Coke Oven Battery Modulation System for Opacity Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for monitoring and manipulating coke oven batteries to control exhaust stack opacity and maintain battery temperatures are inefficient, leading to compliance issues with opacity regulations and compromising the energy efficiency and longevity of coke oven components.
Innovation Solution
A coke oven battery modulation system that includes sensors for opacity and specific gravity, and a controller that adjusts nitrogen and fuel gas flows to maintain optimal conditions, thereby reducing opacity and ensuring energy efficiency and structural longevity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If operators manipulate the coke oven battery to control exhaust stack opacity to comply with regulations, then opacity compliance is improved, but energy efficiency and structural longevity of coke oven components deteriorate
Solution Approach 1:
The system employs multiple sensors (opacity sensor, specific gravity sensor, temperature sensors) that continuously monitor exhaust conditions and provide feedback to the controller. The controller automatically adjusts gas flow rates and oven parameters in real-time based on this feedback, creating a closed-loop control system that maintains opacity compliance while optimizing energy efficiency and component longevity.
Solution Approach 2:
The system dynamically changes operational parameters including gas flow rates, temperature distributions, and pressure differentials across the coke oven battery. By adjusting these parameters in response to real-time sensor data, the system achieves opacity compliance without the detrimental effects of fixed, overly restrictive operational constraints.
2Object-affected harmful factors
If operators manipulate the coke oven battery to control exhaust stack opacity to comply with regulations, then opacity compliance is improved, but structural longevity of coke oven components deteriorates
Solution Approach 1:
Temperature sensors and opacity sensors provide continuous feedback to the controller, which adjusts operational parameters to prevent extreme temperature fluctuations and thermal stress on structural components. This feedback mechanism ensures that opacity control measures do not inadvertently cause thermal shock or excessive heating that would compromise the longevity of heating walls, floor bricks, and corbels.
Solution Approach 2:
The system proactively monitors and adjusts operational parameters to prevent conditions that would lead to component failure. By maintaining temperatures within optimal ranges and avoiding abrupt changes, the system cushions structural components against thermal stress and extends their service life before failure can occur.
3Ease of operation
If traditional monitoring and manipulation methods are used, then operational simplicity is maintained, but compliance with opacity regulations and energy efficiency are compromised
Solution Approach 1:
The system is designed to be largely self-regulating, with automatic control algorithms that adjust operational parameters based on sensor feedback without requiring constant operator intervention. The controller autonomously interprets sensor data and makes adjustments to gas flows and temperature distributions, reducing the operational complexity burden on operators while ensuring continuous compliance with opacity regulations.
Solution Approach 2:
The patent replaces manual operational adjustments with an automated electronic control system that uses sensor data and control algorithms to manipulate gas flows and temperature distributions. This substitution of manual mechanical adjustment with automated electronic control improves both compliance efficiency and energy efficiency while maintaining ease of operation through centralized monitoring and control.
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 system effectively reduces exhaust stack opacity, improves energy efficiency, and extends the lifespan of coke oven components by optimizing gas flows and temperatures within the coke oven battery.
Implementation Method 1
A controller programmed with a modulation program receives information from the sensors and determines a set point for adding nitrogen gas or supplemental fuel gas to the coke oven gas based on the opacity information and the specific gravity information
Implementation Method 2
A controller programmed with a modulation program receives information from the sensors and determines a set point for adding nitrogen gas or supplemental fuel gas to the coke oven gas based on the opacity information
Implementation Method 3
The regenerator is filled with bricks that have a relatively large amount of surface area per unit volume, generally due to slots formed in the bricks. In the regenerator, exhaust waste heat is used to pre-heat incoming combustion air as well as cool the exhaust waste prior to discharge.
Implementation Method 4
The modulation program adjusts one or more of the flows of gases to or through the coke oven battery to maintain a Wobbe index of the coke oven gas or the mixed gas within a predetermined range
Implementation Method 5
Gas is burned within the walls to heat the coal arranged in the ovens
Data Source
AI summary
A coke oven battery modulation system, including a coke oven battery, a coke oven gas supply fluidly connected to the coke oven battery via a first conduit, an exhaust stack fluidly connected to the coke oven battery via a second conduit, a mixed gas supply fluidly connected to the first conduit via a third conduit, a nitrogen supply fluidly connected to the first conduit via a fourth conduit, the fourth conduit including a first valve and a first actuator operatively arranged to adjust the first valve, at least one sensor, and a controller operatively arranged to receive data from the at least one sensor and communicate with the first actuator to adjust the first valve.