Coke Oven Wall Profile Evaluation Using 3D Laser Imaging
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods fail to accurately quantify the relationship between the pushing load in coke ovens and the concaves and convexes on the oven walls, leading to inefficient repair processes and potential coking chamber clogging, which affects coke production capacity.
Innovation Solution
A coke oven wall surface evaluation apparatus and method that uses a water-cooled lance with linear image cameras and laser projectors to measure concave and convex amounts on the oven walls, deriving three-dimensional profile data and resistance indexes to correlate with pushing loads, enabling effective repair planning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional measurement methods are used to diagnose oven wall state, then the diagnosis is based on simplified area metrics, but the measurement precision and ability to quantitatively grasp pushing load relationship is insufficient
Solution Approach 1:
The patent transitions from conventional two-dimensional area-based measurement to three-dimensional surface profile measurement. By introducing the Z-axis (depth direction) to capture concave and convex amounts, the system achieves precise quantitative data about oven wall surface state, enabling correlation with pushing load that was impossible with simple area metrics alone.
Solution Approach 2:
The patent replaces manual measurement methods with an automated optical measurement system using laser projectors and linear image cameras. This substitution enables non-contact, high-precision three-dimensional surface profiling of the oven wall, dramatically improving measurement precision while reducing human labor and subjectivity.
2Loss of information
If detailed three-dimensional profile measurement is implemented, then pushing load can be quantitatively correlated with wall surface state, but the device complexity and measurement cost increase
Solution Approach 1:
The patent divides the oven wall surface into multiple measurement regions and captures three-dimensional profile data at discrete points along the depth and height directions. This segmentation approach provides comprehensive information about local concave and convex conditions that affect pushing load, while keeping the measurement system manageable through systematic data collection.
Solution Approach 2:
The measurement system is designed to capture comprehensive three-dimensional surface data that serves multiple purposes: diagnosing oven wall state, correlating with pushing load, and providing repair guidance. This multi-functional capability maximizes the value of the measurement data while justifying the investment in the measurement apparatus.
3Productivity
If flame gunning repair is performed on oven wall concaves and convexes, then pushing load can be reduced and clogging prevented, but the repair time and production interruption increase
Solution Approach 1:
The patent enables preliminary diagnosis and repair planning by providing detailed three-dimensional profile data of the oven wall surface before repair operations. By identifying and prioritizing critical concave and convex regions that most affect pushing load, repairs can be planned and executed more efficiently, minimizing production interruption while targeting the most impactful areas.
Solution Approach 2:
The measurement system provides feedback on the actual three-dimensional state of the oven wall, allowing for data-driven repair decisions. By quantifying concave and convex amounts and their relationship with pushing load, the system enables optimized repair strategies that balance repair effectiveness with production time constraints, preventing both over-repair and under-repair.
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 approach allows for precise evaluation and management of oven wall states, reducing pushing loads and preventing coking chamber clogging, thereby enhancing coke production efficiency and productivity.
Implementation Method 1
a water-cooled lance with linear image cameras and laser projectors
Implementation Method 2
laser projectors to measure concave and convex amounts on the oven walls
Implementation Method 3
linear image cameras and laser projectors to measure concave and convex amounts on the oven walls
Data Source
Figure 1a
Figure 1b
Figure 2
AI summary
An oven wall three-dimensional profile data (701) representing concave and convex amounts on all over oven walls (14R, 14L) at a right side and left side of a coking chamber (11) is generated by using image signals obtained by a wall surface observation apparatus (200). A resistance index "k" in which a resistance received by pushed coke (15) resulting from a rising gradient existing on the oven wall (14) is indexed is asked by using the oven wall three-dimensional profile data (701). It can be verified that there is a correlation between this resistance index "k" and a pushing load. Accordingly, it is possible to quantitatively evaluate a state of the oven wall (14) affecting on the pushing load.