Energy-saving measures for coking plants
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Depending on the scale and specific conditions of the coking plant, the following energy-saving measures and technologies can be adopted: 1. Stabilize the heating regime and select an appropriate air excess factor to ensure proper combustion of gas and reduce heat consumption. 2. Improve the tightness of gas pipelines and the furnace body to reduce gas leakage and heat loss from the furnace body ； The regenerator uses thin-walled lattice bricks to increase the heat exchange area and reduce the amount of heat carried away by the exhaust gases ； Thin the carbonization chamber walls to improve heat transfer. 3. High-pressure ammonia water is used in place of steam jets to achieve smoke-free coal loading, thereby saving steam. 4. The blower uses a hydraulic coupling, which helps save electricity. 5. For crude benzene, oil-gas heat exchange and rich-poor oil heat exchange can save gas and circulating water. 6. Ammonia evaporation utilizes heat exchange between ammonia water and wastewater, which helps save steam and circulating water. 7. Use energy-efficient transformers and energy-saving lighting fixtures. Everyone, please add more – the more, the better. It helps us learn from each other and improve together!
1. Large motors can use frequency converters to save electricity. 2. Large water pumps can use energy-saving pumps to save electricity
Motors that can be equipped with frequency converters should all use frequency-controlled starting. Fans should have their suction adjusted to control speed, with backflow minimized. Water from the upper section of the pre-cooler is used for heating the factory area. Coal is used to adjust humidity and stabilize the pressure in the gas collection pipes. Gas tanks are employed for external gas supply to reduce gas leakage.
In addition to energy savings through the aforementioned equipment, coking plants can also consider energy savings in terms of processes and management. Managing energy-saving efforts requires little investment, and the results should be good.
There are two ways to achieve energy savings in coking: one is to apply energy-saving technologies to various equipment； Another approach is to save energy through process modifications.
This post was last edited by wangshaobo on 2012-3-31 08:25. I will go into more detail regarding the measures taken by coking plants to save electricity, for everyone’s reference and learning. The electrical equipment in coking plants consists mainly of various types of motors; therefore, improving energy efficiency in these motors is the key way to reduce energy consumption in coking plants. 1. Increase the load factor of motors and transformers, prevent the situation of using oversized equipment for small tasks, control no-load operation, and improve the power factor and efficiency. The efficiency of motors and transformers is generally highest when the load is maintained at 60–80%. 2. For some equipment that operates throughout the year, the time it runs at full load is short, and it is mostly in a light-load operating condition; for such equipment, voltage transformation can be used to save energy, such as Y-transformer operation and thyristor-based voltage regulation ； For motors such as water pumps, a thyristor cascade speed control method can be employed. 3. The blower operates at a controlled speed using a hydraulic coupling. 4. Minimize unnecessary movement of the machinery used in the coke oven operation. 5. Energy savings can be achieved in air compressor operation by reducing the operating pressure and changing the diameter of the compressor nozzle. Reducing the working pressure from 0.6 MPa to 0.5 MPa can save 6% in electricity consumption ； The nozzle diameter can be reduced from 4mm to 2mm, and the motor capacity can be decreased from 10kW to 4kW. Therefore, without affecting the operation, work pressure and nozzle diameter should be reduced as much as possible. 6. Energy savings in lighting: Lighting devices have low conversion efficiency. The main energy-saving measures include: ① Using high-efficiency new light sources; for example, high-pressure sodium lamps have a luminous efficiency 6 to 8 times that of incandescent lamps, while metal halide lamps consume 1/5 as much electricity as incandescent lamps. Fluorescent lamps also offer a conversion efficiency 5 to 6 times higher than that of incandescent lamps. ②Increase environmental reflectivity. ③Select the appropriate installation height for the lighting fixtures. When the height of the light source is the same, its brightness is inversely proportional to the square of the distance; that is, if the distance is halved, the brightness can increase by a factor of 4. ④Turn it on and off in a timely manner, or use an automatic photoelectric control switch for lighting. ⑤Clean the lighting fixtures regularly.
Negative-pressure ammonia steaming and negative-pressure benzene steaming are employed, along with the utilization of waste heat from flue gases; negative-pressure desulfurization makes rational use of the gas temperature in a stepwise manner.
Who else has other energy-saving measures? Such as water conservation and steam conservation?
There seems to be little in the way of energy savings in terms of manufacturing processes. For example, as the original poster mentioned, points two and three are taken into account during the design phase of the furnace itself. I believe that energy savings should be achieved through better management and by reducing costs associated with production; for instance, by extending the lifespan of equipment and delaying its replacement
Depressurization treatment techniques: benzene distillation, ammonia distillation, tar distillation； Multi-stage heat exchange ； Process reengineering: Desulfurization ahead of schedule, benzene washing ahead of schedule ； Waste heat utilization in the riser tube ； Coal moisture adjustment ； Dry quenching of coke ； Flue gas utilization ； Variable frequency equipment ； Residual heat from the primary cooler ； Utilization of waste heat from circulating ammonia water, etc.
Steam energy savings: When the electric tar capturer at our plant was put into operation, steam was used to heat the jacket of the electromagnetic coil; later, electric heating was adopted instead. The gas blowers at our plant were selected with a capacity that was too high – initially, couplers were used for speed control, but these were later removed in favor of frequency converters for speed control, with very good results.