Abstract: A method and apparatus for quenching metallurgical coke made in a coking oven. The method includes pushing a unitary slab of incandescent coke onto a substantially planar receiving surface of an enclosed quenching car so that substantially all of the coke from the coking oven is pushed as a unitary slab onto the receiving surface of the quenching car. The slab of incandescent coke is quenched in an enclosed environment within the quenching car with a plurality of water quench nozzles while submerging at least a portion of the slab of incandescent coke by raising a water level in the quenching car. Subsequent to quenching the coke, the planar receiving surface is tilted to an angle sufficient to slide the quenched coke off of the planar receiving surface and onto a product collection conveyer and sufficient to drain water from the quenched coke.

Abstract: The present technology is generally directed to systems and methods for controlling air distribution in a coke oven. In a particular embodiment, a coke oven air distribution system comprises an oven chamber having an oven floor configured to support a coal bed, a plurality of sidewalls extending upward from the oven floor, and an oven crown covering a top portion of the oven chamber. The air distribution system further includes an air inlet positioned above the oven floor and a distributor proximate to the inlet. The inlet is configured to introduce air into the oven chamber and the distributor is configured to at least one of preheat, redirect, or spread air within the oven chamber.

Abstract: The present technology describes methods and systems for an improved quench tower. Some embodiments improve the quench tower's 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.

Abstract: A volatile matter sharing system includes a first stamp-charged coke oven, a second stamp-charged coke oven, a tunnel fluidly connecting the first stamp-charged coke oven to the second stamp-charged coke oven, and a control valve positioned in the tunnel for controlling fluid flow between the first stamp-charged coke oven and the second stamp-charged coke oven.

Abstract: A coke plant includes multiple coke ovens where each coke oven is adapted to produce exhaust gases, a common tunnel fluidly connected to the plurality of coke ovens and configured to receive the exhaust gases from each of the coke ovens, multiple standard heat recovery steam generators fluidly connected to the common tunnel where the ratio of coke ovens to standard heat recovery steam generators is at least 20:1, and a redundant heat recovery steam generator fluidly connected to the common tunnel where any one of the plurality of standard heat recovery steam generators and the redundant heat recovery steam generator is adapted to receive the exhaust gases from the plurality of ovens and extract heat from the exhaust gases and where the standard heat recovery steam generators and the redundant heat recovery steam generator are all connected in parallel with each other.

Abstract: The present technology is generally directed to systems and methods for improving quenched coke recovery. More specifically, some embodiments are directed to systems and methods utilizing one or more of a screen, barrier, or reflector panel to contain or redirect coke during or after quenching. In a particular embodiment, a quench car system for containing coke includes a quench car having a base, a plurality of sidewalls, and a top portion. The system can further include a permeable barrier covering at least a portion of the top of the quench car, wherein the permeable barrier has a plurality of apertures therethrough.

Abstract: Relatively high speed methods for increasing the bulk density of coal particles without impacting the coal particles and an apparatus for compacting coal for making metallurgical coke. The method includes depositing coal particles onto a charging plate external to a coking oven. The charging plate has side walls, and at least one movable end wall to provide an elongate bed of dry, uncompacted coal having an upper surface on the charging plate. The uncompacted coal is compacted by passing a vibratory cylindrical compactor along a length of the uncompacted coal for a number of passes sufficient to decrease a thickness of the bed of coal to less than about 80 percent of an original thickness of the uncompacted coal. The vibratory cylindrical compactor has a length to diameter ratio ranging from about 1.4:1 to about 2:1.

Abstract: The present technology is generally directed to horizontal heat recovery coke ovens having monolith crowns. In some embodiments, an HHR coke oven includes a monolith crown 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 crown comprises a thermally volume-stable material. In various embodiments, the monolith 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 crown.

Abstract: The present technology is generally directed to systems and methods for improving quenched coke recovery. More specifically, some embodiments are directed to systems and methods utilizing one or more of a screen, barrier, or reflector panel to contain or redirect coke during or after quenching. In a particular embodiment, a quench car system for containing coke includes a quench car having a base, a plurality of sidewalls, and a top portion. The system can further include a permeable barrier covering at least a portion of the top of the quench car, wherein the permeable barrier has a plurality of apertures therethrough.

Abstract: The present technology describes various embodiments of systems and methods for handling emissions. More specifically, some embodiments are directed to systems and methods for collecting heated particulate from a coal processing system. In one embodiment, a method of handling emissions from a coal processing system includes inletting the emissions into a duct. The emissions include heated particulate. The method further includes slowing a speed of the emissions traveling through the duct and disengaging the heated particulate from the emissions without the use of a physical barrier. In some embodiments, the heated particulate is slowed, cooled, and diverted from an emissions pathway into a collection bin.

Abstract: A system for reducing the occurrence of fires in a fabric filter dust collection system. The system includes an elongated housing having a first end and a second end distal from the first end. A gas flow inlet is provided in flow communication with an interior portion of the housing for flow of gas and particulates from a source into the housing. A gas flow outlet is provided in flow communication with the housing for flow of gas and particulates out of the housing and into the dust collection system. An elongated spark arrestor is disposed in the housing between the first end and the second end. The spark arrestor has a plurality of spaced-apart, wedge-shaped members having a gap between adjacent members sufficient to interrupt the flow of combustible particles from the source to the dust collection system.

Abstract: A method and apparatus for quenching metallurgical coke made in a coking oven. The method includes pushing a unitary slab of hot coke onto a substantially planar receiving surface of a hot car. The hot car containing the coke is then transported to a quench car station. The unitary slab of hot coke is pushed onto a substantially planar receiving surface of a quench car at the quench car station. Quenching of the slab of hot coke is conducted in the quench car with a predetermine amount of water. After quenching, the quenched coke is dumped onto a receiving pad for collection thereof.