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    • 专利摘要:
    The present technology is generally aimed at horizontal thermal recovery and non-thermal recovery coke ovens with monolithic components. In certain embodiments, an HHR coke oven includes a monolithic component that measures the width of the oven between opposing oven side walls. The monolith expands on heating and contracts on cooling as a single structure. In further embodiments, the monolithic component comprises a thermally volume-stable material. The monolithic component can be a choir, a wall, a floor, a floor combustion duct or a combination of some or all of the furnace components to create a monolithic structure. In further embodiments, the component is formed as a plurality of monolithic segments that expand between supports such as oven side walls. The characteristics of the monolithic component and thermally stable aspects with respect to volume can be used in combination or individually. These designs can allow the furnace to be reduced below traditionally achievable temperatures while maintaining the structural integrity of the furnace.
    公开号:BR112017004981B1
    申请号:R112017004981-3
    申请日:2015-09-15
    公开日:2021-05-11
    发明作者:Gary Dean West；John Francis Quanci
    申请人:Suncoke Technology And Development Llc；
    IPC主号:
    专利说明:

    CROSS REFERENCE TO RELATED ORDERS
    [001] This application claims priority benefit to U.S. provisional patent application No. 62/050,738 filed September 15, 2014, the description of which is incorporated herein by reference in its entirety. TECHNICAL FIELD
    [002] The present technology is generally directed towards the use of precast geometric shapes. BACKGROUND
    [003] Coke is a carbon fuel source and solid carbon used to melt and reduce iron ore in steel production. In a process known as the "Thompson Coking Process", coke is produced by feeding pulverized coal in batches into an oven that is sealed and heated at very high temperatures for 24 to 48 hours under tightly controlled atmospheric conditions. Coke ovens have been used for many years to convert coal into metallurgical coke. During the coking process, the finely ground coal is heated under a controlled temperature condition to devolatilize the coal and form a coke melt having a predetermined porosity and strength. As coke production is a batch process, several coke ovens are operated simultaneously.
    [004] The melting process subjected to carbon particles during the heating process is an important part of coking. The degree of melting and the degree of assimilation of the coal particles in the molten mass determine the characteristics of the coke produced. In order to produce the strongest coke from a mixture of coal or particular coal, there is a good proposal for reactive entities inert in coal. Porosity and coke strength are important to the ore refining process and are determined by the coal source and/or coking method.
    [005] Coal particles or a mixture of coal particles are loaded into hot ovens, and the coal is heated in the ovens in order to remove volatile matter ("VM") from the resulting coke. The coke process is highly dependent on the design of the kiln, the type of coal and the conversion temperature used. Typically, kilns are set up during the coking process so that each charge of coal is completely coked in approximately the same amount of time. Once the coal is "completely coke," the coke is removed from the oven and tempered with water to cool it below its ignition temperature. Alternatively, the coke is dry quenched with an inert gas. The tempering operation must also be carefully controlled so that the coke does not absorb too much moisture. Once it is quenched, the coke is tracked and loaded onto train cars or trucks for shipment.
    [006] Because coal is fed into hot furnaces, much of the coal feeding process is automated. In slit or vertical furnaces, coal is typically loaded through slits or openings in the top of the furnaces. These ovens tend to be tall and narrow. Non-recoverable or heat recovery horizontal coking ovens are also used to produce coke. In coke ovens without recovery or heat recovery, conveyors are used to transport the coal particles horizontally into the ovens to provide an elongated bed of coal.
    [007] As the source of coal suitable for forming metallurgical coal ("coking coal") has diminished, attempts have been made to blend weak or substandard coals ("non-coking coal") with coking coals to provide a coking charge. charcoal suitable for ovens. One way to combine non-coking coal and coking coal is to use compacted or stamped coal. Charcoal can be compacted before or after being in the oven. In some embodiments, a mixture of non-coking coal and coke is compacted at more than 50 pounds per cubic foot in order to use non-coking coal in the coke manufacturing process. As the percentage of non-coking coal in the coal mix is increased, higher levels of coal compaction are required (eg, up to about 65 to 75 pounds per cubic foot). Commercially, coal is typically compacted to about 1.15 to 1.2 specific degrees (sg) or about 70-75 pounds per cubic foot.
    [008] Horizontal Thermal Recovery ("HHR") furnaces have a unique environmental advantage over chemical by-product furnaces based on the relative atmospheric pressure operating conditions within HHR furnaces. HHR furnaces operate under negative pressure, while chemical by-product furnaces operate at slightly positive atmospheric pressure. Both types of kilns are typically constructed of refractory bricks and other materials in which creating a substantially airtight environment can be challenging because small cracks can form in these structures during day-to-day operation. Chemical by-product furnaces are kept at positive pressure to prevent the oxidation of recoverable products and overheating of the furnaces. Conversely, HHR furnaces are kept at negative pressure, extracting air from outside the furnace to oxidize the coal VM and to release the heat of combustion inside the furnace. It is important to minimize the loss of volatile gases to the environment, so that the combination of positive atmospheric conditions and small openings or fissures in chemical by-product ovens allow natural coke oven gas ("COG") and pollutants dangerous leaks into the atmosphere. Conversely, negative atmospheric conditions and small openings or cracks in HHR ovens or other locations in the coke plant simply allow additional air to be drawn into the oven or other locations in the coke plant, and thus, negative atmospheric conditions resist the loss of COG to the atmosphere. HHR ovens have traditionally been unable to reduce their performance (eg their coke production) significantly below their design capacity without potentially damaging the ovens. This restriction is linked to temperature limitations in the ovens. More specifically, traditional HHR ovens are mainly made of silica bricks. When a silica kiln is built, flammable spacers are placed between the bricks in the kiln crown to allow the brick to expand. Once the oven is heated, the spacers burn and the bricks expand into the adjacency. Since HHR silica brick kilns are heated, they are never allowed to fall below the thermally stable volume temperature of the silica brick, the temperature above which silica is generally volume stable (ie, does not expand or expand. contracts). If the bricks fall below this temperature, the bricks start to contract. Once the spacers have burned out, a traditional crown can contract up to several centimeters after cooling. This move is potentially enough for the crown bricks to start shifting and potentially segregating. Therefore, sufficient heat must be maintained in the kilns to keep the bricks above temperature in thermally stable volume. This is why it has been stated that an HHR oven can never be turned off. As kilns cannot be significantly reduced during periods of low demand for steel and coke, coke production must be maintained. In addition, it can be difficult to service heated HHR ovens. Other parts of the coke oven system may experience similar thermal and/or structural limitations. For example, the crown of a single duct running under the kiln floor may collapse or otherwise suffer from kiln floor elevation, ground adjustment, thermal or structural cycling, or other form of fatigue. These stresses can cause the bricks in the single conduit to shift and fall. BRIEF DESCRIPTION OF THE DRAWINGS
    [009] Figure 1A is a partial isometric view, in section, of a part of a horizontal heat recovery coke installation configured in accordance with embodiments of the present technology.
    [010] Figure 1B is a top view of a hearth duct portion of a horizontal heat recovery coke oven configured according to embodiments of the technology.
    [011] Figure 1C is a front view of a monolithic crown for use with the sill duct illustrated in Figure 1B and configured according to embodiments of the technology.
    [012] Figure 2A is an isometric view of a coke oven with a monolithic crown configured according to embodiments of the technology.
    [013] Figure 2B is a front view of the monolithic crown of figure 2A that moves between a contracted configuration and an expanded configuration according to embodiments of the technology.
    [014] Figure 2C is a front view of the side walls of the oven to support a monolithic crown configured according to additional embodiments of the technology.
    [015] Figure 2D is a front view of the side walls of the oven to support a monolithic crown configured according to additional embodiments of the technology.
    [016] Figure 3 is an isometric view of a coke oven having a monolithic crown configured according to additional embodiments of the technology.
    [017] Figure 4A is an isometric view of a coke oven having a monolithic crown configured according to other additional embodiments of the technology.
    [018] Figure 4B is a front view of the monolithic crown of Figure 4a configured according to other embodiments of the technology.
    [019] Figure 5A is an isometric view, in partial section, of a portion of the monolithic hearth duct of a horizontal heat recovery coke oven configured according to embodiments of the technology.
    [020] Figure 5B is an isometric view of a section of a monolithic hearth duct wall for use with the monolithic hearth duct shown in Figure 5A and configured according to embodiments of the technology.
    [021] Figure 5C is an isometric view of a block wall section for use with the monolithic threshold duct illustrated in Figure 5a and configured according to embodiments of the technology.
    [022] Figure 5D is an isometric view of another section of the monolithic hearth duct wall for use with the monolithic hearth duct illustrated in Figure 5a and configured according to embodiments of the technology.
    [023] Figure 5E is an isometric view of a monolithic outer hearth duct wall section with fluid channels for use with the monolithic hearth duct shown in Figure 5A and configured according to embodiments of the technology.
    [024] Figure 5F is an isometric view of another monolithic threshold duct wall section with open fluid channels for use with the monolithic threshold duct shown in Figure 5a and configured according to embodiments of the technology.
    [025] Figure 5G is an isometric view of a monolithic floor duct corner section for use with the monolithic floor pipe shown in Figure 5A and configured according to embodiments of the technology.
    [026] Figure 5H is an isometric view of a monolithic arch support for use with the monolithic hearth duct tube shown in Figure 5A and configured according to embodiments of the technology.
    [027] Figure 6 is a partial isometric view of a monolithic crown floor and part of the monolithic hearth duct of a horizontal heat recovery coke oven, configured according to the embodiments of the technology.
    [028] Figure 7 is a block diagram illustrating a method of overturning a horizontal thermal recovery coke oven with a monolithic component construction. DETAILED DESCRIPTION
    [029] The present technology is generally directed to horizontal heat recovery coke ovens having monolithic component construction. In some embodiments, an HHR coke oven includes a monolithic crown that spans the width of the oven between opposing side walls of the oven, a monolithic wall that extends the height and length of the coke oven, and/or a monolithic floor that extends. extends to the length and width of the coke oven. The monolithic components expand on heating and contract on cooling as a single structure. In other embodiments, the monolithic components comprise a thermally stable bulk material. In various embodiments, the monolithic component and thermally stable bulk characteristics can be used in combination or alone. These designs can allow the furnace to be turned down below traditionally viable temperatures while maintaining the structural integrity of the monolithic components.
    [030] Specific details of various embodiments of the technology are described below with reference to figures 1A to 7. Other details describing well-known structures and systems often associated with co-ovens that have not been presented in the following description to avoid unnecessary obscuring. description of the various embodiments of the technology. Many of the details, dimensions, angles and other features shown in the Figures are merely illustrative of particular embodiments of the technology. Accordingly, other embodiments may have other details, dimensions, angles and features without departing from the spirit or scope of the present technology. Therefore, one skilled in the art will understand that the technology may have other embodiments with additional elements, or the technology may have other forms of realization that do not have several of the characteristics shown and described below with reference to figures 1A - 7.
    [031] Figure 1A is an isometric view, in partial section, of a portion of a horizontal heat recovery coke ("HHR") installation 100 configured in accordance with embodiments of the technology. Installation 100 includes a series of coke ovens 105. Each oven 105 may include an open cavity defined by a floor 160, a front door 165 forming substantially all of one side of the oven, a rear door (not shown) opposite the door. front 165 forming substantially the entire side of the oven opposite the front door, two side walls 175 extending upwards from the oven floor 160 of the oven between the front door 165 and the rear door, and a crown 180 forming the upper surface of the open cavity of an oven chamber 185. A first end of crown 180 may rest on a first side wall 175 while a second end of crown 180 may rest on an opposite side wall 175 as shown. Adjacent ovens 105 may share a common sidewall 175.
    [032] In operation, the volatile gases emitted from the coal placed inside the kiln chamber 185 collect in the crown 180 and are extracted downstream in the global system into the downpipes 112 formed in one or both of the side walls 175. Descending channels 112 fluidly connect furnace chamber 185 with a hearth duct 116 positioned below the floor of the oven 160. The hearth duct 116 includes a series of side-by-side tracks 117 that form a path tortuous below the kiln floor 160. While the tracks 117 in Figure 1A are shown as substantially parallel to a longitudinal axis of the kiln 105 (i.e., parallel to the side walls 175), in further embodiments, the floor duct 116 can be configured such that at least some segments of the tracks 117 are generally perpendicular to the longitudinal axis of the oven 105 (i.e., perpendicular to the side walls 175), in other additional embodiments. , the threshold duct 116 can be configured such that all or some tracks 117 are not perpendicular to the longitudinal axis and/or are generally serpentine. This arrangement is illustrated in Figure 1B and is discussed in more detail below. The volatile gases emitted from the coal can be burned in the sill duct 116, thus generating heat to support the reduction of coal into coke. Downward channels 112 are fluidly connected to chimneys or intake channels 114 formed in one or both of the side walls 175.
    [033] From time to time, the descending channels 112 may require inspection or maintenance to ensure that the furnace chamber 185 remains in open fluid communication with the hearth duct 116 positioned below the furnace floor 160. Accordingly, in various embodiments, downpipe covers 118 are positioned over the openings in the upper end portions of the individual down channels 112. In other embodiments, as illustrated in Figure 1A , the down channel covers 118 may be formed. from a series of separate covering elements that are positioned in close proximity adjacent to, or attached to, one another. Certain embodiments of the downpipe covers 118 include one or more inspection openings 120 which penetrate into the central portions of the downpipe cover 118. Although depicted as being round, it is considered that the inspection openings 120 can be formed almost in a shape. Curvilinear or polygonal, desired for particular applications. Plugs 12 are provided with shapes that approximate those of inspection openings 120. Therefore, plugs 122 can be removed for visual inspection or repair from descending channels 122 and returned to limit unintended leakage of volatile gases. In additional embodiments, a liner can extend the entire length of the channel to connect with the inspection opening. In alternative embodiments, the liner may extend only part of the length of the channel.
    [034] Coke is produced in kilns 105, first loading the coal into kiln chamber 185, heating the coal in an oxygen-free environment, expelling the volatile fraction of the coal and then oxidizing the VM inside kiln 105 to capture and use the donated heat. Coal volatiles are oxidized within the 105 kilns over an extended coke cycle and release heat to drive, in regenerative mode, the carbonization of the coal into coke. The coke cycle begins when the front door 165 is opened and the coal is loaded onto the floor of the furnace 160. The coal in the floor of the furnace 160 is known as the coal bed. The heat from the oven (due to the previous coking cycle) starts the carbonization cycle. Approximately half of the total heat transfer to the carbon bed is radiated down onto the upper surface of the carbon bed from the luminous flame of the carbon bed and radiant furnace crown 180. The remaining half of the heat is transferred to the coal bed by conduction from the floor 160 of the kiln, which is heated by convection from the volatilization of gases in the sill duct 116. In this way, a "wave" carbonization process of the plastic flow of coal particles and formation of high strength cohesive coke proceeds from both the upper and lower vicinity of the coal bed.
    [035] Typically, each furnace 105 is operated at negative pressure so that air is sucked into the furnace during the reduction process due to the pressure differential between the furnace 105 and the atmosphere. Primary combustion air is added to kiln chamber 185 to partially oxidize the coal volatiles, but the amount of this primary air is controlled so that only a portion of the volatiles released from the coal are burned in the kiln chamber 185, releasing it. so only a fraction of its enthalpy of combustion within kiln chamber 185. Primary air is introduced into kiln chamber 185 above the coal bed. The partially burnt gases pass from the furnace chamber 185 through the downflow tubes 112 to the ground combustion conduit 116 where secondary air is added to the partially burnt gases. As the secondary air is introduced, the partially burned gases are more completely burned in the hearth duct 116, thus extracting the remaining enthalpy of combustion, which is transported through the furnace floor 160 to add heat to the furnace chamber 185 The completely burnt or almost completely burnt exhaust gases exit the sill duct 116 through the absorption channels 114. At the end of the coking cycle, the coal was transformed into coke and was carbonized to produce coke. Coke can be removed from the oven 105 through the rear door using a mechanical extraction system. Finally, the coke is quenched (eg, wet or dry cooled) and sized before delivery to a user.
    [036] As will be discussed in detail below with reference to Figures 2A-4B, in various embodiments, the crown 180, the tread 160 and/or the side walls 175 comprise a monolithic element structure or precast shape. The monolithic crown 160 is configured to span all or a portion of the distance between the monolith sidewalls 175 and/or including the monolith sidewalls. In other embodiments, the monolith crown may include some or all of the monolith sidewalls 175 on one or both sides of the monolithic crown. In still other embodiments, the monolithic floor 160 may include some or all of the monolith sidewalls 175 on one or both sides of the monolithic crown 160. For example, the monolithic crown 180 may comprise a single segment extending between the sidewalls 175 either can comprise two, three, four or more segments that lie between sidewalls 175 and in the combined extent between sidewalls 175, or can comprise a monolithic crown with integral monolith sidewalls 175. similarly, for example, the monolithic floor 160 may comprise a single segment extending between the sidewalls 175 or may comprise two, three, four or more segments which lie between the sidewalls 175 and in combination with spacing between the sidewalls. 175, or may comprise a monolithic floor with integral monolith sidewalls 175. In still other embodiments, the monolithic crown 160, the walls monolithic sides 175 and monolithic floor 160 can form a monolithic structure and can be molded in place or can be pre-molded and then moved into place. The monolithic structure allows crown 180 to expand during kiln heating and retract when cooling without allowing individual bricks to contract and fall into kiln chamber 185, causing monolith crown 180 to fragment. The monolithic crown 180 can, therefore, allow the furnace 105 to be turned off or lowered to temperatures traditionally achievable for a given crown material. As discussed above, some materials, such as silica, generally become thermally stable to volume above certain temperatures (ie, about (1200°F) = 648.9°C for silica). Using a 180 monolith crown, a silica brick kiln can be turned down to below 1200°F = 648.9°C. Other materials, such as alumina, do not have a thermally stable upper limit to volume (i.e., remain in unstable or expandable volume), and the monolithic crown 180 allows the use of these materials without disruption from cooling contraction. In other embodiments, other materials or combinations of materials can be used for the monolithic crown, with different materials having different associated temperatures, thermally stable to volume. Furthermore, the monolithic crown 180 can be quickly installed, as the entire arch can be lifted and placed as a single structure. Furthermore, using monolithic segments rather than numerous individual bricks, the monolithic crown 180 can be constructed in different shapes than the traditional arch, such as a flat or straight edge shape. Some of these drawings are illustrated in Figures 3 and 4A. In various embodiments, the monolithic crown 180 can be preformed or preformed or formed in place. The monolithic crown 180 can have various widths (i.e., sidewall to sidewall) in different embodiments or can include the sidewall in alternative embodiments. In some embodiments, the width of the monolithic crown 180 is about 3 feet or greater, while in particular embodiments, the width is 12 to 15 feet. In other embodiments, the precast shape used in the coke oven in accordance with this description is of various complex geometric shapes, including all three-dimensional shapes with the express exclusion of a simple brick shape.
    [037] In some embodiments, the monolithic crown 180 is at least partially made of a thermally volume-stable material such that, upon heating or cooling of the furnace chamber 185, the monolithic crown 180 does not adjust into position. . As with an overall monolithic kiln design, a monolithic crown 180 made of a thermally volume-stable material allows the kiln 105 to be turned off or lowered without individual bricks in the crown 180 contracting and breaching into the kiln chamber 185. "volume thermally stable material" is used herein, this term may refer to materials that are zero expansion, zero contraction, near zero expansion and/or near zero contraction, or a combination of these characteristics, with heating and/or cooling. In some embodiments, the volume-stable thermal materials can be preformed or prefabricated into designed shapes, including individual shapes or monolithic segments. Furthermore, in some embodiments, thermally volume-stable materials can be repeatedly heated and cooled without affecting the expandability characteristics of the material, whereas in other embodiments the material can be heated and/or cooled only once before undergo a phase or material change that affects subsequent expansion characteristics. In a particular embodiment, the thermally volume-stable material is a material of fused silica, zirconia, refractory material or a ceramic material. In other embodiments, other parts of the oven 105 may additionally or alternatively be formed from thermally volume-stable materials. For example, in some embodiments, the lintel for the door 165 comprises such material. When using thermally stable volume materials, traditional sized bricks or a monolithic structure such as crown 180 can be used.
    [038] In some embodiments, monolithic or volume-stable designs may be used at other points on the plan 100, such as over the sill duct 116, as part of the furnace floor 160 or side walls 175, or other parts of furnace 105. In either of these locations, the monolithic or thermally stable embodiments can be used as a single structure or as a combination of sections. For example, a crown 180 or furnace floor 160 may comprise a monolithic component, several monolithic segments and/or multiple segments made of a thermally stable material in volume. In another embodiment, as illustrated in Figure 1A, a monolithic segment over the threshold duct 116 comprises a series of arcs side by side, each arch covering a loop 117 of the threshold duct 116. Since the arches comprise a single structure, they can expand and contract as a single unit. In additional embodiments (as will be discussed in more detail below), the crown of the threshold duct may comprise other shapes, such as a flat top, and such other shapes may be a single monolithic segment or a series of monolithic segments. In still other embodiments, the monolithic soil combustion crown comprises individual monolith segments (eg, individual arches or flat parts) where each spans only one cycle 117 of the hearth duct 116.
    [039] Figure 1B is a top view of a monolith hearth duct 126 of a horizontal heat recovery coke oven configured according to embodiments of the technology. The monolith hearth duct 126 has several features generally similar to the monolithic hearth duct 116 described above with reference to Figure 1A. For example, the monolithic hearth duct includes a serpentine pattern or labyrinth of tracks127 configured for communication with a coke oven (e.g., coke oven 105 of Figure 1A) through downflow tubes 112 and absorption channels 114 The volatile gases emitted from the coal positioned within a coke oven chamber are extracted downstream into the downflow pipes 112 and into the sill duct 126. The volatile gases emitted from the coal can be combusted in the sill duct 126, thus generating heat to support the reduction of coal into coke. Downflow pipes 112 are fluidly connected to chimneys or collection channels 114, which extract the completely or almost completely burned exhaust gases from the hearth duct 126.
    [040] In Fig. 1B, at least some segments of lanes 127 are generally perpendicular to the longitudinal axis of oven 105 (i.e., perpendicular to sidewalls 175 shown in Fig. 1A). Alternatively, the path of the hearth duct can be serpentine or can include directional flow deflectors. In still other embodiments, the threshold duct 126 can be a single monolithic segment or several adjacent and/or interconnected monolithic segments. As with the monolithic hearth duct 116 shown in Figure 1A, the monolithic hearth duct 126 of Figure 1B may include a monolithic crown portion extending over individual tracks 127 or a series of tracks 127. A monolithic threshold may comprise a flat monolithic segment, a single monolithic arc, a series of adjacent monolithic arcs, a combination of these monolithic shapes, or other monolithic shapes. In addition, the monolith floor flare crown can span and/or follow the turns or curves of the tortuous path of the lane sill duct 127.
    [041] Figure 1C is a front view of a monolithic crown 181 for use with the monolithic sill duct 126 illustrated in Figure 1B and configured according to embodiments of the technology. In the illustrated embodiment, the monolithic crown 181 comprises a series of adjacent arcuate portions 181a, 181b having a flat top 183. Each portion 181a, 181b can be used as a monolithic crown for an individual run on the sill duct 126. flat monolithic top 183 may comprise a monolithic floor or substrate for the furnace chamber 185 described above with reference to Figure 1A. In some embodiments, a layer of bricks may be placed over the flat monolithic top 183.
    [042] In various embodiments, the monolithic crown 181 may comprise a single monolithic segment or a series of individual segments (e.g., individual arcuate portions 181a, 181b) that are separated by an optional gasket 186 shown in line dashed. Accordingly, a single monolith crown 181 may cover one or several adjacent runs in the monolith hearth duct 126. As mentioned above, in other embodiments, the monolithic crown 181 may have shapes other than a lower portion. arched with a flat top. For example, crown 181 may be entirely flat, fully arched or curved, or other combinations of these features. Although the monolithic crown 181 has been described for use with the monolithic hearth duct 126 of Fig. 1B, it could equally be used with the hearth duct 116 or coking chamber 185 illustrated in Fig. 1A.
    [043] Figure 2a is an isometric view of a coke oven 205 having a monolithic crown 280, monolithic walls 275 and monolithic floor 260 configured according to embodiments of the technology. The furnace 205 is generally similar to the furnace 105 described above with reference to Figure 1. For example, the furnace 205 includes the floor 260 of the monolithic furnace and opposing side walls of monolith 275. The monolithic crown 280 comprises a monolithic structure, wherein the monolithic crown 280 extends between monolithic sidewalls 275 and/or monolithic crown 280 and sidewalls 275 are a monolithic structure. In the illustrated embodiment, the monolith crown 280 comprises a series of monolith crown segments 282 generally adjacent to each other and aligned along the length of the furnace 205 between the front and the back of the furnace 205. 282 are illustrated in further embodiments, there may be more or fewer segments 282. In still other embodiments, crown 280 comprises a single monolithic structure extending from the front of the oven 205 to the rear. In some embodiments, multiple segments 282 are used to facilitate construction. The individual segments may meet gaskets 284. In some embodiments, the gaskets 284 are filled with refractory material, such as refractory mat, mortar, or other suitable material, to prevent air ingress and unintended exhaust. In still other embodiments, as will be discussed with reference to Figure 4 below, the monolithic crown 280 may comprise multiple side segments between side walls 275 that meet or adjoin on the floor 260 of the oven to form a monolithic structure.
    [044] The monolithic sidewalls 275 comprise a monolithic structure, wherein the monolithic sidewalls 275 extend from the monolithic floor 260 to the monolithic crown 280 as a monolithic structure. In the illustrated embodiment, the monolith sidewalls 275 comprise a series of monolith wall segments 277 generally adjacent to each other and aligned along the length of the furnace 205 between the front and the back of the furnace 205. Although three segments 277 are illustrated, there may be more or fewer segments 277. In still other embodiments, walls 275 comprise a single monolithic structure that extends from the front of the oven 205 to the rear. In some embodiments, multiple segments 277 are used to facilitate construction. The individual segments may meet gaskets 279. In some embodiments, the gaskets 279 are filled with refractory material, such as refractory mat, mortar, or other suitable material, to prevent air leakage and unintended escape. In still other embodiments, as will be discussed with reference to Figure 4 below, the monolithic walls 275 may comprise multiple side segments between the monolithic crown 280 and the floor 260 of the furnace to form a monolithic structure.
    [045] The monolithic floor 260 comprises a monolithic structure, wherein the monolithic floor 260 extends between the monolithic side walls 275 and/or the monolithic floor 260 and the side walls 275 are a monolithic structure. In the illustrated embodiment, monolithic floor 260 comprises a series of monolithic floor segments 262 generally adjacent to one another and aligned along the length of oven 205 between the front and back of oven 205. 262 are illustrated, there may be more or fewer segments 262. In still other embodiments, the monolithic floor 260 comprises a single monolithic structure extending from the front of the oven 205 to the rear. In some embodiments, multiple segments 262 are used to facilitate construction. The individual segments may meet gaskets 264. In some embodiments, the gaskets 264 are filled with refractory material, such as refractory mat, mortar, or other suitable material, to prevent air leakage and unintended exhaust. In still other embodiments, as will be discussed with reference to Figure 4 below, monolithic floor 260 may comprise multiple side segments between side walls 275 that meet or join under monolithic crown 280 to form a monolithic structure.
    [046] Figure 2B is a front view of the monolithic crown 280 of Figure 2a moving between a contracted configuration 280a and an expanded configuration 280b according to embodiments of the technology. As discussed above, traditional crown materials expand after heating the furnace and contract during cooling. This retraction can create space between the individual kiln bricks and cause the bricks in the crown to collapse into the kiln chamber. Using monolithic segments, for example a monolithic crown, however, the monolithic crown 280 expands and contracts as a single structure and does not break on cooling. Similarly, monolithic floor 260, monolithic walls 275, or monolithic segments combined will expand and contract as a single structure.
    [047] The design of the oven 205 provides structural support for such expansion and contraction between forms or monolithic structures by heating and cooling. More specifically, the monolithic sidewalls 275 supporting the monolithic rim 280 may have a width W that is sufficiently greater than the width of the monolithic rim 280 to fully support the monolithic rim 280 as the monolithic rim 280 moves laterally between the 280a contracted configuration and 280b expanded configuration. For example, the width W can be at least the width of the monolithic crown 280 plus the expansion distance D. Therefore, when the monolithic crown 280 expands or is laterally translated outwardly upon heating, and contracts and laterally translates inwardly after cooling, the monolithic sidewalls 275 maintain support for the monolithic crown 280. The crown monolithic 280 may also expand or translate longitudinally outward on heating, and contract and translate longitudinally inward upon cooling. The front and rear walls (or door frames) of the oven 205 can therefore be sized to accommodate this displacement.
    [048] In other embodiments, the monolithic crown 280 may rest on a crown base other than being directly on the monolith sidewalls 275. Such a base may be coupled to or be a structure independent of the sidewalls 275. in other embodiments, the entire furnace may be made of expansion and contraction material and may expand and contract with crown 280 and may not require side walls as large as the width W shown in Figure 2B because the monolithic crown 280 is generally aligned with the expandable monolith side walls 275 by heating and cooling. Similarly, if both the monolithic shell 280 and the monolithic sidewalls 275 are made of a thermally stable material in volume, then the monolithic sidewalls 275 can generally be aligned with the monolithic shell 280 upon heating and cooling and the sidewalls monolithic crowns 275 need not be substantially wider (or even as wide) as monolithic crown 280. In some embodiments, sidewalls 275 (monolith or brick), front or rear door frames, and/or crown 280 may be held in place through a compression or tension system, such as a spring loaded system. In a particular embodiment, the compression system may include one or more strips on an exterior portion of the sidewalls 275 and configured to inhibit the sidewalls 275 from outward movement. In other embodiments, such a compression system is absent.
    [049] Figure 2C is a front view of kiln monolith side walls 177 for supporting a monolithic crown 281 configured in accordance with other embodiments of the technology. The monolith side walls 177 and the monolithic crown 281 are generally similar to the monolith side walls 175 and the monolithic crown 280 illustrated in Figure 2B. However, in the embodiment illustrated in Figure 2C, the monolithic sidewalls 177 and the monolithic crown 281 have a sloped 287 or angled interface. Thus, when monolithic crown 281 expands distance D after heating (i.e. converts from position 281a to position 281b) monolithic crown 281 converts along the sloping surface of the upper portion of monolithic sidewall 177 following the pattern of interface 287. Similarly, when monolithic sidewall 177 expands on heating to height H, monolithic crown 281 converts along the sloping top surface of monolithic sidewall 177 following the pattern of interface 287 and accommodating for differential thermal expansion.
    [050] In other embodiments, the monolithic crown 281 and the monolith sidewalls 177 may interact with other patterns such as recesses, grooves, overlapping parts and/or mating features. For example, Figure 2D is a front view of the monolith side walls of the furnace 179 for supporting a monolithic crown 283 configured in accordance with other embodiments of the technology. The monolith side walls 179 and the monolithic crown 283 are generally similar to the monolith side walls 175 and the monolithic crown 280 illustrated in figure 2b. However, in the embodiment illustrated in Figure 2D, the monolithic sidewalls 179 and the monolithic shell 283 have a stepped or zigzag interface 289. Thus, when the monolithic shell 283 expands the distance D after heating (i.e. , transforms from position 283a to position 283b) the monolithic crown 283 converts along the step surface of the upper part of the monolithic sidewall 179 following the pattern of the interface 289.
    [051] Similarly, in other embodiments, the monolithic floor and monolith side walls may interact in similar patterns, such as recesses, grooves, overlapping parts and/or interlocking features. For example, the monolithic side walls can be supported by the monolithic floor configured in accordance with additional embodiments of the technology. The monolith side walls and the monolithic floor are generally similar to the monolith side walls 175 and the monolithic floor 260 shown in Figure 2B. However, the monolith side walls and the monolithic floor may have a stepped or zigzag interface similar to the monolith side walls and the monolithic crown interface shown in the embodiment of Figure 2D. In still further embodiments, the monolithic components may include a series of indentations/indentations, tongue and shoulder, sloped interfaces, or the like. Still other interface patterns include recesses, grooves, overlying portions and/or interlocking features.
    [052] Figure 3 is an isometric view of a coke oven 305 having a monolithic crown 380 configured in accordance with additional embodiments of the technology. Because the monolithic crown 380 is preformed, it can take different shapes from the traditional bow. In the illustrated embodiment, for example, the monolithic crown 380 comprises a generally flat surface. This design can provide minimal material costs. In other embodiments, other forms of monolithic crown may be employed to improve gas distribution in furnace 305, to minimize material costs, or for other efficiency factors. In addition, as shown in Figure 3, monolithic crown 380, monolithic floors 360, and monolithic walls 375 can combine to form a monolithic structure or a monolithic coke oven.
    [053] Figure 4A is an isometric view of a coke oven 405 having a monolithic crown 480 configured in accordance with other embodiments of the technology. Ring 405 comprises a series (e.g. two) monolithic parts 482 which meet at a hinge 486 on the floor of furnace 160. Gasket 486 can be sealed and/or insulated with any suitable refractory material, if necessary. In various embodiments, hinge(s) 486 may be centered on crown 480 or may be off center. Monolithic parts 482 can be the same size or a variety of sizes. The monolithic parts 482 can be generally horizontal or angled (as shown) with respect to the floor 160 of the oven. The angle can be selected to optimize air distribution in the oven chamber. There may be more or less monolithic parts 482 in other embodiments. In addition, the monolithic crown, monolithic floors and monolithic walls can combine to form a monolithic structure or a monolithic coke oven.
    [054] Figure 4B is a front view of the monolithic crown 480 of Figure 4a configured according to other embodiments of the technology. As illustrated in Figure 4B, the monolithic portions 482 may include an interface feature at the hinge 486 to better secure the monolithic portions 482 together. For example, in the illustrated embodiment, gasket 486 comprises a pin 492 in a monolithic portion 482 configured to slide in and interface with a slot 490 in an adjacent monolithic portion 482. In other embodiments, the gasket 486 may comprise others. recesses, slots, overlapping features, interlocking features or other types of interfaces. In still other embodiments, mortar is used to seal or fill the joint 486. In still other embodiments, the monolithic crown, monolithic floors, and monolithic walls can combine to form a monolithic structure or a monolithic coke oven .
    [055] Although the illustrated interface feature is along a joint 486 that is generally parallel to the sidewalls 175, in other embodiments, the interface feature can be used in a joint that is generally perpendicular to the sidewalls 175 For example, any of the interface features described above could be used in the joints 284 between the crown segments 282 of Figure 2A. Thus, the interface features can be used in any joint in crown 480, regardless of whether the monolithic parts are oriented side to side or front to back on the oven floor. According to aspects of the disclosure, the precast crown or section may be a kiln crown, an ascending arch, a descending arch, a J-piece, a threshold duct arch or multiple threshold duct arches, and/ or combined parts of any of the above sections. In some embodiments, the monolithic crown is formed at least in part from a thermally stable material in volume. In other embodiments, the monolithic crown is formed as a monolith or a plurality of monolithic segments that extend between supports such as kiln sidewalls. In still other embodiments, the monolithic crown is formed to span multiple ovens. In still other embodiments, the monolithic crown includes integral monolithic sidewalls.
    [056] Figure 5a illustrates a partial cross-sectional view of a portion of the monolith sill duct 516 of a horizontal heat recovery coke oven configured according to embodiments of the technology. Downflow tubes 112 fluidly connect furnace chamber 185 with monolithic hearth duct 516. Monolith floor duct 516 includes a series of side-by-side tracks 517 below the furnace floor. As discussed in connection with oven 105, tracks 517 in Figure 5A are shown substantially parallel to a longitudinal axis of the oven. However, in other embodiments, the monolithic hearth duct 516 can be configured so that at least some segments of the tracks 517 are generally perpendicular to the longitudinal axis of the oven. In still other embodiments the monolithic hearth duct must be configured such that at least some segments of the tracks 517 are non-perpendicular or serpentine.
    [057] The tracks 517 are separated by monolithic floor combustion walls 520, although it is considered that the walls of the monolith sill duct 520 could be formed in a one-piece construction, such as a single casting or casting unit. local molding. However, in other embodiments, a series of monolithic hearth duct wall segments 522 couple together to define the individual monolithic hearth duct walls 520. Referring to Figures 5B and 5D, the individual segments of the monolith soil combustion wall 522 may be provided with a bead 524, which extends outwardly in a vertical manner from one end. Similarly, monolith floor combustion wall segments 522 may include a vertically inwardly extending slit 526 at the opposite end. In this way, the opposing monolith hearth duct wall segments 522 can be positioned closely adjacent to each other so that the rim 524 of a monolith floor combustion wall segment 522 is disposed within the groove 526 of the adjacent sill duct wall 522. In addition to, or in place of coupling flange 524 and groove 526, monolith floor combustion wall segments 522 may be provided with a notch 528 at one end and a projection 530 which fits. extends from the opposite end. Slot 528 and projection 530 are molded and positioned so that a single monolithic hearth duct wall segment 522 can mate with an adjacent monolithic hearth duct wall segment 522 by engaging the slot 528 and the projection. 530. As will be appreciated by a person skilled in the art, geometric systems, alternative, reciprocal or interlocking systems are considered within the scope of this description.
    [058] The volatile gases emitted from the coal in the kiln are directed to the sill duct 516 through descending channels 512, which are fluidly connected to the chimneys or intake channels 514 by the floor flue tube 516. volatile gases are directed along a circular path along sill duct 516. Referring to Figure 5A, volatile gases exit downward flow channels 512 and are directed along a fluid path by tracks 517. , the blocking wall section 531 is positioned to extend transversely between the threshold duct wall 520 and the outer wall of the threshold duct between the downflow channels 512 and the collection channels 514. In at least one embodiment, a floor duct wall segment 523 includes a bead 536 that extends vertically outwardly from the floor duct wall segment 523. locking wall 532 includes a shoulder 538 that extends inwardly in a vertical manner. In this way, the sill duct wall segment 523 can be positioned proximately to the side of the locking wall section 532 so that the lip 536 is within the shoulder 538 to lock the position of the opposing structures together. In this way, volatile gases are substantially prevented from short-circuiting in the fluid path from the downward flow channels 512 and the collection channels 514.
    [059] As volatile gases travel along the fluid path through the sill duct 516, they are forced around the end portions of the walls of the sill duct 520, which can shorten the rendezvous with the end walls of the sill duct 520. sill duct 540. The clearance between the end portion of the sill duct walls 520 and the end walls of the sill duct 540 are, in various embodiments, provided with arched sections 542 to widen the clearance. arched sections 542 may be U-shaped, providing a pair of opposing legs for engaging the floor of the combustion duct 543 and an upper end portion for engaging the floor of the furnace. In other embodiments the arched section 542 may be a cantilevered or flat section integrated with and extending from the sill duct wall 520. In other embodiments such as those illustrated in Figures 5A and 5H, the arcuate segments 542 are J-shaped, having an upper end pate 544 with an arcuate lower surface 546 and an upper surface 548, which is shaped for engagement with the oven floor. A single leg 550 extends below one end of the upper end portion 544 to engage the floor of the floor duct 543. A side portion of the leg 550 is positioned closely adjacent the free end portion of the floor duct wall 520. A free end portion 552 of upper end portion 544 opposite leg 550, in some embodiments engages an anchor point 554 in the wall of sill duct 520 in order to support that side of arcuate section 542. In some embodiments anchor point 554 is a recess or notch formed in the wall of the floor duct 520. In other embodiments, the anchor point 554 is provided as a protruding portion of an adjacent structure, such as an end wall of the floor duct 540. around the end portions of the walls of the hearth duct 520, the volatile gases meet corners, in some embodiments, where the end walls of the hearth duct 540 enc They are the walls of the outer sill duct 534 and the walls of the sill duct 520. These corners by definition have opposing surfaces that engage volatile gases and cause turbulence that disrupts the smooth, laminar flow of volatile gases. Therefore, some embodiments of the present technology include corner sections of the sill duct 556 at the corners in order to reduce disruption of the flow of volatile gases. Referring to Figure 5G, the embodiments of the hearth duct corner section 556 include an angled rear face 558 that is shaped to engage the corner areas of the hearth duct 526. As opposed to the front faces 560 of the corner duct sections thresholds 556 are shaped in the curvilinear or concave mode. In other embodiments the corner section is a curved pocket. In operation the curvilinear shape reduces dead flow zones and smoothes the flow transition. In this way, turbulence in the flow of volatile gases can be reduced as the fluid path traverses the corner areas of the hearth duct 526. The top surfaces of the corner sections of the hearth duct 556 can be shaped to fit the floor of the oven for additional support.
    [060] In several prior art coker ovens, the outer hearth duct walls are formed of brick. Consequently, the downward flow channels and the collection channels extending through the outer walls of the floor duct are formed with opposing flat walls that meet at the corners. Consequently, the fluid path through the descent channels and the collection channels is turbulent and reduces the optimal fluid flow. In addition, the uneven surfaces of the brick and the angular geometry of the descending channels and catchment channels promote the accumulation of debris and particles over time, which further restricts fluid flow. Referring to Figures 5A and 5E, embodiments of the present technology form at least portions of the outer walls of the monolithic floor duct 534 with monolith channel blocks 562. In some embodiments, the channel blocks 562 include one or more channels 564, having open ends that penetrate widths of monolithic channel blocks 562 and closed sidewalls. In other embodiments, the monolith channel blocks 566 include one or more open channels 568 that have open ends that penetrate widths of the monolith channel blocks 566 and sidewalls that are open to one side of the monolith channel blocks 566 to define channel openings 570. In various embodiments, monolith channel blocks 566 are positioned at floor level of the combustion conduit. Channel blocks 562 are positioned on top of monolith channel blocks 566 such that ends of channels 564 and ends of open channels 568 are placed in open fluid communication with each other. In this orientation, channel openings 570 for one set of monolithic channel blocks 566 may serve as an outlet for downflow channels 512. Similarly, channel openings 570 for another set of channel blocks 566 may serve as the entrance to intake channels 514. More than one channel block 562 may be positioned on top of each channel block 566, depending on the desired height of the wall of the outer sill duct 534 and the floor flue tube 516.
    [061] Referring to Figure 6, the tracks 517 of the sill duct 516 can be covered by an oven floor 660, which can comprise multiple segments of monolith 662 made of thermally stable material in volume. In particular, as illustrated in Figure 6, a monolith over the threshold duct 516 is formed from a series of side-by-side arcs, each arch covering a passage 517 of the threshold duct 516. lower ends 664 of the monolithic segments 662 are positioned on the upper surfaces of the hearth duct walls 520 and the outer hearth duct walls 534. According to other aspects, a flat monolithic layer or a segmented brick layer may co- open the top of the monolithic segments 662. In addition, as discussed above with regard to other aspects of the present technology, the entire furnace can be made of monolithic components to expand and contract or structure materials so that some or all the structural components of the furnace may expand and contract with each other. Therefore, if monolithic segments 662, floor combustion walls 520 and outer floor combustion walls 534 are made of a thermally stable material in terms of volume, then monolithic segments 662, floor combustion walls 520 and the external floor combustion walls 534 can generally remain aligned with one another with heating or cooling. However, it is contemplated that, in certain applications, one or more of the monolithic segments 662, floor combustion walls 520 and outer floor combustion walls 534 may be made from materials other than the volume thermally stable material. Such cases can arise during a repair or modernization of an existing coke oven with precast structural components. In other applications, the one or more of the monolithic segments, floor combustion walls and exterior combustion walls may be made of alumina or other thermally expandable materials. It is similarly considered that some or all of the other components described herein, such as the downflow cover 118, the lock wall sections 532, the sill duct end walls 540, the arch sections 542, the hearth duct corner sections 556, channel blocks 522 and channel blocks 523 could be formed from a volume thermally stable material and/or could be coated with a volume thermally stable material.
    [062] According to aspects of the disclosure, the oven can be built in monolithic interconnecting or interface formats forming a precast oven. For example, the monolithic crown with integral side walls can sit on a precast floor with monolith hearth duct walls, so the entire furnace can be constructed in a number of precast shapes as shown in Figure 1A. In alternative embodiments, the entire oven can be constructed from a single precast piece. In other embodiments, the kiln can be constructed of one or more precast shapes that interact with individual bricks to form a hybrid kiln construction. Aspects of the hybrid furnace construction can be particularly effective in furnace repairs, as also shown in the figures.
    [063] Figure 7 is a block diagram illustrating a method 700 of turning a horizontal heat recovery coke oven. The method may include using a precast monolithic component to replace brick structures or may include a horizontal coke oven constructed of precast monolithic sections. At block 710, method 700 includes forming a coke oven structure having a kiln crown over a kiln chamber. The precast crown or section can be a kiln crown, a rising arch, a descending arch, a J-piece, a single threshold duct arch or multiple threshold duct arches, an opening for cleaning, sections curvilinear corners and/or combined parts of any sections above. In some embodiments, the crown is formed at least in part from a thermally stable volumetric material. In other embodiments, the crown is formed as a monolith (or several monolithic segments) that extend between supports, such as oven side walls. In other embodiments, method 700 includes forming a coke oven structure having a series of monolithic sections.
    [064] In block 720, method 700 includes heating the coke oven chamber. In some embodiments, the furnace chamber is heated above the thermally stable volumetric temperature of a given material (e.g., above 1200°F = 648.9°C in the case of a silica furnace). Method 700 then includes lowering the coke oven below a volume stable temperature in block 730. For materials with a thermally stable volume temperature, such as silica, this comprises dropping the oven temperature below this temperature. (eg below 1200°F = 648.9°C in the case of a silica furnace). For thermally stable volume materials, such as fused silica, or materials that do not have a thermally stable volume temperature, such as alumina, the step of dropping the coke oven temperature below a thermal heat stable temperature comprises decreasing the oven temperature to any lower temperature. In particular embodiments, dropping the coke oven temperature comprises completely turning off the coke oven. In other embodiments, the temperature drop of the coke oven comprises dropping the temperature of the coke oven to a temperature of about 1200°F = 648.9°C or less. In some embodiments, the coke oven is reduced to 50% or less of maximum operating capacity. At block 740, method 700 further includes maintenance of the coke oven structure, including the integrity of the oven crown. The oven is therefore reduced in temperature without breaking down, as experienced in traditional ovens. In some embodiments, the furnace is temperature-reduced without causing significant crown shrinkage. The method described above can be applied to a coker chamber, hearth duct, downflow pipe, riser, walls, floors or other parts of the oven. EXAMPLES
    [065] The following examples are illustrative of various embodiments of the present technology. 1. Coke oven chamber, comprising: a monolithic hearth duct section having a serpentine path inside; a front wall extending vertically upward from the monolithic sill duct section and a bottom wall opposite the front wall; a first side wall extending vertically upwards from the floor between the front wall and the rear wall and a second side wall opposite the first side wall; and a monolithic crown placed above the monolithic hearth duct section and extending from the first sidewall to the second sidewall. A coke oven chamber as claimed in claim 1, wherein the monolith crown comprises a series of monolith parts extending from the first side wall to the second side wall, wherein the series of monolith parts are positioned generally adjacent to each other between the front wall and the rear wall. The coke oven chamber of claim 1, wherein: at least one of the monolithic crowns or side walls is configured to transform, contract or expand by an amount of adjustment upon heating or cooling the coke oven chamber. coke; the monolithic crown comprises a first end portion which rests on the first side wall and a second end portion opposite the first end portion and rests on the second side wall; and the first sidewall and the second sidewall have an interface area greater than the amount of fit. A coke oven chamber as claimed in claim 3, wherein the monolithic crown comprises a series of adjacent arcs. A coke oven chamber as claimed in claim 1, wherein the monolithic crown comprises an unarched shape. The coke oven chamber of claim 1, wherein the monolithic crown comprises a generally flat shape. The coke oven chamber of claim 1, wherein the monolithic crown comprises a thermally stable volumetric material. The coke oven chamber of claim 1, wherein the monolithic crown comprises at least one of fused silica, zirconia or refractory material. The coke oven chamber of claim 1, wherein the chamber comprises a horizontal heat recovery coke oven chamber. A coke oven chamber as claimed in claim 1, wherein the monolith crown meets at least one of the first sidewall or the second sidewall with an overlapped or interlocked gasket. A coke oven chamber as claimed in claim 1, wherein the first and second side walls are monolithic sections. The coke oven chamber of claim 1, wherein the hearth duct section, first and second side walls and crown section are monolithic components. A coke oven chamber as claimed in claim 1, wherein the oven includes substantially no bricks. 14. Coke oven chamber, comprising: a chamber floor; a series of side walls generally orthogonal to the floor of the chamber; and a monolithic component positioned above the floor of the chamber and at least partially covering an area between at least two side walls, wherein the monolithic component comprises a thermally stable volumetric material. The coke chamber of claim 14, wherein the volumetric thermostable material comprises fused silica or zirconia. A coke oven chamber as claimed in claim 14, wherein the monolithic component comprises a parallel, arcuate or inclined surface with respect to the floor. A coke oven chamber according to claim 14, characterized in that the chamber comprises a coking chamber or a threshold duct. 18. Process according to claim 17, characterized in that the chamber comprises a series of monolithic components. 19. A process of lowering a horizontal heat recovery coke oven, the method comprising: forming a coke oven structure with a floor, a first side wall and a second side wall opposite the first side wall and a kiln crown on the floor in a space at least partially between the first side wall and the second side wall, wherein at least one of the floor, the first side wall, the second side wall, or the kiln crown are monolithic components; coke oven heating; reduce the coke oven below a volumetric thermally stable temperature; and maintenance of the coke oven structure. The method of claim 19, wherein forming the coke oven structure comprises forming an oven at least partially of volumetric thermally stable material. The method of claim 19, wherein forming the coke oven structure comprises forming a monolith that measures at least a portion of a distance between the first sidewall and the second sidewall. The method of claim 19, wherein forming the coke oven structure comprises forming a coke oven structure at least partially from silica brick, and wherein reducing the coke oven below a Thermally stable temperature comprises reducing the coke oven below a temperature of 1200°F = 648.9°C. The process of claim 19, wherein reducing the coke oven comprises decreasing the kiln operation to 50% of operating capacity or less. The method of claim 19, wherein reducing the coke oven comprises turning off the oven. 25. Coke oven chamber, comprising: an oven floor; a front end portion and a rear end portion opposite the front end portion; a first side wall extending vertically upwards from the floor between the front wall and the rear wall and a second side wall opposite the first side wall; a crown positioned above the floor and extending from the first sidewall to the second sidewall; and a threshold duct comprising a thermally stable material in volume and having a series of adjacent tracks between the first sidewall and the second sidewall. The coke oven chamber of claim 25, wherein the volume thermally stable material comprises fused silica or zirconia. The coke oven chamber of claim 25, wherein the hearth duct includes at least one hearth duct wall comprising a series of hearth duct wall segments. The coke oven chamber of claim 27, wherein the sill duct wall segments are made of a material that is thermally stable in volume. The coke oven chamber of claim 27, wherein the sill duct wall segments are coupled together by cooperating features of ribs and grooves associated with end portions of the duct wall segments. of threshold. A coke oven chamber as claimed in claim 27, wherein the floor combustion chamber wall segments are coupled together by feature of ribs and grooves associated with end portions of the combustion chamber wall segments of floor. The coke oven chamber of claim 25, characterized in that the hearth duct includes at least one interlocking wall section coupled with and generally extending transversely to the from at least one wall of the threshold duct, to at least one blocking wall section comprising a thermally stable volumetric material. The coke oven chamber of claim 31, wherein at least one locking wall section and at least one floor combustion chamber wall are coupled together by cooperating features of ribs and grooves associated with an end part of the at least one locking wall segment and a side part of the at least one floor combustion chamber wall. The coke oven chamber of claim 25, wherein the hearth duct includes at least one generally J-shaped arched section spanning a space between an end portion of at least one wall of the hearth duct and an end wall of the sill duct. The coke chamber of claim 33, wherein the arch section includes an arcuate top end portion and a leg depending on one end of the top end portion; An opposite free end of the arcuate upper end portion operatively coupled to the hearth duct end wall between a floor of the hearth duct and the floor of the furnace. The coke oven chamber of claim 33, wherein the at least one arc section is comprised of a thermally volumetric stable material. The coke oven chamber of claim 25, wherein the floor combustion chamber includes at least one floor combustion chamber corner section having a rear face that is molded to fit a corner area of the floor. at least one of several adjacent lanes and an opposite, curvilinear or concave front section; the corner section of the hearth duct being positioned to direct fluid flow beyond the corner area. A coke oven chamber as claimed in claim 36, wherein at least one corner section of the hearth duct is comprised of a volumetric thermally stable material. The coke oven chamber of claim 25, wherein the floor combustion chamber includes at least one floor combustion chamber corner section having a rear face that is molded to engage a fur corner area. at least one of the series of adjacent races facing an opposing, curvilinear or concave front face; the only combustion corner section being positioned to direct fluid flow away from the corner area. The coke oven chamber of claim 25, wherein the oven chamber is further composed of downward flow channels extending through at least a first side wall and a second side wall; the descending channels being in open fluid communication with the furnace chamber and the hearth duct. The coke oven chamber of claim 39, wherein the descending channels have curved side walls. The coke oven chamber of claim 39, wherein the descending channels have a number of geometrically shaped cross sections. The coke oven chamber of claim 39, wherein the descending channels are melted using a volumetric thermally stable material. The coke oven chamber of claim 39, wherein the downward channels are formed from a series of channel blocks with channels that penetrate the channel blocks; the series of channel blocks being stacked vertically such that the channels of adjacent channel blocks line up with each other to define downward channel sections. The coke oven chamber of claim 43, wherein the at least one channel block includes channels that penetrate upper and lower end portions of the channel block and a side of the channel block to provide outlets for the channels. downward flow. The coke oven chamber of claim 39, further comprising a downward channel cover operatively coupled with an opening for at least one downward channel; the down channel cap including a cap which is shaped to be received within an access opening which penetrates the down channel cap. The coke oven chamber of claim 25, wherein the oven chamber further comprises collection channels extending through at least one of the first side wall and the second side wall; the collection channels being in open fluid communication with the floor combustion tube and a fluid outlet from the coke oven chamber. The coke oven chamber of claim 46, wherein the collection channels have a number of geometrically shaped side walls. The coke oven chamber of claim 46, wherein the collection channels have a number of geometrically shaped cross sections. The coke oven chamber of claim 46, wherein the absorption channels are molded using a thermally stable volumetric material. The coke oven chamber of claim 46, wherein the absorption channels are formed from a series of channel blocks with channels that penetrate the channel blocks; the series of channel blocks being vertically stacked such that the channels of adjacent channel blocks line up with each other to define sections of pickup channels. The coke oven chamber of claim 50, wherein the at least one channel block includes channels that penetrate upper and lower end portions of the channel block and a side of the channel block to provide inlets to the absorption channels.
    [067] From the foregoing it will be appreciated that, although the specific embodiments of the technology have been described here for illustration purposes, various modifications can be made without deviating from the spirit and scope of the technology. For example, although various embodiments have been described in the context of HHR furnaces, in other embodiments, monolithic or volumetric thermal stable designs may be used in non-HHR furnaces, such as by-product furnaces. Furthermore, certain aspects of the new technology described in the context of particular embodiments may be combined or eliminated in other embodiments. For example, although certain embodiments have been discussed in the context of a crown for a coker chamber, the flat crown, the monolithic crown, thermally stable volumetric materials and other features discussed above can be used in other parts of a kiln system. of coke, such as a crown for a sill duct. Furthermore, while the advantages associated with certain embodiments of the technology have been described in the context of those embodiments, other embodiments may also have such advantages, and not all embodiments necessarily need to have such advantages to be fall within the scope of technology. Accordingly, the disclosure and associated technology may encompass other embodiments not expressly illustrated or described herein. Thus, disclosure is not limited, except by the appended claims.
    权利要求:
    Claims (13)
    [0001]
    1. Coke oven chamber, CHARACTERIZED by the fact that it comprises: a monolithic hearth duct section having a serpentine path, the monolithic hearth duct section comprising: a vertically upwardly extending hearth duct front wall from a hearth duct floor and a hearth duct bottom wall opposite the hearth duct front wall; a first hearth duct side wall extending vertically upwards from the hearth duct floor between the hearth duct front wall and the hearth duct rear wall and a second hearth duct side wall opposite the first sill duct sidewall; and a monolithic hearth duct crown disposed above the hearth duct floor and extending from the first hearth duct side wall to the second hearth duct side wall; the hearth duct front wall, the hearth duct bottom wall, the first hearth duct side wall, the second hearth duct side wall, the hearth duct floor and the monolithic hearth duct crown defining a serpentine fluid path; a front wall extending vertically upward from the monolithic sill duct section and a bottom wall opposite the front wall; a first side wall extending vertically upwards from the floor between the hearth duct front wall and the hearth duct rear wall and a second side wall opposite the first side wall; and a monolithic crown placed above the monolithic hearth duct section and extending from the first sidewall to the second sidewall.
    [0002]
    2. Coke oven chamber according to claim 1, CHARACTERIZED in that the threshold duct monolith crown comprises a plurality of monolith parts extending from the first threshold duct side wall to the second wall hearth duct side, wherein the plurality of monolith parts are positioned adjacent to each other between the hearth duct front wall and the hearth duct rear wall.
    [0003]
    3. Coke oven chamber, according to claim 1, CHARACTERIZED by the fact that: at least one of the monolithic hearth duct crown, the first hearth duct side wall or the second hearth duct side wall are configured to translate, contract or expand by an amount of adjustment on heating or cooling the coke oven chamber; the monolithic hearth duct crown comprises a first end part which rests on the first hearth duct side wall and a second end part opposite the first end part and rests on the second hearth duct side wall, each part end forming an interface area with the sill duct sidewall having an interfacial length perpendicular to an axial length of the furnace; and the first hearth duct side wall and the second hearth duct side wall have an interfacial length greater than the amount of fit.
    [0004]
    4. Coke oven chamber, according to claim 3, CHARACTERIZED by the fact that the monolithic crown of the sill duct comprises a plurality of adjacent arches.
    [0005]
    5. Hearth duct coke oven chamber, according to claim 1, CHARACTERIZED by the fact that the monolithic hearth duct crown comprises a non-arched shape.
    [0006]
    6. Coke oven chamber, according to claim 1, CHARACTERIZED by the fact that the monolithic crown comprises a generally flat shape.
    [0007]
    7. Coke oven chamber, according to claim 1, CHARACTERIZED by the fact that the hearth duct monolith crown comprises a thermally stable material in volume.
    [0008]
    8. Coke oven chamber, according to claim 1, CHARACTERIZED by the fact that the hearth duct monolith crown comprises at least one of fused silica, zirconia or refractory material.
    [0009]
    9. Coke oven chamber according to claim 1, CHARACTERIZED by the fact that the oven chamber comprises a horizontal heat recovery coke oven chamber.
    [0010]
    10. Coke oven chamber according to claim 1, CHARACTERIZED by the fact that the crown of a threshold duct monolith meets at least one of the first threshold duct side wall or the second threshold duct side wall with an overlap or interlocking joint.
    [0011]
    11. Coke oven chamber according to claim 1, CHARACTERIZED by the fact that the first threshold duct side wall and the second threshold duct side wall are monolithic sections that extend between the threshold duct floor and the sill duct crown.
    [0012]
    12. Coke oven chamber, according to claim 1, CHARACTERIZED by the fact that the first hearth duct side wall, the second hearth duct side wall and the hearth duct crown comprise monolithic components.
    [0013]
    13. Coke oven chamber, according to claim 1, CHARACTERIZED by the fact that the oven does not include substantially any bricks.
    类似技术:
    公开号 | 公开日 | 专利标题
    BR112017004981B1|2021-05-11|coke oven chamber
    BR112016030880B1|2021-05-04|horizontal heat recovery coke oven chamber
    CA2903836C|2017-08-22|Horizontal heat recovery coke ovens having monolith crowns
    US10920148B2|2021-02-16|Burn profiles for coke operations
    US5704781A|1998-01-06|Refractory wall brick for a heating channel of a ring pit furnace
    BR102013000285B1|2016-10-11|method of coke oven gas sharing to decrease a coke production rate, method of controlling a coke production amount in a heat recovery coke oven and method of decreasing a coke production rate
    同族专利:
    公开号 | 公开日
    US20170253803A1|2017-09-07|
    RU2702546C2|2019-10-08|
    EP3194531A1|2017-07-26|
    CA2961207A1|2016-03-24|
    AU2015317909B2|2020-11-05|
    EP3194531A4|2018-06-20|
    RU2017112974A3|2019-02-21|
    KR20170055507A|2017-05-19|
    RU2017112974A|2018-10-17|
    US10968393B2|2021-04-06|
    JP2017526798A|2017-09-14|
    US20210363426A1|2021-11-25|
    CO2017003281A2|2017-08-31|
    CN106687564A|2017-05-17|
    AU2015317909A1|2017-03-23|
    JP2020176277A|2020-10-29|
    BR112017004981A2|2017-12-05|
    WO2016044347A1|2016-03-24|
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    法律状态:
    2021-03-30| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|
    2021-05-11| B16A| Patent or certificate of addition of invention granted [chapter 16.1 patent gazette]|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 15/09/2015, OBSERVADAS AS CONDICOES LEGAIS. |
    优先权:
    申请号 | 申请日 | 专利标题
    US201462050738P| true| 2014-09-15|2014-09-15|
    US62/050,738|2014-09-15|
    PCT/US2015/050295|WO2016044347A1|2014-09-15|2015-09-15|Coke ovens having monolith component construction|
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