Coke Oven Coal Leveling via Pulsed Gas Jets
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Solution Overview
Problem
Conventional coke oven charging methods require extensive leveling operations that prolong charging time, cause coal packing, and lead to localized oven wall erosion, while existing solutions like continuous air flow are resource-intensive and obstruct charging holes.
Innovation Solution
A method utilizing a gas blaster with a blasting pipe introduced through the charging hole to emit gas blasts, collapsing conical coal heaps and achieving leveling without a conventional leveling bar, thereby reducing resource consumption and charging time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional leveling bar is used to level the coal charge, then the coal bed surface is leveled, but the charging time is extended and coal packing occurs at the top of the charge
Solution Approach 1:
The patent replaces the mechanical leveling bar system with a pneumatic gas jet system. Compressed gas is directed through nozzles onto the coal charge, using gas flow and pressure to level the coal bed surface instead of mechanical contact. This substitution eliminates the time-consuming back-and-forth movement of a mechanical bar while achieving effective leveling without coal packing.
Solution Approach 2:
The invention employs compressed gas (pneumatics) as the active medium for leveling operations. Gas jets are directed at the coal charge through nozzles, utilizing gas pressure and flow dynamics to redistribute and level the coal. This pneumatic approach provides rapid, contactless leveling that significantly reduces charging time compared to mechanical methods.
2Manufacturing precision
If excessive leveling is performed to achieve a flat surface, then the coal bed is well-leveled, but the leveler door must remain open longer and coal packing occurs
Solution Approach 1:
Replacing the mechanical leveling bar with a gas jet system allows for precise, controlled leveling action. The gas jets can be selectively directed and adjusted in intensity, enabling effective leveling to be achieved in fewer passes. This prevents excessive leveling operations that would otherwise be required with mechanical bars to compensate for inefficiencies.
Solution Approach 2:
The gas jet system allows dynamic adjustment of gas pressure, flow rate, and nozzle positioning parameters to optimize leveling efficiency. By controlling these parameters, the system achieves effective surface flatness with minimal leveling passes, maintaining high charging rates without the need for excessive leveling that would prolong door opening time.
3Manufacturing precision
If a leveling bar is used to level the coal, then the coal peaks are leveled into valleys, but localized erosion of the oven wall occurs
Solution Approach 1:
The patent replaces direct mechanical contact between the leveling bar and coal with a pneumatic gas jet system. The gas jets level the coal charge through gas pressure and flow without mechanical contact, eliminating the friction and mechanical stress that cause oven wall erosion. This contactless approach maintains effective coal distribution while protecting the oven structure.
4Manufacturing precision
If continuous air flow is used to level coal (as in existing solutions), then leveling is achieved, but resource consumption increases and charging holes are obstructed
Solution Approach 1:
Instead of continuous air flow, the invention uses periodic or pulsed gas jets directed at the coal charge. The gas is delivered in controlled bursts through nozzles, providing effective leveling action only when and where needed. This periodic action significantly reduces gas consumption compared to continuous flow systems while maintaining effective coal leveling.
Solution Approach 2:
The gas jet system directs compressed gas locally and selectively onto specific areas of the coal charge that require leveling. Rather than applying continuous air flow across the entire charging area, nozzles are positioned to target peaks and uneven areas precisely. This localized application reduces overall gas consumption while achieving effective leveling.
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 results in a more efficient, resource-conserving, and faster charging process with improved coal bed leveling, reduced spillage, and enhanced gas flow, leading to increased productivity and reduced maintenance costs.
Implementation Method 1
releasing at least one gas blast through the blasting end in the heap of coal in order to cause a leveling thereof
Implementation Method 2
releasing at least one gas blast through the blasting end in the heap of coal in order to cause a leveling thereof
Data Source
AI summary
A method of charging a coke oven with coal includes the steps of charging coal in a coke oven chamber, whereby a heap of coal forms in the chamber; and leveling the heap of coal, where the leveling step includes: introducing a blasting end of a blasting pipe into the heap of coal, the blasting pipe being in communication with a pressurized gas storage vessel configured to release gas blasts; releasing at least one gas blast through the blasting end in the heap of coal in order to cause a leveling thereof; removing the blasting pipe from the chamber.