US2064484A - Coking apparatus - Google Patents

Description

' Dec. 15,1936. J.V.MEIGS 2,064,484.

COKING APPARATUS I Original Filed April 27, 1929 e Sheets-Sheet 1 Illi 2 6B 6 3 J5 r 3/ K 2 2 IA; 4B 4 9; A 6A g7 I Q y" J R -2 Q U .I i I TOR v Dec. 15, 1936. J. v. MEIGS COKING APPARATUS 6 Sheets-Sheet 2 Original- Filed April '27, 1929 Dec. 15, 1936. J. v. MEIGS 2,064,484

GOKING APPARATUS v Original Filed April 27, 1929 6 Sheets-Sheet 5 w 3% Q N \2 (f5 N N INVENTOR :5

Dec. 15, 1936. v ME|G5 COKING APPARATUS I Original Filed April 27, 1929 6 Sheets-Sheet 4 M 7 M m 0mm 1 N w H M ZW/ 7 ;m g

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COKING APPARATUS Original Filed April 27, 1929 6 Sheets-Sheet 5 Dec. 15, 1936. v, M GS 2,064,484

COKING APPARATUS Original Filed April 2'7, 1929 6 Sheets-Sheet 6 Patented ea. 15, 1936 UNETED PATENT OFFICE COKING APPARATUS Application April 27, 1929, Serial No. 358,645

Renewed June 8, 1934 13 Claims.

This invention relates to the distillation and carbonization of substances, particularly bitu minous materials, including coal tar pitch and other pitches, asphalts, petroleum residues and the like and provides improved apparatus for such carbonization and distillation.

Numerous attempts have been made to provide practically successful means for carbonizing pitches at low cost for labor, upkeep and other charges, for producing satisfactory coke and for recovering the by-products.

The ordinary by-product coke oven is not well adapted for the purpose. The intumescence a'nd frothing of the material during its conversion from the melted condition to the solid one, or to coke, may cause the charge to be ejected through the various openings, such as the uptake.

pipe and charging holes.

Petroleum coke and pitch coke may be made in iron or steel stills, but the method is attended with numerous disadvantages, such as rapid depreciation of the apparatus, loss of time in cooling the charge and difilculty in removing it from the still.

In efforts to overcome the-difficulties experienced in carbonizing pitches, asphalts and the like in large masses it has been proposed also to carry out the carbonization in small pots; to

- flow oil residuum, wax tailings, etc. down the inside surfaces of a tower counter current to a stream of hot combustion gas; to carbonize pitch in films in apparatus somewhat similar to a drum dryer; to mix pitch with non-combustible-material and run the mixture through a rotating cylindrical'still resembling, in part, a rotary kiln; and to carry out other processes which seek a solution of the problem of producing pitch coke and recovering the-by-products of the coking process, at sufficiently low cost and in such manner as to render the process attractive from the financial, commercial and technical points of view.

The present invention provides process and apparatus whereby pitch and analogous materials may be carbonized in upright, relatively narrow, horizontally elongated chambers or ovens, whereby the ebullition or intumescence of the material is provided for.

It furthermore provides means whereby the bituminous material may be charged into the hot ovens immediately upon discharge therefrom of ,the previously produced coke, without the intervention of a cooling period.

It provides improved means whereby the pitch may be thoroughly carbonized in large masses,

improved freed of volatile matter and converted into hard, strong, massive coke in a relatively short period of time.

It provides improved means for obtaining and handling the volatile by-products whereby increased yields of the vapors of oils and solid materials may be obtained, purified and condensed and, means whereby the pressure in the coking chambers may be kept uniform and whereby the charging of bituminous material is facilitated.

It provides improved means whereby the coke tenaciously adhering to the interior surfaces of the heating walls may be removed by a carbonconsuming gas, such as highly heated steam, as a result of which the coke charge may be readily ejected and whereby useful gas is produced. It provides improved 'means for removing volatile products from the pitch and coke and forrecovering the same.

In using the apparatus bituminous material is charged into a group of horizontally elongated, relatively narrow, upright coking chambers communicating freely with each other through a relatively wide space at the top of the chambers common to all the chambers of the group. Heat is applied to or maintained at the sides of the chambers to distill and carbonize the bituminous material and drive off gases and readily condensible vapors, and the latter are removed, under carefully controlled pressure conditions, from the coking chambers and the common communieating and expanding space lying above the same and treated to recover valuable products. Gas and vapor are driven off from the bituminous material and the mixture of the, same with liquid bituminous material may travel more or less rapidly up through the narrow chamber spaces. Upon reaching the space above the chambers the upward movement is retarded andseparation of gas and/or vapor and liquid or plastic bituminous material may be effected. The narrow chambers may be charged to somewhat less than their capacities; or some of the chambers may be fully and others less fully charged; or some may be fully charged and others not charged at all, sothat bituminous material may foam over or be transferred through the space lying above the chambers from the more fully charged chambers into those less fully charged or not charged. When foaming has subsided additional bituminous material may be charged into any of the narrow chambers and distillation and carbonization continued so that at the end of the coking cycle all the narrow chambers may be fully charged with coke, At the endof the coking process, doors at the ends of the group of chambers are removed and the coke is discharged horizontally.

Between the individual coking chambers of the group of such chambers, horizontally elongated heating structures are located having, in sections thereof at right angles to the horizontal axis of the coking chambers, an inverted U or inverted V shape or modifications of such shapes. These heating structures are adapted to be heated from the inside and the invention comprises the process of heating such structures, regulating the heating thereof and flowing melted bituminous material over the outside surface thereof, distilling, solidifying and carbonizing the bituminous material and building up layers of carbonized material on the vertical or inclined suriaces of the said structures.

From the apparatus standpoint the invention comprises, broadly, horizontally elongated upright or vertical coking chambers alternating with similarly disposed flue-chambers or heating elements, combined into a group, and combinations of such groups. The individual coking chambers of each group are in free communication through a common space above the said chambers and the vertical longitudinal sections of the said common space are preferably substantially greater than the horizontal section of any individual coking chamber.

In addition to the general features and provisions recited above, the invention includes such further provisions, objects, improvements and advantages as are found to obtain in the processes, structures and devices hereinafter described, shown or claimed.

.The invention will be described more particularly with reference to the accompanying drawings, which form a part of the specification and which illustrate certain embodiments of the apparatus of the invention and of means for the practice of the processes thereof. It is intended' andwill be understood that the invention is illustrated by and not limited to the specific embodiments so illustrated and described.

Figure 1 represents an enlarged vertical section transversely of the coking chambers through a portion of a combination of groups of coking chambers, taken on the lines DD of Figure 3 and EE of Figure 2.

.Figure 2 is a vertical section on the line AA, Figure 1, with the doors at the ends of the coking chambers removed, showing fuel gas supply header pipes in elevation. 4

Figure 3 is' a vertical transverse section on the line BB, Figure 1.

Figure 4 is an enlarged horizontal partial section on the line 0-0 of Figure 1.

Figure 5 is a partial vertical section on the line E--E of Figure 4.

Figures 6 and '7 are vertical sections taken transversely of the coking chambers and showing modified forms of the structure shown in Figures 1, 2, and 3.

Figure 8 is an elevation, partly in section, of one end of a coking chamber showing an uptake pipe for removing volatile products from the chamber, a purifying device, a pressure regulating device, conduits for gases and vapors, condenser and gas pump or exhauster.

The figures are more or less diagrammatic and like parts are designated by like numerals.

IA, IB, IC, and ID represent in section coking chambers with heating walls 3 and 6A and soles. I2. The walls 3 enclose and contain vertical heating fiues I5, as shown in greater detail in Figure 3, and support the arches 2. The flues I5 are separated by partitions I4, which brace the Walls 3. The partitions I4 and the walls Bare in turn supported by the heavy walls 4, which extend longitudinally of the coking chambers from the wall 2i, on the coke discharge side, to the wall 2 IA on the pusherside of the battery, as shown in Figure 3. The heavy walls 4 rest upon the mat or platform 5, which constitutes the subioundation of the structure.

The coking chambers, as for example IB and IC, are separated by the structure 6. This comprises the walls 6A, which may be parallel to the walls 3, connected at the top by the arch 6B. The walls 6A are secured in the base 26. The latter is supported by the walls I0 and I I, which like the walls 4 extend from front to rear of the ovens or coking chambers. The spaces between the walls A, II], and I I contain regenerators, as more fully described below. For the purpose of the present invention the coke discharge side of the ovens will be regarded as the front thereof and the pusher side as the rear.

The construction shown provides great strength for the entire structure, as well as for its constituent parts including the structures 6. The walls of the latter possess great resistance to lateral thrust by virtue of their internal bracing, as will be described below, and through their secure anchorage in the solid bases 26 and oven soles I2, said bases 26 and soles I2 being adequately supported on the walls I0, II, and 4.

The structures 6, one of which is shown in Figure 2 in a vertical section taken in a plane substantially parallel to the walls 3 and 6A, extend from front-to rear of the coking chambers. They are closed at the ends and these ends, 2IC and 2 ID, are substantially flush with and form a part or extension of the corresponding front and rear walls of the battery, 2| and 2lA,.respectively. The structures 5 are braced internally by the vertical walls 9 anchored in the bases 26, and by horizontal members 8. The latter are arranged in staggered formation, as shown in Figure 2, forming horizontal flues 1 which communicate with each other and with regenerators 21 and 28.

There are two sets of horizontal flues 1, one set on each side of the wall 9, and corresponding to and communicating with each set of flues there are a pair of regenerators 21 and 28, as shown in Figure 2. The pairs of regenerators are separated by the wall II and the individual regenerators of each pair are separated by the vertical wall 29 and the baflle 33. The walls 29 connect and brace the walls l0 and II and are substantially at right angles to the same. The walls 29 do not extend all the way up to the base 26 and stop at the arches 29A, which form, with the horizontal bafiles 33, passages 3I constituting continuations of the passages 30, said passages 30. SI, and 32A constituting respectively direct communication between the regenerators 21 and the lowermost of the twin series of flues 1 on either side of the walls 9.

In addition to the horizontal flues 1 two vertical flues 31, each of which communicates directly with one of the uppermost horizontal lines 1, are formed by the walls or partitions 33A which connect the walls 6A and 9. Each of the flues 31 communicates also directly with one of the regenerators 28 through openings 32 in the base 25. A baffle 39 extends under a portion of each of the regenerators 28 to give proper direction to the gases passing therethrough. Ports 25 and 25A under the regenerators 21 and 28 serve for the passage of air or Waste gas into and out of the regenerators, respectively.

The flues l and 31 are provided with fuel gas by nozzles 38 which communicate through valves 35 with fuel gas supply headers 34 and 34A. The nozzles 38 extend from the valves 35 through the brick end walls NC and 2ID. The nozzles passing through, the wall 2|D pass also through the flue 31 and the wall 33A. The portions of those nozzles which extend through the flue 31 are covered with insulating material 36 to protect the nozzles from the action of highly heated combustion gas.

The temperature in the individual lines can be regulated by adjustment of the gas valves 35, which are located outside the ends of the structure 6 and are therefore readily accessible from a position outside the coking chamber.

Each series of flues, one series on each side of the-walls 9, are provided respectively with gas supply headers 34 and 34A, gas valves 35 and nozzles 38. This provides numerous points of temperature control so that the walls 6A of the structures may be heated to different temperatures at different points thereof. In the particular arrangement shown, there are sixteen individual flues for each of the structures 6 and therefore sixteen zones of temperature control. each individually controllable by manipulation of the valves 35 located outside the coking chambers.

Fresh air to maintain combustion of fuel gas in the flues I and the flue 31 is alternately supplied to regenerators 21 and 28. Likewise waste products of combustion from the flues I and the flue 3'! are passed alternately through regenerators 28 and 21, whereby heat is stored up in those regenerators and then imparted to the air for combustion that passes through the same. Subterranean conduits or mains not shown, one on each side of the battery, serve to alternately supply air and to withdraw waste gas from the regenerators in the manner known in the art.

For example, air is supplied to the regenerator 21 from a main (not shown) through the port 25, passes through the checkerwork, through the passage 30, over the baflle 33, through the opening 32A, through the flues 1- and the vertical flue 31, and then passes through the checkerwork in the regenerator 28 to the port 25A and finally to a waste gas main (not shown). Combustion takes place in the flues by means of fuel gas supplied as described above.

At the end of a suitable period, for example one half an hour, the air supply is reversed. It is then supplied from the Waste gas main last mentioned above to the port 25A, and passes through the heated checkerwork in the regenerator 28, through the opening 32, through the flue 31, the flues 1, the opening 32A. the passages 3| and 30, through the regenerator 21 and finally to the main, via the port 25.

The walls 3 contain vertical flues l5 communieating with the horizontal top or bus flues '6. Under the sole of each coking chamber a pair of regenerators 23 and 24 are situated. The members of each pair are separated by the walls 203 located between the individual regenerators of each pair. The walls 20B extend from the base 5 up to the soles l2 and not only separate the regenerators 23 and 24 but also assist in supporting the soles l2 and the adjacent structures and in bracing the walls 4 and ID. The pairs, 23

and 24, of regenerators are on opposite sides of the walls 4 and each pair communicates with each of the flues- [5 through ports 18. Each flue may communicate also with one of the gas mains 20 and 20A through ports I9.

Combustion in the fiues l5 may be effected by the use of regeneratively preheated air, and coke oven gas or other gas with a high heatng value, such as gas produced by the carbon'zation of pitch, asphalt or petroleum residues. Combustion may also be carried out by using regeneratively preheated air and regeneratively preheated gas such as producer gas, blast furnace gas or other gas with a low heating value, with a corresponding release for other purposes of the more valuable gas made by the carbonization process.

Combustion in the flues l5 takes place in only one half of those flues at one time, viz. that half which is on one or the other side of the wall 20B and super-lying partition I4. While combustion is taking place in an upward direction in one half of the flues, the products of combustion pass downwardly through the remaining half of the' fines into the regenerators below and on either side of that half.

Assuming, for example, that coke oven gas is to be employed for heating purposes. this is supplied through the conduit 20 to the fiues M above the conduit 23 through parts l8. Assuming also that regenerators 23 have been heated by previous passage through them of hot combustion products, air is supplied through ports 25, passes upwardly through regenerators 23 and the ports [8 communicating with those rc-. generators and burns the coke oven gas supplied from the conduit 20. The products of combusticn pass through the overhead bus flue l8 down wardly through the other half of the flues l5 and ports l8, downwardly through regenerators 24 and are educted through ports 25A. During this time, fuel gas is turned off from the fuel gas main 20A. At the end of a suitable period, such as one half hour, the direction of air and fuel gas is reversed. Fuel gas is turned off from the conduit 20 and turned on in the conduit 20A and air is supplied to the regenerators 24 through ports 25A. Combustion now takes place in that half of the fines above regenerators 24, flames move upwardly in these flues, and the combustion products pass through the fiue '5'. and then downwardly through the other half of the vertical fiues and through the regenerators 23 and are educted through ports 25.

If' a gas such as producer gas is to be employed for heating purposes, the mains 20 and 29A are valved off. One member of each set of regenerators under the sole of the coking chambers is then alternately used for preheating producer gas supplied to it through its port 25 and the corresponding regenerator of the other set, on the other side of the wall 4, is simultaneously used for preheating air.

The means for supplying producer gas and .air to the ports of the regenerators and richer gas to the mains 20 and 20A, for educting the products of combustion frcm the regenerator ports and for reversing the supp'y of fuel gas and air are not shown. By the means described and shown the walls 3 may be heated, optt'onally, by producer gas, by the gas made as a result of the coking process or by ordinary coke oven gas. This permits the conservation of a large part of the gas made by the coking process described below, which, in many cases, possesses a high heating value.

The size of the openings in the ports 18 and 19 may be adjusted by the use of suitable plugs or nozzles and those openings may be completely covered by the use of closure bricks, not shown.

By the use of such closure bricks on the bottom.

of the fines and closure bricks ISA on the top thereof. any flue or group of flues may be put out of operation or the draft in any flue may be controlled. By the means described the temperature in each flue is subject to control. Access to the bottom of the flues l5 and the plugs and closure devices of the ports I8 is had through the passages H and bus flue port holes llA by means of a rod thrust down through these openings. The port holes "A are closable by sliding bricks SB and the passages I? may be closed at the top thereof by bricks properly shaped and resting upon the shoulders shown in Figure 3. Access to the bus flue 16 may be had through holes IEC normally closed with suitable closures.

The soles l2 of the coking chambers, as shown in Figures 1, 4, and 5 and, in modified form, in Figure 6, are specially constructed to permit the admission of gases, as for example, superheated steam, as described below. Figure 4 represents a partial plan view and Figure 5 a vertical section of the sole of an individual coking chamber and adjacent parts. The sole I2 is securely anchored in the brick work lying underneath it and is separated from the walls 3 and 5A by narrow slits 41. Rectangular recesses 43, forming a pair of horizontal conduits, extend from one end of the sole to the other and each conduit communicates with the adjacent wall through apertures 46. Perforated pipes 45 made of heat resistant metal extend through the conduits 43, the perforations facing the apertures 46 and being adapted to deliver gas through them. The conduits 43 extend to within about one foot of each end of the oven soles l2. The ends of the conduits near the wall 2IA are closed, preferably by removable closures so that access may be had to the conduits at those ends for cleaning or other purposes. The ends near the wall 2| communicate with recesses 49 in the bases 26 of the structures 6. Valved pipes 50 extend through the wall ZIC of the structures 6 into the recesses 49 'and communicate therein with pipes 45 to deliver steam or other gas, as desired, to said pipes 45. The slits 41 extend, substantially the same length of the soles 12 as the conduits 43.

, The coking chambers, for example IB and 'IC, are provided at each end with removable doors (not shown) which are removed when the charge of coke is to be pushed and are secured in place and suitably sealed prior to charging and carrying out the coking cycle. The doors may have an inverted U-shape corresponding to the shape of the section of the coking chambers, e. g. IB and IC, and the space above connecting the same.

They are removed, e. g., in the manner customary material, constructed and provided with closures in the usual manner.

Valved nipples 4! for the admission of steam or other suitable gas and larger valved nipples 40 for the admission of melted bituminous material are also provided,

lateral thrust.

in multiple series, as shown in Figures 1 and 2.

The dimensions of the coking chamber may be varied to a large degree. As a specific example of dimensions, the width may be eighteen inches, the length twenty-five feet and the height ten feet. By height is meant the perpendicular distance from the soles 12 to the top of the arches of the structures 6. The maximum vertical width of the spaces 2A may be four feet. The transverse widths of the structures 6 may be four feet. It is desirable that the width of the structures 6 be substantially greater than the Width of the coking chambers, in order that the structures 6 may possess suificient strength and resistance to While the present invention provides means for greatly reducing the pressure on the structures 6 and walls 3 (particularly during the pushing operation) by providing means for cutting the coke charge away from the retaining heating walls as described above, there may be cases where it is not desired to carry out the said cutting" or coke consuming operation and in such event the walls 3 and structures 6 must be sufficiently stifi and strong to withstand any pressure encountered during pushing. Undue length of the coking chambers and structures 6 should be avoided to avoid undue difficulty and undue stresses during pushing.

As shown in Figures 1 and 2. the coking chambers, as for example IB and I C, freely communicate with each other through the space 2A above those chambers. The widths of the space 2A, that is, the varying distances between the arch 6B and arch 2, are greater than the width of the chambers IB and IC (which is the distance between the walls BA and walls 3). The space 2A thus provides an expansion chamber between the communicating chambers IB and IC and is substantially co-extensive horizontally with said chambers.

The elements of the structure shown in Figures 1, 2, and 3 cooperate in a combination to provide structural and operative improvements. The walls 4, 3, l0, and H, arches 2 and bases 26, as well as the bracing and dividing walls 20B and 29 are combined, the parts of which cooperate to brace and strengthen each other and to provide secure foundations 26 for the heating elements 6. The latter, as shown in Figure 1, stand alone, may be subject to great lateral or side-wise thrust during the pushing operation and are therefore not only thoroughly braced internally but also securely anchored externally in heavy bases 25, which derive strength from the structure as a whole as well as from the immediately adjacent parts.

The invention is not however limited to the specific details of structures and methods described or shown herein. For example, other arrangements of flues' and regenerators, consistent with suitable strength and control of the coking and gas making processes, may be employed. The heating flues in the structures 6 may be vertical instead of horizontal and means may be provided to supply such flues with regeneratively preheated lean gas such as producer gas.

The portions of the structures herein described or shown that are subject to contact with highly heated gas are preferably made of high grade refractory material such as silica brick.

In order to further increase the strength of the structures 6, these may be re-enforced by alloy steel, capable of retaining its strength at high temperatures, embedded in the walls 6A and anchored in the bases 26.

Figures 6 and 7 show modified forms of coking chambers. In Figure 6, the arch 53 is supported on walls 51, which are, preferably, supported by heavy walls (not shown) similar to the walls 6 in Figure 1. The walls 51 enclose heating flues 58 which may be horizontal or vertical. The

.central heating structure 60 is shown as heated The walls of the strucby horizontal flues 59. ture 60 are, preferably, supported on heavy foundation walls (not shown). The coking chambers 98 and 99 formed between the structure 6D and walls 51 have a pronounced taper from top to bottom, asclearly shown. This particular form of construction is correlated with the practice of one form of the process of the invention, as will be explained below. The oven shown in Figure 6 is provided with charging holes above the coking chambers as indcated at 56, for solid bituminous material, and with a double series of valved nipples 54, for charging melted bituminous material, only two of which are shown. The soles l2 conform to the taper of the walls adjacent thereto, and are constructed to perform gasor steam-admitting functions in amanner similar to that described in connection with Figures 1, 2, 4, and 5.

In Figure '7, two structures, 6| and 62, containing heating flues form, together with walls 14, three coking chambers, 10, H, and 12 communicating with each other through the common space beneath the arch 15, which acts as a communicating and expansion chamber. The walls 14 contain heating flues which may be vertical or horizontal and are shown as vertical flues. The structures 6| and 62 may as shown be joined by the brick work or wall 16. This greatly strengthens these structures and provides great resistance to lateral thrust upon the same.

The chamber H augments the expansion and communication space described above. Charging holes 63 are provided for solid bituminous materials and a series of valved nipples 66A, 66B, 67A and 613, only four of which are shown, for melted bituminous materials. The heating flues in the walls 14 preferably communicate with twin sets of regenerators (not shown) located under the coking chambers 10 and I2, respectively, in the manner described above with reference to the flues l5 and regenerators 23 and 2d in Figures 1 and 3. The heating structures 6| and 62 are provided respectively, as shown, with horizontal flues communicating respectively with sets of regenerators (not shown) under each series of flues in the manner shown in Figures 1 and 2 and described above with reference to the respective sets of regenerators, 21 and 28, under each respective series of horizontal flues in each structure 6. .The various flues in the walls 74 may be supplied with rich or regeneratively heated lean fuel gas in the manner described for heating the flues 15, as hereinabove described in connection with Figures 1 and 3, and the flues in the structures 6i and 62 may be supplied with fuel gas as shown and described with reference to Figure 2.

Instead of the single heating elements or structures, 6, or double elements, 6| and 62, multiple heating elements may be employed. For example, three, four or even more of such heating elements may be used. These may have the shape shown in Figures 1. 6 or 7, i. e., an inverted U-shape or inverted V-shape, in sections taken at right angles to the long axis of the coking chambers. The heating elements enclose heating flues and the group of elements and the group of coking chambers formed thereby are enclosed by elongated walls, such as 3, or M, or 57, and by the arches supported by the said elongated walls. The heating elements may be braced by solid walls between them as shown in Figure 7.

Figure 8 illustrates diagrammatically in end elevation, partly sectional, means for removing and recovering distillates, such as oil and gas produced by the destructive distillation of bituminous materials. The uptake pipe 11 communicates with the opening l3 and the pipe 19. The latter leads into the expansion chamber" 80, provided with clean out doors 86 and draw-oil pipe 91 in which valve 96 is located. Spray means 96 connected with valved supply pipe Si is located in theupper part of the chamber 80. Pipe 8i leads from the chamber 80 to the condenser 82, provided with draw-oil pipe 84 for condensed material, said pipe 841 being provided with a suitable valve, not shown. The exhauster 83 is adapted to exhaust gas from the condenser 82 and to deliver it to storing and/or purifying means (not shown).

In order to care for large volumes and surges of vapors produced during distillation and carbonization of bituminous materials such as asphalt, pitch, et cetera, the pipes ll, 19, and 8! are made of ample size and a butterfly valve 95 is located in the pipe 8! and is adapted to be operated by the motor 94 working in conjunction with the'pressure control device 93 which communicates through pipe 92 with the pipe MA. The exhauster 83, valve 95 and pressure control device 93 are adapted to operate to maintain .pressure in the coking chambers substantially at atmospheric pressure at all times during the coking period or cycle. To further assist in carrying out'this object, a plurality of openings l3 with corresponding uptake pipes Tl may be provided at more or less regular space intervals distributed in the arches 2 above and aligned with the structures 6 and connected together by means of a header leading to the chamber 80. In the drawings only one such opening l3 and uptake pipe F1 is shown.

The chamber 80 may be individual to each pair or group of communicating coking chambars as shown in Figure 8, or may be common to a series or battery of coking chambers. The Valve 81, operated by the spindle 88 and handle 89, controls communication between the chamber 80 and the coking chambers connected with the pipe 19. The spray means 90 is adapted to receive from the pipe 9| either liquid or gaseous materials, for example, superheated steam or heated liquids such as condensate from condenser 82, and to deliver such materials as a spray into the gas stream from the pipe 8IB.

The practice of the process of the invention in its various forms may be carried out with a variety of bituminous materials, such as native asphalts including Gilsonite, petroleum residues and pitches, coal tar pitches, et cetera. In practicing the process of the invention, assuming that coke has just been pushed from the coking chambers, as for example IB and I0, that these chambers are in a highly heated condition; that the doors at the ends of the coking chambers have been put in place and made tight, that the valve 81 is closed, and that pitch from coke oven tar is the material selected for carbonizing, coke from a previous operation is charged through openings 42 in amount sufficient to cover soles l2 and slits 41 to a depth ofv about one foot. The openings 42 are then closed and valve 81 is opened. Melted pitch is then gradually charged, from a source (not shown) through the nipples 40, so that it strikes the top of the arch 6B and fiows down the walls 9. By virtue of its contact with the highly heated structure 6, volatile material is removed from the pitch. By use of the regenerators 21 and 28 and by proper control of the air-gas mixture in the fiues 1 by manipulation of the valves 35, the arch BB and walls 6A are maintained at high temperature. The rate at which melted pitch flows down over those Walls is then regulated by valves in the nipples 40 so that by the time the pitch reaches the layer of coke on thesoles l2, the pitch has become solidified to such an extent that it is not capable of penetrating the coke layer and not capable therefore of clogging the slits 41. As this procedure is continued, layers of carbonized pitch gradually build up on the surface of the walls 6A.

After this procedure has supplied sufiicient solidified or coked pitch to cover the coke layer on the soles l2 to a depth of six inches or one foot or thereabouts, the melted pitch is more rapidly admitted through the nipples 40. The chambers, for example IB and IC, are however charged to difierent heights. The chamber lB, for example, is charged to a height about opposite to the highest of the fiues 1 in the structure 6, while the chamber IC is charged to only about one half of this height. This is done by adding pitch to a greater or lesser extent through one or the other of the sets of nipples 40 positioned, as shown in Figure 1, on either side of the center of the arches 2.

Combustion is maintained in the fines l5, 1, and 31, and volatile material is progressively removed from the pitch, with concurrent foaming thereof to a greater or less degree. That portion of the charge which expands and foams over from, for example, chamber IB through the expansion space 2A, is delivered into chamber IC which was not previously fully charged. Expansion and foaming are, to a substantial extent at least, due to the release of vapor or gas from viscous material and are therefore particularly active as the coking period approaches, when the material is approaching the solid stage and when gas in large volumes is being evolved. The space 2A and the unfilled portion of the space lC provide expansion and separating chambers where mixtures of gas or vapor and liquid material may be separated prior to the delivery of the gas and/or Vapor through the port or ports l3 into the by-product recovery system.

By means of the method and apparatus herein described, the pitch, instead of expanding up into the various charging holes and outlets and clogging the same, has ample opportunity to merely pass from one coking chamber to another through a large communicating and expanding space. After the foaming or expansion has subsided, additional pitch may be added to any coking chamber, i. e., 113 or l0, so that at the end of the process, the coking chambers may be fully charged with coke.

During the period when expansion and foaming are taking place, steam or other suitable gas may be directed downwardly upon the pitch from the nipples 4|, to repress the foaming and to assist in making the resulting coke less porous. The steam or gas so used is preferably highly superheated.

At the end or shortly before the end of the coking period, highly heated steam is supplied through valve 50 to the pipes 45 and conduits 43 and is delivered through the slits 41, in the form of layers of steam. The object of this step is, in part, to clean or scour the walls of the coking chamber by consuming and converting into useful fuel gas the coke immediately adjacent to the walls of the coking chambers, thus facilitating the release of the coke charge from the walls during the pushing operation and decreasing the pressure exerted on the walls of the structures 6. For this purpose any gas may be used that will react with heated coke and convert it to a gas, such as steam or carbon dioxide. From the point of view of convenience in the use and in the disposal of an excess thereof, steam is preferred. /In addition to the scouring action which it has on the walls of the coking chamber, it also forms useful blue" gas by reaction with the coke film or layer immediately adjacent to those walls and such gas together with excess steam assists in removing volatile matter from the coke and producing an improved coke. Coke made by carbonizing fusible bituminous materials adheres, in many cases at least, more firmly to the walls of coke ovens, retorts, etc., than coke made from coal and may therefore be more difficult to push than ordinary coke, and the present invention provides the means herein described for overcoming this difficulty.

The admission of steam or other suitable gas .need not be delayed until the end of the coking cycle but may also be effected during the distillation of the pitch to assist in the removal of the volatile products therefrom.

The heavy grease-like and resinous matters evolved from bituminous material during the latter or final periods of distillation thereof are somewhat difficult to remove completely and the use of steam or other suitable gas, as herein described, assists in the removal of such material and presents an improved step in the carbonization process for the preparation of high grade coke.

At the end of the coking period, the front and rear oven doors are removed and the coke in the chambers is ejected therefrom by .the use of pushers in the known manner.

Prior to the pushing operation any layer or film of coke on top of the arches 6B may be converted into gas by the action of steam, preferably highly heated steam, at a temperature of '100 degrees centigrade for example, which may be admitted through those members of the nipples 4| lying vertically above the top of he arches 6B.

After the pushing operation, any coke adhering to the walls of the coking chambers may be burned off by air, preferably heated air supplied from an air preheater (not shown) and admitted from the pipes 45 and conduits 43 through the slits 41. During this process the coking chambers may be beehived, that is, the holes 42 are opened and the valves 81 (see Figure 8) are closed.

Prior to admitting pitch into the coking chambers as described above, those chambers may be purged of air by blowing steam into the chambers through the slits 41, having previously closed valves 81, and continuing such purging until steam issues freely through the valves 18 (see Figure 8).

The process of the invention, in other forms, may be carried out in other forms of the appashown in Figures 6 and 7.

Referring to Figure '7, molten bituminous material may be charged through nipples 66A and 61A up to the full or partial capacities of the chambers 10 and 12 and heat applied through,

the walls of these chambers, to distill and carbonize the bituminous material. The chamber H provides a reservoir to receive bituminous material which foams over from the chambers 10 and 72, and which is carbonized in the chamber 1|. Moreover, the chamber H and the space lying above it and above the structures 61 and 62 provide ample expansion space. Masses of vapor and bituminous material which may more or less rapidly move upward in the relatively narrow chambers in and 12 move much more slowly upon reaching the expansion spaces described and such reduction in speed affords opportunity for separation of vapor from the bituminous material. If the chamber H is not filled by material from the chambers 10 and 12, additional material may be charged into chamber ll through the nipples 66B and 613.

At the close of the coking period, steam, preferably in a highly heated condition, may be directed from the nipples 68 downwardly on top of the structures 6| and 62, and any incandescent coke thereon, to consume the same and convert it into blue gas. During such operation, intense combustion may be maintained in the top flues of the structures 6| and 62. The object of this operation is to facilitate the pushing of the coke charge from the chambers 10, H, and 12 by severing any films or layers of coke which may connect the charges in the chambers 10, H, and H.

The soles of the chambers 10, H, and 12 may be provided with means for admitting steam thereto as hereinabove described.

Referring to Figure 6, the soles l2 of the coking chambers 98 and 99 may be covered with a layer of coke (as hereinabove described) charged through openings 56. Fusible bituminous material is then admitted through .nipples 54 and flows down over the highly heated walls of the structure 60. One of the chambers, as 98, is subsequently charged with molten bituminous material up to a height corresponding'to that of the highest horizontal partition in the structure 60 while the other chamber 99 is charged only partially. Preferably the extent of free space in the chamber 99, from the top of the structure 60 down to the surface of the bituminous material, is adjusted, by regulating the extent to which the chamber 99 is charged, so that the material which foams over from chamber 98 is equal in volume to the free space described. Additional bituminous material may be added to each chamber or both chambers to make up for shrinkage, so that at the end of the process each chamber is filled with coke, from the sole I2 up to about the middle of the top flue in the structure 60. By application of heat through the walls 51 and walls of the structure 60, the bituminous material is reduced to coke. Vapors and gas. are removed and handled as above described, and shown in connection with Figures 2 and 8. At the end of the coking process, highly heated steam is forced through the slits between the soles l2 and adjacent walls and consumes the layer of coke immediately ad hering to those walls. Since the steam layer tends to spread out as it rises, a gradually thicker layer of coke will be converted into gas. However, by virtue of the wedge-shaped form of the coke charge prior to steaming, the final column of coke will be more rectangular in shape than would be the case if the walls of the coking chambers were perpendicular. Since the conversion of coke to blue gas by the action of steam is an endothermic reaction, it is desirable to maintain a high temperature in the flues and heating walls and to use highly heated steam, or other suitable gas.

It is very desirable to maintain pressures in the coking chambers at a value very closely approaching atmospheric pressure in order to facilitate charging the bituminous material into the coking chambers and to prevent leakage of volatile products out of the same.

By providing and maintaining suitable correlation between the capacity ofthe exhauster 83, the available free space in the condenser 82, the adjustment and operation of the butterfly valve 95 (controlled by the pressure control device 93) and the size of the conduits H, '79, 81B, MA, and 8|, pressure in the coking chambers and expansion spaces 2A is maintained at a uniform value. By the correlation and coaction of the elements described, increases of pressure are quickly relieved by the exhauster 83 with a minimum of time lag. In other words the gas exhausting and vapor condensing system is responsive in a sensitive manner to the pressure conditions within the coking chambers.

The cooling surfaces in the condenser 82 are preferably so designed as to provide maximum cooling surface together with maximum free space for the vapors passing through the condenser.

To maintain such sensitivity it is necessary to prevent stoppages in the condenser and other gas and vapor conduits and prevent deposits of dirt, soot and solid or viscous condensates from building up therein.

To prevent accumulation of condensates solid at ordinary temperatures, the condensing surfaces of the condenser 82 or of sections thereof are supplied with a cooling medium which has a tem perature above the melting or flowing point of the condensate, such as hot water, or steam at. atmospheric, super-atmospheric or sub-atmospheric pressures. Such cooling medium is supplied through pipe 85 and withdrawn through pipe 85A. Other condensers (not shown) may be provided and employed in series with the condenser 82 to condense material with lower boiling point range and melting point range than that separated in condenser 82. Instead of separate condensers in series the condenser 82 may be divided into sections (not shown).

The number of condensers or number of sections in a single condenser is influenced by the nature of the bituminous material being carbonized.

Material such as Gilsonite yields in destructive distillation and carbonization distillates containing not only heavy viscous oils but also medium oils and light oil. According to the present invention such distillates are condensed in more than one fraction in different condensers or different sections of the same condenser at different temperatures, so that the normally more viscous or solid condensates are condensed at higher temperatures than the more volatile and less viscous oils and so that the material collecting on the several condensing surfaces readily flows off and such condensing surfaces are maintained clean. On the other hand, certain high melting coal tar residues or pitches yield a distillate substantially free of light oils and such distillate may be condensed in one stage by employing warm or hot water or other heated cooling medium.

The special means provided by the present invention for maintaining correct and uniform pressure in the coking chambers is especially necessary in the case of many fusible bituminous materials, such as pitches as distinguished from coals, which pitches, when introduced into highly heated chambers, evolve volatile material more rapidly than is the case with many coals.

The invention provides still further means of maintaining free and quickly responsive communication, between the several parts of the byproduct and condensing system and preventing the fouling of the condensing surfaces and the contamination of the condensates. This means comprises the chamber 80, in which settling and spraying functions are carried out.

By virtue of the relatively larger cross section of the chamber 80 as compared with that of pipe 8lB, the gases and vapors entering the chamber undergo a diminution of velocity and this provides to some extent an opportunity for solid and liquid material to settle out. Furthermore the gases and vapors are subjected to washing by a spray delivered through the nozzle 95. This spray is preferably the oily condensate, or one of the oily condensates condensed in the condenser 82, although numerous other washing media may be employed, including not only liquids but gases, such as for example steam. Impact of the spraying medium against the current of gas from the pipe 8 IB tends to throw down impurities such as soot or other finely divided particles of carbon and pitch dust or liquid pitch or tar particles, and to prevent such impurities from passing into the condenser.

The word arch as used herein is to be given a broad construction and includes any suitable means of joining walls at the top thereof to accomplish the objects set forth herein.

The coking chambers may have, as shown, a

pronounced taper from top to bottom, or a slight taper. They may also taper from end to end, and in such case the chambers are narrower at the pusher end than at the coke discharge end.

Different groups of chambers are charged, ceked and discharged at different times and in predetermined rotation. This makes for practical convenience in charging and discharging. Moreover, the volume of gas evolved from any one group of chambers is different at different periods of the coking cycle and by suitably staggering the cycles, the volume and composition of the gas and vapors from a combination of groups is rendered more nearly uniform than would otherwise be the case.

While the description of the preferred form of the process of the invention describes the charging of the ovens with melted bituminous material, it will be understood that the ovens may be charged instead with bituminous material in solid form.

It is also to be understood that various changes may be made in the operations as described herein, and in the form and arrangement of the apparatus without departing from the invention and without going beyond the scope thereof.

What I claim is:

l. A coking retort oven, comprising a pair of substantially parallel heating walls spaced horizontally from each other supporting and connected by an arch and forming part of a first heating structure, and enclosing a second pair of substantially parallel heating walls having an arch at the tops thereof and forming part of a second heating structure which encloses and is braced by partitions forming heating fines within said second heating structure, the walls of the second heating structure being spaced horizontally from the respective walls of the first heating structure thereby partly defining a pair of coking chambers and the respective arches being spaced from each other vertically a distance greater than the horizontal distance between each of the respective walls of the first heating structure and the adjacent wall of the second heating structure,

and forming thereby a communicating space between the coking chambers which have soles connecting the walls of the respective heating chambers.

2. A structure containing horizontally elongated chambers adapted for the carbonization of fusible bituminous material which comprises, in combination, a plurality of substantially parallel heavy foundation walls spaced horizontally from each other and supporting a plurality of substantially parallel heating walls spaced horizontally from each other and substantially parallel to said foundation walls and containing heating fiues, respectively, said heating walls in turn supporting arches which are connected to the heating walls at the tops thereof; the said heating walls and arches partly defining said chambers, a heating partition in each of said chambers extending horizontally from one end of the chamber to the other and from the bottom toward the top thereof and being spaced from the top and from the sides thereof, the heating partitions containing heating fines and beingsupported on heavy bases which in turn are supported, in part by foundation walls which are spaced horizontally from each other and are substantially parallel and coextensive with the first mentioned heavy foundation walls and are spaced horizontally therefrom, and in part by the latter, the spaces between the respective foundation walls containing regenerators and the spaces between each of the heating partitions and the heating walls adjacent thereto constituting narrow, upright, horizontally elongated coking chambers, each of said coking chambers adjacent each of the heating partitions communicating freely with the coking chamber at the opposite side of the heating partition through the space between the top of the partition and the arch thereabove; and means to communicably connect the flues in the heating walls and heat ing partitions with the regenerators.

3. A structure as described in claim 2 in which the regenerators on either side and immediately adjacent to each of the first mentioned heavy foundation walls communicate with vertical fines in the said heating walls, the latter being adapted to supply heat to coking chambers adjacent to said heating walls.

4. A structure as described in claim 2- in which the regenerators on either side and immediately adjacent to each of the first mentioned heavy foundation walls communicate with vertical flues in the said heating walls, the latter being adapted to supply heat to coking chambers adjacent to said heating walls, and in which each vertical flue in the said heating walls communicates with both of the said regenerators.

5. A coking retort oven comprising in combination a pair of heating walls which are substantially parallel in a horizontal direction and are spaced horizontally from each other the said walls supporting and being connected at the top thereof by an arch, the said walls and arch partly defining a chamber which is subdivided into a plurality of smaller chambers by partitions each of which comprises a pair of walls spaced horizontally from each other and connected at the top thereof by an arch said walls of said partitions being substantially parallel to said heating walls, the said partitions being spaced from one another and from the first mentioned walls and extending from one horizontal end of the first mentioned chamber to the other end andfrom the bottom toward the top thereof and being respectively spaced from the top of said chamber, the partitions thus partly defining within the first mentioned'chamber a group of coking chambers partly defined by the pair of first mentioned heating walls and the first mentioned arch which is common to and extends over and above all the said coking chambers, each partition containing heating flues, the partitions being mutually connected at the bottom thereof by respective soles and the first mentioned heating walls being connected to the adjacent partitions at the respective bottoms thereof by soles.

6. In a battery of coke ovens, a series of horizontally elongated coking chambers and heating walls therefor alternately arranged side by side in a row, each of said heating walls comprising combustion flues, a vertical partition in each of said coking chambers extending from one end thereof to the other end thereof and from the sole of the coking chamber toward the top of the same and spaced oflz from the top and lateral sides of the coking chamber, each of the partitions comprising combustion fiues.

7. In a battery of coke ovens, a series of horizontally elongated coking chambers and heating walls therefor alternately arranged side by sidein a row, each of said heating walls comprising combustion flues, a vertical partition in each of said coking chambers extending from one end thereof to the other end thereof and from the sole of the coking chamber toward the top of the same and spaced off from the top and lateral sides of the coking chamber, each of the partitions comprising combustion flues, the width of the partitionsbeing greater than the width of the chambers between the partitions and the said heating walls.

8. In a, battery of coke ovens, a series of horizontally elongated coking chambers and heating walls therefor alternately arranged side by side in a row, each of said heating walls comprising combustion flues, .a vertical partition in each of said coking chambers extending from one end thereof to the other end thereof and from the sole of the coking chamber toward the top of the same and spaced off from the top and lateral sides of the coking chamber, each of the partitions comprising combustion flues, the width of the partitions being greater than the width of the chambers between the partitions and the said heating walls, said flues being horizontal communicating passageways between successive horizontal cross walls situated in the said partitions and joined with the vertical walls thereof, whereby the said partitions are internally braced and are provided with a plurality of horizontal communicating combustion fiues.

9. A structure as in claim 8 in which the said horizontal combustion fines are each provided with gas supply nozzles controllable from a position outside of the coking chambers and are in communication with regenerators located beneath the said partitions.

10. In a battery of coke ovens, a series of horizontally elongated coking chambers and heating walls therefor alternately arranged side by side in a row, each of said heating walls comprising combustion flues, a vertical partition in each of said coking chambers extending from one end thereof to the other end and from the sole of the coking chamber toward the top of the same and spaced off from the top andlateral sides of the coking chamber, the distance between the top of the partition and the top of the said coking chamber being greater than the lateral distance between the said heating walls and the partition, each partition containing internal bracing parti- 'tions and heating i'lues between said internal bracing partitions.

11. A group of substantially parallel, upright, horizontally elongated coking chambers, this group being enclosed and partly defined by heating walls and'an arch supported thereby, the said heating walls being substantially parallel in a horizontal direction, the said chambers being separated by at least one partition horizontally elongated and substantially parallel to the said heating walls, which partition contains heating fiues and extends from the bottom of the chain'- bers toward the arch and is spaced vertically therefrom, the said chambers freely communicating with each other through a common space under the said arch and above the said partition, which space is defined in part by the interior surface of said arch, the distance along a vertical line from the top of the partition to the said surface of the arch being greater than the width of the respective chambers.

12. Apparatus for coking bituminous material rendered substantially entirely liquid at coking temperatures comprising side walls, a top wall and a substantially imperforate fioor defining a substantially horizontal coking chamber, a heating wall within and extending entirely through said coking chamber in a horizontal direction, said heating wall also extending from the floor of said coking chamber toward but not entirely to the top thereof, said heating wall and said top wall forming a passage permitting flow of said bituminous material over said heating wall during the coking operation, means for passing hot gases through said heating wall to heat said bituminous material, and additional means for imparting heat to said bituminous material, said chamber being provided with a closure through which the charge of coke may be directly removed substantially in block in a horizontal direction.

13. Apparatus for coking pitch comprising substantially vertical side walls, a top wall and a substantially imperforate floor defining a horizontal coking chamber, a heating wall provided with a plurality of fiues within and extending entirely through said coking chamber in a horizontal direction, said heating wall extending from the floor toward but not entirely to the top of said chamber, thereby dividing said chamber into two portions connected at their tops by a passage permitting flow of pitch from one of said portions to the other, means for passing hot gases through the flues of said heating wall to heat said pitch and additional means for heating said pitch, said chamber being provided with a clo sure through which the charge of coke is directly removed substantially in block in a horizontal

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