Not too wet, not too dry, not too cold, not too warm: perfection is required in coke quenching and post-quenching. Too much water in coke increases energy costs in blast furnace processes and impairs process stability. The quality of pig iron quality may also then suffer. Yet too little water can lead to fires on the journey to the blast furnaces. Any damage to conveyor belts might interrupt material flows and drive costs up even further.

Last but not least, conventional, manual coke post-quenching is a high health hazard. Manual post-quenching is made more difficult by small pockets of embers (“hotspots”) on the coke ramp often not being visible to the naked eye. Steam, smoke or bright sunlight can also impair visibility. Post-quenching is therefore often inefficient with the coke water content then becoming too variable.

Optimizing coke water content is directly linked to cost and energy savings in pig iron production in steel mills. So how can coke post-quenching be improved?

PYROsmart® is a smart infrared system for temperature monitoring and fire prevention. PYROsmart® uses a high-resolution, high frame-rate infrared thermal imaging camera. PYROsmart® is therefore capable of reliably detecting coke hotspots on ramps within fractions of a second. Thermal detection also means that ember hotspots invisible to the naked eye can also be reliably detected. Locating and sizing of all hotspots takes place continuously with real time updating while the material is under constant motion. PYROsmart® therefore always knows where there’s “fire”.

Then comes the highlight: PYROsmart® targets the quenching and post-quenching of ember hotspots using fully-automated fire monitor extinguishers. Locating hotspots on the coke ramp means the plant can minimize the required amount of water. Quenching only takes places where it is required, according to the principle of as much water as necessary, but as little as possible!

Infrared radiation penetrates steam and smoke

PYROsmart® keeps watch long after the naked eye is no longer capable. Coke quenching produces large amounts of steam and smoke, but infrared radiation is practically able to penetrate such conditions unimpeded. The infrared image shows the location and current temperatures of ember hotspots. Quenching/cooling thereby happens continuously in a controlled and targeted way!

Steam is generated during coke post-quenching. The quenching jet is clearly visible in the infrared image, as are actual temperatures.

PYROsmart® is low maintenance and functions autonomously 24/7

The system is autonomous and is made up of the PYROsmart® detection system, multiple fire monitors (left in image) as well as an operating terminal and a control center (right in image).

Despite the harsh conditions, PYROsmart® is a low-maintenance installation. The system operates reliably 24/7 and meets all the requirements of state-of-the-art coke plant technology. PYROsmart® has undergone all relevant stress tests in laboratories as well as in practical continuous operation. During standard operation, no personnel are required to be present in the hazardous area.

The detection unit’s electronics and sensors undergo continuous compressed air flushing to prevent the ingress of fumes and coal dust. PYROsmart® guarantees a clear view.

PYROsmart® is upgradable and will remain state-of-the-art for many years with remote maintenance available at any time.