Coke Dry-Quenching Flow Control for Temperature Stability
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Solution Overview
Problem
Current coke dry-quenching devices require significant operator intervention to monitor and adjust various parameters, making it difficult to automate the process and reducing efficiency, as adjustments in one parameter often affect multiple others, leading to increased operator burden and potential equipment degradation.
Innovation Solution
A coke dry-quenching device with a controller that calculates and adjusts the chamber inlet flow rate by subtracting bypass and diffusion flow rates from the circulation flow rate, automatically controlling gas flow rates in the bypass, diffusion, and assisting gas lines to maintain target ratios and temperatures, thereby reducing operator burden and stabilizing discharged coke and boiler-inlet gas temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual monitoring and adjustment of multiple parameters is performed, then the discharged coke temperature, boiler-inlet gas temperature, CO concentration, and generated steam amount can be controlled, but the operator burden increases significantly
Solution Approach 1:
The control device automatically monitors and adjusts multiple parameters (discharged coke temperature, boiler-inlet gas temperature, CO concentration, generated steam amount) without requiring continuous manual intervention. The system self-regulates by processing sensor data and controlling actuator devices, enabling the equipment to serve itself and eliminate the need for constant operator attention.
Solution Approach 2:
The patent replaces manual mechanical adjustment with an automated control system that uses sensors, processors, and actuators. The control device electronically monitors parameters and automatically adjusts flow rates and temperatures, substituting the mechanical manual adjustment process with an automated electronic control system.
2Manufacturing precision
If adjustment of one parameter is made to control a specific variable, then that variable can be controlled, but other parameters are affected requiring further manual adjustments
Solution Approach 1:
The control device continuously monitors multiple parameters including discharged coke temperature, boiler-inlet gas temperature, CO concentration, and generated steam amount. Based on feedback from these sensors, the system automatically adjusts control variables to maintain all parameters within target ranges, preventing the ripple effects that would require sequential manual adjustments.
Solution Approach 2:
The control device performs multiple functions simultaneously: it monitors discharged coke temperature, boiler-inlet gas temperature, CO concentration, and generated steam amount, while also controlling gas flow rates and assisting gas flow rates. This multi-functional capability allows a single device to manage all parameter interdependencies without requiring separate control mechanisms for each parameter.
3Extent of automation
If automatic control of assisting gas flow rate and circulation flow rate is implemented, then some parameters can be controlled automatically, but CO concentration variation due to other factors still requires manual adjustment
Solution Approach 1:
The control device automatically monitors CO concentration and adjusts the assisting gas flow rate and circulation flow rate without manual intervention. The system processes CO concentration data from sensors and self-regulates the gas flow parameters to maintain CO levels within acceptable ranges, eliminating the need for manual CO concentration adjustments.
Solution Approach 2:
The patent replaces manual CO concentration adjustment with an automated control system that uses CO concentration sensors and electronically controls gas flow actuators. The system substitutes manual mechanical adjustment with automated electronic control based on real-time CO concentration measurements.
4Manufacturing precision
If bypass flow rate and assisting gas flow rate are changed to control CO concentration and temperature, then gas composition can be adjusted, but chamber inlet flow rate changes affect discharged coke temperature
Solution Approach 1:
The control device simultaneously monitors discharged coke temperature, boiler-inlet gas temperature, and CO concentration. When bypass flow rate or assisting gas flow rate is adjusted to control gas composition, the system detects resulting temperature changes through feedback sensors and makes compensating adjustments to maintain discharged coke temperature within the target range of 150°C to 250°C.
Solution Approach 2:
The control device dynamically adjusts multiple parameters including bypass flow rate, assisting gas flow rate, and circulation flow rate in a coordinated manner. When one parameter is changed to control CO concentration, the system changes other parameters to compensate for temperature effects, maintaining overall system balance and discharged coke temperature stability.
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 automatic adjustment of gas flow rates in the coke dry-quenching device reduces operator burden, stabilizes discharged coke and boiler-inlet gas temperatures, and prolongs the life of equipment by minimizing manual intervention and maintaining efficient heat recovery.
Implementation Method 1
a cooling chamber (2) for accepting red-hot coke, cooling the red-hot coke by using a cooling gas
Implementation Method 2
a boiler (3) for recovering energy from heat that the red-hot coke generates
Implementation Method 3
a turbine generator (31) for generating electricity by using steam from the boiler (3)
Data Source
Figure 1
Figure 2
AI summary
A coke dry-quenching device 1 includes a cooling chamber 2, a boiler 3, a first gas line L1 that guides a cooling gas from the cooling chamber 2 to the boiler 3, a second gas line L2 that guides the cooling gas from the boiler 3 to the cooling chamber 2, a bypass line L3 that guides part of the gas passing through the second gas line L2 to the first gas line L1, a diffusion line L4 that guides part of the gas passing through the second gas line L2 to the outside, and an inlet flow rate controller that subtracts the gas flow rates in the bypass line L3 and the diffusion line L4 from the gas flow rates in upstream sections 5b and 5c of the second gas line L2 to calculate a chamber inlet flow rate and adjusts the gas flow rates in the upstream sections 5b and Sc of the second gas line L2 or the gas flow rate in the diffusion line L4 in such a way that the ratio between the amount of coke discharged from the cooling chamber 2 and the chamber inlet flow rate approaches a target ratio.