Claims:1. A method for determining bulk density of coal cake, the method comprising:
compacting, powdered coal blend by stamping process to form the coal cake, wherein the stamping process applies compressive load on the coal cake;
determining, by a control unit (M), a load applied on the coal cake and a deformation of the coal cake while applying the compressive load, based on signals received from one or more sensors (S) associated with a stamping unit (1) carrying out the stamping process;
comparing, by the control unit (M), the determined load and deformation data with a pre-stored data; and
determining, by the control unit (M), the bulk density of the coal cake based on the comparison.

2. The method as claimed in claim 1, wherein the pre-stored data corresponds to relationship between load and deformation data with bulk density.

3. The method as claimed in claim 1 comprises indicating, by the control unit (M), determined bulk density on an indication unit (I) associated with the control unit (M).

4. The method as claimed in claim 1, wherein the pre-stored data is determined by:
subjecting, a plurality of coal cakes of predetermined bulk densities to compressive load;
determining, by the control unit (M), the load and deformation data of each of the plurality of coal cakes of predetermined bulk densities; and
storing, by the control unit (M), the load and deformation data corresponding to the predetermined bulk densities of the coal cakes.

5. The method as claimed in claim 1, wherein the load and deformation data are stored in a memory unit associated with the control unit (M).

6. A system (10) for determining bulk density of coal cake, the system (10) comprising:
a stamping unit (1) defined with a cavity, to receive powdered coal blend to be compacted;
a piston (2) configured to compact the powdered coal blend and subject the coal blend to a compressive load, the piston (2) is dispensed within the stamping unit (1); and
a control unit (M) associated with the stamping unit (1), wherein the control unit (M) is configured to:
determine, a load applied on the coal cake and a deformation of the coal cake while applying the compressive load, based on signals received from one or more sensors (S) associated with the stamping unit (1);
compare, the determined load and deformation with the pre-stored data; and
determine, the bulk density of the coal cake based on the comparison.

7. The system (10) as claimed in claim 6, the control unit (M) is configured to indicate determined bulk density on an indication unit (I) associated with the control unit (M).

8. The system (10) as claimed in claim 6, wherein the one or more sensors (S) is at least one of a pressure sensor and a load cell.

9. The system (10) as claimed in claim 6 comprises a memory unit associated with the control unit (M), wherein the memory unit is configured to store the pre-stored data.

10. The system (10) as claimed in claim 6, wherein pre-stored data corresponds to relationship between load and deformation data with bulk density.
, Description:TECHNICAL FIELD:
Present disclosure relates in general to a field of metallurgy. Particularly, but not exclusively, the present disclosure relates to a system and a method for determining bulk density of coal. Further embodiments of the present disclosure disclose the system and a method for determining bulk density of the coal by exploiting relationship between bulk density and compression strength.

BACKGROUND OF THE DISCLOSURE:

Stamping is a process which may be employed to produce wide variety of products. Stamping also referred as sintering which involves compaction of material in a substantially powdered form in a stamping unit, using stamping members such as mechanical hammers. The stamping may be performed with or without the application of heat. The stamping process results in a compacted product of the material. Generally, coke is used as a fuel and a reducing agent in blast furnaces, as coke includes less percentage of impurities and high calorific value in comparison with coal, which aids in generating more heat in the blast furnace and, aids in reduction process. Usually, coal blend is compacted by a stamping process, which is performed in a stamping unit. In the stamping process, the coal blend, which is disposed within the stamping unit, is subjected to stamping or compacting i.e., a desired pressure is applied by a plurality of stamping members such as mechanical hammers, till an optimum bulk density of the coal blend is obtained. Further, the stamped coal blend having optimum bulk density is coked i.e., baked in coke ovens to obtain coke. As operational or campaign life and efficiency of the produced coke majorly depends on bulk density of the stamped coal blend, it is crucial in producing the coal blend having optimum bulk density. If the bulk density of the coal blend is greater than the optimum value, the coal blend may swell resulting in damage to the blast furnace and, if the bulk density of the coal blend is lesser than the optimum value, the blast furnace may not operate at its efficiency.

Considering the above, it is inevitable to measure the bulk density of the coal blend during compaction, for producing a good quality coke for efficient operation of the blast furnace. Several attempts have been made in the art to measure the bulk density. One such attempt includes, weighing the coal blend by placing it on a weighing machine and then measuring volume of the coal blend by utilizing dimensions (length, breadth, and height) of the stamping unit, in which the coal blend is disposed. However, this attempt does not provide data about local variation and inhomogeneity in the bulk density of the coal blend at different locations within the stamping unit. is This conventional technique demands for stopping or halting of the stamping process, to determine the bulk density, which is time consuming. Also, the stamping process has to be continued to attain desired bulk density, if the bulk density is lesser than the optimum value, which is tedious. Further, these techniques may not facilitate in determining the bulk density on dynamic basis, which may lead to excessive stamping, which is undesired.

Further, with the advancements in technology, ultrasonic testing is adapted to measure bulk density of the coal blend. In ultrasonic testing, ultrasonic probes (transmitter and receiver) are positioned in contact with the coal blend disposed in the stamping unit. The transmitter probe generates ultrasonic waves, which travels through the stamped coal blend and is received by the receiver positioned at the other end of the stamping unit. Based on the travel time and velocity of the ultrasonic waves, bulk density of the coal blend is determined. Also, this technique is prone to vibrations, which leads to energy losses and thus resulting in inaccurate values, in addition to the technical challenge of making the system viable for coal cakes with thicknesses greater than 500 mm

The present disclosure is directed to overcome one or more limitations stated above or any other limitations associated with the conventional arts.

The information disclosed in this background of the disclosure section is only for enhancement of understanding of the general background of the invention and should not be taken as an acknowledgement or any form of suggestion that this information forms the prior art already known to a person skilled in the art.

SUMMARY OF THE DISCLOSURE

One or more shortcomings of the conventional arts are overcome by an apparatus and a method as claimed and additional advantages are provided through the provision of system and method as claimed in the present disclosure.

Additional features and advantages are realized through the techniques of the present disclosure. Other embodiments and aspects of the disclosure are described in detail herein and are considered a part of the claimed disclosure.

In one non-limiting embodiment of the disclosure, a method for determining bulk density of coal is disclosed. The method comprises compacting powdered coal blend by stamping process to form a coal cake. The stamping process applies compressive load on the coal cake. The method further includes determining a load applied on the coal cake and a deformation of the coal cake while applying the compressive load by a control unit based on signals received from one or more sensors associated with the stamping unit carrying out the stamping process. Further, the control unit compares load and deformation data with a pre-stored data and determines the bulk density of the coal cake based on the comparison.

In an embodiment of the disclosure, the pre-stored data corresponds to relationship between load and deformation data with bulk density.

In an embodiment of the disclosure, the method comprises indicating by the control unit determined bulk density on an indication unit associated with the control unit.

In an embodiment of the disclosure, the prestored data is determined by subjecting a plurality of coal cakes of pre-determined bulk densities to compressive load. The control unit determines the load and deformation data of each of the plurality of coal cakes of presetermined bulk densities. The load and deformation data corresponding to the predetermined bulk densities of coal cakes is stored in the control unit. The load and deformation data are stored in a memory unit associated with the control unit.

In yet another non-limiting embodiment of the disclosure, a system for determining bulk density of coal cake is disclosed. The system includes a stamping unit defined with a cavity to receive powdered coal blend to be compacted. A piston is disposed the stamping unit. The piston is configured to compact the powdered coal blend and subject the coal blend to a compressive load. A control unit is associated with the stamping unit. The control unit is configured to determine a load applied on the coal cake and a deformation of the coal cake when applying the compressive load. The determined load and deformation data is compared with the pre-stored data. Based on the comparison the control unit may determine the bulk density of the coal cake.

In an embodiment of the disclosure, the one or more sensors is at least one of a pressure sensor and a load cell.

It is to be understood that the aspects and embodiments of the disclosure described above may be used in any combination with each other. Several of the aspects and embodiments may be combined to form a further embodiments of the disclosure.

The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description.

BRIEF DESCRIPTION OF THE ACCOMPANYING FIGURES

The novel features and characteristics of the disclosure are set forth in the appended claims. The disclosure itself, however, as well as a preferred mode of use, further objectives, and advantages thereof, will best be understood by reference to the following detailed description of an illustrative embodiment when read in conjunction with the accompanying figures. One or more embodiments are now described, by way of example only, with reference to the accompanying figures wherein like reference numerals represent like elements and in which:

FIG.1 illustrates a schematic view of a system for determining bulk density of coal, in accordance with an embodiment of the present disclosure.

FIG.2 is a flow diagram of a method for determining bulk density of coal, in accordance with an embodiment of the present disclosure.

FIG.3 illustrates a graphical representation of load and deformation data for pre-determined bulk density of coal, in accordance with an embodiment of the present disclosure.

FIG.4 illustrates a graphical representation of load vs deformation data determined by a control unit, in accordance with an embodiment of the present disclosure.

The figures depict embodiments of the disclosure for purposes of illustration only. One skilled in the art will readily recognize from the following description that alternative embodiments of the structures and methods illustrated herein may be employed without departing from the principles of the disclosure described herein.

DETAILED DESCRIPTION

The foregoing has broadly outlined the features and technical advantages of the present disclosure in order that the detailed description of the disclosure that follows may be better understood. Additional features and advantages of the disclosure will be described hereinafter which form the subject of the claims of the disclosure. It should be appreciated by those skilled in the art that the conception and specific embodiments disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present disclosure. It should also be realized by those skilled in the art that such equivalent processes do not depart from the scope of the disclosure as set forth in the appended claims. The novel features which are believed to be characteristics of the disclosure, both as to its organization and method of operation, together with further objects and advantages will be better understood from the following description when considered in connection with the accompanying figures. It is to be expressly understood, however, that each of the figures is provided for the purpose of illustration and description only and is not intended as a definition of the limits of the present disclosure. It will be readily understood that the aspects of the present disclosure, as generally described herein, and illustrated in the figures, can be arranged, substituted, combined, and designed in a wide variety of different configurations, all of which are explicitly contemplated and make part of this disclosure.

Embodiments of the present disclosure discloses a method for determining bulk density of a coal. The method according to the present disclosure ensures real time quantification of bulk density of coal without hindering the operations at coke oven plant. The method of the present disclosure exploits the relationship between the compressive strength and the bulk density for determining the bulk density. The method may include determining load and deformation data of coal cakes of pre-determined bulk densities. The determined load and deformation data may be stored in memory unit associated with a control unit. The load and deformation data stored in the control unit may correspond to a plurality of coal cakes of known densities. The plurality of coal cakes may be formed by compacting powdered coal blend of known densities. The plurality of coal cakes of known densities may be subjected to compressive load. Simultaneous to the application of compressive force on the plurality of coal cakes, deformation of the plurality of coal cakes may also be determined and stored in the control unit.

The said pre-stored data stored in the control unit may further be used to determine bulk density of unknown coal cakes. To determine the same, powdered coal blend of unknown density may be subjected to stamping process in a stamping unit. The stamping process compacts the powdered coal blend to form a coal cake. The coal cake may be subjected to compressive loads. The control unit associated with the stamping process may monitor load applied on the coal cake of unknown density and deformation of the coal cake. The control unit may determine the load and deformation data and compare the same with the pre-stored data. In an embodiment, the load and deformation data may be determined in the form of load vs deformation curve i.e., a graphical plot. Based on comparison of the pre-stored data and the determined load and deformation data, the control unit may be configured to determine bulk density of the coal.

The terms “comprises…. a”, “comprising”, or any other variations thereof used in the specification, are intended to cover non-exclusive inclusions, such that system that comprises a list of components or steps does not include only those components or steps but may include other components or steps not expressly listed or inherent to such setup or method. In other words, one or more elements in the system proceeded by “comprises… a” does not, without more constraints, preclude the existence of other elements or additional elements in the assembly.

Henceforth, the present disclosure is explained with the help of one or more figures of exemplary embodiments. However, such exemplary embodiments should not be construed as limitation of the present disclosure.

The following paragraphs describe the present disclosure with reference to FIG(s) 1 to 4. In the figures, the same element or elements which have similar functions are indicated by the same reference signs. For the purposes of promoting an understanding of the principles of the disclosure, reference will now be made to specific embodiments illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the disclosure is thereby intended, such alterations and further modifications in the illustrated methods, and such further applications of the principles of the invention as illustrated therein being contemplated as would normally occur to one skilled in the art to which the invention pertains.

The following detailed description is merely exemplary in nature and is not intended to limit application and uses. Furthermore, there is no intention to be bound by any theory presented in the preceding background or summary or the following detailed description. It is to be understood that the disclosure may assume various alternative orientations and step sequences, except where expressly specified to the contrary. It is also to be understood that the specific devices or components illustrated in the attached drawings and described in the following specification are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hereinafter, preferred embodiments of the present disclosure will be described referring to the accompanying drawings. While some specific terms directed to a specific direction will be used, the purpose of usage of these terms or words is merely to facilitate understanding of the present invention referring to the drawings. Accordingly, it should be noted that the meanings of these terms or words should not improperly limit the technical scope of the present invention.

Conventionally, different techniques are employed for measuring the bulk density, and one such technique involves weighing the coal blend by placing it on a weighing machine and measuring volume of the coal blend by utilizing dimensions of the stamping unit, in which the coal blend is disposed. Further, in some techniques, ultrasonic testing has been adapted to measure bulk density of the coal blend. In ultrasonic testing, ultrasonic probes (transmitter and receiver) are kept in contact with the coal blend, disposed in the stamping unit. The transmitter probe generates ultrasonic waves, which travel through the coal blend and is received by the receiver at the other side of the stamping unit. Based on the travel time and velocity of the ultrasonic waves, bulk density of the coal blend is determined. However, these techniques do not provide any information about local variation in bulk density of the coal blend and inhomogeneity in the bulk density of the coal blend at different locations in the stamping unit. Further, these techniques demand for stopping the stamping process, for determining the bulk density, which is time consuming. Further, these techniques may not facilitate in determining the bulk density on dynamic basis, which may lead to excessive stamping, which is undesired. Accordingly, embodiments of the disclosure disclose a method for determining bulk density of coal cake and a system for performing the method. It should be noted that neither the entire coking process nor the entire system is depicted in the figures of the present disclosure to simplify and enable better understanding of the present disclosure.

FIG.1 is an exemplary embodiment of the present disclosure, illustrating a system (10) for determining coal bulk density. The system (10) may be used determine bulk density of a material in real time and aid in attaining desired bulk density. In an embodiment, the material may be but not limiting to coal, metallurgical materials, and the like. As apparent from FIG.1, the system (10) may include a stamping unit (1). The stamping unit (1) may be defined with a cavity, for receiving coal to be compacted. The coal loaded into the cavity of the stamping unit (1) may be in powdered form. In an illustrated embodiment, the stamping unit (1) may be defined in a rectangular shape, which should not be construed as a limitation, as the stamping unit (1) may include any other geometrical shapes such as but not limiting to square, cylindrical and the like. Further, a piston (2) may be configured to apply pressure on to the powdered coal blend for compacting. Applying pressure over the powdered coal blend may compact the powdered coal blend into a coal cake. The shape of the piston (2) may correspond to shape of cavity of the stamping unit (1). Further, the system (10) may include a control unit (M). The control unit (M) may be associated with the stamping unit (1) and may be communicatively coupled to one or more sensors. In an embodiment, the one or more sensors (S) are configured to determine compressive load (henceforth referred to as load) acting on the coal cake and deformation of the coal cake subsequent to the compressive load. In an embodiment, the one or more sensors (S) may be a pressure sensor such as but not limiting to a load cell and the like. The system (10) may include an indication unit (I) associated with the control unit (M). The indication unit (I) may be configured to indicate load and deformation data and corresponding bulk densities of coal cake. Henceforth, the method of determining the bulk density of the coal cake is elucidated with reference to FIG.2.

FIG.2 is an exemplary embodiment of the present disclosure, illustrating a flowchart of the method for determining bulk density of the coal cake.
As illustrated in FIG.2, the method comprises one or more blocks illustrating the method for determining bulk density of the coal cake. The method may be described in the general context of computer-executable instructions. Generally, computer-executable instructions can include routines, programs, objects, components, data structures, procedures, modules, and functions, which perform functions or implement abstract data types.

The order in which the method is described is not intended to be construed as a limitation, and any number of the described method blocks can be combined in any order to implement the method. Additionally, individual blocks may be deleted from the methods without departing from the spirit and scope of the subject matter described herein. Furthermore, the method can be implemented in any suitable hardware, software, firmware, or combination thereof.

Now referring to FIG.2 in conjunction with FIG.1, the powdered coal blend may be compacted initially to form coal cake [at block 100]. The powdered coal blend may be compacted in the stamping unit (1) as iterated above in the present disclosure. The density of the coal thus compacted is not known and may be quantified by the method set forth. The coal cake of unknown density may then be subjected to compressive loads (hereinafter referred to as load) in the stamping unit (1). At block 101, the one or more sensors (S) associated with the stamping unit (1) may be configured to detect the load acting on the coal cake. Also, the one or more sensors (S) may be configured to determine the deformation of the coal cake corresponding to the load applied on the coal cake. The control unit (M) may be configured to receive the signal corresponding to the load and deformation data of the coal cake determined by the one or more sensors (S). In an embodiment, the control unit (M) may be configured to indicate the determined load and deformation data on the indication unit (I). The control unit (M) may be configured to indicate load and deformation data in a graphical representation i.e., a graph corresponding to load vs deformation.

At block 102, the control unit (M) further compares the determined load and deformation data with a pre-stored data i.e., pre-stored load and deformation data. In an embodiment, the pre-stored data may be stored in a memory unit associated with the control unit (M). The pre-stored data may be determined by quantifying a plurality of coal cakes of pre-determined bulk densities. The method for determining the pre-stored data may be elucidated henceforth. The method may include subjecting the plurality of coal cakes of predetermined bulk densities to compressive load. The control unit (M) may be configured to determine load and deformation data corresponding to each of the plurality of coal cakes of predetermined bulk densities. The load and deformation data may be stored in the memory unit associated with the control unit (M). In an embodiment, the pre-stored data may resemble relationship between load and deformation with bulk density. At block 103, based on the comparison between the determined load and deformation data and the pre-stored data, the control unit (M) may be configured to determine/quantify the bulk density of the coal cake and indicate the bulk density on indication unit (I).

The method employed in the present disclosure may exploit relationship between compressive strength/load, deformation, and density. In more density material i.e., coal cake the particles are closely packed and hence, more load will be required to create deformation. Higher the density, coal cakes tend to have higher compressive strength. Similarly, when the compressive load is applied, the coal cake with low density starts deforming easily. Therefore, the relationship between compressive load and density may be used to determine the bulk density.

Exemplary Experimental analysis

Following paragraphs may be illustrate exemplary experimental results illustrating the method employed to determine bulk density of coal cake. In order to establish relationship between bulk density of the coal cakes and compressive load/strength, various samples of known density are prepared. The densities of the samples are varied from 900 Kg/m^3 to 1300 Kg/m^3 in the interval of 50 Kg/m^3. The prepared cakes are tested for its compressive strength in a compressive strength instrument where the sample are placed under the piston. The piston exerted compressive force on the coal cake gradually until the cake breaks into powder. During such test, compression resistance offered by the cake is monitored and plotted as shown in FIG.3. The compression test performed on the samples to obtain the load vs deformation plot, maximum load in the load vs deformation plot indicates compressive strength of the cake, as it is the load at which the coal cake fails. Also, as all the cakes are made of same dimension, for compressive strength-based comparison values of the cakes can be used directly.

The experimental results indicate an increasing trend in compressive strength of the coal cake with increase in bulk density. The obtained relationship may be used for prediction of bulk density based on the compressive load/strength of the coal cake as shown in FIG.4.

The said methodology advantageously aids in determining the bulk density of the coal cake in real time. Determining the bulk density in real time ensures that the coal cake has achieved desired densities. The method of the present disclosure enables determination of local variation in densities of the coal cake.

In an embodiment of the disclosure, the control unit (M) may be a centralized control unit, or a dedicated control unit associated with the system (10). The control unit may be comprised of a processing unit. The processing unit may comprise at least one data processor for executing program components for executing user- or system-generated requests. The processing unit may be a specialized processing unit such as integrated system (bus) controllers, memory management control units, floating point units, graphics processing units, digital signal processing units, etc. The processing unit may include a microprocessor, such as AMD Athlon, Duron or Opteron, ARM’s application, embedded or secure processors, IBM PowerPC, Intel’s Core, Itanium, Xeon, Celeron or other line of processors, etc. The processing unit may be implemented using a mainframe, distributed processor, multi-core, parallel, grid, or other architectures. Some embodiments may utilize embedded technologies like application-specific integrated circuits (ASICs), digital signal processors (DSPs), Field Programmable Gate Arrays (FPGAs), etc.

In some embodiments, the processing unit may be disposed in communication with one or more memory devices (e.g., RAM, ROM etc.) via a storage interface. The storage interface may connect to memory devices including, without limitation, memory drives, removable disc drives, etc., employing connection protocols such as serial advanced technology attachment (SATA), integrated drive electronics (IDE), IEEE-1394, universal serial bus (USB), fiber channel, small computing system interface (SCSI), etc. The memory drives may further include a drum, magnetic disc drive, magneto-optical drive, optical drive, redundant array of independent discs (RAID), solid-state memory devices, solid-state drives, etc.

It is to be understood that a person of ordinary skill in the art may develop a system and a method of similar configuration without deviating from the scope of the present disclosure. Such modifications and variations may be made without departing from the scope of the present disclosure. Therefore, it is intended that the present disclosure covers such modifications and variations provided they come within the ambit of the appended claims and their equivalents.

Equivalents

With respect to the use of substantially any plural and/or singular terms herein, those having skill in the art can translate from the plural to the singular and/or from the singular to the plural as is appropriate to the context and/or application. The various singular/plural permutations may be expressly set forth herein for sake of clarity.

It will be understood by those within the art that, in general, terms used herein, are generally intended as "open" terms (e.g., the term "including" should be interpreted as "including but not limited to," the term "having" should be interpreted as "having at least," the term "includes" should be interpreted as "includes but is not limited to," etc.). It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present. For example, as an aid to understanding the description may contain usage of the introductory phrases "at least one" and "one or more" to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles "a" or "an" limits any particular claim containing such introduced claim recitation to inventions containing only one such recitation, even when the same claim includes the introductory phrases "one or more" or "at least one" and indefinite articles such as "a" or "an" (e.g., "a" and/or "an" should typically be interpreted to mean "at least one" or "one or more"); the same holds true for the use of definite articles used to introduce claim recitations. In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should typically be interpreted to mean at least the recited number (e.g., the bare recitation of "two recitations," without other modifiers, typically means at least two recitations, or two or more recitations). Furthermore, in those instances where a convention analogous to "at least one of A, B, and C, etc." is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., "a system having at least one of A, B, and C" would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). In those instances where a convention analogous to "at least one of A, B, or C, etc." is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., "a system having at least one of A, B, or C" would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). It will be further understood by those within the art that virtually any disjunctive word and/or phrase presenting two or more alternative terms, whether in the description, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both terms. For example, the phrase "A or B" will be understood to include the possibilities of "A" or "B" or "A and B."

While various aspects and embodiments have been disclosed herein, other aspects and embodiments will be apparent to those skilled in the art. The various aspects and embodiments disclosed herein are for purposes of illustration and are not intended to be limiting, with the true scope and spirit being indicated in the description.

Referral Numerals:

Referral Numerals Description
100-103 Method flowchart
10 System
1 Stamping unit
2 Piston
S Sensors
M Control unit
I Indication unit