Coke Oven #2

Performance Improvement Team

Date:- 27/02/2019

Formerly known as Bhushan Steel Limited

COKE OVENS
COKE OVEN - COKE OVEN -
1 2

Technology adopted : Shougang Technology adopted : Paul Wurth

China
Capacity : 0.85 MTPA Capacity : 1.25 MTPA

By Product Facilities : COG, Crude Tar, By Product Facilities : COG, Crude Tar,
Ammonium and crude
benzol
Sulphate and
crude benzol

CORPORATE COMMUNICATIONS
 Crushed and blended coal

Coal Tower
Bag Filter House
Raw Coke Oven gas Charging Car
to By Product Plant Pushing Emissions

Coke Transfer Car

Treated Water from

BTP

Guide
Pushing Car Ram
(Equipped with De dusting system) Quenching Tower

Clean Coke Oven gas Coke Oven Battery

from By Product Plant+ Quenching Car
Blast furnace gas for
coking of coal
Coke Dry Quenching
FLOW DIAGRAM OF COKE OVENS Coke Wharf
Coal Route

COAL BLDG CJ 6
2 BC01, BC02,BC03

BLENDING SILOS 12
735 T EACH
2 BC05, 2 RC01

CRUSHERS :3 NOS.
500 TPH EACH

MIXERS : 2 NOS.
750 TPH EACH
2 BC06 A/B, FW01A/B, BC 07A/B

COAL TOWER
3 POCKETS 5300 T
2 BC08, BC09A, BC09B
Coke Route

Wharf/CDQ
+80MM 25 BC01, 25BC01A,
25BC91A/B

Coke Cutter(2) Vibrating Screen 1A/B

100 TPH EACH
2 5BC03, 25 DG01
-80MM
+25MM
25 BC12
Vibrating Screen 2A/C 15-25MM
25 DG12 25 DG11 25 BC31
400 TPH EACH
C4 C5 25 BC13
25 DG31
-15MM 25 BC21
BF COKE 25 BC32 NUT COKE
BF1 BF2 25 DG21 25 BC34
STORAGE STORAGE
25 BC22
FINE COKE
STORAGE FINE/NUT COKE
TO BF/SP
25 BC 41
Battery Specifications
Number. of Ovens 74
Oven Length 20800 mm
Oven Height 7600 mm
Average Width 550 mm
Oven Taper 70 mm
Useful Volume 79.75 Cu.m
Thickness of oven roof 1700 mm
No. of vertical flue chambers 38
No. of coal charging holes 4
Height of chimney 130 mtr.
Min. Coking Period 22.7 Hr.
Dry coal charge/oven 57-58 T
Pushing potential per Day 78

CORPORATE COMMUNICATIONS
BATTERY EQUIPMENT

MACHINES NOS Features

PUSHER CAR 2 Installed with coke pan & Dedusting unit

CHARGING CAR 2 4 hoppers with 24 T capacity each &

HPLA pr. Display in HMI.

COKE TRANSFER CAR 2 Installed with coke pan & Dedusting unit

LOCO 2 Anti-collision device installed

BUCKET 2 Rotatory CDQ bucket.

WAGON 2 26m length of wagon

BATTERY MACHINE AUTOMATION
ADVANTAGES:

 Enhanced safety
 Less human machine intervention
 Less human error
 High accuracy
 Less time consuming
 Software interlocks
 Machine anti collision device
 Machine coordination system
BATTERY MACHINE INTERLOCKS

 Position interlock
 Prepare for door removal interlock
 Guide lock & OK for pushing interlock
 Loco position interlock to remove C/S door
 Loco and pusher ram speed synchronization interlock
 Quenching tank level interlock
 Prepare for charging interlock
 Oven close interlock after charging
BATTERY PROCESS AUTOMATION
HEATING SYSTEM AUTOMATION
• Heating Stops automatically in case of
 Power Failure
 Pressure Fluctuation beyond the set points
 Reversing winch failure
 Heating starts
 Heating starts with single click from the control room
 Less human intervention
• Explosion flapper
 Provided at the end of BFG & COG line to enhance safety
 35 fixed CO monitor installed in Battery Cellar.
Equipment & Process Flow
CDQ Specifications
Maximum coke throughput 170 TPH

CDQ cycle time Minimum 7 minutes

Input coke temperature 1050 deg C

Output coke temperature < 180 deg C

Boiler steam production capacity Max 95.4 tph

Steam pressure 11.56 Mpa

Steam temp 550+-5 deg C

Circulation gas volume Max 229,000 m3/ hr

Circulation gas temperature at boiler inlet 980 deg C

Circulation gas temperature at cooling chamber inlet 120deg C

CORPORATE COMMUNICATIONS
Coke Oven Gas Circuit
Raw COG

Primary Gas
Cooler (3
nos.)
Downcomer

Battery (74 Ovens)

ETP
(2nos.) Exhauster ( 2 nos.)

Liquor +Tar

To battery
for heating

Flare Stack
Clean COG

BTX Ammonia Combi H2S

To consumer Scrubber Scrubber Scrubber Scrubber
By-Product Design Specifications

BY-PRODUCT QUANTITY

Coke Oven Gas 70000 Nm3/hr

Coal Tar 120Ton/day

Raw BTX 45 Ton/day

Solid Sulphur 9 Ton/day

CORPORATE COMMUNICATIONS
Design Quality Parameters of COG

Parameter Inlet to BPP(mg/Nm3) Outlet from BPP(mg/Nm3)

NH3 – Ammonia 5000-8000 ≤ 30

H2S – Hydrogen Sulphide 5000-7000 ≤ 500

C10H8 - Naphthalene 4000-5000 ≤ 50

BTX - Benzol 25000-35000 ≤ 3000

Tar fog 60000-120000 ≤ 20

Quality Report

Session 2016-17 2017-18 2018-19

NH3 cont. in raw
3833 3811 3475
gas, mg/Nm3
NH3 cont. in clean
65 42 64
gas, mg/Nm3
Tar fog in clean gas, 20 25 10
mg/Nm3
Naphthalene in 22 22 22
clean gas, mg/Nm3
BYPRODUCT PLANT AUTOMATION
1. EXHAUSTER TRIPPING INTERLOCKS:
 Vibration >0.122 mm
 N2 Pressure for sealing < 1.02 bar
 Axial shift > 0.3 mm
 Bearing Oil Temp > 80 deg C
 Current > 90 Amps
2. Exhauster emergency oil pump starts if oil
pressure : < 3.61 bar
3. Exhauster shaft turning motor starts if RPM:
<216 / Minute
4. ETP trips if O2 : > 0.8%, Alarm: > 0.6%
5. If HPLA pump trips standby pump runs in auto
mode
BYPRODUCT PLANT AUTOMATION
6. Standby Flushing Liquor pump starts in auto mode if running
pump trips
7. Standby Chilled Water pump starts in auto mode if running
pump trips
8. Flare stack pressure control valve in auto mode
9. If Flare stack pressure control valve fails, emergency seal pot
breaks at high pressure
10. All process tanks are always under N2 pressure of 200 mm
and vapor sent to exhauster
10. In case of high pressure in Ammonia stripper:
 Steam control valve closes
 Vapor control valve opens
Biological Effluent Treatment Plant

• Technology: MULTI MUMWELT, Germany

• Design Capacity: 110 m3/hr
• Current Operating Capacity: 65- 70 m3/hr
• First to use pure oxygen in aeration tank
• Mutag bio chips (3000m2/m3) used for better bacterial sustainability
• Current Sludge discharge- 5 t/d
 FeCl3
Dosing

Pre clarifier Emergency tank Equalization Tank

Waste
water

Gutter
Channel

Heat Exchanger

FeCl3 + Poly
electrolyte Antifoaming H3PO4
NaOH Antifoaming
dosing Dosing
Intermediate
Clarifier

BTP
Process Denitrification
tank

Flow Nitrification tank

Air Pure
Oxygen
COD Aeration Tank

Diagram RAS

Nitrate return

Post denitrification tank FeCl3 + Poly

Post Aeration Final Clarifier
electrolyte
Tank

Pressure Sand
Filter

Buffer Tank

Bio Sludge Poly electrolyte Centrifuge m/c

Thickner
Effluent Storage tank
To Coke/Slag
quenching

Sludge to coal
yard
BTP Operational Parameters
Present Scenario
Parameters Influent(mg/L) Effluent(mg/L)
(Feb’19)
PH 9 - 9.5 6-8 7.2

Phenols ≤ 180-220 ≤ 0.7 0.78

CN ≤ 5- 10 ≤ 0.2 8

NH3 -N ≤ 300 ≤ 50 38

Sulphides ≤ 50 ≤1 -

oil ≤200 ≤10 89

TSS ≤500 ≤100 58

BOD ≤800-1000 ≤30 13

COD ≤1800-2500 ≤250 173

CORPORATE COMMUNICATIONS
 PRODUCTION REPORT

BF Coke NUT Coke Coke Fines Gross Coke Cr. Tar BTX
Session Pushings Avg Pushing
(*1000 MT) (*1000 MT) (*1000 MT) (*1000 MT) (*1000 MT) (*1000 MT)

2016-17 22474 61.6 916.7 38.8 85.9 1042 31.6 5.3

2017-18 24737 67.8 995.9 42.3 93.4 1132 40 5.7

2018-19 895.9 36.8 80.9 1014 34.3 4.5

22292 72.8
Till Jan

CORPORATE COMMUNICATIONS
 Gross Coke production
1300000
2018-19; 1190000
2017-18; 1131621
1100000 2016-17; 1041473

Till Jan-
900000 1013544

700000

500000

300000

2017-18; 24737
100000 2016-17; 22474 2018-19; 22292

2016-17 2017-18 2018-19

Pushings NaN 22474 24737 22292

Gross Coke (MT) NaN 1041473 1131621 1190000

Pushings Gross Coke (MT)

COKE QUALITY
Coke quality 2016-2017 2017-2018 2018-2019

Moisture,% 5.26 5.28 3.73

Ash,% 12.62 12.62 12.25

VM,% 0.81 0.90 0.90

M40 82.13 83.17 83.77

M10 7.34 7.33 7.23

CRI 26.41 25.52 24.89

CSR 65.07 65.25 65.55

MPS 50.99 50.69 48.72

CORPORATE COMMUNICATIONS
Coke Quality:-

M40 M10
7.36
84 7.34
83.77
7.34 7.33

83.5 7.32
83.17 7.3
83 7.28
7.26
82.5
7.24 7.23
82.13
7.22
82
7.2

81.5 7.18
7.16
2016-2017 2017-2018 2018-2019
81
2016-2017 2017-2018 2018-2019
Coke Quality:-

CSR CRI
65.6 65.55 27

65.5
26.5 26.41
65.4

65.3 26
65.25
25.52
65.2 25.5
65.1 65.07
25 24.89
65

64.9 24.5

64.8
2016-2017 2017-2018 2018-2019 24
2016-2017 2017-2018 2018-2019

CORPORATE COMMUNICATIONS
ENVIRONMENT REPORT
Session SOx Nox DUST

unit mg/m3 mg/m3 mg/m3

2016-17 67.9 83.6 46.2

2017-18 128.8 65.5 47.4

2018-19 137.2 77.4 39.9

Session PLD PLL PLO

2016-17 2.81 0 0

2017-18 1.71 0 0

2018-19 2.26 0.13 0.12

CORPORATE COMMUNICATIONS
 Utilities Consumption:-

Parameters 2016-17 2017-18 2018-19

Sp. Heat Consumption / ton of dry coal( M.Cal) 583 538 553

Sp. Steam Cons./ ton of dry coal ( kg ) 159.48 146.39 146.68

Sp. Power Cons./ ton of dry coal ( KWH ) 35.97 33.47 39.08

Sp. Nitrogen Cons/ton of dry Coal ( Cu.m ) 7.08 6.98 9.34

Sp. Water Cons/ton of dry Coal ( Cu.m ) 0.83 0.82 0.69

Sp. Comp. Air Cons/ton of dry Coal ( Cu.m ) 3.87 4.08 7.85

Sp. Instrument Air /ton of dry Coal ( Cu.m ) 2.34 2.88 3.70
Coke Cost:-

Month (2018-19) Coke Cost (Rs/MT)

October 23602

November 23778

December 26287

January 25781
Challenges:-

1. Reduction in total cyanide in Treated water (<0.2 ppm).

2. BTX recovery as per design(45 tons /day).
3. Poor Efficiency of heat exchangers in BPP.
4. Non-holding Butterfly valves in COG Circuit.
5. Low end vertical temperature in some heating walls.
6. Quenching Tower repair.
Thank You
CORPORATE COMMUNICATIONS