Closed Coke Slurry System for Solidified Petroleum Coke Recovery
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Solution Overview
Problem
The conventional pit/pad system for removing solidified petroleum coke from coke drums is environmentally hazardous, requiring substantial manual labor and generating large amounts of steam polluted with coke fines, which poses health risks to personnel and results in inefficient operations.
Innovation Solution
A closed system and method involving a coke drum unit, coke crushing unit, closed slurry pipe, dewatering bin, drain water pit, water settling tank, and clean water tank, where the coke drum is flooded with quench water to harden and cool the coke, and the petroleum coke slurry is processed through a closed system to separate and collect sellable coke pieces, reducing atmospheric pollution and manual labor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the conventional pit/pad system is used to remove solidified petroleum coke, then the coke can be removed from the coke drum, but large amounts of steam polluted with coke fines are discharged into the atmosphere, causing environmental pollution and health problems to personnel
Solution Approach 1:
The patent employs a closed system with enclosed pits and channels that contain the steam and coke fines within a controlled environment. The steam is condensed within the closed pit structure, preventing its direct discharge into the atmosphere. This enclosure approach transforms the harmful open-system steam discharge into a controlled contained process, eliminating environmental pollution while maintaining coke removal efficiency
Solution Approach 2:
The patent converts the harmful hot steam into a beneficial resource by utilizing it for preheating the incoming oily residue feedstock. The steam generated during coke removal is captured and used to preheat the feed, thereby converting the waste heat into a useful energy source. This simultaneously reduces atmospheric pollution and improves energy efficiency of the coking process
2Ease of operation
If the pit/pad system with manual operation is used, then coke chunks can be handled and crushed, but substantial manual labor is required for operating overhead cranes or front loaders, increasing operational costs
Solution Approach 1:
The patent implements an automated slurry pump system that automatically transports the coke slurry from the pit to the crushing facility and back. The system self-regulates the slurry flow, eliminates the need for manual operation of cranes and front loaders, and continuously maintains the pit at the optimal level. This automation reduces manual labor while maintaining ease of operation through automated control mechanisms
Solution Approach 2:
The patent replaces the manual mechanical systems (overhead cranes, front loaders) with an automated slurry pump system that uses hydraulic or electric drive mechanisms. The slurry pump automatically handles the transportation and positioning of coke slurry, eliminating the need for manual mechanical operation. This substitution reduces operational complexity and manual labor while improving consistency and reliability of the coke handling process
3Productivity
If the open pit/pad system is used, then coke can be processed, but huge steam clouds are generated that can be seen from great distances, creating safety hazards and environmental issues
Solution Approach 1:
The patent uses a closed pit structure with enclosed channels and coverings that contain the steam generation process within a confined space. The steam is condensed and managed within the closed system, preventing the formation of visible steam clouds that can be seen from distances. This enclosure eliminates safety hazards while maintaining full coke processing capability
Solution Approach 2:
The patent converts the harmful visible steam clouds into a beneficial preheating medium by capturing the steam and using it to preheat the incoming feedstock. The steam that would otherwise be a safety hazard and environmental pollutant is transformed into a useful thermal energy source, eliminating the visibility problem while improving energy efficiency
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The closed system significantly reduces atmospheric pollution, minimizes manual labor, and enhances operational efficiency by allowing continuous, automatic processing, improving workplace hygiene and safety, and reducing cycle time while maintaining high-quality coke production.
Implementation Method 1
the coke drum unit is flooded by means of a quench water line leading from a clean water tank via the coke drum unit to a slurry pit, thereby hardening and cooling the solidified petroleum coke
Implementation Method 2
a water settling tank receiving the filtered water and the petroleum coke from the drain water pit and for separating the petroleum coke fines from the water such that the petroleum coke fines collect in the bottom part of the water settling tank
Data Source
AI summary
A closed system for gaining sellable petroleum coke pieces out of solidified petroleum coke in a coke drum unit, comprises a coke drum unit containing solidified petroleum coke; a coke crushing unit for crushing petroleum coke into sellable petroleum coke pieces; a closed slurry pipe leading petroleum coke slurry to a closed slurry pit; a dewatering bin unit for receiving petroleum coke slurry from the slurry pit, for collecting the sellable petroleum coke pieces and for leading filtered water and petroleum coke fines out of it; a closed drain water pit, separate from the slurry pit, for receiving the filtered water and the petroleum coke fines from the dewatering bin unit; a water settling tank receiving the filtered water and the petroleum coke from the drain water pit and for separating the petroleum coke fines from the water such that the petroleum coke fines collect in the bottom part of the water settling tank, and for leading the petroleum coke fines into the slurry pit where they mix with the petroleum coke slurry; a clean water tank for receiving the purified water from the upper part of the water settling tank; and a removal unit for removing the sellable petroleum coke pieces from the dewatering bin unit.