Multi-Unit Coking System for Needle Coke Stability
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Solution Overview
Problem
Conventional coking systems for producing needle coke face challenges with large operation fluctuations due to temperature and pressure changes, leading to unstable needle coke product performance, primarily due to variations in heating unit temperature control and feeding properties during the coking process.
Innovation Solution
A coking system comprising multiple heating units and coke towers, where each heating unit is specifically controlled to manage temperature and feeding rates, with a sequential material transport process and filtration of coke-pulling feedstocks to stabilize the coking process and improve needle coke quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a conventional one-furnace and two-tower delayed coking mode is used, then the production process is simple, but the operation fluctuation is large and product performance is unstable
Solution Approach 1:
The patent divides the single heating furnace into multiple heating units (first heating unit, second heating unit, etc.), each capable of independently heating different feedstocks. This segmentation allows for separate control of heating parameters for different materials, reducing operational fluctuations and improving product stability while maintaining overall system simplicity.
2Adaptability or versatility
If variable temperature control is used in the heating unit, then different feedstocks can be heated, but the temperature range is wide and stable operation is difficult
Solution Approach 1:
The patent assigns different temperature control parameters to different heating units based on their specific feedstock requirements. The first heating unit operates at lower temperatures (400-480°C) for fresh feedstock, while the second heating unit operates at higher temperatures (460-510°C) for coker middle distillate oil. This localized temperature optimization enables versatile feedstock processing while maintaining stable operation within each unit's optimized temperature range.
3Adaptability or versatility
If different heating stages are used for different feedstocks, then complete feedstock processing is achieved, but the feeding amount changes greatly causing control difficulty
Solution Approach 1:
The patent implements dynamic feedstock switching between different heating units based on the coking process stage. During the coke-forming stage, fresh feedstock is fed to the first heating unit, while during the coke-pulling stage, coker middle distillate oil is fed to the second heating unit. This dynamic allocation balances the feeding amounts across multiple units, making control easier while ensuring complete processing of different feedstocks at appropriate times.
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 achieves stable performance and improved quality of needle coke with reduced thermal expansion and uniform texture, meeting the requirements for high-power graphite electrodes by optimizing temperature control and feeding processes across multiple heating units and coke towers.
Implementation Method 1
the coefficient of thermal expansion of the needle coke is reduced
Data Source
AI summary
A coking system comprises the 1st to the m-th heating units and the 1st to the n-th coke towers, each of the m heating units being in communication with the n coke towers, respectively, each of the n coke towers being in communication with one or more separation towers, respectively, in communication with the m-th heating unit and optionally with the i-th heating unit. The coking system can at least utilize petroleum series or coal series raw materials to produce high-quality needle coke with stable performance.