A coke oven includes an oven chamber configured to support and heat a coal bed, a castable slab below the oven chamber, and a foundation supporting the heat recovery oven. One or more beams are positioned between the castable slab and the foundation. The beams extend from a first end of the oven chamber to a second end of the oven chamber, forming a plurality of air gaps between the castable slab and the foundation. Heat from the oven chamber is dissipated by the one or more beams.

A coke oven may comprise an upper oven and a lower oven beneath the upper oven. Crude gas produced in a coking chamber of the upper oven during a coking process is incompletely combusted in the upper oven and may subsequently be conducted into the lower oven via downwardly directed downcomer channels. The crude gas may flow through an outer sole flue, may be deflected in a transition region, may flow through an inner sole flue, and may exit the lower oven via an exhaust gas collecting channel. The outer and inner sole flues may be supplied with secondary air such that the gas initially partially combusted in the upper oven by means of primary combustion is completely combusted in the lower oven by means of secondary combustion. The transition region in which the gas is deflected in the lower oven may be divided into a plurality of flow channels.

A coke oven may comprise an upper oven and a lower oven beneath the upper oven. Crude gas produced in a coking chamber of the upper oven during a coking process is incompletely combusted in the upper oven and may subsequently be conducted into the lower oven via downwardly directed downcomer channels. The crude gas may flow through an outer sole flue, may be deflected in a transition region, may flow through an inner sole flue, and may exit the lower oven via an exhaust gas collecting channel. The outer and inner sole flues may be supplied with secondary air such that the gas initially partially combusted in the upper oven by means of primary combustion is completely combusted in the lower oven by means of secondary combustion. The transition region in which the gas is deflected in the lower oven may be divided into a plurality of flow channels.

The present technology is generally directed to horizontal heat recovery and non-heat recovery coke ovens having monolith components. In some embodiments, an HHR coke oven includes a monolith component that spans the width of the oven between opposing oven sidewalls. The monolith expands upon heating and contracts upon cooling as a single structure. In further embodiments, the monolith component comprises a thermally-volume-stable material. The monolith component may be a crown, a wall, a floor, a sole flue or combination of some or all of the oven components to create a monolith structure. In further embodiments, the component is formed as several monolith segments spanning between supports such as oven sidewalls. The monolith component and thermally-volume-stable features can be used in combination or alone. These designs can allow the oven to be turned down below traditionally feasible temperatures while maintaining the structural integrity of the oven.

The present technology is generally directed to horizontal heat recovery and non-heat recovery coke ovens having monolith components. In some embodiments, an HHR coke oven includes a monolith component that spans the width of the oven between opposing oven sidewalls. The monolith expands upon heating and contracts upon cooling as a single structure. In further embodiments, the monolith component comprises a thermally-volume-stable material. The monolith component may be a crown, a wall, a floor, a sole flue or combination of some or all of the oven components to create a monolith structure. In further embodiments, the component is formed as several monolith segments spanning between supports such as oven sidewalls. The monolith component and thermally-volume-stable features can be used in combination or alone. These designs can allow the oven to be turned down below traditionally feasible temperatures while maintaining the structural integrity of the oven.

Systems and apparatuses for neutralizing acidic compounds in flue gases emitted from a heat recovery coke oven. A representative system includes a spray dry absorber having a barrel that includes a plurality of wall plates that form sidewalls of the barrel. The wall plates include a steel plate and a corrosion resistant alloy cladded to the steel plate and the wall plates are oriented such that the corrosion resistant alloy faces toward and is in fluid communication with an interior area of the barrel. The alloy is resistant to corrosion caused by the acidic compounds in the flue gas and can prevent the steel plate from being corroded by these acidic compounds.

A coke plant includes multiple coke ovens where each coke oven is adapted to produce exhaust gases, a common tunnel fluidly connected to the plurality of coke ovens and configured to receive the exhaust gases from each of the coke ovens, multiple standard heat recovery steam generators fluidly connected to the common tunnel where the ratio of coke ovens to standard heat recovery steam generators is at least 20:1, and a redundant heat recovery steam generator fluidly connected to the common tunnel where any one of the plurality of standard heat recovery steam generators and the redundant heat recovery steam generator is adapted to receive the exhaust gases from the plurality of ovens and extract heat from the exhaust gases and where the standard heat recovery steam generators and the redundant heat recovery steam generator are all connected in parallel with each other.

The present technology is generally directed to vent stack lids and associated systems and methods. In particular, several embodiments are directed to vent stack lids having improved sealing properties in a coke processing system. In a particular embodiment, a vent stack lid comprises a first lid portion proximate to and at least partially spaced apart from a second lid portion. The vent stack lid further comprises a first sealing portion coupled to the first lid portion and a second sealing portion coupled to the second lid portion. In several embodiments, the second sealing portion at least partially overlaps the first sealing portion over the space between the first and second lid portions. In further embodiments, at least one of the first or second sealing portions includes layers of tadpole seals, spring seals, rigid refractory material, and/or flexible refractory blanket.

A system and method for repairing a coke oven having an oven chamber formed from ceramic bricks. A representative system includes a insulated enclosure insertable into the oven chamber and includes removable insulated panels that define an interior area for workers to work in. The insulated enclosure is movable between an expanded configuration and a compact configuration and moving the enclosure to the expanded configuration will decrease the distance between the insulated enclosure and the walls of the oven chamber. Removing the panels exposes the ceramic bricks and allows workers within the interior area to access and the bricks and repair the oven chamber while the oven chamber is still hot. A loading apparatus lifts and inserts the insulated enclosure into the oven chamber. The insulated enclosure can be coupled to additional insulated enclosures to form an elongated interior area.

A coke oven can include an oven body, a foundation, and a plurality of beams separating the oven body from the foundation, A buckstay applies force to the oven body to maintain compression on the oven body during thermal cycling of the coke oven. The coke oven further comprises a spring-loaded compression device, which can include a restraining device, an anchor coupled to the restraining device, and a spring coupled to the restraining device. The anchor can be attached to one or more of the beams, the foundation of the oven, or to a similar compression device on an opposite side of the oven. The spring applies force between the restraining device and the one or more beams or foundation to compress the buckstay against the oven. The force applied by the spring can maintain structural stability of the coke oven over a plurality of thermal cycles.