Scrolling down you see a concept I developed for cleaning coal spill while I was working for the steel factory SSAB.

SSAB is a Swedish steel factory that produce sheet metal. A year ago a conveyor belt, transporting coal-spill, was broken. This has created an environment in which the employees are unable to work in. The company wanted to explore new solutions to remove the coal-spill.

Problem one:

Preventing coal from falling on the platform.

 

 

Solution one:

The first solution is a movable lip on an existing scoop to prevent coal to spill from the oven to the platform.

Problem two:

Removing unavoidable spill.

Solution two:

The second solution is  removing the coal with a scrape that pushes the spill to an outlet.

Context

The factory

The process of making coal-coke

 

In the left picture you see a coal-coke factory. It heats coal in ovens to transform its physical properties (below). The coal is used as a fuel for the furnace and as an additive in the process of creating steel.

The orange block is a steering wagon (left). It travels in sequences across the platform to empty the ovens. For each sequence it stops at every fifth oven to empty it (below).

When the sequence is over it travels back to its starting position without stopping at the ovens (left). The picture below shows the space between the steering wagon and the ovens.

The problem

The scoop

 

Coal-spill is created between the oven and a scoop when the oven is emptied. The scoop  should prevent coke from falling on the platform but can not get close enough to the oven wall, because the doors all have different angles, and pushing the scoop against the ovens to hard damages both the oven and the scoop.

The platform

 

Piles of coal are left behind which are in the way and causes accidents has to be removed by hand.

Consequences

The environment

 

A smokestack is created with the current solution of removing the spill with a brush. The smokestack  makes the environment impossible to work in and important tasks like sealing leaking gas from the doors can not be carried out.

Disrupted process

 

The spill ends up on to the train track below the platform where a wheel loader has to be hired to remove it. This can cause disruption in the process and adds an extra cost.

Goals

Healthy working environment

Reduced maintenance

Undisrupted process

Low repair cost

Solutions

1. Preventing the spill

2. Removing the spill

Adjustable steel lip

 

The first solution is to mount a lip on the scoop to prevent the spill from happening when the machine empties the ovens.

How it works

 

The movable lip is mounted on the front of the scoop. It is held in place on two rails making it able to change the front angle to fit the oven walls and create a tight seal.

An adaptable front angles itself after the oven to create a tight seal.

The scoop is rotated down and pushed forward towards the oven.

The flexibility of the lip is necessary because each oven has a unique angle. It also makes it possible for the scoop to get closer to the oven without risking to damage any part.

1. Preventing the spill

2. Removing the spill

Scraping up the coal without interrupting the process

 

A scrape is mounted on the steering wagon. This makes it able to push the spill to the start of the sequence where the spill goes into an outlet for a wheel loader to easily transport it back into the process.

When the scrape is inactive it is lifted from the ground.

When the steering wagon is travelling back to start a new sequence the scrape first rotates in position.

It is then lowered to the ground to scrape the spill in front of it.

Angled

 

The scrape is slightly angled to the traveling direction so the spill is pushed to one side. The spill is then piled together in a corner of the scrape in order to align it for an outlet in the starting position.

The spill is removed with a rubber list at the front of the scrape. The list is easy to replace and is reachable from both sides.

No particles/smoke or

coke on the platform

Less maintenance

Easier repair

Works within the process

Less maintenance cost

No wheel loader

johan.edzen@gmail.com                 2018