Patent Publication Number: US-10323192-B2

Title: Systems and methods for improving quenched coke recovery

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation of U.S. patent application Ser. No. 14/952,267, filed Nov. 25, 2015, which is a continuation of U.S. patent application Ser. No. 13/730,598, filed Dec. 28, 2012, the disclosure of which is incorporated by reference in their entirety. 
    
    
     TECHNICAL FIELD 
     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. 
     BACKGROUND 
     Quenching is an important step in many types of mineral processing, including coke processing. During quenching, a quench tower releases a large amount of water onto heated coke in a quench car in order to quickly cool the coke. The pre-quench coke is extremely hot, sometimes having a temperature greater than 2,000 degrees Fahrenheit. Once the coke is cooled, it can be handled on transfer belts and be screened and sent to the customer. 
     Traditionally, a large amount of coke is lost in the quenching process. More specifically, the combination of the force of the quench spray and the expansion of the quench water as it forms steam causes some of the coke to pop or fly out of the top and upper side edges of the quench car. This coke then falls by the wayside or is passed into a collecting water pit. To recover this coke, the water pit must be dredged, a costly and time-consuming process. The coke recovered from the pit is high in moisture and requires drying and sieving to reclaim, as the coke must have a relatively low moisture content to be useful to many customers. Therefore, there exists a need to improve coke recovery during the quench process. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is an isometric, partial cut-away view of a quench car that is entering a quench tower and is configured in accordance with embodiments of the technology. 
         FIG. 2A  is an isometric view of a quench car that has side containment plates for channeling quenched coke onto a quench wharf and is configured in accordance with embodiments of the technology. 
         FIG. 2B  is an isometric, partial cut-away view of a quench car having a tailgate containment plate configured in accordance with embodiments of the technology. 
         FIG. 3  is a partially schematic illustration of a quench car positioned in a quench tower that has coke retaining features and is configured in accordance with embodiments of the technology. 
         FIG. 4  is a partially schematic illustration of a quench car positioned in a quench tower that has coke retaining features and is configured in accordance with further embodiments of the technology. 
         FIG. 5  is a front view of a quench car having coke retaining features configured in accordance with embodiments of the technology. 
     
    
    
     DETAILED DESCRIPTION 
     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, where the permeable barrier has a plurality of apertures therethrough. 
     In another embodiment, a coke quenching system includes a quench car having a plurality of sidewalls for containing coke and a quench tower configured to supply fluid for quenching the coke. The quench tower includes a deflection barrier positioned over the quench car and configured to contain coke in the car. 
     In another embodiment, a coke quench car includes a base and a plurality of sidewalls extending generally orthogonally upward from the base and surrounding a central region configured to contain coke. Individual sidewalls can comprise a lower portion adjacent to the base and an upper portion opposite the lower portion. The upper portion of at least one sidewall can be angled laterally inward toward the central region. 
     Specific details of several embodiments of the technology are described below with reference to  FIGS. 1-5 . Other details describing well-known structures and systems often associated with coal processing and/or quenching have not been set forth in the following disclosure to avoid unnecessarily obscuring the 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 can have other details, dimensions, angles, and features without departing from the spirit or scope of the present technology. A person of ordinary skill in the art, therefore, will accordingly understand that the technology may have other embodiments with additional elements, or the technology may have other embodiments without several of the features shown and described below with reference to  FIGS. 1-5 . 
       FIG. 1  is an isometric, partial cut-away view of a quench car  100  that is entering a quench tower  104  and is configured in accordance with embodiments of the technology. The quench car  100  includes a plurality of sidewalls  102  arranged to enclose or at least partially surround a space configured to contain coke in a coke processing system. In further embodiments, the quench car  100  can be used in other mineral processing systems. While the car  100  is described herein as a “quench” car, it can comprise a “hot” car configured to receive coke from a coke oven, a quench train, a coke-moving car, a combined hot/quench car, or other container. 
     The quench car  100  includes a permeable deflection barrier  106  having a top portion  108  and one or more sidewall portions  110 . In some embodiments, the barrier  106  comprises only one of a top portion  108  or sidewall portion  110 , or extends across only a portion of the top of the quench car  100 . In various embodiments, the top portion  108  is integral with the sidewall portions  110  or can be detachably coupled to the sidewall portions  110  or to the sidewalls  102 . While the barrier sidewall portion  110  is illustrated as occupying only an upper portion of the sidewalls  102 , in further embodiments more or less of the sidewalls  102  can comprise the permeable barrier. For example, including apertures or a permeable barrier on a lower portion of the sidewalls  102  can allow quench water to exit the car  100  after the quench and prevent the coke from sitting in quench fluid. 
     The permeable barrier  106  can be removably or permanently coupled to the quench car  100 , or it can be spaced apart from (e.g., positioned above) the quench car  100 . For example, as will be discussed in further detail below, the barrier  106  can be held above the car  100  by the quench tower  104  or other structure. In embodiments where the permeable barrier  106  is removably coupled to the quench car  100 , the permeable barrier can be latched, friction fit, draped over, or held by cords, chains, hinges, or hooks to the car  100 . For example, the barrier  106  can be coupled to the car  100  (e.g., to a sidewall  102 ) with a hinge or similar device and can open like an automobile hood. In some embodiments, the barrier  106  can have a lock or latch to fix the barrier  106  in a closed or open configuration. In some embodiments, the permeable barrier  106  can lift or otherwise be moved during car loading or unloading. In further embodiments, other attachment mechanisms can be used. The barrier  106  can be angled or generally horizontal. In some embodiments, the car  100  can include quench spray nozzles under the barrier  106  that can provide all or a portion of the quench fluid. 
     The permeable barrier  106  can comprise one or more of a screen, curtain, mesh, or other structure configured to contain coke during the quench process while allowing quench fluid to pass therethrough and reach the contained coke. In particular embodiments, the permeable barrier  106  comprises a screen having apertures therein. In some embodiments, the apertures have a diameter of approximately 0.25 inch to about 0.75 inch. In another particular embodiment, the apertures have dimensions of about 1.6 inch by about 0.56 inch. In still further embodiments, different portions of the barrier  106  can have different size apertures. For example, in some embodiments, one sidewall portion  110  can have larger apertures than an opposing sidewall portion  110 . In another embodiment, an aperture pattern on the barrier  106  can match or complement a nozzle pattern in the quench tower  104 . For example, the barrier  106  can have larger apertures on regions of the top portion  108  that are positioned under nozzles in the quench tower  104 . These larger apertures can better receive quench water. In still further embodiments, apertures are exclusively placed under quench tower nozzles. In other embodiments, other aperture patterns are used to optimize quench water distribution in the quench car  100 . Further, the apertures can have different shapes in different embodiments of the technology. 
     In some embodiments, the barrier  106  comprises stainless steel, high-carbon steel, AR400-AR500 steel, or other suitable material that can withstand the temperature and humidity conditions of the quench process. In a particular embodiment, a chain-link-fence type of material can be used as a barrier  106 . In another embodiment, steel chains can be used. The barrier  106  can be flexible or rigid. 
     In some embodiments, the quench car  100  includes a deflection or containment plate  112  coupled to the sidewall  102 . In various embodiments, as will be described in further detail below, one or more containment plates  112  can be coupled to other sidewalls, quench car gates, the barrier  106 , or the base of the quench car  100 . In particular embodiments, the containment plate  112  can be positioned at a junction or corner between two sidewalls or between a sidewall and a top or base portion of the car  100 . The containment plate  112  can overlap at least a portion of a sidewall  102  or car base. 
     The containment plate  112  can have different shapes in various embodiments of the technology. For example, the containment plate  112  can be shaped as a rectangle, circle, triangle, or other shape. The containment plate  112  can be curved or otherwise shaped to complement the shape of the quench car  100  or can be shaped to achieve a funneling or confining effect on the coke during processing. For example, as will be described in further detail below with reference to  FIG. 2 , the containment plate  112  shown in  FIG. 1  is shaped as a fin extending along an edge of the sidewall  102 . In some embodiments, the containment plate  112  can fit against the car  100  tightly enough to contain coke while allowing used quench water to pass out of the car  100  to prevent the contained coke from sitting in water. The containment plate  112  can be on an internal or external surface of the quench car  100 , or it can extend from an internal to an external portion. The containment plate  112  can be a solid surface or can have apertures therein. 
     In operation, the barrier  106  can serve to contain coke and/or reflect “popping” coke back into the quench car  100  during quenching. More specifically, the barrier  106  can be sufficiently permeable to allow quench fluid to pass through and reach the coke while having small enough apertures to prohibit coke from jumping or popping from the car  100 . The barrier  106  further allows quench steam to escape the car. The barrier sidewall portions  110  can further allow a cross-breeze to flow over the cooling coke. 
       FIG. 2A  is an isometric view of a quench car  200  having side containment plates  212  configured to channel quenched coke onto a quench wharf  220  after the coke has been quenched in a quench tower  204 . As described above with reference to  FIG. 1 , the quench car  200  can have containment plates  212  coupled to a sidewall  202  of the car  200 . In the illustrated embodiment, the sidewall  202  functions as a dump gate; when the car  200  is tilted toward the wharf and the sidewall gate  202  is open, the quenched coke is funneled by the containment plates  212  onto the wharf  220  to reduce side spillage. In further embodiments, the containment plates  212  can serve to contain the coke during quenching or can prevent the coke from spilling out of the car  200  at junction points (i.e., the junction between two adjacent sidewalls or a sidewall and the base of the car  200 ). 
       FIG. 2B  is an isometric partial cut-away view of a quench car  250  having a tailgate containment plate  262  configured in accordance with embodiments of the technology. The tailgate containment plate  262  functions generally in the manner of the containment plates  212  described above with reference to  FIG. 2A . More specifically, the tailgate containment plate  262  can bridge space between a base  264  of the car  250  and a sidewall gate  252 . In several embodiments, the tailgate containment plate  262  is inclined relative to the base  264  of the car  250  and the sidewall gate  252 . When the gate  252  is open, the tailgate containment plate  262  can prevent coke from falling between an opening between the base  264  and the gate  252 . The tailgate containment plate  262  can further inhibit coke from building up at this junction and preventing the gate  252  from opening and closing. In several embodiments, the tailgate containment plate  262  is movable relative to the sidewall gate  252  and/or the base  264  such that the tailgate containment plate  262  assumes different positions depending on whether the sidewall gate  252  is open or closed. 
       FIG. 2B  also illustrates that the gate  252  can have a solid lower portion and a permeable upper portion. In further embodiments, the gate  252  can be fully solid or fully permeable, or the lower portion can be permeable and the upper portion can be solid. In still further embodiments, the gate  252  can comprise multiple, separate portions (e.g., an upper portion and a lower portion) that can move independently of each other. In still further embodiments, the upper portion can be fixed (e.g., fixed to the car sidewalls) and the lower portion can be movable (i.e., open and close on a hinge) relative to the fixed upper portion. The upper and lower portions can be any combination of permeable and impermeable surfaces. In embodiments where at least a portion of the gate  252  is solid, the solid portion can help contain or channel quench steam. In some embodiments, the gate  252  joins or can be sealed against a top portion (e.g., the top portion  108  shown in  FIG. 1 ) when the gate  252  is in a closed configuration. 
       FIG. 3  is a partially schematic illustration of a quench car  300  positioned in a quench tower  304  that has coke retaining features and is configured in accordance with embodiments of the technology. The quench tower  304  can be a byproduct quench tower, heat recovery quench tower, or any other similar system. The quench tower  304  includes a barrier  306  coupled thereto. The barrier  306  can be attached to any portion of the quench tower  304  framework and in various embodiments can be positioned above or below an array  370  of quench nozzles. In embodiments where the barrier  306  is below the nozzle array  370 , the barrier  306  can be permeable to allow quench fluid to flow through. In embodiments where the barrier  306  is coplanar or above the nozzle array  370 , the barrier  306  can be permeable or impermeable. In any of these embodiments, the barrier  306  can serve to reflect or contain coke in the quench car  300  in the manner described above with reference to  FIG. 1 . In still further embodiments, as discussed above with reference to  FIG. 1 , the nozzle array  370  and barrier  306  can be positioned on the quench car  300  (either in addition to or lieu of placement on the tower  304 ). 
     In several embodiments, the barrier  306  can further comprise one or more sidewall portions  372  that extend downward from the generally horizontal plane. In further embodiments, the barrier  306  exclusively has sidewall portions  372  and not an upper portion. The sidewall portions  372  can be rigid or flexible curtains and can channel coke that flies during the quench process back into the quench car  300 . In various embodiments, the sidewall portions  372  can comprise numerous generally adjacent panels/chains or a single continuous panel. In still further embodiments, the sidewall portions  372  can be positioned on a track, rod, or other similar system to extend along or around the quench car  300  and then move away from the car  300  when not in use. In various embodiments, the barrier  306  or sidewall portions  372  are permanent in their placement relative to the quench tower  304  or can be retracted upward into the quench tower  304  and drop downward over the car  300 . In other embodiments, the barrier  306  can be dropped over the car  300  and/or retracted upward outside of the quench tower  304  by a crane or other lifting/dropping device. In further embodiments, the barrier  306  can detach from the quench tower  304 . In some embodiments, a bottom portion of the sidewall portions  372  can be positioned in the interior portion of the car  300 , such that any coke that hits the sidewall portions  372  will slide back into the car  300 . In further embodiments, a bottom portion of the sidewall portions  372  is exterior of the car  300 . 
       FIG. 4  is a partially schematic illustration of a quench car  400  positioned in a quench tower  404  having coke reclaim plates  472  configured in accordance with further embodiments of the technology. In the illustrated embodiment, the reclaim plates  472  extend downward and slope laterally inward toward the quench car  400 . In other embodiments, the reclaim plates  472  can have different angles either more or less directed inward toward the car  400 . The reclaim plates  472  can channel coke that flies during the quench process back into the quench car  400  to increase coke recovery and reduce build-up at the base of the quench tower  404 . In further embodiments, the reclaim plates  472  are coupled to the car  400  instead of or in addition to being coupled to the quench tower  404 . Further, in some embodiments, the reclaim plates  472  can be movable to adjust their angle with reference to the quench tower  404 . This adjustability can be useful to vary the coke diversion characteristics of the reclaim plates  472  or to accommodate different sizes of quench cars  400  or movement of the car  400  with reference to the quench tower  404  (e.g., the reclaim plates  472  can fold away while the car  400  is driving into or out of the quench tower  404 ). While the illustrated embodiment shows the reclaim plates  472  below a nozzle array  470 , in further embodiments the reclaim plates  472  are above or coplanar with the nozzle array  470 . 
       FIG. 5  is a front view of a quench car  500  having containment plates  572  configured in accordance with embodiments of the technology. The containment plates  572  can extend upward from sidewalls  502  of the car  500  and reflect coke back into the car  500  during the quench process. The containment plates  572  can comprise any permeable or impermeable material, or a combination of these materials. For example, in a particular embodiment, a portion of the containment plates  572  closest to the sidewalls  502  is solid and impermeable while a portion of the containment plates  572  that extends farthest into the center of the car  500  is permeable. All or only some of the sidewalls  502  may include containment plates  572 . For example, in some embodiments, only two opposing sidewalls  502  have containment plates thereon. In particular embodiments, the containment plates  572  are on one or more drain or dump gates on the car  500 . 
     While the sidewalls  502  can be generally orthogonal to the base of the car  500 , the containment plates  572  can be angled inward at angle θ such that flying coke hits the bottom of the containment plates  572  and deflects downward. The angle θ can vary in alternate embodiments of the technology or can be adjustable (e.g., the containment plates  572  can be on hinges). In particular embodiments, the angle θ can be from about 10 degrees to about 90 degrees relative to a vertical plane. The containment plates  572  can reduce coke breeze from moving downstream or clogging process flow. In some embodiments, the car  500  can further include a top portion, such as the top portion  108  described above with reference to  FIG. 1 , that extends between sidewalls  502  (e.g., between the containment plates  572 . The containment plates  572  can be used alone or in conjunction with any of the top portions (solid or permeable) described above. 
     Examples 
     1. A quench car system for containing coke prepared for quenching at a quenching site, the quench car system comprising:
         a quench car having a base and a plurality of sidewalls defining an opening, the quench car having a top; and   a permeable barrier covering at least a portion of the top of the quench car, the permeable barrier having a plurality of apertures therethrough.       

     2. The quench car system of example 1 wherein the permeable barrier is removably coupled to the quench car. 
     3. The quench car system of example 1 wherein the permeable barrier extends across the top of the quench car and at least one sidewall. 
     4. The quench car system of example 1 wherein the individual apertures have a diameter from about ¼ inch to about ¾ inch. 
     5. The quench car system of example 1 wherein the quench car further comprises a containment plate coupled to one or more sidewalls and configured to contain or funnel coke or quench water. 
     6. The quench car system of example 5 wherein an individual sidewall comprises a movable gate, and wherein the containment plate extends along the gate and is movable between a first position when the gate is open and a second position when the gate is closed. 
     7. The quench car system of example 5 wherein two sidewalls meet at a corner, and wherein the containment plate is positioned adjacent to the corner and overlaps at least one of the sidewalls. 
     8. The quench car system of example 1 wherein the permeable barrier is permanently coupled to the quench car. 
     9. The quench car system of example 1 wherein the permeable barrier comprises stainless steel. 
     10. The quench car system of example 1 wherein the permeable barrier is spaced apart from the top of the quench car. 
     11. The quench car system of example 1, further comprising a quench tower having a nozzle positioned above the quench car, wherein an individual aperture generally vertically aligned with the nozzle has a diameter larger than a diameter of another individual aperture. 
     12. A coke quenching system, comprising:
         a quench car having a plurality of sidewalls for containing coke; and   a quench tower configured to supply fluid for quenching coke, wherein the quench tower includes a deflection barrier positioned over the quench car and configured to contain coke in the car.       

     13. The coke quenching system of example 12 wherein the quench tower includes a nozzle, and wherein the deflection barrier comprises an angled deflection plate coupled to or positioned below the nozzle. 
     14. The coke quenching system of example 12 wherein the quench tower includes a plurality of nozzles directed toward the quench car, and wherein the deflection barrier is positioned above the nozzles. 
     15. The coke quenching system of example 12 wherein the deflection barrier comprises a permeable barrier. 
     16. The coke quenching system of example 12 wherein the deflection barrier comprises a plurality of vertical draping barriers. 
     17. The coke quenching system of example 12 wherein the deflection barrier comprises a movable barrier. 
     18. The coke quenching system of example 12, wherein deflection barrier comprises a plurality of confining plates. 
     19. The coke quenching system of example 18 wherein the confining plates extend laterally inward toward an interior portion of the quench tower and are angled relative to a horizontal plane. 
     20. The coke quenching system of example 12 wherein the quench tower includes a plurality of nozzles directed toward the quench car, and wherein the deflection barrier comprises a permeable barrier positioned at or below the nozzles. 
     21. The coke quenching system of example 12 wherein the deflection barrier comprises a chain mesh. 
     22. A coke quench car, comprising:
         a base; and   a plurality of sidewalls extending generally orthogonally upward from the base and surrounding a central region configured to contain coke, wherein the individual sidewalls comprise a lower portion adjacent to the base and an upper portion opposite the lower portion, and wherein the upper portion of at least one sidewall is angled laterally inward toward the central region.       

     23. The coke quench car of example 22 wherein the upper portion comprises a solid barrier. 
     24. The coke quench car of example 22 wherein the upper portion is angled inward at an angle from about 10 degrees to about 90 degrees relative to a vertical plane. 
     25. The coke quench car of example 22 wherein the upper portions of two opposing sidewalls are angled laterally inward toward the central region. 
     26. The coke quench car of example 22 wherein the upper portions are movable between a first angle and a second angle. 
     27. The coke quench car of example 22 wherein two sidewalls meet at a corner, and wherein the quench car further comprises a laterally extending fin that is coupled to the car adjacent to the corner and is configured to contain or funnel coke or quench water. 
     28. The coke quench car of example 22 wherein the upper portion comprises an at least partially permeable barrier. 
     29. The coke quench car of example 22, further comprising a top portion configured to extend across at least a portion of the central region, wherein the top portion comprises an at least partially permeable barrier. 
     From the foregoing it will be appreciated that, although specific embodiments of the technology have been described herein for purposes of illustration, various modifications may be made without deviating from the spirit and scope of the technology. Further, certain aspects of the new technology described in the context of particular embodiments may be combined or eliminated in other embodiments. Moreover, while advantages associated with certain embodiments of the technology have been described in the context of those embodiments, other embodiments may also exhibit such advantages, and not all embodiments need necessarily exhibit such advantages to fall within the scope of the technology. Accordingly, the disclosure and associated technology can encompass other embodiments not expressly shown or described herein. Thus, the disclosure is not limited except as by the appended claims.