Note: Descriptions are shown in the official language in which they were submitted.
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SYSTEMS AND METHODS FOR IMPROVING QUENCHED COKE
RECOVERY
TECHNICAL FIELD
[0001] The present technology is generally directed to systems and methods
for
improving quenched coke recovery. More specifically, some embodiments are
directed to
systems and methods utilizing one or more of a screen, barrier, or reflector
panel to contain or
redirect coke during or after quenching.
BACKGROUND
[0002] Quenching is an important step in many types of mineral processing,
including
coke processing. During quenching, a quench tower releases a large amount of
water onto
heated coke in a quench car in order to quickly cool the coke. The pre-quench
coke is
extremely hot, sometimes having a temperature greater than 2,000 degrees
Fahrenheit. Once
the coke is cooled, it can be handled on transfer belts and be screened and
sent to the
customer.
[0003] Traditionally, a large amount of coke is lost in the quenching
process. More
specifically, the combination of the force of the quench spray and the
expansion of the quench
water as it forms steam causes some of the coke to pop or fly out of the top
and upper side
edges of the quench car. This coke then falls by the wayside or is passed into
a collecting
water pit. To recover this coke, the water pit must be dredged, a costly and
time-consuming
process. The coke recovered from the pit is high in moisture and requires
drying and sieving
to reclaim, as the coke must have a relatively low moisture content to be
useful to many
customers. Therefore, there exists a need to improve coke recovery during the
quench
process.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] Figure 1 is an isometric, partial cut-away view of a quench car that
is entering a
quench tower and is configured in accordance with embodiments of the
technology.
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[0005] Figure 2A is an isometric view of a quench car that has side
containment plates
for channeling quenched coke onto a quench wharf and is configured in
accordance with
embodiments of the technology.
[0006] Figure 2B is an isometric, partial cut-away view of a quench car
having a
tailgate containment plate configured in accordance with embodiments of the
technology.
[0007] Figure 3 is a partially schematic illustration of a quench car
positioned in a
quench tower that has coke retaining features and is configured in accordance
with
embodiments of the technology.
[0008] Figure 4 is a partially schematic illustration of a quench car
positioned in a
quench tower that has coke retaining features and is configured in accordance
with further
embodiments of the technology.
[0009] Figure 5 is a front view of a quench car having coke retaining
features
configured in accordance with embodiments of the technology.
DETAILED DESCRIPTION
[0010] The present technology is generally directed to systems and methods
for
improving quenched coke recovery. More specifically, some embodiments are
directed to
systems and methods utilizing one or more of a screen, barrier, or reflector
panel to contain
or redirect coke during or after quenching. In a particular embodiment, a
quench car system
for containing coke includes a quench car having a base, a plurality of
sidewalls, and a top
portion. The system can further include a permeable barrier covering at least
a portion of the
top of the quench car, where the permeable barrier has a plurality of
apertures therethrough.
[0011] In another embodiment, a coke quenching system includes a quench
car having
a plurality of sidewalls for containing coke and a quench tower configured to
supply fluid for
quenching the coke. The quench tower includes a deflection barrier positioned
over the
quench car and configured to contain coke in the car.
[0012] In another embodiment, a coke quench car includes a base and a
plurality of
sidewalls extending generally orthogonally upward from the base and
surrounding a central
region configured to contain coke. Individual sidewalls can comprise a lower
portion
adjacent to the base and an upper portion opposite the lower portion. The
upper portion of at
least one sidewall can be angled laterally inward toward the central region.
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[0013] Specific details of several embodiments of the technology are
described below
with reference to Figures 1-5. Other details describing well-known structures
and systems
often associated with coal processing and/or quenching 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, 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, 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
Figures 1-5.
[0014] Figure 1 is an isometric, partial cut-away view of a quench car
100 that is
entering a quench tower 104 and is configured in accordance with embodiments
of the
technology. The quench car 100 includes a plurality of sidewalls 102 arranged
to enclose or
at least partially surround a space configured to contain coke in a coke
processing system. In
further embodiments, the quench car 100 can be used in other mineral
processing systems.
While the car 100 is described herein as a "quench" car, it can comprise a
"hot" car
configured to receive coke from a coke oven, a quench train, a coke-moving
car, a combined
hot/quench car, or other container.
[0015] The quench car 100 includes a permeable deflection barrier 106
having a top
portion 108 and one or more sidewall portions 110. In some embodiments, the
barrier 106
comprises only one of a top portion 108 or sidewall portion 110, or extends
across only a
portion of the top of the quench car 100. In various embodiments, the top
portion 108 is
integral with the sidewall portions 110 or can be detachably coupled to the
sidewall portions
110 or to the sidewalls 102. While the barrier sidewall portion 110 is
illustrated as
occupying only an upper portion of the sidewalls 102, in further embodiments
more or less
of the sidewalls 102 can comprise the permeable barrier. For example,
including apertures
or a permeable barrier on a lower portion of the sidewalls 102 can allow
quench water to exit
the car 100 after the quench and prevent the coke from sitting in quench
fluid.
[0016] The permeable barrier 106 can be removably or permanently coupled
to the
quench car 100, or it can be spaced apart from (e.g., positioned above) the
quench car 100.
For example, as will be discussed in further detail below, the barrier 106 can
be held above
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=
the car 100 by the quench tower 104 or other structure. In embodiments where
the
permeable barrier 106 is removably coupled to the quench car 100, the
permeable barrier can
be latched, friction fit, draped over, or held by cords, chains, hinges, or
hooks to the car 100.
For example, the barrier 106 can be coupled to the car 100 (e.g., to a
sidewall 102) with a
hinge or similar device and can open like an automobile hood. In some
embodiments, the
barrier 106 can have a lock or latch to fix the barrier 106 in a closed or
open configuration.
In some embodiments, the permeable barrier 106 can lift or otherwise be moved
during car
loading or unloading. In further embodiments, other attachment mechanisms can
be used.
The barrier 106 can be angled or generally horizontal. In some embodiments,
the car 100
can include quench spray nozzles under the barrier 106 that can provide all or
a portion of
the quench fluid.
[0017] The permeable barrier 106 can comprise one or more of a screen,
curtain, mesh,
or other structure configured to contain coke during the quench process while
allowing
quench fluid to pass therethrough and reach the contained coke. In particular
embodiments,
the permeable barrier 106 comprises a screen having apertures therein. In some
embodiments, the apertures have a diameter of approximately 0.25 inch to about
0.75 inch.
In another particular embodiment, the apertures have dimensions of about 1.6
inch by about
0.56 inch. In still further embodiments, different portions of the barrier 106
can have
different size apertures. For example, in some embodiments, one sidewall
portion 110 can
have larger apertures than an opposing sidewall portion 110. In another
embodiment, an
aperture pattern on the barrier 106 can match or complement a nozzle pattern
in the quench
tower 104. For example, the barrier 106 can have larger apertures on regions
of the top
portion 108 that are positioned under nozzles in the quench tower 104. These
larger
apertures can better receive quench water. In still further embodiments,
apertures are
exclusively placed under quench tower nozzles. In other embodiments, other
aperture
patterns are used to optimize quench water distribution in the quench car 100.
Further, the
apertures can have different shapes in different embodiments of the
technology.
[0018] In some embodiments, the barrier 106 comprises stainless steel,
high-carbon
steel, AR400-AR500 steel, or other suitable material that can withstand the
temperature and
humidity conditions of the quench process. In a particular embodiment, a chain-
link-fence
type of material can be used as a barrier 106. In another embodiment, steel
chains can be
used. The barrier 106 can be flexible or rigid.
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[0019] In some embodiments, the quench car 100 includes a deflection or
containment
plate 112 coupled to the sidewall 102. In various embodiments, as will be
described in
further detail below, one or more containment plates 112 can be coupled to
other sidewalls,
quench car gates, the barrier 106, or the base of the quench car 100. In
particular
embodiments, the containment plate 112 can be positioned at a junction or
corner between
two sidewalls or between a sidewall and a top or base portion of the car 100.
The
containment plate 112 can overlap at least a portion of a sidewall 102 or car
base.
[0020] The containment plate 112 can have different shapes in various
embodiments of
the technology. For example, the containment plate 112 can be shaped as a
rectangle, circle,
triangle, or other shape. The containment plate 112 can be curved or otherwise
shaped to
complement the shape of the quench car 100 or can be shaped to achieve a
funneling or
confining effect on the coke during processing. For example, as will be
described in further
detail below with reference to Figure 2, the containment plate 112 shown in
Figure 1 is
shaped as a fin extending along an edge of the sidewall 102. In some
embodiments, the
containment plate 112 can fit against the car 100 tightly enough to contain
coke while
allowing used quench water to pass out of the car 100 to prevent the contained
coke from
sitting in water. The containment plate 112 can be on an internal or external
surface of the
quench car 100, or it can extend from an internal to an external portion. The
containment
plate 112 can be a solid surface or can have apertures therein.
[0021] In operation, the barrier 106 can serve to contain coke and/or
reflect "popping"
coke back into the quench car 100 during quenching. More specifically, the
barrier 106 can
be sufficiently permeable to allow quench fluid to pass through and reach the
coke while
having small enough apertures to prohibit coke from jumping or popping from
the car 100.
The barrier 106 further allows quench steam to escape the car. The barrier
sidewall portions
110 can further allow a cross-breeze to flow over the cooling coke.
[0022] Figure 2A is an isometric view of a quench car 200 having side
containment
plates 212 configured to channel quenched coke onto a quench wharf 220 after
the coke has
been quenched in a quench tower 204. As described above with reference to
Figure 1, the
- quench car 200 can have containment plates 212 coupled to a sidewall 202
of the car 200. In
the illustrated embodiment, the sidewall 202 functions as a dump gate; when
the car 200 is
tilted toward the wharf and the sidewall gate 202 is open, the quenched coke
is funneled by
the containment plates 212 onto the wharf 220 to reduce side spillage. In
further
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embodiments, the containment plates 212 can serve to contain the coke during
quenching or
can prevent the coke from spilling out of the car 200 at junction points
(i.e., the junction
between two adjacent sidewalls or a sidewall and the base of the car 200).
[0023] Figure 2B is an isometric partial cut-away view of a quench car 250
having a
tailgate containment plate 262 configured in accordance with embodiments of
the
technology. The tailgate containment plate 262 functions generally in the
manner of the
containment plates 212 described above with reference to Figure 2A. More
specifically, the
tailgate containment plate 262 can bridge space between a base 264 of the car
250 and a
sidewall gate 252. In several embodiments, the tailgate containment plate 262
is inclined
relative to the base 264 of the car 250 and the sidewall gate 252. When the
gate 252 is open,
the tailgate containment plate 262 can prevent coke from falling between an
opening
between the base 264 and the gate 252. The tailgate containment plate 262 can
further
inhibit coke from building up at this junction and preventing the gate 252
from opening and
closing. In several embodiments, the tailgate containment plate 262 is movable
relative to
the sidewall gate 252 and/or the base 264 such that the tailgate containment
plate 262
assumes different positions depending on whether the sidewall gate 252 is open
or closed.
[0024] Figure 2B also illustrates that the gate 252 can have a solid lower
portion and a
permeable upper portion. In further embodiments, the gate 252 can be fully
solid or fully
permeable, or the lower portion can be permeable and the upper portion can be
solid. In still
further embodiments, the gate 252 can comprise multiple, separate portions
(e.g., an upper
portion and a lower portion) that can move independently of each other. In
still further
embodiments, the upper portion can be fixed (e.g., fixed to the car sidewalls)
and the lower
portion can be movable (i.e., open and close on a hinge) relative to the fixed
upper portion.
The upper and lower portions can be any combination of permeable and
impermeable
surfaces. In embodiments where at least a portion of the gate 252 is solid,
the solid portion
can help contain or channel quench steam. In some embodiments, the gate 252
joins or can
be sealed against a top portion (e.g., the top portion 108 shown in Figure 1)
when the gate
252 is in a closed configuration.
[0025] Figure 3 is a partially schematic illustration of a quench car 300
positioned in a
quench tower 304 that has coke retaining features and is configured in
accordance with
embodiments of the technology. The quench tower 304 can be a byproduct quench
tower,
heat recovery quench tower, or any other similar system. The quench tower 304
includes a
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barrier 306 coupled thereto. The barrier 306 can be attached to any portion of
the quench
tower 304 framework and in various embodiments can be positioned above or
below an array
370 of quench nozzles. In embodiments where the barrier 306 is below the
nozzle array 370,
the barrier 306 can be permeable to allow quench fluid to flow through. In
embodiments
where the barrier 306 is coplanar or above the nozzle array 370, the barrier
306 can be
permeable or impermeable. In any of these embodiments, the barrier 306 can
serve to reflect
or contain coke in the quench car 300 in the manner described above with
reference to
Figure 1. In still further embodiments, as discussed above with reference to
Figure 1, the
nozzle array 370 and barrier 306 can be positioned on the quench car 300
(either in addition
to or lieu of placement on the tower 304).
[0026] In several embodiments, the barrier 306 can further comprise one or
more
sidewall portions 372 that extend downward from the generally horizontal
plane. In further
embodiments, the barrier 306 exclusively has sidewall portions 372 and not an
upper portion.
The sidewall portions 372 can be rigid or flexible curtains and can channel
coke that flies
during the quench process back into the quench car 300. In various
embodiments, the
sidewall portions 372 can comprise numerous generally adjacent panels/chains
or a single
continuous panel. In still further embodiments, the sidewall portions 372 can
be positioned
on a track, rod, or other similar system to extend along or around the quench
car 300 and
then move away from the car 300 when not in use. In various embodiments, the
barrier 306
or sidewall portions 372 are permanent in their placement relative to the
quench tower 304 or
can be retracted upward into the quench tower 304 and drop downward over the
car 300. In
other embodiments, the barrier 306 can be dropped over the car 300 and/or
retracted upward
outside of the quench tower 304 by a crane or other lifting/dropping device.
In further
embodiments, the barrier 306 can detach from the quench tower 304. In some
embodiments,
a bottom portion of the sidewall portions 372 can be positioned in the
interior portion of the
car 300, such that any coke that hits the sidewall portions 372 will slide
back into the car
300. In further embodiments, a bottom portion of the sidewall portions 372 is
exterior of the
car 300.
[0027] Figure 4 is a partially schematic illustration of a quench car 400
positioned in a
quench tower 404 having coke reclaim plates 472 configured in accordance with
further
embodiments of the technology. In the illustrated embodiment, the reclaim
plates 472
extend downward and slope laterally inward toward the quench car 400. In other
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embodiments, the reclaim plates 472 can have different angles either more or
less directed
inward toward the car 400. The reclaim plates 472 can channel coke that flies
during the
quench process back into the quench car 400 to increase coke recovery and
reduce build-up
at the base of the quench tower 404. In further embodiments, the reclaim
plates 472 are
coupled to the car 400 instead of or in addition to being coupled to the
quench tower 404.
Further, in some embodiments, the reclaim plates 472 can be movable to adjust
their angle
with reference to the quench tower 404. This adjustability can be useful to
vary the coke
diversion characteristics of the reclaim plates 472 or to accommodate
different sizes of
quench cars 400 or movement of the car 400 with reference to the quench tower
404 (e.g.,
the reclaim plates 472 can fold away while the car 400 is driving into or out
of the quench
tower 404). While the illustrated embodiment shows the reclaim plates 472
below a nozzle
array 470, in further embodiments the reclaim plates 472 are above or coplanar
with the
nozzle array 470.
[0028] Figure 5 is a front view of a quench car 500 having containment
plates 572
configured in accordance with embodiments of the technology. The containment
plates 572
can extend upward from sidewalls 502 of the car 500 and reflect coke back into
the car 500
during the quench process. The containment plates 572 can comprise any
permeable or
impermeable material, or a combination of these materials. For example, in a
particular
embodiment, a portion of the containment plates 572 closest to the sidewalls
502 is solid and
impermeable while a portion of the containment plates 572 that extends
farthest into the
center of the car 500 is permeable. All or only some of the sidewalls 502 may
include
containment plates 572. For example, in some embodiments, only two opposing
sidewalls
502 have containment plates thereon. In particular embodiments, the
containment plates 572
are on one or more drain or dump gates on the car 500.
[0029] While the sidewalls 502 can be generally orthogonal to the base of
the car 500,
the containment plates 572 can be angled inward at angle 0 such that flying
coke hits the
bottom of the containment plates 572 and deflects downward. The angle 0 can
vary in
alternate embodiments of the technology or can be adjustable (e.g., the
containment plates
572 can be on hinges). In particular embodiments, the angle 0 can be from
about 10 degrees
to about 90 degrees relative to a vertical plane. The containment plates 572
can reduce coke
breeze from moving downstream or clogging process flow. In some embodiments,
the car
500 can further include a top portion, such as the top portion 108 described
above with
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reference to Figure 1, that extends between sidewalls 502 (e.g., between the
containment
plates 572. The containment plates 572 can be used alone or in conjunction
with any of the
top portions (solid or permeable) described above.
Examples
1. A quench car system for containing coke prepared for quenching at a
quenching site, the quench car system comprising:
a quench car having a base and a plurality of sidewalls defining an opening,
the
quench car having a top; and
a permeable barrier covering at least a portion of the top of the quench car,
the
permeable barrier having a plurality of apertures therethrough.
2. The quench car system of example 1 wherein the permeable barrier is
removably coupled to the quench car.
3. The quench car system of example 1 wherein the permeable barrier extends
across the top of the quench car and at least one sidewall.
4. The quench car system of example 1 wherein the individual apertures have
a
diameter from about 1/4 inch to about 3/4 inch.
5. The quench car system of example 1 wherein the quench car further
comprises a containment plate coupled to one or more sidewalls and configured
to contain or
funnel coke or quench water.
6. The quench car system of example 5 wherein an individual sidewall
comprises a movable gate, and wherein the containment plate extends along the
gate and is
movable between a first position when the gate is open and a second position
when the gate
is closed.
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7. The quench car system of example 5 wherein two sidewalls meet at a
corner,
and wherein the containment plate is positioned adjacent to the corner and
overlaps at least
one of the sidewalls.
8. The quench car system of example 1 wherein the permeable barrier is
permanently coupled to the quench car.
9. The quench car system of example 1 wherein the permeable barrier
comprises
stainless steel.
10. The quench car system of example 1 wherein the permeable barrier is
spaced
apart from the top of the quench car.
11. The quench car system of example 1, further comprising a quench tower
having a nozzle positioned above the quench car, wherein an individual
aperture generally
vertically aligned with the nozzle has a diameter larger than a diameter of
another individual
aperture.
12. A coke quenching system, comprising:
a quench car having a plurality of sidewalls for containing coke; and
a quench tower configured to supply fluid for quenching coke, wherein the
quench
tower includes a deflection barrier positioned over the quench car and
configured to contain coke in the car.
13. The coke quenching system of example 12 wherein the quench tower
includes
a nozzle, and wherein the deflection barrier comprises an angled deflection
plate coupled to
or positioned below the nozzle.
14. The coke quenching system of example 12 wherein the quench tower
includes
a plurality of nozzles directed toward the quench car, and wherein the
deflection barrier is
positioned above the nozzles.
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15. The coke quenching system of example 12 wherein the deflection barrier
comprises a permeable barrier.
16. The coke quenching system of example 12 wherein the deflection barrier
comprises a plurality of vertical draping barriers.
17. The coke quenching system of example 12 wherein the deflection barrier
comprises a movable barrier.
18. The coke quenching system of example 12, wherein deflection barrier
comprises a plurality of confining plates.
19. The coke quenching system of example 18 wherein the confining plates
extend laterally inward toward an interior portion of the quench tower and are
angled relative
to a horizontal plane.
20. The coke quenching system of example 12 wherein the quench tower
includes
a plurality of nozzles directed toward the quench car, and wherein the
deflection barrier
comprises a permeable barrier positioned at or below the nozzles.
21. The coke quenching system of example 12 wherein the deflection barrier
comprises a chain mesh.
22. A coke quench car, comprising:
a base; and
a plurality of sidewalls extending generally orthogonally upward from the base
and
surrounding a central region configured to contain coke, wherein the
individual sidewalls comprise a lower portion adjacent to the base and an
upper portion opposite the lower portion, and wherein the upper portion of at
least one sidewall is angled laterally inward toward the central region.
23. The coke quench car of example 22 wherein the upper portion comprises a
solid barrier.
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24. The coke quench car of example 22 wherein the upper portion is angled
inward at an angle from about 10 degrees to about 90 degrees relative to a
vertical plane.
25. The coke quench car of example 22 wherein the upper portions of two
opposing sidewalls are angled laterally inward toward the central region.
26. The coke quench car of example 22 wherein the upper portions are
movable
between a first angle and a second angle.
27. The coke quench car of example 22 wherein two sidewalls meet at a
corner,
and wherein the quench car further comprises a laterally extending fin that is
coupled to the
car adjacent to the corner and is configured to contain or funnel coke or
quench water.
28. The coke quench car of example 22 wherein the upper portion comprises
an at
least partially permeable barrier.
29. The coke quench car of example 22, further comprising a top portion
configured to extend across at least a portion of the central region, wherein
the top portion
comprises an at least partially permeable barrier.
[0030] 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.
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