Method for preventing coke pushing accident of coke oven
By implementing refined management of the coke oven production process, the problem of frequent accidents caused by difficult coke pushing has been solved, the stable and efficient operation of the coke oven has been achieved, production costs and safety hazards have been reduced, and coke quality has been improved.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-11-21
- Publication Date
- 2026-03-10
AI Technical Summary
Frequent accidents due to difficulties in pushing coke during coke oven production affect production stability and safety. Existing technologies are insufficient in coal blending methods, control of graphite growth in furnace walls, coal yard inventory management, and information technology application, leading to frequent accidents.
Advanced coal quality analysis technology and online detection equipment are adopted to dynamically monitor the coal blending process; the amount of coal added, volatile matter and coal fineness are controlled, and the growth of graphite in the furnace wall is rationally managed; an intelligent coal yard inventory management system is established to monitor the coke pushing current and apply an information-based metering system to ensure the accuracy and automation of coal management.
It significantly reduces the incidence of coke pushing accidents, improves the stability and efficiency of coke oven production, reduces equipment failure rate, improves coke quality, and achieves economic and social benefits.
Abstract
Description
Technical Field
[0001] This invention belongs to the field of coke oven production technology, and in particular relates to a method for preventing accidents caused by difficulty in pushing coke in coke ovens. Background Technology
[0002] In coke oven production, difficulties in pushing coke are frequent, severely impacting normal production order and efficiency, increasing production costs, and potentially damaging equipment and posing safety hazards. These accidents are closely related to factors such as improper coal blending, abnormal graphite growth in the furnace walls, inadequate coal yard inventory management, insufficient monitoring of pushing current, and inaccurate coal management. As a core piece of equipment, the coke oven plays a crucial role in the dry distillation of blended coal into coke, and its stable operation is vital to the entire production process. However, the frequent occurrence of coke pushing difficulties has become a major obstacle to the efficient and stable production of coking enterprises.
[0003] Currently, existing coke oven production processes have many shortcomings in preventing coke pushing difficulties. Traditional coal blending methods often rely solely on conventional coal type indicators, failing to fully consider the impact of key characteristics such as coal expansion and contraction on the coke pushing process. Regarding graphite growth control in the furnace walls, there is a lack of systematic and effective monitoring and control methods, making it difficult to accurately control the growth rate and thickness of graphite. Coal yard inventory management largely relies on manual experience, which cannot adapt to fluctuations in coal quality and changes in production demand. Monitoring and analysis of key parameters such as coke pushing current are not in-depth enough, failing to promptly detect potential coke pushing difficulties. The level of information technology application is low, resulting in insufficient accuracy and automation in coal management. Therefore, a comprehensive and effective method for preventing coke pushing difficulties in coke ovens is urgently needed to address these problems and ensure the safe, stable, and efficient operation of coke ovens. Summary of the Invention
[0004] To address the aforementioned technical problems, the purpose of this invention is to provide a method for preventing accidents related to difficult coke pushing in coke ovens.
[0005] To solve the above-mentioned technical problems, the present invention adopts the following technical solution:
[0006] The present invention provides a method for preventing accidents caused by difficulty in pushing coke in coke ovens, comprising:
[0007] S1. Methods for rational coal blending
[0008] S1.1: Utilizing advanced coal quality analysis technology, we conduct comprehensive and detailed testing on incoming coal, not only measuring conventional indicators such as ash content, sulfur content, volatile matter, and caking properties, but also focusing on analyzing key characteristics of coal such as expansion, shrinkage, caking, and fluidity; and using thermogravimetric-differential thermal analysis and plastic layer index determination methods to obtain characteristic parameters of coal during the pyrolysis process.
[0009] S1.2: Dynamic monitoring and real-time adjustment of coal blending process. During the coal blending process, high-precision online detection equipment is installed to monitor various indicators of coal blending in real time, including the proportion of coal types, particle size composition, and moisture content.
[0010] S2, Controlling graphite growth in furnace walls
[0011] S2.1: Control the amount of coal added and monitor its impact on the temperature of the furnace top space to avoid insufficient coal feeding in the carbonization chamber. Insufficient coal feeding will cause the coke line to drop, which in turn will lead to graphite growth. By controlling the amount of coal added, the coke line will increase on average after the coal is fully fed, thereby reducing the temperature of the furnace top space.
[0012] S2.2: Control the volatile matter content of the blended coal, monitor the influence of the volatile matter content of the blended coal on the temperature of the furnace top space, and control the combustible volatile matter content of the blended coal within a suitable range. Starting from ensuring reasonable coke shrinkage and reducing the temperature of the furnace top space, the volatile matter content is kept at 26% ± 0.5%.
[0013] S2.3: Control the fineness of the blended coal. Taking into account the impact of the blended coal's caking properties and other indicators on coke quality and yield, formulate a reasonable coal blending fineness. The coal blending fineness is specified to be 72% ± 2% to avoid the formation of graphite due to the increase of fine coal dust at the furnace top caused by excessively fine blended coal and low moisture content.
[0014] S2.4: Clean the coke oven graphite regularly;
[0015] S2.5: Precisely control the operation of the coke oven to ensure that the center temperature of the coke cake is controlled at 980-1000℃ and the pressure of the gas collecting pipe is controlled according to the operating procedures.
[0016] S3. Ensure reasonable coal yard inventory. Given that large fluctuations in coal yard inventory and small inventory of major coal types will cause the coal yard to lose its function of uniformly mixing incoming coal quality, and large fluctuations in the shrinkage of various coal types will cause fluctuations in coking current, it is required that each major coal type maintain an inventory of at least 7 days.
[0017] S4. Monitor the coke pushing current, implement a statistical, tracking, and inspection system for furnaces with high coke pushing current, formulate evaluation indicators for the stability of the coke pushing current, and directly reflect the magnitude of the coke cake movement resistance through the magnitude of the coke pushing current to promptly identify potential coke pushing difficulties.
[0018] S5. Apply an information-based metering system. Through information technology upgrades and the metering system, the stacker-reclaimer can be automatically positioned, and the information can be entered into the MES system to avoid incorrect coal stacking and reclaiming, and to ensure the accuracy and stability of coal blending.
[0019] Furthermore, this includes routine manual cleaning of graphite.
[0020] Furthermore, measures include: gradually welding steel plates onto the head of the coke pusher, scraping graphite from the empty furnace after coke discharge, and cleaning up excessively thick graphite that has already grown using air ducts.
[0021] Furthermore, the stacker-reclaimer is equipped with a high-precision positioning device that seamlessly integrates with the workshop's MES system.
[0022] Furthermore, during the stacking and reclaiming operation, the location information of the stacker-reclaimer is transmitted to the MES system in real time. The system automatically guides the stacker-reclaimer to accurately perform the stacking and reclaiming operations according to the preset operation plan, thus avoiding the occurrence of stacking or reclaiming the wrong coal.
[0023] Furthermore, the MES system records and analyzes coal entry and exit data in real time, providing accurate data support for production decisions.
[0024] Furthermore, this method significantly reduces the incidence of coke pushing accidents; greatly improves the stability of coke oven production, reduces equipment failure rate, increases production efficiency, and effectively guarantees coke quality, achieving significant economic and social benefits.
[0025] Compared with the prior art, the beneficial technical effects of the present invention are as follows:
[0026] The method for preventing coke pushing difficulties in coke ovens provided by this invention achieves significant economic and social benefits through refined coal blending management, fully considering the characteristics of different coal types, optimizing the blending scheme, ensuring coke quality while rationally utilizing various coal types. Regarding the control of graphite growth in the furnace walls, it comprehensively controls graphite growth by addressing multiple key factors such as coal feed rate, volatile matter, and coal fineness, reducing the problem of increased coke pushing resistance caused by excessive graphite thickness. Maintaining reasonable coal yard inventory effectively solves the problem of fluctuating coke pushing current caused by coal quality fluctuations and unreasonable inventory. Monitoring the coke pushing current and establishing corresponding systems enables timely detection of abnormal coke pushing situations. The application of an information-based metering system improves the accuracy and automation of coal management. Through the synergistic effect of these multiple measures, this invention can effectively prevent coke pushing difficulties in coke ovens, improve the stability and efficiency of coke oven production, reduce production costs, and minimize equipment damage and safety hazards. Detailed Implementation
[0027] The present invention will be described in detail below with reference to specific embodiments.
[0028] Example 1: In a large coke oven production workshop, its coke oven coal blending system is equipped with 20 coal blending bins, providing a hardware foundation for refined coal blending.
[0029] S1, Fine Coal Blending Operation
[0030] S1.1: Utilizing advanced coal quality analysis technology, we conduct comprehensive and detailed testing on incoming coal. This includes not only measuring conventional indicators such as ash content, sulfur content, volatile matter, and caking properties, but also focusing on analyzing key characteristics such as coal's expansion, shrinkage, caking, and flowability. We employ methods such as thermogravimetric-differential thermal analysis (TG-DTA) and plastic layer index determination to obtain characteristic parameters of coal during the pyrolysis process.
[0031] S1.2: Dynamic monitoring and real-time adjustment of the coal blending process. During coal blending, high-precision online detection equipment is installed to monitor various indicators of the blended coal in real time, including the proportion of different coal types, particle size distribution, and moisture content. When the expansion or contraction properties of the incoming coal fluctuate significantly, the proportions of each coal type are adjusted promptly to ensure the stability of the blended coal quality and prevent accidents such as difficulty in coking caused by improper coal blending from the source.
[0032] S2, Multi-dimensional control of graphite growth in furnace walls
[0033] S2.1: Precise control of coal feeding. A high-precision coal feeding monitoring device has been installed in the carbonization chamber, linked to the automated coal feeding equipment. Real-time monitoring of the coal feeding process ensures that the carbonization chamber is always fully filled with coal. Taking a certain carbonization chamber as an example, before implementing precise coal feeding, the average temperature of the furnace top space reached 869℃ due to insufficient coal feeding, and the coke temperature dropped significantly. After implementation, fully filling the chamber increased the average coke temperature by 338mm, and the furnace top space temperature successfully dropped to 799℃, effectively inhibiting graphite growth.
[0034] S2.2: Strict control of volatile matter. To accurately control the combustible volatile matter content of the blended coal, the workshop has introduced advanced online volatile matter monitoring equipment connected to the coal blending system. Once the volatile matter deviates from the set target value of 26% ± 0.5%, the system automatically adjusts the proportion of each coal type. For example, when the volatile matter is detected to rise to 28%, the system immediately reduces the amount of high-volatile-matter coals and increases the proportion of low-volatile-matter coals. After multiple adjustments, the volatile matter is stabilized within a suitable range, fundamentally reducing the problems of excessive coke cake shrinkage and excessively high furnace top space temperature caused by excessively high volatile matter.
[0035] S2.3: Reasonable setting of coal fineness. In the coal crushing stage, a new type of intelligent crushing equipment is adopted. The particle size of the coal is monitored in real time by sensors, and the working parameters of the crusher are automatically adjusted according to the preset coal fineness target of 72% ± 2%. If the coal fineness is detected to be too high, the equipment automatically reduces the crushing intensity and increases the number of screenings to ensure that the coal fineness meets the requirements, thereby reducing the increase of fine coal dust on the furnace top and the formation of graphite caused by excessively fine coal.
[0036] S2.4: Graphite Cleaning Measures. In addition to assigning experienced workers to perform daily manual graphite cleaning, the workshop has also innovatively modified the coke pusher. Special steel plates with excellent wear resistance and scraping properties are gradually welded onto the pusher head. After each coke discharge, taking advantage of the empty furnace push, the pusher is remotely controlled to allow the welded steel plates to scrape against the furnace wall, effectively cleaning the attached graphite. Simultaneously, high-pressure air ducts are installed to periodically blow away the furnace wall, thoroughly removing any loosened graphite debris.
[0037] S2.5: Key parameters are stably controlled. A high-precision coke cake center temperature monitor is installed to ensure that the coke cake center temperature is consistently controlled between 980-1000℃. Regarding gas collecting pipe pressure control, an advanced automated pressure regulation system is adopted to automatically adjust the gas collecting pipe pressure according to the real-time operating conditions of the coke oven, strictly adhering to the operating procedures.
[0038] S3 Scientific Management of Coal Yard Inventory
[0039] An intelligent coal yard inventory management system was established, using various sensors installed in the coal yard to monitor the inventory levels of each major coal type in real time. Combining the workshop's production plan with historical coal consumption data, the system automatically calculates the reasonable lower limit for the inventory of each major coal type and sets up an early warning mechanism. When the inventory of a major coal type approaches a 7-day usage period, the system immediately issues an early warning, reminding the purchasing department to make timely purchases. Simultaneously, utilizing the intelligent scheduling system of the coal yard's stacker-reclaimers, stacking and reclaiming operations are rationally arranged according to the characteristics and inventory status of different coal types, ensuring that the coal yard has a good mixing and uniform function for incoming coal quality.
[0040] S4. The coke pushing current is strictly monitored.
[0041] A self-developed coke pushing current monitoring and analysis system was established. This system is connected to the electrical control system of the coke pushing equipment to collect coke pushing current data in real time. Once the coke pushing current exceeds the set normal range, the system immediately triggers an alarm and automatically records relevant furnace number, time, and other information. Simultaneously, professional technicians are assigned to statistically analyze, track, and inspect furnaces with high coke pushing current. Through in-depth analysis of the coke pushing current data, an evaluation index system for the stability of the coke pushing current was established, using factors such as the fluctuation amplitude and duration of the coke pushing current as key evaluation indicators to promptly identify and resolve potential coke pushing difficulties.
[0042] S5, Efficient Application of Information-based Metering System
[0043] A comprehensive information technology upgrade of the workshop's metering system was completed, introducing advanced Internet of Things (IoT) technology and automated control equipment. The stacker-reclaimer was equipped with a high-precision positioning device, seamlessly integrating with the workshop's Manufacturing Execution System (MES). During stacking and reclaiming operations, the stacker-reclaimer's position information is transmitted to the MES system in real time. Based on a pre-set work plan, the system automatically guides the stacker-reclaimer to accurately perform stacking and reclaiming operations, preventing the incorrect stacking or reclaiming of coal. Simultaneously, the MES system records and analyzes coal inflow and outflow data in real time, providing accurate data support for production decisions.
[0044] After a year of implementation, the incidence of coke pushing accidents in the workshop has been significantly reduced, with a decrease of up to 30%. The stability of coke oven production has been greatly improved, the equipment failure rate has been reduced by 40%, production efficiency has increased by 25%, and coke quality has been effectively guaranteed, achieving significant economic and social benefits.
[0045] Example 2: Another coke oven production workshop has only 10 coal blending bins in its coal blending system.
[0046] S1. Targeted optimization of coal blending strategy
[0047] Given the limited number of coal blending bins, workshop technicians focused their research on coal types such as Class II 1 / 3 coking coal. Through laboratory analysis and industrial trials of numerous coal samples, they selected coal types with good shrinkage as the main blending targets. For example, they determined that blending Class II 1 / 3 coking coal from a specific mine with local prime coking coal with good shrinkage in a 4:6 ratio could effectively stabilize the coking current. In actual coal blending operations, workers strictly followed the established blending scheme, utilizing the workshop's existing coal blending equipment to ensure accuracy through multiple precise weighing and mixing operations.
[0048] S2. Graphite Growth Control Measures in Furnace Walls
[0049] Similar to Example 1, in terms of coal feed control, a combination of manual and automated monitoring was used to ensure the carbonization chamber was filled with coal, thereby reducing the temperature of the furnace top space. For volatile matter control, the blended coal was sampled and analyzed periodically. Based on the volatile matter test results, the proportions of each coal type were manually adjusted to stabilize the volatile matter content at 26% ± 0.5%. Regarding coal fineness control, the working state of the pulverizer was adjusted based on manual experience and regular particle size testing to ensure a coal fineness of 72% ± 2%. For graphite cleaning, in addition to manual cleaning, a simple coke pusher scraping device and manual air duct blowing were used to clean the graphite on the furnace walls. Simultaneously, the coke cake center temperature and gas collecting pipe pressure were strictly controlled to ensure that all parameters met the requirements of the regulations.
[0050] S3, Coal Yard Inventory Optimization Management
[0051] Establish a simple and practical coal yard inventory ledger, and assign dedicated personnel to regularly check the inventory quantities of each major coal type. Based on the workshop's production plan and past experience, set a 7-day lower limit for the inventory of each major coal type. When the inventory approaches the lower limit, promptly report to the purchasing department and urge them to make purchases. In the process of coal yard management, manually and rationally arrange the stacking positions of coal piles to ensure that different coal types can be fully mixed, thus maximizing the coal yard's function of uniformly mixing incoming coal quality.
[0052] S4. Coke Pushing Current Monitoring and Management
[0053] A system for recording and analyzing coke pushing current was established, requiring operators to manually record the current data each time coke is pushed. Any abnormal increase in coke pushing current must be immediately reported to technicians. Technicians, through analysis of historical coke pushing current data, preliminarily established evaluation criteria for coke pushing current stability, such as using a coke pushing current exceeding the normal average by 20% as an anomaly criterion, and promptly addressed any abnormal coke pushing situations.
[0054] S5. Preliminary Application of Information-based Metering System
[0055] A simple information technology upgrade was carried out on the metering equipment in the workshop to achieve automatic recording and transmission of coal inflow and outflow data. Regarding stacking and reclaiming operations, simple positioning markers and operation guidance systems were installed on the stacker-reclaimers, combined with on-site manual supervision, to reduce the occurrence of incorrect coal stacking or reclaiming.
[0056] After six months of implementation, the incidence of coke pushing difficulties in the workshop has decreased significantly, with a reduction of 25%. The production order of the coke oven has been effectively guaranteed, equipment maintenance costs have been reduced by 30%, production efficiency has increased by 15%, and coke quality has remained basically stable, achieving good application results.
[0057] The embodiments described above are merely preferred embodiments of the present invention and are not intended to limit the scope of the present invention. Various modifications and improvements made by those skilled in the art to the technical solutions of the present invention without departing from the spirit of the present invention should fall within the protection scope defined by the claims of the present invention.
Claims
1. A method for preventing the occurrence of coke pushing difficulty in coke ovens, characterized by: Comprise; S1, the method of reasonable coal blending S1.1: Use advanced coal quality analysis techniques to conduct comprehensive and detailed testing of incoming coal, not only to determine conventional indicators: ash content, sulfur content, volatile matter and caking property; but also to focus on analyzing the key properties of coal expansion, shrinkage, caking property, fluidity; use thermogravimetric-differential thermal analysis, gum layer index determination method to obtain the characteristic parameters of coal during pyrolysis; S1.2: Dynamic monitoring and real-time adjustment during coal blending process, install high-precision online detection equipment during coal blending process, real-time monitor various indicators of coal blending, including coal type proportion, particle size composition, moisture content; S2, control the growth of graphite in the furnace wall S2.1: Control the coal charging amount, monitor the influence of coal charging amount on the temperature of the furnace top space, avoid insufficient coal charging in the carbonization chamber; insufficient coal charging will cause the coke line to drop, and then cause graphite growth, by controlling the coal charging amount, make the coke line average height increase after full coal charging, reduce the temperature of the furnace top space; S2.2: Control the volatile matter of blended coal, monitor the influence of volatile matter of blended coal on the temperature of the furnace top space, control the combustible volatile matter of blended coal in a suitable range, from the perspective of ensuring reasonable shrinkage of coke and reducing the temperature of the furnace top space, keep the volatile matter at 26%±0.5%; S2.3: Control the fineness of blended coal, comprehensively consider the influence of caking property and other indicators of blended coal on coke quality and yield, develop a reasonable coal blending fineness, specify the coal blending fineness at 72%±2%, avoid the increase of fine coal dust in the furnace top space due to too fine blended coal and too low moisture, and form graphite; S2.4: Regularly clean the coke oven graphite; S2.5: Fine control of coke oven operation, ensure that the center temperature of the coke cake is controlled at 980-1000℃, and the manifold pressure is controlled according to the operating procedures; S3, ensure reasonable inventory of coal yard, due to the large fluctuation of coal yard inventory and the small inventory of main coal types, the coal yard will lose the function of mixing uniform quality of incoming coal, the fluctuation of shrinkage of various coals will cause the fluctuation of coke pushing current, it is required to maintain at least 7 days of inventory of each main coal type; S4, monitor the coke pushing current, implement the statistics, tracking and inspection system of coke pushing high current furnace number, develop evaluation indicators of coke pushing current stability, directly reflect the size of coke cake moving resistance through the size of coke pushing current, and find potential coke pushing difficulties in time; S5, apply information-based measurement system, through information-based transformation and measurement system, realize automatic positioning of the stacker-reclaimer, and input the information into the MES system, avoid stacking and taking wrong coal, and ensure the accuracy and stability of coal blending.
2. The method for preventing the occurrence of a coke pushing difficulty in a coke oven according to claim 1, characterized by: Including daily manual cleaning of graphite.
3. The method for preventing the pushing difficulty of coke oven according to claim 1, characterized in that: Also includes: Take gradually welding steel plates on the coke pushing rod head, scrape the grown too thick graphite after pushing out the coke, and use the air pipe blowing measures to clean the grown too thick graphite.
4. The method for preventing the occurrence of the coke pushing difficulty in the coke oven according to claim 1, characterized by: The stacker-reclaimer is installed with high-precision positioning device, which is seamlessly connected with the MES system of the workshop.
5. The method for preventing the occurrence of a coke pushing difficulty in a coke oven according to claim 1 or 4, characterized by: During the stacking and reclaiming operation, the position information of the stacker-reclaimer is transmitted to the MES system in real time, the system automatically guides the stacker-reclaimer to accurately perform the stacking and reclaiming operation according to the preset operation plan, and avoids the stacking and reclaiming of wrong coal.
6. The method for preventing the occurrence of a coke pushing difficulty in a coke oven according to claim 1, characterized by: The MES system records and analyzes the data of coal entering and leaving the warehouse in real time, and provides accurate data support for production decision-making.
7. The method for preventing the occurrence of the coke pushing difficulty in the coke oven according to claim 1, characterized in that: The method can significantly reduce the incidence of pushing difficult accident, greatly improve the stability of coke oven production, reduce the equipment failure rate, improve the production efficiency, effectively guarantee the coke quality, and achieve significant economic and social benefits.