Coke Extrusion Force Estimation via Wall Profile Measurement
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Solution Overview
Problem
Existing methods for estimating coke extrusion force in coke ovens are indirect and costly, often leading to extrusion stoppage and oven clogging due to irregularities on the oven walls, which decrease productivity.
Innovation Solution
A method that measures irregularities on the inner wall surface of carbonization chambers to estimate the outer shape of coke, defines active and passive states based on coke width relative to oven width, and calculates friction forces using apparent Young's modulus to accurately estimate extrusion force, thereby preventing extrusion stoppage and oven clogging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If extrusion force is increased to extrude coke from carbonization chambers, then coke discharge is achieved, but extrusion stoppage and oven clogging occur due to irregularities on oven walls
Solution Approach 1:
The system performs preliminary measurement of oven wall irregularities and estimation of extrusion force before actual extrusion operations. This allows proactive identification of potential extrusion stoppage risks and enables preventive maintenance scheduling, avoiding the harmful effects of forced extrusion that causes oven clogging
Solution Approach 2:
The system continuously monitors oven wall conditions and extrusion force requirements, providing feedback on the state of the carbonization chamber. This feedback mechanism allows dynamic adjustment of extrusion parameters and timely detection of deteriorating conditions that could lead to extrusion stoppage
2Device complexity
If conventional indirect methods are used to estimate extrusion force, then measurement complexity is reduced, but measurement precision and reliability are insufficient
Solution Approach 1:
The system replaces complex mechanical measurement systems with a computational approach. By measuring simple geometric parameters of oven wall irregularities and using elastic theory calculations, the system achieves high-precision extrusion force estimation without requiring complex force sensors or test equipment
Solution Approach 2:
The system introduces an intermediate computational model based on elastic theory that bridges the gap between simple geometric measurements and the complex extrusion force. The model uses measured irregularity parameters as input and calculates extrusion force as output, providing accurate results without direct mechanical measurement
3Measurement precision
If repeated extrusion load tests are performed to calculate extrusion load, then measurement precision is improved, but time consumption and cost increase significantly
Solution Approach 1:
The system performs preliminary measurement of oven wall irregularities and calculates extrusion force in advance using computational methods. This eliminates the need for repeated time-consuming extrusion load tests, as the force estimation is obtained directly from geometric measurements and elastic theory calculations
Solution Approach 2:
The system replaces physical extrusion load tests with computational elastic theory calculations. By substituting mechanical testing with mathematical modeling based on measured irregularity parameters, the system achieves accurate extrusion force determination without the time loss and cost associated with repeated physical tests
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
This method allows for high-accuracy estimation of coke extrusion force, effectively preventing extrusion stoppage and oven clogging, reducing the need for costly and troublesome extrusion load tests, and improving productivity by quantitatively determining necessary repairs.
Implementation Method 1
calculating oven wall friction force for each side surface position of the coke using a previously set apparent Young's modulus of the coke in accordance with definition of the active state or the passive state for the side surface position of the coke so as to estimate the extrusion force
Data Source
AI summary
A coke extrusion force estimation method includes: measuring irregularities on an inner wall surface of a carbonization chamber to acquire an oven wall profile; estimating an outer shape of a coke produced in the carbonization chamber based on the oven wall profile; defining an active state for a side surface position of the coke at which a coke width is smaller than an oven width and defining a passive state for a side surface position of the coke at which a coke width is larger than an oven width based on the oven wall profile and the estimated outer shape; and calculating oven wall friction force for each side surface position of the coke using a previously set apparent Young's modulus of the coke in accordance with definition of the active state or the passive state to estimate the extrusion force based on the oven wall friction force.