Abstract: A duct intersection comprising a first duct portion and a second duct portion extending laterally from a side of the first duct portion. At least one flow modifier is mounted inside one of the first and second duct portions. The flow modifier is a contoured duct liner and/or the flow modifier includes at least one turning vane. The duct intersection may also include a transition portion extending between the first and second duct portions, wherein the transition portion has a length extending along a side of the first duct portion and a depth extending away from the side of the first duct portion, wherein the length is greater than a diameter of the second duct portion.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: Systems and methods for particle leak detection generally include a separation or collection device configured to filter particulate from a stream and a detection device downstream of the separation or collection device. The detection device can be positioned to detect particulate that passes the separation or collection device and can include a probe configured to detect the solid particles. The particle leak detection systems can be configured to be disposed on moveable systems, such as moveable systems in coke oven operations.

Abstract: 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.

Abstract: The present technology is generally directed to methods of increasing coal processing rates for coke ovens. In various embodiments, the present technology is applied to methods of coking relatively small coal charges over relatively short time periods, resulting in an increase in coal processing rate. In some embodiments, a coal charging system includes a charging head having opposing wings that extend outwardly and forwardly from the charging head, leaving an open pathway through which coal may be directed toward side edges of the coal bed. In other embodiments, an extrusion plate is positioned on a rearward face of the charging head and oriented to engage and compress coal as the coal is charged along a length of the coking oven. In other embodiments, a false door system includes a false door that is vertically oriented to maximize an amount of coal being charged into the oven.

Abstract: Systems and methods for an overall oven health optimization system and method are disclosed. The oven health optimization system computes one or more metrics to measure/compare oven health performance data, computes oven life indicator values, generates one or more oven health performance plans, and so on, based on oven operation and/or inspection data parameters.

Abstract: 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.

Abstract: The present technology is generally directed to systems and methods for optimizing the burn profiles for coke ovens, such as horizontal heat recovery ovens. In various embodiments the burn profile is at least partially optimized by controlling air distribution in the coke oven. In some embodiments, the air distribution is controlled according to temperature readings in the coke oven. In particular embodiments, the system monitors the crown temperature of the coke oven. After the crown reaches a particular temperature range the flow of volatile matter is transferred to the sole flue to increase sole flue temperatures throughout the coking cycle. Embodiments of the present technology include an air distribution system having a plurality of crown air inlets positioned above the oven floor.

Abstract: 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.

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 non-perpendicular connections between coke oven uptakes and a hot common tunnel, and associated systems and methods. In some embodiments, a coking system includes a coke oven and an uptake duct in fluid communication with the coke oven. The uptake duct has an uptake flow vector of exhaust gas from the coke oven. The system also includes a common tunnel in fluid communication with the uptake duct. The common tunnel has a common flow vector and can be configured to transfer the exhaust gas to a venting system. The uptake flow vector and common flow vector can meet at a non-perpendicular interface to improve mixing between the flow vectors and reduce draft loss in the common tunnel.

Abstract: 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.

Abstract: The present technology is generally directed to providing beds of coking material to charge a coking oven. In various embodiments, a quantity of first particulate material, having a first particulate size and bulk density, is combined with a second particulate material, having a second particulate size and bulk density, to define a multi-modal bed of coking material. The multi-modal bed of coking material exhibits an optimized bulk density that is greater than an ideal bulk density predicted by a linear combination of the bulk densities of the individual materials.

Abstract: A duct intersection comprising a first duct portion and a second duct portion extending laterally from a side of the first duct portion. At least one flow modifier is mounted inside one of the first and second duct portions. The flow modifier is a contoured duct liner and/or the flow modifier includes at least one turning vane. The duct intersection may also include a transition portion extending between the first and second duct portions, wherein the transition portion has a length extending along a side of the first duct portion and a depth extending away from the side of the first duct portion, wherein the length is greater than a diameter of the second duct portion.

Abstract: The present technology is generally directed to providing beds of coking material to charge a coking oven. In various embodiments, a quantity of first particulate material, having a first particulate size and bulk density, is combined with a second particulate material, having a second particulate size and bulk density, to define a multi-modal bed of coking material. The multi-modal bed of coking material exhibits an optimized bulk density that is greater than an ideal bulk density predicted by a linear combination of the bulk densities of the individual materials.

Abstract: The present technology is generally directed to providing beds of coking material to charge a coking oven. In various embodiments, a quantity of first particulate material, having a first particulate size and bulk density, is combined with a second particulate material, having a second particulate size and bulk density, to define a multi-modal bed of coking material. The multi-modal bed of coking material exhibits an optimized bulk density that is greater than an ideal bulk density predicted by a linear combination of the bulk densities of the individual materials.

Abstract: 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.