Integrated Coke Handling Car for Collision-Free Transport and Dust Control
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Solution Overview
Problem
The existing coke production processes face challenges in maintaining safety and coordination among machines, generating significant dust and pollution during coke transportation, and experiencing non-uniform quenching and increased cycle times due to the use of multiple independent machines and inefficient dust collection methods.
Innovation Solution
A method and apparatus that utilize a hot car to transport hot caked coke in an enclosed container to a transfer station, where it is tilted and separated into loose bulk coke, collected by a quench car, and then transported to a quenching apparatus for efficient quenching, using a dust collection system and sprays for water quenching, minimizing machine interference and optimizing dust collection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple independent machines (hot car, stationary ram, quench car, door machine) are used for transporting hot coke, then the coke can be transported from oven to quenching apparatus, but the machines can interfere with one another and cause collisions or accidents
Solution Approach 1:
The patent combines the functions of multiple independent machines (hot car, stationary ram, quench car) into a single integrated machine that performs all operations. This eliminates the coordination problems and collision risks between multiple independent machines while maintaining the complete coke transportation function from oven to quenching apparatus.
Solution Approach 2:
The single machine is designed with multi-functionality, serving as both the hot car for receiving coke from the oven, the stationary ram for pushing coke, and the quench car for transporting to the quenching apparatus. This universal machine performs multiple functions that previously required separate specialized machines.
2Productivity
If hot caked coke is discharged from coke oven into hot car, then coke can be transported, but significant dust and pollution is generated at the output portal location
Solution Approach 1:
The patent converts the harmful dust-generating discharge process into a beneficial enclosed transfer process. The machine's enclosure contains the coke during transfer, preventing dust escape. The dust collection system then captures any generated dust and directs it to a collection point, transforming the harmful uncontrolled dust generation into a controlled and collectible process.
Solution Approach 2:
The enclosed transfer mechanism acts as an intermediary between the coke oven output portal and the hot car receiving area. This intermediate enclosed structure prevents direct exposure of dust to the environment during the transfer process, while the dust collection system provides another layer of intermediary control to capture and remove dust particles.
3Object-affected harmful factors
If a large shed covers the entire coke side of the battery including hot car and tracks, then dust can be captured, but the dust collection is costly and inefficient
Solution Approach 1:
The patent extracts the dust collection function from the large shed structure and concentrates it at the specific transfer station location. Instead of covering the entire coke side battery with an expensive and inefficient large shed, the dust collection system is localized to where dust is actually generated during coke transfer, significantly reducing system complexity and cost while maintaining effective dust capture.
Solution Approach 2:
The dust collection system is applied locally at the transfer station where dust generation occurs, rather than uniformly across the entire battery area. This localized approach focuses dust collection resources where they are most needed, improving efficiency and reducing the overall cost and complexity of the dust collection infrastructure.
4Ease of operation
If hot car is positioned tangential to and at lower elevation than coke oven output portal, then coke can drop onto hot car, but caked coke separates into smaller pieces generating significant dust
Solution Approach 1:
The enclosed transfer mechanism serves as an intermediary that controls the separation process. Instead of allowing free falling and chaotic separation that generates dust, the enclosure guides the coke through a controlled separation process, containing dust particles and directing them to the dust collection system while still achieving the necessary size reduction.
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 reduces the risk of collisions among machines, minimizes production cycle times, enhances dust collection efficiency, and ensures uniform quenching of coke, thereby improving safety and reducing operational costs.
Implementation Method 1
a dust collection system for collecting dust generated proximate the transfer station during transfer of the hot caked coke to the quench car and resultant separation of the hot caked coke
Implementation Method 2
sprays for water quenching
Implementation Method 3
sprays for water quenching
Data Source
AI summary
A method and apparatus for transporting and quenching coke, useful in quenching a batch of coke produced in one of a plurality of coke ovens forming a coke oven battery, is disclosed. A hot car defining a substantially planar receiving surface is positioned adjacent a coke oven of the coke oven battery, and a unitary cake of unquenched coke is placed onto the hot car receiving surface. The hot car and unquenched coke are transported to a transfer station having a dust collection system. A quenching car is positioned at the transfer station adjacent the hot car, under the dust collection system. The unitary cake of unquenched coke is dumped into the quenching car receptacle, thereby separating the unitary cake. At least a portion of the dust generated by separation is collected. The quench car is then transported to a quenching station, where the separated coke is quenched.