Coke Density Separation via Oscillating Table
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Solution Overview
Problem
Current methods for producing carbon anodes for aluminum production rely on calcined petroleum coke with varying densities and particle sizes, which affects the mechanical and electrical properties of the anodes, and existing separation technologies do not effectively produce a densified coke fraction with consistent density and particle size distribution.
Innovation Solution
A process and apparatus that combines size and controlled density separation using a multi-deck vibrating screen and oscillating table density separators to stratify and separate petroleum coke into dense and light fractions, maintaining equivalent particle size distribution while increasing the density of the coke fractions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If petroleum coke is separated into size fractions only, then the particle size distribution is controlled, but the density of the coke fractions varies and cannot be consistently maintained
Solution Approach 1:
The invention applies segmentation by using a multi-deck vibrating screen to separate coke into multiple size fractions (oversize, mid-size, undersize). Each size fraction is then individually processed through density separation, allowing independent control of both particle size and density for each fraction while maintaining overall consistency.
Solution Approach 2:
The invention changes the separation parameter from solely particle size to a combination of particle size and density. By introducing density as an additional separation parameter through oscillating table density separators, the process achieves simultaneous control of both particle size distribution and density consistency.
2Device complexity
If existing separation technologies are used, then the process is simple, but the densified coke fraction cannot be produced with consistent density
Solution Approach 1:
The invention introduces dynamic elements through oscillating table density separators that use controlled oscillation to enhance density separation. The oscillating motion creates dynamic stratification layers that improve the separation efficiency and consistency of density fractions, achieving precise density control while managing system complexity.
Solution Approach 2:
The invention replaces simple mechanical screening with a combination of mechanical screening and oscillating table density separation. This substitution enables density-based separation while maintaining particle size control, achieving consistent densified coke fraction production.
3Strength
If coke density is increased to improve anode properties, then mechanical and electrical properties enhance, but the particle size distribution may be altered
Solution Approach 1:
The invention segments the coke stream into distinct size fractions first, then applies density separation to each fraction independently. This segmentation ensures that density enhancement is applied uniformly across all particle sizes, improving anode mechanical properties while preserving the original particle size distribution through controlled fractional processing.
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 process consistently produces a densified coke fraction with enhanced mechanical and electrical properties, self-regulating to maintain target densities despite fluctuations in incoming coke material, improving anode performance without altering the particle size distribution.
Implementation Method 1
using the density separator to stratify and separate the first particulate coke stream into at least two separate particulate fractions of different average density
Implementation Method 2
A process and apparatus that combines size and controlled density separation using a multi-deck vibrating screen and oscillating table density separators
Implementation Method 3
A process and apparatus that combines size and controlled density separation using a multi-deck vibrating screen
Implementation Method 4
an inclined oscillating table comprising an upper end discharging the dense coke fraction, a lower end, and a particulate coke retaining deck extending between the upper end and the lower end, the deck being gas-pervious and adapted for receiving a first coke stream to be densified
Data Source
AI summary
The invention describes a process and apparatus producing a dense coke fraction from a first particulate coke fraction having a first average density and a first average particle size distribution, stratifying the coke fraction in a density separator into at least two fractions, the at least two fractions comprising a light coke fraction and the dense coke fraction. The dense fraction having an average density greater than the first average density and a particle size distribution substantially equivalent to the first average particle size distribution. The apparatus includes an inclined oscillating table comprising a gas-pervious deck, and a gas mover.