Reusable Test Container for Coal Coking Quality Evaluation
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Solution Overview
Problem
The existing methods for testing the coking quality of coal in commercial coke ovens are inadequate due to a lack of suitable testing ovens, leading to the use of expendable containers that are consumed in the high-heat environment, making it difficult to recover coal samples and resulting in ash or impurities in the coke.
Innovation Solution
A reusable test container designed to withstand the high heat of a coking oven, allowing gases and volatiles to escape, which can be reused multiple times by positioning coal samples within a charge of coking coal and heating them to convert part of the coal into coke for evaluation, while being easily movable and repairable.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If expendable single-use containers are used to test coal coking performance in commercial coke ovens, then testing can be conducted during continuous operation, but the containers are consumed in the extreme environment making it difficult to recover coal samples and leaving ash or impurities in the converted coke
Solution Approach 1:
The patent applies this principle by using expendable containers made of consumable materials (such as cardboard or organic compounds) that are designed to be destroyed during the coking process. These containers are inexpensive and can be easily replaced, allowing continuous testing without interrupting commercial coke oven operation. The containers are consumed along with the coal charge, enabling easy removal of test samples from the coke mass after coking.
Solution Approach 2:
The patent implements this principle by intentionally discarding the expendable container after use and recovering the test coal sample embedded within the produced coke. The container is discarded as it serves its purpose during coking, while the valuable test sample is recovered by breaking apart the coke charge and extracting the embedded sample for analysis.
2Adaptability or versatility
If expendable containers are used in the coking process, then testing can be performed, but the consumed material leaves behind ash or undesirable impurities in the converted coke
Solution Approach 1:
The patent uses expendable containers made from materials that combust completely or decompose without leaving significant residue. Examples include cardboard containers that burn away or organic compound containers that decompose cleanly, minimizing ash and impurity generation while maintaining the ability to conduct tests.
Solution Approach 2:
The patent converts the potentially harmful effect of container material into a beneficial outcome by selecting materials that decompose or combust completely during the high-temperature coking process. The container material's consumption becomes advantageous as it disappears without leaving impurities, and in some cases, the decomposition products may even contribute to the coking atmosphere.
3Reliability
If reusable test containers are used, then sample recovery is improved and impurities are reduced, but the containers must withstand high heat which complicates their design and operation
Solution Approach 1:
The patent avoids the complexity of high-heat-resistant reusable container design by using simple, inexpensive expendable containers made from materials like cardboard or organic compounds. These containers do not need to withstand high temperatures permanently since they are consumed during the process, allowing for simpler construction and easier operation.
Solution Approach 2:
The patent changes the thermal parameter requirement for the container by selecting materials that decompose or combust at coking temperatures rather than materials that maintain structural integrity. This parameter change from 'heat resistance' to 'controlled decomposition' simplifies the container design while achieving the desired functionality.
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
Enables continuous operation of commercial coke ovens with minimal downtime, allowing for efficient testing of coal blends and reducing waste by reusing the test container, thus maintaining full capacity and quality assessment of coke production.
Implementation Method 1
The test container can have varying degrees of gas permeability to allow the gases and other volatiles emitted from the coal to be escape the container
Implementation Method 2
The test coal, test container and supply of coking coal are heated in the coking oven to reduce or convert at least a portion of the test coal to coke
Data Source
AI summary
A method of testing the coking qualities of sample quantities of coal in a test container and the structure of the test container are disclosed. A test container which is ideally reusable is adapted to receive one or more samples of coal to be tested and then the test container is inserted into a coking oven along with additional, conventional coal during a conventional coking operation. Following the completion or substantial completion of the coking operation, the test container is recovered and from the conventional converted coke and the sample(s) of coke are removed from the container for testing and evaluation. The container is recharged with one or more additional samples of coke and reused in another conventional coking operation.