Integrated coke plant automation and optimization using advanced control and optimization techniques
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.
1. A method of optimizing operation of a coke plant, comprising:
operating a plurality of coke ovens to produce coke and exhaust gases, wherein each coke oven comprises a crown and a sole flue adapted to operate in a determined temperature range, the crown and the sole flue including controllable openings for introducing air, wherein each coke oven comprises an uptake damper adapted to control an oven draft in the coke oven;
directing the exhaust gases from each coke oven to a common tunnel;
fluidly connecting a plurality of heat recovery steam generators to the common tunnel;
operating all of the heat recovery steam generators and dividing the exhaust gases such that a portion of the exhaust gases flows to each of the heat recovery steam generators;
automatically controlling the uptake damper of each coke oven to maintain the oven draft of each coke oven at or within a deadband of a targeted oven draft;
automatically controlling the controllable openings of the crown and/or sole flue of each coke oven to maintain the oven temperature of each coke oven in the determined temperature range; and
in a gas sharing operating mode, stopping operation of one of the heat recovery steam generators and directing the exhaust gases through the common tunnel such that a portion of the exhaust gases flows through each of the remaining operating heat recovery steam generators while maintaining the oven temperature of each coke oven in the determined temperature range.
2. The method of claim 1 , further comprising:
at least one emergency vent stack, having an emergency vent stack draft, operatively coupled with the plurality of heat recovery steam generators;
each of the plurality of heat recovery steam generators having an associated pressure control valve, downstream of the heat recovery steam generator, and
controlling the pressure control valves to maintain the emergency vent stack draft at a predetermined level using a pressure indicating controller.
3. The method of claim 1 , further comprising:
automatically controlling the uptake damper, the controllable openings of the crown, and/or the controllable openings of the sole flue of each coke oven to maintain an oven temperature in each coke oven within the determined temperature range.
4. The method of claim 3 , further comprising:
automatically controlling the uptake damper, the controllable openings of the crown, and/or the controllable openings of the sole flue of each coke oven to maintain an uptake duct oxygen concentration near each uptake damper within an oxygen concentration range.
5. The method of claim 1 , further comprising:
automatically controlling the uptake damper, the controllable openings of the crown, and/or the controllable openings of the sole flue of each coke oven to maintain an uptake duct oxygen concentration near each uptake damper within an oxygen concentration range.
6. The method of claim 1 , further comprising:
automatically controlling the uptake damper, the controllable openings of the crown, and/or the controllable openings of the sole flue of each coke oven to maintain a common tunnel temperature in the common tunnel within the determined temperature range.
7. The method of claim 1 , further comprising:
automatically controlling the controllable openings of the crown and/or the sole flue of each coke oven in response to a temperature sensor input.
8. The method of claim 7 , further comprising:
automatically controlling the controllable openings of the crown and/or the sole flue of each coke oven in response to an oxygen sensor input.
9. The method of claim 8 , further comprising:
automatically controlling the uptake damper of each coke oven in response to a temperature sensor input and/or oxygen sensor input.
10. The method of claim 7 , further comprising:
automatically controlling the uptake damper, the controllable openings of the crown, and/or the controllable openings of the sole flue of each coke oven to maintain an oven chamber temperature in each coke oven within a temperature range.
11. The method of claim 7 , further comprising:
automatically controlling the uptake damper of each coke oven to maintain a sole flue temperature in each coke oven within the determined temperature range.
12. The method of claim 7 , further comprising:
automatically controlling the uptake damper of each coke oven to maintain an uptake duct temperature in each coke oven within the determined temperature range.
13. The method of claim 7 , further comprising:
providing a plurality of crossover ducts, wherein each crossover duct is connected to one of the heat recovery steam generators and connected to the common tunnel at an intersection.
14. The method of claim 7 , further comprising:
providing a heat recovery steam generator damper adapted to control a flow of exhaust gases through the heat recovery steam generator downstream of each heat recovery steam generator; and
automatically controlling at least one heat recovery steam generator damper to maintain a targeted vent stack draft within a draft range.
15. The method of claim 7 , further comprising:
automatically controlling at least one uptake damper to a fully open position; and
providing a heat recovery steam generator damper adapted to control a flow of exhaust gases through the heat recovery steam generator downstream of each heat recovery steam generator; and
automatically controlling the heat recovery steam generator dampers to fall within a common tunnel draft range.