This disclosure relates to a spring-loaded system and method for maintaining compression on heat recovery or non-recovery ovens during thermal expansion and contraction of the ovens.
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.
Because coke ovens cycle between very high temperatures during the coking process and lower temperatures between coking processes, the ovens often undergo expansion and contraction. To avoid damage to the oven, structures that can maintain compression on the oven during this expansion and contraction are needed.
The present technology is generally directed to systems and methods for maintaining compression on coke ovens during thermal expansion and contraction of the ovens. A coke oven, which can be any of a variety of types of heat recovery ovens or non-recovery ovens, 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 as the oven body expands and contracts during thermal cycling. 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, to a similar compression device on an opposite side of the oven, or to another object outside 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.
Embodiments of the compression device described herein beneficially allow for expansion and contraction of the oven body as the oven is heated and cooled while maintaining compression on the oven. The compression device can maintain structural stability of the oven over a plurality of thermal cycles. Because the compression device can be coupled to either the foundation or the beams supporting the oven, the compression device design described herein does not need to be coupled to an opposite side of the oven in order to maintain compression the oven. For example, if space under the oven fills in (e.g., due to a beam collapsing), components of the compression device do not need to be threaded through the collapsed region. Rather, embodiments of the compression device described herein can be coupled to a structure on the same side of the oven at which the compression device is located. Various embodiments described herein also reduce interference with machines that operate at either end of the oven body. For example, embodiments of the compression device described herein maintain a low profile so as not to be hit by a machine that cleans material (coal or coke) that falls out of the oven. The components of the compression device can also be visually inspected to discover structural problems before any of the structures fail. Furthermore, although embodiments of the spring-loaded compression device are described herein as being used to maintain compression on heat recovery ovens, similar devices may be used for other types of ovens such as non-recovery ovens.
Specific details of several embodiments of the technology are described below with reference to
In operation, volatile gases emitted from heated coal in the oven 100 collect in the crown 115 and are drawn downstream into a sole flue 120 positioned beneath the oven floor 105. The sole flue 120 includes a plurality of side-by-side runs that form a circuitous path beneath the oven floor 105.
Coke is produced in the oven 100 by first loading coal into the oven chamber, heating the coal in an oxygen-depleted environment, driving off the volatile fraction of coal, and then oxidizing the volatile matter within the oven 100 to capture and utilize the heat given off. The coking cycle begins when coal is charged onto the oven floor 105 through the front door 108. The coal on the oven floor 105 is known as the coal bed. Heat from the oven 100, due to the previous coking cycle, starts a carbonization cycle. Roughly half of the total heat transfer to the coal bed is radiated down onto the top surface of the coal bed from the luminous flame of the coal bed and the crown 115. The remaining approximately half of the heat is transferred to the coal bed by conduction from the oven floor 105, which is convectively heated from the volatilization of gases in the sole flue 120. In this way, a carbonization process “wave” of plastic flow of the coal particles and formation of high strength cohesive coke proceeds from both the top and bottom boundaries of the coal bed. At the end of the coking cycle, the coal has coked out and has carbonized to produce coke. The coke can be removed from the oven 100 through the rear door 109 opposite the front door 108 using a mechanical extraction system. Finally, the coke is quenched and sized before delivery to a user.
Primary air for combustion can be added to the oven chamber 101 to partially oxidize coal volatiles, but the amount of primary air can be controlled so that only a portion of the volatiles released from the coal are combusted in the oven chamber 101, thereby releasing only a fraction of their enthalpy of combustion within the oven chamber 101. The partially combusted gases pass from the oven chamber 101 into the sole flue 120, where secondary air can be added to the partially combusted gases. As the secondary air is introduced, the partially combusted gases are more fully combusted in the sole flue 120, thereby extracting the remaining enthalpy of combustion that can be conveyed through the oven floor 105 to add heat to the oven chamber 101. However, at least part of the heat produced by the combustion in the sole flue 120 is conveyed downward to structural components below the flue 120.
Beneath the sole flue 120 is a castable slab 125. The slab 125, comprising concrete, a ceramic, or other castable refractory, can form a bottom floor of the sole flue 120 and support the oven 100. The slab 125 can have a width that is approximately equal to the width of the oven 100, or the slab 125 can extend the width of multiple ovens.
The oven 100 is supported by a foundation 130, for example comprising concrete. Between the foundation 130 and the castable slab 125 are one or more beams 140 that form a plurality of air gaps 142 between the foundation and slab. The beams 140 an extend a length of the oven from a first end to a second end. For example, the beams 140 can extend from the front door 108 to the rear door 109. Each beam 140 can be a continuous structure extending the length of the oven 100, or two or more beams 140 placed end-to-end can together extend the length of the oven. The air gaps 142 can similarly extend the length of the oven 100. The air gaps 142 can be open at a first end of the oven 100 and a second end of the oven 100 opposite the first end, allowing air movement through the gaps 142 and around the beams 140. The beams 140 comprise a structural material capable of supporting the oven 100 while leaving air gaps 142 below the castable slab 125. In some embodiments, the beams 140 are manufactured out of a metal, such as steel.
As shown in
In various embodiments, the beams 140 can be between six inches and eighteen inches high (i.e., leaving a gap between the foundation 130 and the castable slab 125 that is between six and eighteen inches). For example, the beams 140 can have a height of eight inches or twelve inches. The height of the beams 140 may be selected based on material properties of the beams, as well as an amount of natural or forced air flow through the air gaps 142. For example, because taller beams allow more air to flow through the gaps 142 under natural airflow than shorter beams, taller beams can be used in circumstances where more natural cooling is desired. The beams 140 can have a distance between them that depends on structural capacity of each beam. The beams 140 may have uniform spacing under the ovens, or more beams can be placed under heavier components of the ovens while fewer beams are placed under lighter components. For example, the beams 140 can be closer together under the sidewalls 110 than they are under the sole flue 120. The air gaps created by the beams 140 can thermally isolate the oven body from the foundation 130 and/or improve heat dissipation from the oven body by allowing airflow under the oven body. The heat dissipation caused by the airflow reduces the temperature of the castable slab 125 and reduces heat transfer between the sole flue 120 and the foundation 130. Because the slab 125 or foundation 130 may fail at high temperatures, the dissipation of heat helps reduce the likelihood of failure of either component. Similarly, heat transferred to subgrade below the foundation 130, in particular if the subgrade includes a high proportion of slag, can cause the subgrade to become unstable. Reducing the heat transfer into the foundation 130 similarly reduces heat transfer to the subgrade and reduces the likelihood of the subgrade becoming unstable.
The air gaps created by the beams 140 enable air to flow around the beams 140 to reduce heat transfer between the slab 125 and the foundation and the cool the beams and other structures of the oven, such as a compression device. Depending on a location of the oven 100, natural air flow through the air gaps (e.g., due to wind) may be sufficient to cool the beams. However, in some embodiments, the oven 100 includes a forced cooling system that forces air a fluid can be forced through at least one of the air gaps between the beams 140 to increase convection and further reduce the amount of heat transfer from the sole flue 120 to the foundation 130. The forced cooling system can, for example, force air through an air gap using one or more fans, nozzles, air horns, air multipliers, air movers, or vacuums. Gases other than air may be forced through the air gaps instead of, or in addition to, air. As another example, the forced cooling system can include cooling pipes positioned in the air gaps, adjacent to the beams 140, or passing through the beams 140 or foundation 130. A cooling fluid can be pumped through the pipes continuously or on a periodic basis to dissipate heat from the beams 140.
Various other configurations of the beams 140 are described in U.S. patent application Ser. No. 16,729,212, filed Dec. 27, 2019 (Attorney Docket No. 84553-8052.US01), which claims the benefit of U.S. Provisional Patent Application No. 62/786,320, filed Dec. 28, 2018, both of which are incorporated herein by reference in their entirety.
The heat recovery coke oven 100 further includes buckstays 150. Each buckstay 150 comprises a mechanical structure that constrains movement of the oven 100, for example during thermal expansion and contraction. As shown in
Associated with each buckstay 150 is a spring-loaded compression device 155. The compression device 155 can be coupled to various components of the heat recovery oven 100, such as the foundation 130 or one or more beams 140, or to objects outside the oven 100, such as a flume. The compression device 155 applies force to the buckstay 150 to maintain compression of the buckstay against the oven. The compression device 155 can provide force against a single buckstay or multiple buckstays 150. For example, one compression device 155 can apply force to two adjacent buckstays 150 (e.g., a buckstay 150 positioned at the right sidewall 110 of a first oven, and a buckstay 150 positioned at a left sidewall 110 of a second oven to the right of the first oven). If the compression device 155 couples two buckstays 150, the compression device effectively can spring-load two adjacent ovens together. In some embodiments, the compression device 155 can be a bridle assembly.
The compression device 155 can include a restraining device, such as a bridle, and one or more springs. In some embodiments, the restraining device can pass over a buckstay 150 on an outside (away from the oven) or an inside (toward the oven) of the buckstay, without passing through the buckstay. Other embodiments of the restraining device can pass through the buckstay. The restraining device can be coupled to one more anchors that anchor the compression device, for example to the beams 140, the foundation 130, the castable slab 125, a compression device on an opposite side of the oven, or an object outside the oven. The restraining device and springs compress the buckstay 150 against the oven 100, while allowing the buckstay 150 to move as the oven expands or contracts. Various embodiments of the compression device 155 are illustrated in
In some embodiments, as shown for example in
The first and second compression devices 155 can both be spring-loaded compression devices, in which a spring applies force to a component of the compression device to compress a the buckstay 150 against the oven body. In other cases, one compression device can be spring-loaded while the other compression device is fixed. For example, the fixed compression device can be welded or otherwise attached to the buckstay 150 while the buckstay 150 is welded or otherwise attached to a beam 140.
In the example compression device 155 configuration shown in
A smaller example compression device 155 is shown in
In various embodiments, any of the springs described with respect to
Any of a variety of other configuration of the spring-loaded compression device 155 may be used instead of those shown in
From the foregoing it will be appreciated that, although specific embodiments of the technology have been described herein for purposes of illustration, various modifications may be made without deviating from the spirit and scope of the technology. Further, certain aspects of the new technology described in the context of particular embodiments may be combined or eliminated in other embodiments. Moreover, while advantages associated with certain embodiments of the technology have been described in the context of those embodiments, other embodiments may also exhibit such advantages, and not all embodiments need necessarily exhibit such advantages to fall within the scope of the technology. Accordingly, the disclosure and associated technology can encompass other embodiments not expressly shown or described herein. Thus, the disclosure is not limited except as by the appended claims.
This application claims the benefit of U.S. Provisional Patent Application No. 62/786,325, filed Dec. 28, 2018, the disclosure of which is incorporated herein by reference in its entirety.
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