Movable Plate Segments for Coke Quenching
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Highly compacted coke cakes from carbonization processes hinder efficient quenching and cooling due to the Leidenfrost effect and uneven water distribution, leading to incomplete cooling and potential damage to downstream processing equipment, while also resulting in elevated water content and reduced coke quality.
Innovation Solution
A method utilizing movable plate segments in the receiving container of a quenching car to break up the coke batch before quenching, allowing cooling agents to penetrate and evenly distribute, thereby enhancing quenching efficiency and reducing environmental pollution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the coke batch is highly compacted during carbonization, then the coke quality and density are improved, but the water penetration during quenching is hindered due to the Leidenfrost effect and uneven water distribution
Solution Approach 1:
The receiving container bottom is divided into multiple movable plate segments that can be independently actuated. These segments create channels and gaps in the compacted coke batch, allowing water to penetrate more uniformly throughout the quenching process, thereby resolving the contradiction between maintaining high coke density and achieving effective water distribution.
Solution Approach 2:
The plate segments are made movable rather than fixed, allowing the system to dynamically adjust the internal structure of the receiving container during quenching. The segments can shift position based on coke batch characteristics and quenching requirements, enabling adaptive water distribution that maintains both coke quality and quenching efficiency.
2Productivity
If the coke batch is pushed into the receiving container as a solid compacted cake, then the carbonization process is efficient, but the Leidenfrost effect prevents uniform cooling and causes overheating in certain areas
Solution Approach 1:
The compacted coke cake is segmented by the movable plates during quenching, creating multiple pathways for water penetration. This segmentation breaks up the continuous compacted structure that causes the Leidenfrost effect, allowing uniform heat extraction throughout the coke batch while maintaining the benefits of efficient carbonization.
Solution Approach 2:
The movable plate segments create a porous or channelled structure within the compacted coke batch during quenching. This artificial porosity allows water to penetrate deep into the coke cake, overcoming the Leidenfrost effect and achieving uniform cooling without compromising the density and quality gains from efficient carbonization.
3Temperature
If water is applied to the surface of hot coke during quenching, then the cooling process starts, but the Leidenfrost effect causes water to evaporate before penetrating, leading to incomplete cooling
Solution Approach 1:
The water application system is coupled with the segmented movable plates, which create channels that guide water directly into the coke batch interior. This segmentation prevents water from simply evaporating on the surface by providing immediate pathways for penetration, improving cooling efficiency and reducing water consumption.
Solution Approach 2:
The movable plate segments act as intermediaries that facilitate water penetration into the hot coke batch. By creating physical channels and gaps, these plates mediate between the water application system and the coke interior, ensuring water reaches the hot zones for effective cooling rather than evaporating uselessly on the surface.
4Device complexity
If the coke batch is not broken up before quenching, then the receiving container structure is simple, but the water distribution remains uneven and quenching time is extended
Solution Approach 1:
The receiving container incorporates movable plate segments that can be actuated during quenching to break up the coke batch. This dynamic feature allows the container to transition from a simple storage structure to an active quenching aid, creating channels for water penetration without requiring a completely complex pre-designed structure.
Solution Approach 2:
The movable plate segments serve multiple functions: they support the coke batch during storage, create channels for water penetration during quenching, and can be repositioned or adjusted for different quenching requirements. This multi-functionality reduces the need for separate dedicated quenching equipment, balancing structural simplicity with quenching effectiveness.
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 method ensures uniform cooling of the coke batch, reduces pollution by washing away harmful ash and dust, and improves coke quality by ensuring all parts reach ambient temperature, thus preventing damage to processing equipment and maintaining product quality.
Implementation Method 1
Highly compacted coke cakes from carbonization processes hinder efficient quenching and cooling due to the Leidenfrost effect and uneven water distribution
Implementation Method 2
an increased amount of water can flow into the inside of the coke batch during the subsequent quenching process
Data Source
AI summary
A method and a device for breaking up a fresh and hot coke charge in a receiving trough having mobile plate segments, the coke charge being conveyed to a quenching tower in the receiving trough of a flatbed transport car in which the coke charge is cooled down to ambient temperatures by mobile plate segments so that the coke structure is broken up and crevice-type cavities are formed in the compacted coke charge. These crevice-type cavities then allow an increased amount of water to flow into the interior of the coke charge during the subsequent quenching step, resulting in a high profitability of the method, a higher coke quality and a reduced burden on the environment due to reduced quenching times and lower water consumption. A device for carrying out the method is also disclosed.