Sole Flue Crack Sealing With High-Temperature Impermeable Patches
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Solution Overview
Problem
Coke plants face challenges in maintaining airtight environments due to cracks in refractory brick structures, leading to uncontrolled air leaks, which affect the coking process and environmental footprint, especially under negative pressure conditions.
Innovation Solution
The use of high-temperature, gunable, flexible, and impermeable patches or seals made from materials like ceramic blankets or polymers to reduce airflow through cracks, applied during operation without shutting down the plant, using multiple layers for enhanced sealing and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If refractory brick structures are used to construct coke ovens, then high-temperature resistance is improved, but cracks form in the structures leading to air leaks
Solution Approach 1:
The refractory structure is divided into multiple segments with expansion joints between them, allowing each segment to expand and contract independently without forming cracks that would compromise airtightness
Solution Approach 2:
A composite sealing system is used combining refractory bricks for heat resistance with flexible sealing materials (such as ceramic fiber blankets and refractory mortars) filled into cracks and gaps to maintain airtightness while withstanding high temperatures
2Object-affected harmful factors
If the coke plant operates under negative pressure, then environmental control is improved, but uncontrolled air leaks into the system through cracks
Solution Approach 1:
Flexible sealing materials act as intermediaries between the refractory brick structure and the external environment, blocking air leakage paths while allowing the structure to maintain negative pressure operation for environmental control
Solution Approach 2:
Flexible ceramic fiber blankets and refractory mortars are applied to seal cracks and joints, providing a flexible barrier that accommodates thermal expansion and contraction while preventing uncontrolled air ingress that would disrupt process control
3Object-affected harmful factors
If the coke plant operates under positive pressure, then gas containment is improved, but gases escape through cracks increasing environmental footprint
Solution Approach 1:
Sealing materials serve as intermediaries that contain gases under positive pressure while preventing their escape through cracks, thereby reducing the environmental footprint by keeping gases within the controlled system
Solution Approach 2:
Flexible sealing compounds and ceramic fiber materials are applied to cracks and joints to create a gas-tight barrier that contains process gases under positive pressure, preventing their release to the environment
4Duration of action of stationary object
If repair materials are applied to withstand coking environment, then durability is improved, but the oven temperature cannot drop below thermally-volume-stable temperature
Solution Approach 1:
Repair materials are selected and applied based on their thermal stability parameters, using materials that maintain their structural integrity and sealing properties at the minimum thermally-volume-stable temperature while allowing the oven to operate within the required temperature range
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
Significantly reduces air leakage by up to 90%, maintaining process efficiency and environmental control, while withstanding high temperatures and thermal expansion, thus improving coke quality and reducing environmental impact.
Implementation Method 1
withstanding high temperatures and thermal expansion
Data Source
AI summary
The present technology relates to systems and methods for reducing leaks in a system for coking coal. For example, some embodiments provide systems and method for treating a cracked or leaking surface in a system for coking coal. In particular, the present technology includes systems having one or more substances configured to reduce an airflow through one or more cracks by creating an at least partially impermeable patch. The present technology further includes methods for treating surfaces having one or more cracks to reduce an airflow through the one or more cracks.