Gastight Coke Drum System Preventing Steam Emissions
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Solution Overview
Problem
Existing systems for gaining sellable petroleum coke pieces from solidified petroleum coke in a coke drum unit result in substantial steam and coke fine emissions into the environment, and are costly.
Innovation Solution
A closed, gastight system and method that includes a coke crushing unit, a closed sluice way, a slurry basin, a dewatering bin unit, a drain water basin, a single water tank, and vent collection lines to prevent steam and coke fine emissions, using cooling water to control quench water temperature and pressure, and a centrifugal separation device for water purification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a conventional coke slurry system is used to handle solidified petroleum coke, then the system can process coke from the coke drum unit, but substantial steam and coke fine emissions are released into the environment
Solution Approach 1:
The patent implements a closed, gastight system that creates a controlled environment where quench water is cooled below its boiling point before entering the slurry basin. This prevents steam generation and maintains an inert atmosphere, eliminating harmful emissions of steam and coke fines into the environment while preserving the coke processing capability.
Solution Approach 2:
The patent introduces a cooling water line as an intermediary element that cools the quench water before it enters the slurry basin. This intermediary cooling mechanism prevents the water from reaching temperatures that would generate steam, thereby eliminating emissions while maintaining the necessary coke handling operations.
2Temperature
If quench water is used to cool solidified petroleum coke in the coke drum unit, then the coke can be hardened and cooled, but the quench water heats up to high temperatures and pressure causing steam generation
Solution Approach 1:
The patent applies preliminary cooling action by cooling the quench water in a cooling water line before it enters the slurry basin. This pre-cooling step ensures the water temperature remains below the boiling point, preventing steam generation during the coke quenching process while maintaining effective cooling of the solidified coke.
Solution Approach 2:
The cooling water line serves as an intermediary that transfers heat from the quench water to the cooling water, preventing direct steam generation. This intermediary heat exchange mechanism allows the quench water to cool the coke effectively without reaching temperatures that would produce harmful steam emissions.
3Object-generated harmful factors
If a closed, gastight system is implemented to prevent emissions, then steam and coke fine emissions are eliminated, but installation and operation costs increase
Solution Approach 1:
The patent extracts the cooling function from the main quenching process by separating the cooling water line from the quench water system. This extraction allows the system to achieve emission-free operation through targeted cooling of quench water without requiring complete redesign of the entire coke handling system, thereby reducing overall complexity and cost.
Solution Approach 2:
The system uses the existing quench water infrastructure to serve dual purposes: cooling the solidified coke and, through the cooling water line, preventing steam generation. This self-service approach leverages existing system components to achieve emission-free operation without requiring entirely new systems, thereby reducing installation and operation costs.
4Object-generated harmful factors
If quench water is cooled to prevent steam generation, then emissions are prevented, but additional cooling infrastructure and water consumption are required
Solution Approach 1:
The patent implements water recycling by recovering cooled quench water from the slurry basin and returning it to the cooling water line. This recycling loop allows the same water to be used multiple times for cooling purposes, significantly reducing overall water consumption while maintaining the ability to prevent steam generation through continuous cooling.
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 prevents steam and coke fine emissions, reduces installation and operation costs, and enables efficient water recycling with minimal maintenance, achieving a zero-emission and cost-effective coke handling process.
Implementation Method 1
a cooling water line leading from the water tank, particularly from a intermediate portion thereof, to the hot quench water draining line, in particular to a joining point in the hot quench water draining line at a position above the closed slurry basin, configured to feed cooling water from the water tank to the hot water in the hot quench water draining line, in order to prevent steam generation within the slurry basin
Implementation Method 2
a centrifugal separation device for water purification
Data Source
AI summary
A closed, gastight system for gaining sellable petroleum coke pieces out of solidified petroleum coke in a coke drum unit, wherein the system is configured to be connected to a coke drum unit (X) containing solidified petroleum coke and comprisesa coke crushing unit (C) for crushing the petroleum coke into sellable petroleum coke pieces, configured to be connected to the coke drum unit (X), particularly by means of a flexible transition piece (A);a closed sluice way (D) leading petroleum coke slurry to a closed slurry basin;a closed slurry basin (E);a dewatering bin unit (G) configured to receive the petroleum coke slurry from the slurry basin (E), to collect the sellable petroleum coke pieces, and to act as a filter leading runoff drain water from a lower area thereof as filtered water and petroleum coke fines out of it;a closed drain water basin (I), separate from the slurry basin (E), configured to receive the filtered water and the petroleum coke fines from the dewatering bin unit (G);a water tank (L) configured to receive the filtered water from the drain water basin (I);a hot quench water draining line (2) configured to receive hot quench water from the coke drum unit (X) and to lead the same to the closed slurry basin (E); andcharacterised:in that the water tank (L) is configured as single water tank (L) without a separate second tank; andby comprising one or more of the following elements:a first vent collection line (15a) extending from a top portion of the closed slurry basin (E) to the clean water tank (L), particularly a top portion thereof, for collecting excess amounts of gaseous phase from the slurry basin (E) and for feeding the same to the clean water tank (L);a second vent collection line (15b) extending from the dewatering bin unit (G), particularly a top portion thereof, to the clean water tank (L), particularly a top portion thereof, for collecting excess amounts of gaseous phase from the dewatering bin unit (G) and for feeding the same to the clean water tank (L); anda third vent collection line (15c) extending from the closed drain water basin (I), particularly a top portion thereof, to the clean water tank (L), particularly a top portion thereof, for collecting excess amounts of gaseous phase from the closed drain water basin (I) and for feeding the same to the clean water tank (L);and by comprising a fourth vent collection line (15d) extending from the water tank (L), particularly a top portion thereof, to a vent treatment unit, in particular to a vent incineration unit.