 may also be used to develop the oven floor profile. When the pusher ram 102 pushes the charged coke from the pusher side opening 306 of the oven 304 towards the coke side opening 308 of the oven 304, the pusher ram 102 experiences a resistance that is based at least in part on the height and/or weight of the charged coke bed, wherein a higher resistance implicitly indicates a thicker layer of charged coke at that particular position. The varying resistance, which may be reflected in, for example, variation in a hydraulic or electric signal, can then be used to create an oven profile to be used by the control system 340 to dynamically vary the height of the charging ram 302, as described above.
In addition to the resistance experienced by the pusher ram 102, an auto-leveling system may also be included on the pusher ram 102. The pusher ram 102 can dynamically move in any direction (i.e. along any of the x-y-z axes) and has skid shoes positioned behind the pusher ram and in contact with the oven floor 312. Accordingly, the oven floor profile can be captured and then transferred to the control system 340 for use during subsequent oven charges.
The oven capacity represents an estimate for the amount of coal that can be charged into the oven for a single cycle. The oven capacity can be calculated by using the scan of the oven floor 312 to determine a surface area of the oven floor 312 that is covered by buildup and then estimate a volume associated with the surface area. This estimated volume can then be subtracted from the design oven capacity for a particular oven.
The oven floor profile quantifies variations in the oven floor 312. In addition to considering the leftover buildup, the oven floor profile may also consider permanent buildup, oven construction variation, trenches, valleys, divots, etc. that may contribute to the variations or unevenness of the oven floor 312. After determining areas of unevenness and assigning a location to those areas, using, for example, the virtual grid 344, the oven profile can create a real-time loading map, which can then be used to provide a height that the charging ram 302 needs to be at each section during the subsequent charge. The scanning system 342, therefore allows the control system 340 to dynamically charge an oven 304 such that the thickness of the coal bed is constant throughout. For example, prior to charging an oven 304, the scanning system 342 can scan the oven floor 312 and determine which if any sections along the x-y coordinate area have an amount of carbon remaining. As shown in the embodiment of
In addition to scanning the oven floor 312, the scanning system 342 can also be used to scan an overall oven 304 to create an oven profile. This can help determine other opportunities to charge additional coal into an oven 304 and achieve a maximum amount of coke with each oven cycle. For example, some ovens have ducts (i.e., downcommers) connected to the flue tunnels beneath the oven floor 312 that are present on one or both of the opposite side walls 310 of the oven 304. These downcommers have openings which are commonly located approximately midway up the side walls 310 of the oven 304. If the level of charged coal is higher than these open ends, the coal can fall into the downcommers and block them. The scanning system 342 can be used to identify the locations where these downcommers are and the locations where these downcommers are not. By knowing and translating these locations to the control system 340, the control system 340 can avoid charging coal in discrete areas adjacent to the openings of the downcommers and can charge additional coal in those areas not adjacent to the openings of the downcommers. In this instance, “adjacent” refers to the area surrounding the openings of the downcommers wherein charged coal would fall into the openings of the downcommers. Accordingly, based on the oven profile provided by the scanning system 342, an oven 304 can be charged to maximize its oven capacity by charging additional coal in areas not adjacent to the openings of the downcommers.
The scanning system 342 can also be used to create an oven profile for an oven 304 after it has been charged. For example, once an oven 304 is fully charged, the charging ram 302 retracts towards the pusher side opening 306 and exits the oven 304 to begin charging a subsequent oven. In some embodiments, the scanning system 342 can create an oven profile after the charging ram 302 exits the oven 304 and before it begins charging the subsequent oven. This oven profile represents an actual oven profile, including the level or thickness of coal within the oven 304, and can be used to adjust the method for charging that particular oven in a subsequent load. For example, by knowing the oven floor profile before an oven 304 was charged and the actual oven profile after the oven 304 was charged, an operator can continually adjust the method for charging and know whether the adjustments are leading to improvements. According to additional embodiments, an oven 304 may be charged multiple times for a single firing of that oven 304. For example, the control system 340 can be configured to scan the oven 304 to generate a first oven floor and/or oven profile, charge the oven 304 based on the oven floor and/or oven profile, retract the charging ram 302, re-scan the oven 304 to generate a second oven profile, and charge additional coal into the oven 304 to ensure the coal has a constant thickness throughout the oven 304 or to maximize the amount of coal in the oven 304. The scanning system 342 can also be used to create an oven profile for an oven 304 and after it has been coked out.
Once the locking mechanism is released, the method 800 proceeds to decision block 816, wherein the control system 340 determines if the charging pressure is above the preset operating charging pressure. In some embodiments, the preset operating charging pressure will be equal to or slightly above the preset locking charging pressure. If the current charging pressure as determined by the control system 340 is not above the preset operating charging pressure, then the control system 340 may maintain its current position and wait for charging pressure to continue to build 818. If the current charging pressure is above the preset operating charging pressure, then the control system 340 may automatically move the charging ram 302 generally toward the coke side opening 308 of the oven 304820. Moving the charging ram 302 toward the coke side opening 308 can also include moving the charging ram 302 toward opposite side walls 310 of the oven 304, or moving the charging ram away from the oven floor 312. As the control system 340 automatically moves the charging ram 302, decision block 822 determines whether the oven 304 is fully charged. The control system 340 may determine that the oven 304 is fully charged if the charging ram 302 is positioned at a set position near the coke side opening 308 of the oven. This position may be a manual input by the operator or be determined automatically by the control system 340. If the control system 340 determines that the oven 304 is fully charged, the method ends. If the control system 340 determines that the oven 304 is not fully charged, then the control system 340 returns prior to decision block 816 to determine whether the charging pressure as determined by the control system is above the preset operating charging pressure.
Notably, the dynamic leveler ability of the control system 340 may also be utilized to adjust the height of the charging ram 302 while the charging ram 302 is being retracted from the oven back towards the pusher side 306 of the oven 304. As the charging ram 302 is retracted, the charging ram 302 can be raised to clear the coal or adjusted to contact the coal such that coal is dragged back by the charging ram 302 to further help distribute the coal evenly across the oven or to further maximize the amount of coal to be charged. In some embodiments, the oven profile and/or oven capacity used to charge the oven 304 may also be utilized during retraction of the charging ram 302 to further optimize the charge of each oven 304. Retraction of the charging ram 302 is discussed in further detail below with reference to
As has been previously described, one method to optimize dynamic charging in a coke oven is to use the automatic oven charging control system, scanning system and/or dynamic leveler system. Another method to optimize charging is to mechanically strengthen the charging ram to reduce the sag of the charging ram. Referring next to
As shown in
Each support brace 322 provides additional structure support to further limit the sag of the charging frame 320 as the distal end 314 extends further away from the structural support of the PCM 100. To further limit this sag, additional structural supports may be coupled to each end of the cross support braces 322.
RIB support members 380 are also included to provide additional mechanical support to each cross support brace 322. Specifically, the diamond-shaped support braces 322 and coupling arrangement to the side walls 318 of the charging ram 302 result is additional weight at the lower portion 386, or bottom corner, of the support brace 322. The RIB support 380 helps to distribute the load and increase the weld length of that area. Each RIB support member 380 is thus positioned at a lower portion 386 of the support braces 322, such that a first surface 382 of the RIB support member 380 is mechanically coupled to the interior facing surface 372 of the stiffener plate 370 and a second surface 384 of the support member 380 is mechanically coupled to the lower portion 386 of the support brace 322. The RIB support member 380 may be composed of material similar to that of the stiffener plate 370.
Data taken during testing of installed stiffener plates 370 and RIB support members 380 indicates a dramatic improvement in the amount of stress experienced by the support brace 322. For example, the maximum stress exhibited at an interior surface 372 of the opposite side walls 318 of the charging ram 302 near a lower portion 386 of the support brace 322 without the stiffener plate 370 or RIB support 380 was upwards of 3400 psi. The max stress exhibited at a lower portion 386 of the support brace 322 with the stiffener plate 370 decreased to approximately 1740 psi, and further decreased to approximately 1665 psi with the RIB support 380. Similar tests at an exterior surface 378 of the opposite side walls 318 of the charging ram 302 near the lower portion 386 of the support brace 322 shows a maximum stress of 5000 psi with no stiffener plate 370 or RIB support 380, 3585 psi with the stiffener plate 370 and 3530 psi with the stiffener plate 370 and RIB support 380. This approximately 40% improvement in decreased maximum stress was consistent across a number of experimental analysis tests.
Various embodiments of the charging head 604 include a pair of opposing wings 628 and 630 that are shaped to have free end portions 632 and 634. In some embodiments, the free end portions 632 and 634 are positioned in a spaced-apart relationship, forwardly from the charging head plane. In particular embodiments, the free end portions 632 and 634 are spaced forwardly from the charging head plane a distance of six inches to 24 inches, depending on the size of the charging head 604 and the geometry of the opposing wings 628 and 630. In this position, the opposing wings 628 and 630 define open spaces rearwardly from the opposing wings 628 and 630, through the charging head plane. As the design of these open spaces is increased in size, more material is distributed to the sides of the coal bed. As the spaces are made smaller, less material is distributed to the sides of the coal bed. Accordingly, the present technology is adaptable as particular characteristics are presented from coking system to coking system.
In some embodiments, such as depicted in
With reference to
In use, coal is shuffled to the front end portion of the coal charging system 300, behind the charging head 604. Coal piles up in the opening between the conveyor and the charging head 604 and conveyor charging pressure starts to build up gradually until reaching approximately 2500 to 2800 psi. With reference to
The test results, depicted in
Although many features of the present technology have been described herein as separate embodiments, these embodiments may also be combined with each other. For example, aspects of the opposing wings 628 and 630, and extrusion plate 666 can be incorporated into those embodiments of the control system 340 described throughout the application.
The following Examples are illustrative of several embodiments of the present technology.
1. A coal charging system, the system comprising:
2. The coal charging system of claim 1, further comprising a locking mechanism configured to hold the charging ram in an initial charging position.
3. The coal charging system of claim 2 wherein the control system is configured to automatically release the locking mechanism and move the charging ram toward the coke side opening after a preset locking charging pressure is reached, and wherein the control system is further configured to maintain an operating chain pressure within a preset operating range.
4. The coal charging system of claim 3 wherein the preset locking charging pressure is greater than 1700 psi.
5. The coal charging system of claim 3 wherein the preset operating range is between 2000-3500 psi.
6. The coal charging system of claim 3 wherein the preset operating range is between 2300-2900 psi.
7. The coal charging system of claim 1 wherein the charging ram movement between the pusher side opening towards the coke side opening is a horizontal movement in a first direction.
8. The coal charging system of claim 7 wherein the charging ram is horizontally movable in a second direction between the opposite side walls of the oven, such that the control system is configured to automatically move the charging ram towards at least one of the opposite side walls of the oven.
9. The coal charging system of claim 1 wherein the charging pressure is a chain pressure.
10. A coal charging system comprising:
11. The coal charging system of claim 10, further comprising a drive system in communication with the control system, wherein the drive system is operably coupled to the charging ram, and wherein the control system utilizes the drive system at least to vertically move the charging ram in the third direction.
12. The coal charging system of claim 11 wherein the drive system is at least one of a hydraulic drive, electrical drive or screw drive.
13. The coal charging system of claim 10 wherein the charging ram is horizontally movable toward at least one of the opposite side walls of the oven, and wherein the control system is configured to automatically move the charging ram towards at least one of the opposite side walls of the oven.
14. The coal charging system of claim 10, further comprising a scanning system attached to the charging ram and in communication with the control system.
15. The coal charging system of claim 14 wherein the scanning system is configured to scan the oven to determine at least one of an oven floor profile or oven profile.
16. The coal charging system of claim 15 wherein the control system is configured to automatically move the charging ram in the vertical direction away from the oven floor in response to the determined oven floor profile or oven profile.
17. The coal charging system of claim 14 wherein the scanning system is at least one of a camera, laser, or radar.
18. The coal charging system of claim 10 wherein each of the opposite sides of the charging ram includes an interior surface and an exterior surface, the charging ram further comprising:
19. The coal charging system of claim 18, further comprising a support member mechanically coupled to the stiffener plate and the cross support brace.
20. The coal charging system of claim 19 wherein the support member is positioned at a lower portion of the cross support brace, and wherein the support member includes first and second surfaces configured approximately normal to each other, the first surface of the support member being connected to the interior facing surface of the stiffener plate and the second surface of the support member being connected to the lower portion of the cross support brace.
21. The coal charging system of claim 18 wherein the plurality of cross support braces are hollow and include a hole opening on a lower portion of the cross support brace, the hole opening being configured to drain fluid from the hole opening.
22. The coal charging system of claim 10 wherein the opposite sides of the charging ram include an upper portion and a lower portion, the coal charging system further comprising:
23. The coal charging system of claim 10 wherein the distal end portion the charging ram is configured to penetrate a vertical plane of the pusher side opening of the oven, the coal charging system further comprising:
24. The coal charging system of claim 23 wherein the extrusion plate further includes an upper deflection face that is oriented to face rearwardly and upwardly with respect to the charging head, the coal engagement face and deflection face being operatively coupled with one another to define a peak ridge facing rearwardly away from the charging head.
25. The coal charging system of claim 23 wherein the control system is configured to maintain an operating charging pressure within a preset operating range between 2000-3500 psi.
26. The coal charging system of claim 10 wherein the distal end portion the charging ram is configured to penetrate a vertical plane of the pusher side opening of the oven, the coal charging system further comprising:
27. The coal charging system of claim 26 wherein each wing includes a first face adjacent to the charging head plane and a second face extending from the first face toward the free end portion, wherein the first face is angularly disposed from the charging ram plane toward adjacent sides of charging ram and the second face resides within a wing plane that is parallel to the charging head plane.
28. The coal charging system of claim 10 wherein the charging pressure is a chain pressure.
29. The coal charging system of claim 10, further comprising a plurality of downcommer openings within the oven, wherein each of the downcommer openings faces opposite the oven floor, and wherein the control system is configured to vary coal thickness within the oven to maximize the amount of coal charged into the oven, such that a first thickness of coal adjacent to the downcommer openings is greater a second thickness of coal not adjacent to the downcommer openings.
30. A method for dynamically charging a coal system, the method comprising:
31. The method of claim 30 wherein automatically moving the charging ram includes both automatically moving the charging ram in a horizontal first direction and a horizontal second direction, wherein the horizontal first direction is along a z-axis toward the coke side opening of the oven, and wherein the horizontal second direction is along an x-axis toward one of the opposite side walls of the oven.
32. The method of claim 30 wherein automatically moving the charging ram further includes automatically moving the charging ram in a vertical third direction along a y-axis away from the oven floor.
33. The method of claim 32, further comprising utilizing a drive system to automatically move the charging ram in the vertical third direction, wherein the drive system includes at least one of a hydraulic drive, electrical drive or screw drive.
34. The method of claim 30 wherein automatically moving the charging ram further includes automatically moving the charging ram in a rotatable fourth direction around the z-axis.
35. The method of claim 30 wherein automatically moving the charging ram further includes automatically moving a proximal end of the charging ram in a rotatable fifth direction around an x-axis, such that when the charging ram is moved in the fifth direction, the charging ram is angled upwards or downwards and the proximal end of the charging ram is lower or higher than a distal end of the charging ram.
36. The method of claim 32 wherein the charging ram further comprises a proximal end portion, a distal end portion and opposite sides that define a length of the charging ram, and wherein the initial charging position includes an initial charging height, the method further comprising:
37. The method of claim 30 wherein the initial charging position includes an initial charging height, and wherein automatically moving the charging ram includes automatically moving the charging ram in a vertical third direction to maintain the initial charging height.
38. The method of claim 30 wherein the fully charged coke oven includes a coal bed having a generally constant thickness.
39. The method of claim 30 wherein the oven further includes a plurality of downcommer openings positioned proximate to the opposite side walls of the oven, the method further comprising:
40. The method of claim 30 wherein the fully charged coke oven includes a coal bed having a generally uniform density throughout.
41. The method of claim 30, further comprising:
42. The method of claim 30, further comprising:
43. The method of claim 42, wherein scanning the oven floor occurs before charging coal into the oven at the initial charging position; the method further comprising:
44. The method of claim 42 wherein scanning the oven floor to determine an oven profile occurs after the oven is fully charged, and wherein the oven profile includes a thickness or height of the charged oven.
45. The method of claim 32, further comprising:
46. The method of claim 45 wherein automatically adjusting the charging ram includes adjusting the charging ram in the vertical third direction to achieve a generally constant thickness throughout the oven.
47. The method of claim 30 wherein charging coal into the oven at the initial charging position includes charging coal into the oven at an initial charging height, the method further comprising:
48. The method of claim 30, further comprising:
49. The method of claim 30, further comprising:
50. A coal charging system comprising:
51. The coal charging system of claim 50 wherein the oven further includes a plurality of downcommer openings positioned adjacent to the opposite side walls of the oven, and wherein charging coal into the oven results in a thickness of coal within the oven, the one or more processors further causing the computer to:
52. A computer-readable medium containing computer-executable instructions for causing a processing device to perform a method for automatically charging a coal system, the method comprising:
receiving a set point corresponding to a desired charging pressure to be maintained by the coal system during charging of the coal system;
This application is a continuation of U.S. patent application Ser. No. 15/392,942, filed Dec. 28, 2016, which claims the benefit of priority to U.S. Provisional Patent Application No. 62/271,963, filed Dec. 28, 2015, the disclosure of which is incorporated herein by reference in their entirety.
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| Number | Date | Country | |
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| 20200231876 A1 | Jul 2020 | US |
| Number | Date | Country | |
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| Number | Date | Country | |
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