Patents by Inventor John Francis Quanci
John Francis Quanci has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).
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Publication number: 20240150659Abstract: Methods and systems for coking coal blends to produce foundry coke products are disclosed herein. Methods for producing coke products can include charging a coal blend into a coke oven; and heating the charged coal blend such that a crown temperature of the coke oven is greater than a lower bound coking temperature. The pyrolysis duration begins when the crown temperature of the oven is greater than the lower bound coking temperature, and ends when the crown temperature of the oven is less than the lower bound coking temperature.Type: ApplicationFiled: November 3, 2023Publication date: May 9, 2024Inventors: John Francis Quanci, John Michael Richardson, Jonathan Hale Perkins
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Publication number: 20240150667Abstract: Coal blends used to produce foundry coke products are disclosed herein. Coal blends can include first coals having a first volatile matter mass fraction less than or equal to a first threshold, and second coals having a second volatile mass fraction greater than or equal to a second threshold that is less than the second threshold. The coal blend can have an ash fusion temperature less than 2600° F. and an aggregated volatile matter mass fraction between 15% and 25%.Type: ApplicationFiled: November 3, 2023Publication date: May 9, 2024Inventors: John Francis Quanci, John Michael Richardson, Jonathan Hale Perkins
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Publication number: 20240110103Abstract: Systems and methods for removing carbonaceous clinker material from a coke oven are described. A coke oven can be provided including an oven floor, coke, and clinker material deposited on the oven floor. After a temperature of the coke oven has reached a first temperature (e.g., after heating coal in the oven to produce coke), the method includes increasing the temperature of the coke oven to a second temperature that is higher than the first temperature for a predetermined amount of time. After the predetermined amount of time, the temperature is reduced to a third temperature that is lower than the first temperature.Type: ApplicationFiled: May 8, 2023Publication date: April 4, 2024Inventors: John Francis QUANCI, Daniel C. CHARLES, Gary Dean WEST, Sharla EVATT, Mark Anthony BALL, Jason Francis CRUM
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Patent number: 11946108Abstract: Foundry coke products, and associated methods and systems for melting iron in a cupola furnace with the coke products are disclosed herein. A representative method can include receiving a population of coke products and iron in a cupola furnace, and melting the iron in the cupola furnace to form molten iron having a carbon content higher than a carbon content of the received iron. The coke products can comprise (i) an elongate shape including a length:width dimension of at least 1.5:1, (ii) an ash fusion temperature of no more than 2400° F., and/or (iii) a coke reactivity index (CRI) of at least 30%.Type: GrantFiled: November 4, 2022Date of Patent: April 2, 2024Assignee: SUNCOKE TECHNOLOGY AND DEVELOPMENT LLCInventors: John Francis Quanci, John Michael Richardson, Jonathan Hale Perkins
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Publication number: 20240059994Abstract: High quality coke products made in horizontal ovens such as heat recovery, non-recovery or Thompson ovens from an optimized coal blend. The coke products have unique properties such as an oblong shape and improved Coke Strength after Reaction (CSR) and Coke Reactivity Index (CRI) properties.Type: ApplicationFiled: August 1, 2023Publication date: February 22, 2024Inventors: John Francis Quanci, Jonathan Perkins
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Publication number: 20230416629Abstract: High quality coke products made in horizontal ovens such as heat recovery, non-recovery or Thompson ovens from an optimized coal blend. The coke products have unique properties such as an oblong shape and improved Coke Strength after Reaction (CSR) and Coke Reactivity Index (CRI) properties.Type: ApplicationFiled: September 13, 2023Publication date: December 28, 2023Inventors: John Francis Quanci, Jonathan Perkins
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Patent number: 11851724Abstract: A coke product configured to be used in foundry cupolas to melt iron and produce cast iron products is disclosed herein. In some embodiments, the coke product has a Coke Reactivity Index (CRI) of at least 30% and an ash fusion temperature (AFT) less than 1316° C. Additionally or alternatively, the coke product can comprise (i) an ash content of at least 8.0%, (ii) a volatile matter content of no more than 1.0%, (iii) a Coke Strength After Reaction (CSR) of no more than 40%, (iv) a 2-inch drop shatter of at least 90%, and//or (v) a fixed carbon content of at least 85%.Type: GrantFiled: November 4, 2022Date of Patent: December 26, 2023Assignee: SUNCOKE TECHNOLOGY AND DEVELOPMENT LLC.Inventors: John Francis Quanci, John Michael Richardson, Jonathan Hale Perkins
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Patent number: 11845898Abstract: A system and method for repairing a coke oven having an oven chamber formed from ceramic bricks. A representative system includes a insulated enclosure insertable into the oven chamber and includes removable insulated panels that define an interior area for workers to work in. The insulated enclosure is movable between an expanded configuration and a compact configuration and moving the enclosure to the expanded configuration will decrease the distance between the insulated enclosure and the walls of the oven chamber. Removing the panels exposes the ceramic bricks and allows workers within the interior area to access and the bricks and repair the oven chamber while the oven chamber is still hot. A loading apparatus lifts and inserts the insulated enclosure into the oven chamber. The insulated enclosure can be coupled to additional insulated enclosures to form an elongated interior area.Type: GrantFiled: November 8, 2021Date of Patent: December 19, 2023Assignee: SUNCOKE TECHNOLOGY AND DEVELOPMENT LLCInventors: Jason Crum, Mark Anthony Ball, Gary Dean West, John Francis Quanci, Chun Wai Choi
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Patent number: 11845897Abstract: A coke oven includes an oven chamber configured to support and heat a coal bed, a castable slab below the oven chamber, and a foundation supporting the heat recovery oven. One or more beams are positioned between the castable slab and the foundation. The beams extend from a first end of the oven chamber to a second end of the oven chamber, forming a plurality of air gaps between the castable slab and the foundation. Heat from the oven chamber is dissipated by the one or more beams.Type: GrantFiled: January 26, 2022Date of Patent: December 19, 2023Assignee: SUNCOKE TECHNOLOGY AND DEVELOPMENT LLCInventors: John Francis Quanci, Chun Wai Choi, Mark Anthony Ball, Jason Crum, Milos J. Kaplarevic
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Patent number: 11845037Abstract: The present technology is generally directed to systems and methods for removing mercury from emissions. More specifically, some embodiments are directed to systems and methods for removing mercury from exhaust gas in a flue gas desulfurization system. In one embodiment, a method of removing mercury from exhaust gas in a flue gas desulfurization system includes inletting the gas into a housing and conditioning an additive. In some embodiments, conditioning the additive comprises hydrating powder-activated carbon. The method further includes introducing the conditioned additive into the housing and capturing mercury from the gas.Type: GrantFiled: August 27, 2021Date of Patent: December 19, 2023Assignee: SUNCOKE TECHNOLOGY AND DEVELOPMENT LLCInventors: John Francis Quanci, Ashley Nicole Seaton, Justin Leigh Prien, Jennifer Renee McLaren
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Patent number: 11819802Abstract: Systems and apparatuses for neutralizing acidic compounds in flue gases emitted from a heat recovery coke oven. A representative system includes a spray dry absorber having a barrel that includes a plurality of wall plates that form sidewalls of the barrel. The wall plates include a steel plate and a corrosion resistant alloy cladded to the steel plate and the wall plates are oriented such that the corrosion resistant alloy faces toward and is in fluid communication with an interior area of the barrel. The alloy is resistant to corrosion caused by the acidic compounds in the flue gas and can prevent the steel plate from being corroded by these acidic compounds.Type: GrantFiled: June 17, 2022Date of Patent: November 21, 2023Assignee: SUNCOKE TECHNOLOGY AND DEVELOPMENT LLCInventors: John Francis Quanci, Mayela Carolina Fernandez, Daniel C. Charles
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Patent number: 11807812Abstract: The present technology describes various embodiments of methods and systems for improved coke quenching. More specifically, some embodiments are directed to methods and systems for improving the coke quenching process by partially cracking coke before it is quenched. In one embodiment, coke is partially cracked when placed in horizontal communication with one or more uneven surfaces. In another embodiment, a coke loaf is partially broken when dropped a vertical distance that is less than the height of the coke loaf. In another embodiment, a mass of coke is partially broken when first placed in vertical communication with one or more uneven surfaces and then placed in horizontal communication with the same or different one or more uneven surfaces. In some embodiments, the one or more uneven surfaces may be mounted to a coke oven, train car, hot car, quench car, or combined hot car/quench car.Type: GrantFiled: January 4, 2021Date of Patent: November 7, 2023Assignee: SUNCOKE TECHNOLOGY AND DEVELOPMENT LLCInventors: John Francis Quanci, John Shannon Essman, James Eric Bond, Khambath Vichitvongsa, Chun Wai Choi
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Patent number: 11795400Abstract: The present technology is generally directed to horizontal heat recovery and non-heat recovery coke ovens having monolith components. In some embodiments, an HHR coke oven includes a monolith component that spans the width of the oven between opposing oven sidewalls. The monolith expands upon heating and contracts upon cooling as a single structure. In further embodiments, the monolith component comprises a thermally-volume-stable material. The monolith component may be a crown, a wall, a floor, a sole flue or combination of some or all of the oven components to create a monolith structure. In further embodiments, the component is formed as several monolith segments spanning between supports such as oven sidewalls. The monolith component and thermally-volume-stable features can be used in combination or alone. These designs can allow the oven to be turned down below traditionally feasible temperatures while maintaining the structural integrity of the oven.Type: GrantFiled: March 3, 2021Date of Patent: October 24, 2023Assignee: SUNCOKE TECHNOLOGY AND DEVELOPMENT LLCInventors: Gary Dean West, John Francis Quanci
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Integrated coke plant automation and optimization using advanced control and optimization techniques
Patent number: 11788012Abstract: The present technology is generally directed to integrated control of coke ovens in a coke plant in order to optimize coking rate, product recovery, byproducts and/or unit lime consumption Optimization objectives are achieved through controlling certain variables (called control variables) by manipulating available handles (called manipulated variables) subject to constraints and system disturbances that affect the controlled variables.Type: GrantFiled: February 10, 2021Date of Patent: October 17, 2023Assignee: SUNCOKE TECHNOLOGY AND DEVELOPMENT LLCInventors: John Francis Quanci, Parthasarathy Kesavan, Jack Ziegler, Katie Russell, Mike Muhlbaier, Rakshak Khanna, Sharla Evatt, Milos Kaplarevic, Peter Chun -
Patent number: 11767482Abstract: High quality coke products made in horizontal ovens such as heat recovery, non-recovery or Thompson ovens from an optimized coal blend. The coke products have unique properties such as an oblong shape and improved Coke Strength after Reaction (CSR) and Coke Reactivity Index (CRI) properties.Type: GrantFiled: May 3, 2021Date of Patent: September 26, 2023Assignee: SUNCOKE TECHNOLOGY AND DEVELOPMENT LLCInventors: John Francis Quanci, Jonathan Perkins
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Patent number: 11760937Abstract: Systems and apparatuses for controlling oven draft within a coke oven. A representative system includes an uptake damper coupled to an uptake duct that receives exhaust gases from the coke oven and provides the exhaust gases to a common tunnel for further processing. The uptake damper includes a damper plate pivotably coupled to a refractory surface of the uptake duct and an actuator assembly coupled to the damper plate. The damper plate is positioned completely within the uptake duct and the actuator assembly moves the damper plate between a plurality of different configurations by causing the damper plate to rotate relative to the uptake duct. Moving the uptake damper between the different configurations changes the flow rate and pressure of the exhaust gases through the uptake duct, which affects an oven draft within the coke oven.Type: GrantFiled: December 27, 2019Date of Patent: September 19, 2023Assignee: SUNCOKE TECHNOLOGY AND DEVELOPMENT LLCInventors: John Francis Quanci, Gary Dean West
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Patent number: 11746296Abstract: The present technology describes methods and systems for an improved quench tower. Some embodiments improve the quench towers ability to recover particulate matter, steam, and emissions that escape from the base of the quench tower. Some embodiments improve the draft and draft distribution of the quench tower. Some embodiments include one or more sheds to enlarge the physical or effective perimeter of the quench tower to reduce the amount of particulate matter, emissions, and steam loss during the quenching process. Some embodiments include an improved quench baffle formed of a plurality of single-turn or multi-turn chevrons adapted to prevent particulate matter from escaping the quench tower. Some embodiments include an improved quench baffle spray nozzle used to wet the baffles, suppress dust, and/or clean baffles. Some embodiments include a quench nozzle that can fire in discrete stages during the quenching process.Type: GrantFiled: January 22, 2021Date of Patent: September 5, 2023Assignee: SUNCOKE TECHNOLOGY AND DEVELOPMENT LLCInventors: Chun Wai Choi, Rajat Kapoor, John Francis Quanci
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Publication number: 20230258326Abstract: Systems and apparatuses for cooling flue gases emitted from an industrial facility, such as a coke oven in a coke manufacturing plant. A representative system includes a heat recovery steam generator (HRSG) having a steam generation system that converts liquid feedwater into steam by absorbing heat from the flue gases. The steam generation system includes a plurality of tubes that carry the liquid water feedwater and the steam. Some or all of the tubes include steel and a non-corrosive material cladded to the steel that helps to reduce corrosion caused by the high temperature flue gases and extremely corrosive contaminants within the flue gas that can corrode steel.Type: ApplicationFiled: September 19, 2022Publication date: August 17, 2023Inventors: John Francis QUANCI, Anthony HANLIN, Jennifer MCLAREN
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Patent number: 11680208Abstract: A coke oven can include an oven body, a foundation, and a plurality of beams separating the oven body from the foundation, A buckstay applies force to the oven body to maintain compression on the oven body during thermal cycling of the coke oven. The coke oven further comprises a spring-loaded compression device, which can include a restraining device, an anchor coupled to the restraining device, and a spring coupled to the restraining device. The anchor can be attached to one or more of the beams, the foundation of the oven, or to a similar compression device on an opposite side of the oven. The spring applies force between the restraining device and the one or more beams or foundation to compress the buckstay against the oven. The force applied by the spring can maintain structural stability of the coke oven over a plurality of thermal cycles.Type: GrantFiled: July 29, 2021Date of Patent: June 20, 2023Assignee: SUNCOKE TECHNOLOGY AND DEVELOPMENT LLCInventors: John Francis Quanci, Wes Alderman, Milos J. Kaplarevic, Suresh Mehta, F. Robert Carroll, Chun Wai Choi
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Publication number: 20230147916Abstract: A coke product configured to be used in foundry cupolas to melt iron and produce cast iron products is disclosed herein. In some embodiments, the coke product has a Coke Reactivity Index (CRI) of at least 30% and an ash fusion temperature (AFT) less than 1316° C. Additionally or alternatively, the coke product can comprise (i) an ash content of at least 8.0%, (ii) a volatile matter content of no more than 1.0%, (iii) a Coke Strength After Reaction (CSR) of no more than 40%, (iv) a 2-inch drop shatter of at least 90%, and//or (v) a fixed carbon content of at least 85%.Type: ApplicationFiled: November 4, 2022Publication date: May 11, 2023Inventors: John Francis Quanci, John Michael Richardson, Jonathan Hale Perkins