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LECTURE NOTES

COKE OVEN AND CHEMICAL DIVISION

VOLUME-1
(COKE OVEN)

@ “7h '5
a6900100“‘45-

MECON LlMITED
RANCHI — 834 002
. March, 2006
 Coal & Chemical DivisioniC-1)
VOL-I-COKE OVENS

SLNo. Lecture By Topic Page

' No.
, 1 Mr. S.K.Sinha Coal Carbonisation 1-9
M ‘ Fundamentals
2 ' Mr.C.P.Singh Characteristics , 10-40
Chemical Analysis
CSR,CR|, of Coking
_ Coal -
3 Mr. R.D.Pandey Coal Handling & Coke 41—49
‘ Sorting Plant
1,. 4 Mr.N.S Tekaday Design/Classification 50—67 .
’ of Coke Oven‘s .
. 5‘ Mr.Barun Kumar Refractories in Coke 68-72
Oven Battery ‘
6 Mr. M.S.Pillai Coke Oven Battery 73-83
V Heating —Up and: ‘
‘ . . Commissioning ,. .
7 Mr. ‘Ajoy Kumar- Coal Conversion ‘ ' 84-97.
' ' Process '
,, 8 Mr. S.K.Gupta Coke Oven Battery 98-103 .
V ' Construction & Repairs
9 Mr.A.Prabhu CDCP Process 104-108
10 Mr.A.K.Ghosh CDCP Equipment & '
Piping Layout
 KIA-kw: Hr"!

COAL CARB‘ONISATION FUNDAMENTALS -

By

S.K. SINHA
DY. GENERAL MANAGER
COKE OVEN & CHEMICALS DIVISION

COAL THE BLACK DIAMOND

I

COAL
CARBONACEOUS
FOSSILIZED
INFINITE VARIETY

Rank of coal depends on geological and biological ‘maturity. Coals undergo

metamorphism progressing from peat, lignite, bituminous, anthracite, meta- anthracite

etc.

COKING COALS j - . I/
v_.|'

When heated to sufficiently high temperature, pass through a transxent plastic stage in

. which they successively soften, swell and re—solidify into a coherent and cellular mass,

called coke.

NON-COKING COALS - When heated produce char.

HARD COALS ( I S O Classification) - Gross CV>V 10,260 Btu/lb on moist

ash —— free basis

COAL SCENARIO IN INDIA

Total coal reserves~ 23 5' Billion tonnes

Out of this Coking Coal reserves ~ 15% and prime coking coal reserves ~ 4%

Total coal production in India ~ 340 Mt/yr Coking Coal ~30 Mt/yr

Indian Coking Coals characterised by :,

high ash content

inferior caking/ coking properties

low 're-ac'tives content

low rank

petrographically heterogeneous

poor washing characteristics

Coking coals are subjected to washing for improvement in above characteristics.

‘ India is currently importing about 15 Mt/yr Coking'Coals to make up quality and

' .- quantity deficit mainly from Australia, NewZealand, South Africa, China etc.

Typical imported coal usage

BSP _- 73%

Esp." 59%.“
DSP '— 57%
RSP — 51%
TISCO - 40%
RI‘NL - 90%
Jindal Steel - 100%
NINL ~ 100%
Typical Imported Coal Specification

Size - 0-50 mm

- Fractions below 0.5 mm -25% max.

Proximate analysis (air dried basis)

- VM - ' 23—28%

- . Ash - 7-9%

- Moisture . - 8-10%

- Fixed Carbon - by difference

- Phdshphorous — 0.1% max.

- Sulphur _ - 0.7% max.

'Coking pronerties

- GK Coke Type — GS min

- CSN(crucible swelling no) . 9 6 min

Giesler Plastometer

- max. fluidity ddpm — -' ~600min a

- fluidity range, (at 5 ddpm) - 60°C min i I“

- Initial softening temp (at 5 ddpm) . - 410 :1: 15°C

.Mean max reflectance of vitrinite — 1.15 min

Vitrinite percentage — 55% min

Vitrinite destribution V9-V 14 - 80% min

Coal Characterization & Processing

Proximate analysis

- Volatile matter.

- Ash

-. Moisture

- _Fixed carbon (by difference)‘

Ultimate Analysis

-' elemental analysis viz.‘C, N, H, S, 0 etc.

Gross Calorific Valve

No. of heat units liberated when a unit mass of fuel in burnt at constant

volume in oxygen saturated with waterovapor under standard conditions.

Gross CV includes the heat given by condensation of water vapor present

in product of combustion.

Net Calorific Valve

_,-' Net CV is obtained by deducting the latent heat of vaporization of water-

from gross CV.

,. Coal Ash

— . Incombustible mineral matter left when coal i n burnt.

Volatile matter

Matter expelled on heating of coal in absence of oxygen under standard

conditions. The expelled matter consists of

- Water derived from chemical decomposition of coal on heating

 Complex mixture of combustible gases including hydrogen,

methane, ethane, benzene etc._ (Coke Oven Gas)

Tar, a complex mixture, of hydrocarbons and other organic

compounds. .

- Gasification of Coal

Reaction of solid fuels with air, oxygen, steam, carbon dioxide or mixture

of these to yield a gaseous product that is suitable for use either as source

of energy or as a raw material for synthesis of chemicals, liquid or gaseous

fuels.

- Carbonization of Coal

Process 'of heating coal in absence of oxygen is called destructive

distillation or carbonization ‘of coal. It results in a gaseous product

consisting of a complex mixture of low boiling hydrocarbons and

_ hydrogen , a liquid product— tar,.c0nsisting of high boiling hydrocarbons

and a solid residue'called coke. ' "

Coke yield:_(l_OQ—_VM%),+.1 . _'

Functions of Coke in blast furnace -" ' --

- V To supply heat of reduction."

- To act as a reductaut

- i To support the burden

Estimated coke demand 2006-07 - ‘27.3 Mt

Estimated coke availability 18.0 Mt

Gap (-) 8.4 Mt

 Major Coke Consuming Industries

Blast furnace arid sinter plants in integrated steel plants

. - Merchant pig iron producers‘

' - Perm-alloy Industry

- Zinc and lead smelters

- Iron foundries

- Soda ash Industry

' Typical BF Coke Quality for a High Capaeity Blast Furnace

- Ash % - 17i0.5%

- Sulphur - <O.6%

~ M10 - 8 max .

- CR1 ' - <24

2 ' ' CSR — >65

_ - BF Coke size — ‘ 25 — 80 mm

65-80mm ~ 55%

40-69mm ~ 16%
 m u ‘ fi fl fi was.“
W

._,_1.
Elk!"

1. Wha1 is Coke?
.._.....__._.____...

Cer1ain Types 0*." pulverized coal, when hea'ied in absence of air, coal first
swells, par‘ily melts and volatile mofier is evolves. Then The coal charge
' shrinks and a solid lump is ob’rained. This product is called coke and the coal
charge from which 1his solid lump is ob1ained is called coking coal. ter
/ 1ypes_ of coals, called non—coking cools do l‘lO'l’ form lump.

2. Role of Coke

.- - After iron are (or sin1er), coke is The mosf impor’ran1 raw mo’reridl which is
_ fed mm a Blos1 Turnoce 1o produce molien iron (H01 NIe.1ai) Coke plows
_ '. . following roles In 1he Blas1 Furnace. -

V -. ' I1 ads as a source of energy required 10 mel1 1116 iron :5: slag.

M '.~ '_ I1 ac1s as a rcduc1an1 10 reduce 1he iron are, which is presen1 in
i i- / oidised form In 1he Iron ore.

Coke remains 1he only solid nIGTeriol in hear1h zone of BF and

~l ' 1 ‘ , supporfs 1'he en1'ire weigh1 of BF charge.
‘BF 'w’WIEFI hem5135‘; ——-.__-___
._ IiproyldespasSage~fonevolVIng-gosemn'fhe
- « I ' ' oper orion of 1116 BF.

I l 3. Progerijes of BF Coke . ,

Basically BF coke should be

Low in ash con1en1 and high in carbon con1eI11' Low ash corrieni also
lowers 1he slag volume.
I _ - Coke should be sufficienfly s1rong 1o wi1hsland 1hr Munich 01" 1:
v ‘ charge, even (111 or Severe carbon loss reac’rion during i1s do.scen’r in
W e BlasT Furnace
Roac1ivi1y of coke should be in on op‘rimum range. 11- Ihe coke
v_.. ‘ -' ' reac1ivi1y is hiah rafe 01" carbon loss will be high and H19. col.e will
3 weaken Q1 :1 fas1er M16 and crumbles 1o 1ine size blocking 11m,
passage 01‘ BF gases. If The reac’rivi1y is low,’ 1hen BF producTiviTy wilI
bc afreci ed. ’

- BF coke should have an op1imum size range 10 prouide suiiable voids

for passage of gaSes.

Ci‘El-‘S-llSCO".CPS‘IWlul is Colmdoc
 ' Apart from ash content, ash composition alSo plays an important role.
Sulphur and phosphorous content should be low. Alkali content (Nazca.
K20) should also be low, as it enhances the reactivity of coke. Silica -
Alumina ratio in Indian coal is considered to be favorable. Basicity of
ash components also plays an important role.

4. trenqth Indices of BF Coke J

As explained earlier, strength of BF coke plays a vital role in Blast furnace.

' For determining the strength at coke, various drum indi'ces haVe been
developed in world‘ i.e. Micum drums, Irsid apparatus etc. 1 Some times
shatter test is also carried out. In India, Micum drum test has been adopted
by steel plants. In addition to the above, two new indices namely CSR & CRI
have been developed by Japanese and theSe are conSidered most important I
parameters at preSent and have been adopted world over with some
variations. ’

A brief description at Micum test and CSR-CRI test is given below.

4.1 Micum drum test j"

'-._5‘______. .we.-.._+_.._Mscunuirumsare—l—meter-m—cltelneterrand-l-meterrm length and are prowded

with baffle plates inside the drum.

Sized coke (+ 50 mm) sample is put into the Miculn drum and the drum is
rotated @ 25 rotationsper minute for 4_minutes. During the rotation coke
. sample is lifted by the battle plates and then falls as battle plates .
y approache the drum top and coke pieces break depending upon their.
strength.

After completion of the drum's rotation, the sample. is taken out from the
drum and is screened at 40-min size. The‘percent of + 40 mm fraction
obtained from the above screening is reported as {Noam—40 (Ni 40). Further,
the sample is screened at 10 mm. Percent of (—) 10 mm traction obtained the .
above screening is reported as Micum-IO (M10).

M 40 index indicates impact strength of the coke piece and should be 2 7f}
tor 8F cake. The M 10 value indicates the strength of bonding bc‘l’w-zgzn
rains. Lower the M 10 value, better the coke as lower amount at fines are.
generated. For modern Blast Furnace it should be 3 9

CIT-C ['3-ilSCi)\C!‘I\-‘.’\V hat is Col;~:.dn-‘.

,1: 7 -.
-:,.« | \ .. ' J
4.02 Coke Strength after Reaction 4 CSR as Coke Reactivity Index — CRI
\/
During Blast Furnace (BF) operation, coke reacts with Oxygencr with carbon
dioxide (cog) to formtwo molecules of carbon monoxide (CO). This reaction
causes loss of carbon from the coke. This loss of carbon gradually weakens
the coke. The CSR index has been formulated to simulate this carbon lass
reaction in the Blast Furnace. A goodpiece of coke should have sufficient
strength to withstand the charge burden and should provide Sufficient
passage for evolving Blast Furnace gaSes. Thus BF coke should have a high
CSR value.

The CSR value of coke, to a large extent, depends upon reactivity of cake
which is guided by Coke Reactivity Index (CRI). If coke is highly reactive, it
will react at a faster rate with Oxygen or carbon dioxide (C02) and the
carbon loss would also be aster. This cauSes foster weakening of' coke leading
to lower value of CSR. On the other hand, if reactivity of coke is very low
(Le. low CRI), then it will burn on a very slow rate, resulting in poor
productivity, of Blast Furnace. Thus CRI value should be within an optimum
range. '

For an efficient operation of modern large size Blast Furnace, the CSR value
should be 2 65 and CR1 should be. within a range of 21-24.

Further, with introduction o f large ratelot' coal dust or other fuel injection -
technologies, the coke rate at BF has reduced sharply. Thus, leSSer «mind
of coke has to withstand the load of BF burden. Thus a higher CSR value is a
must for efficient dI economic operation: of Blast Furnace.

wcoke is sainpled and sized between 19 21 mm.

For testing for CSR dI CRI,
Is
specified aniount of coke sample is put .into an apparatus and the SL‘Ii‘i‘IPlEA
heated to a temperature of liOOOC. Carbon dioxide (C03) is passed through
the hot coke at a Specified rate and time. A t ter cooling the sample, weighi
* loss of the solid sample is measured. The percent weight loss is defined as
Coke Reactivity Index (CRI)

The solid scrapie obtained from the above test is screened at 10 mm The
+10 mm sample Is put into a special apparatIIs which is rotated at a specified
rate for a specified time The coke Sample breaks during the test Arter the,
test, (+) 10 mm fraction is measured. The (+) 10 mm fraction percent is
defined as coke strength otter reaction (CSR). .

C:'\CF‘S-IISCO‘iCFS‘NlhaL is Cokcfluc
 _;__3___
like meta-anthracne Among Its many properties is the ability of some types of
coal to form coke when h e a t é d 'in ovens __or retorts. _During the application of

o s thatwhen h‘catc'd- t o sufiimenttigh

" ‘ which they Successiveiy’,
c.11uia1;
ii 'and resolldxfy“nto a oh'er‘ent'e ohk'e The fact that coking
1-; w-r»a...
"ppiy methods of measuring
\-

.- “*1-
n y ' b almostc mp1 'telyjna,”
": volatile content swelhng

plastic state neceSSary foi‘

_ same coal by the rate at w
 I"
I
I
' SOLIDIFICATION I
’ 20NE {
I
l
L__

' swE‘iLLING
ZONE

“'1 -. ..
: SOFTENING .
.|.__ ZONE. '
_J . ' . . . ' ~ - s '

.‘.<' ; i
Figure I . Pla‘stic zones of coking coals.“
- . x
.w'w -_.a - . ~ ‘. .-~_- '

ahighly plastic coal (ifit is dEsirable to change its plasticity) is by preoxidation.

_ - or heat treatment before coking. Some coals, on the other hand, may appear
inferior under slow rates of heating but may produce a satisfactory coke undEi . .
more rapid heating rates.’- ' '

tion or treatment of thE sample be completely known. A fresh, unexposed

sample of coal may possess suitable coking properties, but if tested after '
oxidation through Eiposure to the atmOSphcre for various lengths of time;
may contrarily exhibit negative or inferior. results. Accordingly, samples of
 v . . ' I‘ . “' t‘reslIilIyI mined oal'
' Coal'1n place near
Iburden, may als'
Such weathering pIro
than 30 to I50 feet fro ,
accompanied by earthy. stains along m m or IcleavIage suIIrItaces within theIcoalII .
. I I bed.. In any case, this must be checked to ensure a representative sampl
.‘I,_ g I -' Another factor that must- be taken into consideration Im testing aSample' of”
1 coal f o r 'us coking properties is_ the amount of extraneous impurities (such as:
shaLpanings or-other non-coal material) it may contain. The presence IofII
l "'5; I ' ' notable 'amounts of such extraneous materials may be sufficient to lower. or ”:5 i
' destroy the natural coking characteristics of the coal. Thus, a necessaryad- "
V1 junct to preparing a sample for carbonization tests may be the rembval of
l ., ' I I these impurities, at least to- the extentI that they can be reImoyed by normal
,_:~ ‘ i ' ' ' 1 ' coal—washing procedures, , - ' .-
\' _1' 'I‘ ~ I' Although coal Irank,1: as expressed Iby fixed carbon contents or related
' ' parameters, can be- used as a general guideline for identifying the range"of
x“ 1. IcIole1ng coals, it it not always a determining factor. While'at is true that North

\_,

4' , 'I".‘._ I
x. I . '

:1 1

V ‘1 toidIatiIon
.I may appear
a»? ' . coke under ‘

V ' .l the condi—

.
unexposed
, 'tcsted after
\-— ‘ -'Ihs.of time,
”samples of
‘g

\N1 "—

K,
 ,_ p asxzcdihat vc few goals are used snugly to make cg?”
-'v-
prgctvlcallyvallrstcél prodficérs use blends oftgn._ __t_' Widely différing 'cOals So
 : .erious ing need for steel, andgtheret‘ore coke. is generatedgFurthermore, these areas ._
of the world are generally deficient in indigenous cokiné'coal sourcésf ‘1'; " ‘ g -
coke; ' The largest importer of coking coal of any of the advanced industrialized ' ' ' ‘
c 115.80; nations is Japan, which has relatively} Small sources of its own. Despite the .1 . ‘3- ': 1.
that a current slowing'down of its steel industry, its need for high-grade coking coal ‘ . ' ..
w ~__en<iing in large tonnages will be a fact for the foreseeable future.
It is our opinion that the need fore-oking coal Will always be substantial.
. -.-many and that the knowledge of coking coal characteristics is_vital tothose wishing
:. s,refer _ L. to enter the market _or continue their coking coal markets.
{minus
a will rely
\» .ilinsist
i .equire a
‘t'chase.
:( ’gsample
"noresent
\‘ i
.1. .C .IOUId
7 "iditional
kir coke
" e ovens
if rivristics);
{naditiVCL

. . 3;; coking
:— .écns.
1 "om coal
heuseof
industry is
»-, z. {m. . . . .of the
--.-.u..ai

‘oke," a n .,
fazed, and
v . -nology of
. .;cceptab;le

3 . - - i n the
, 3 of coking
- ' -‘ could be
idles.

1.5 millio n
ately 12.7 .
‘ould reach
, ,

' p o n many

r s to be in
inincreas-
 .
Moist _bnsij refers to nattIJruI Inherent mmsture, and Itioes not include ex-
traneous surface water. I t 'is Sometimes referred to as air dry basis, a term

a a
5..
frequently uIsecIl'in standard laboratory analyses. '

Table I. ASTM Classification-of C'ocilsvbyllilank ' -

.
. .
s
-

‘ - . "ArtalylicalLimilS Requisile Physical

Class -’ Group (Mineral-Matter-Free Basis) PraB’ern‘ex

\ I. , Anthracite l. Vida—Anthracite _ IIDry FC 98% or more; "

. Dry VM 2% I'or less.
2. Anthracite Dry FC 92% or more
7 and_ less than 98%;
3’ 1‘ssential Dry VM 8% or less
" "re many - ". . - and 'more than 2%.
1 0 - s men- 3. Semianth'racitc Dry FC 86% or more
um), coals ' "‘ anii less than 92%;
, .There- ”Dry VM 14% or less I Non-agglomerating . '
at :7 com- and more than 8%.
0". w
:- "-:_..UI'IS. II. Bituminous I. Low-Volatile I D r y FC 78% org..., Agglomerating
' i

1r :1e clas— = = i and less than 86%; commonly

r: et‘mcemed 1:. Dry VMZZ‘PBLagt-less . '-
net is the __ -' .. ’ t - - and moregthanI14%.I '
s

a' _73rganiza- 2. Medium-Volntile _ -Dry FC 69% or _moreI

' ‘ ' ' -' and less than 78%;
-I.conIorniC
i f

. ipry VM 31% or less

".t :15 are re; - . and more than 22%.
b l e 3, at the Dry FC less than 69%;
» J , Dry VM more than 31%
e

s have their
F

i Liedby the: 8' ‘

I-:n adopted
“"01-1973.‘I
~‘assification .
. . ”n.
_. 1 j. I _ IanclIIessI thIarIi -l_0_. I590, I
~ -i_—' .. abasi . .
. - . ....e
3..Subbituminous .MIoist Btti 8 300 or mareI'
,Ju an,” a dry " and less than 9.SOIO.
.' toist b_ai_Is.
it: between 1V.‘ Lignitic l . Lignite A , ' Moist Btu less than 8 .300. ' Non-agglomeratiné
' 2. LigniteB C ;. . IMIoistI Btu less than 6..300 _ "1 ~-
' non-ban ded Shurce: ASTMID-388-66 (reprinted by perinission‘):
a n d that fall
= Fixed Carbon .
.atile bitumi-
' = Volatile Matter“H
'.ess than 48
=BritishI ThermIal Units
r. than 15,500
"-free basis. . I N a t e : 429.923 B t u = I MIJ/kg (meIgajoulcsl, spcIcIiIfic energy, SI.
 . . . »
gm.
. . . 9
. 4 fl £ 3 “9. cmr .e aB2m., wo oi tw h .1 : ‘0 5 . : w e n — : 85 :1 }s a3 3. 6 2
8 S6.5 !5 : 8 »E 3 ?o n 5 2 - a E 0s 5 9 : 3 9c
3: 6. 5 3. .0 n o .= t .o § 3o n -2 _
3 : 3 53: cu>5
I .
h . .
n « = 5
.
3 2 : 8 .w o u n2fi:é 2a 1 s. g9 : 3 - . . i
. .
. 5 n .u n 9n— c: fl 22 : .3 3 —5 ca. . . .
5£ : 32
m a i n - = 2 5 » :

box/(Nara QPERTIES 0F COAL

// / # x / / fl z x / /
€ 3 5 3 : 9 5 : 3 3 .
. . . _ 1
d , ‘ 5 3 5 5 7 6 5
: n . _ .
5 : 3 2 . . Eu 9 , . .@ .3 .2 3£5. 3 u3 3 E.35 3.=5,. : .9
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. 5.3 9 . . . 9 n5 o. n 3— »E :5 0 3
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9.50n
 _
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J

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,
i

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~ $ “ I

t
I # ' 2 : w

.;
“ :_ . é

1‘4

'«
w 2 yM : l
m ‘" ‘ '

.3
we ' é l mdr

l ’ a
:
I: n u m ‘ hyfl loni ‘l m

Eg
o wWmn

‘ 0 -
‘ 5
N [I] l e d

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e c

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nI m' u ms "

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lpproyrlnlr -‘ h hcs -u. m

g-
pm(i g"s}. :sqa

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.- (ii) . M
. 520 VM

tu er mé a ‘
7 m mc l aa sl sI : iFi ' gz

f F C ==7E2 fixed.cafbon
British. thermal units (cfiecxfic energy)
 The ISO class1fi‘catto‘ divxde coal into tw‘o principai categories; Thfi 1rs
" " '_c_<_)al and defined as coal havmg a gross caldrific v

‘ d
and Lignite A arid B",The term type in the internationaiclassrfication system'is
qgiggpnt to‘ ra‘nk'mN—m.:ll“l‘—
the Amencan«a:
sistem. These terms_ _refér to ihé degrggg
“L“ f
metamorphismhor pro wesswe alteration from [ignite to anthracite. The ISO

Percent v

Volatile:Mqtter

.; <20'
' . 20-30
30-40 I
40-50 "
. .50-60
60-70
 ‘ "[‘he first l'SO classes are further divided into groups on the basis of results of sten-‘ll
~'
value of dard tests, which will be described In Chapter 4 of this manual The nine
.tudes all classes of hard coal are divided into groups according to- their caking proper- "
nther ISO
.—

ties in the following manner'.‘

‘1 and C .
L’. system is ‘ FreeSweIii ng
_ *egree‘, of - Group No. " Index RonaIndex . .
FhLISO 0 ’ 0-1/2 _ 0-51 . :
onadry, 1 1-2 5-20 . ‘ :
2 21/14 . 20-45 ' -‘ "_ '5
._ 3 >4 >45 ‘ -= ' ,7'
The coal groups are 'further subdivided according to coking properties, as
measured by dilatation (using the Audibert Arnu method), or by the Gray—
King coke type: - .

Gray-King
Subgroup No. Maximum Dilatation Coke Type e .1.
’0 ' Non-softening - ' .A
l , Contraction only ,- _ B-D
2 .' 'Oand less zE-Q
._ ' 3 ‘2 a , 0-30 t, Gl-G4 _
" 4 50-140 '_ . 'Gs—os .. . _
5 >140 AboveGS- ‘ . ' '~

. :2 A three—digit code number 15 used to express the class1ficat10n of a coal.

in: he first digit indicates class,‘ ' t h e second indicates“,g'roup, ‘and the third
igit indicatés‘ subgroup "As an example, Code No. 634 refer t “
tting into Class 6, Group 3, and Subgroup 4.

5 blue of less 7
' ‘gtotal mois- _;
:1 coal: 0 Group 10
0" I

COMPARISON OF ASTM
AND ISO CLASSIFECATIONS

f T h e terms caking and coking are frequently used inteI changeably. butqaking_ge_ne1;afl_ly_1;gie~1iito '
\veaklmking coals. 'Caking particles adhere, or agglomerate, i n contrast with non cakingparti- 1X, .
.cles, which farmust when heated to coking temperatures In the international system, calcing
properties a r e a measure of behavior when coal Is heated rapidly. a s i n t h e free-Welling test or the
Rage test.
 s, m 1111

3 Chemical analyses
for coking coals w.

u
i
General tests for quality include those normal or conventional analyses

_
.
that are required for any coal and should be obtained as part of the study of a

4
coal's characteristics. They»would include proximate and ultimate analyses

.
~
«and also, the analyses of the as and the ash fusion temperatures Determina-

£
try. weakly tion of the coal's spec1fic gravity should be made. The specific energy

e
111' if“ ' (calonfic value) of the coal should be obtained. One should also include the

1
.
free-swelling index (crucible-swelling'index) and the Hardgrove grindability

—
index. The latter IS a physical test. but [5 frequently included along with

7
‘11
1;
.. -‘ chemical analyses. . .

.
Since most coals (especially those destined for coking or metallurgical

n
on—caking

i
"1 .USes)1’equire cleaning, o r I 'washing," washability (float arid sink) tests should
“be conducted at yarious relative densities, and an econonuc recovery of

-
clean coal" should be determined. Obviously. the various analyses should

‘
e made on this‘ clean-coal" basis, as this bestrepresents the productfor end

.
. . -
1 ' 1'1er alone the
1 ..'re not criteria

.s
,
1*" “1‘3 .35 percent
~ ' uy rank coding

1 1
1‘- “agh the present
:o'enizc more than

".
elO,200~and '
111211. 7.0l.

x/ ‘1 ‘ “15t by one to viiiuch reference is generally made.

The term moisture can mean the amount of surface or extraneous mois-
re; the inherent, or natural—bed, moisture; or the combined total moisture.
Where the l a s t '15 given, the analyses are often reported on an 'as-received“
asis. When given on a n ”air- dry" basis. the results include the inherent
moisture. “Dry"ba5151s of course thOLt moisture Forpurposes of deng-
111111113 rank of coal, results are given on a ‘moisture and ash-free" basis, or
hey can be given on a “moisture and mineral- matter-free" basis. (See the
formula for the latter 1n Chapter 2.)The percentane of mi_ne1;a1 matterin coal 1;
not the same a s percent ash, the latter being obtained as the EflduF-from
prescribed combustion procedures

- Chemical hnalyse:
 _ . .1 One can see,1hen the 11nponance of ltnowmg on whatbams the p1ox1ttgaale
' '5 ' analysis 13 given. This also affects two other analyses that are generally pirtof-
"complete_‘_ prox1mates namely, the sulfur and calorific valu'e's.- _
. _. .. . fljmflfigur playing 5'11 Ch a vital role 111 both steaming and coking eoalsl. the
’4' sulfur content is almost invariably included 111 the proximate ariilysw.._
aenerallyreported as ‘ ‘ total? sulfur. sulfur, however,‘18 in three forms'1111
pyritic sulfate and organic Py11't'1c__ sulfur 15 iron sulfide. Sulfate, usually" _
result of various sulfate compounds such as nsum. is generally preSe "
' ‘ 1.15- Orgamc sulfur 1s [sulfur chemically bonded 1n the i111.

m'gs on a coal's ,. cOltabihty , £21516 determmes the rank of “a coal 115;

. prommate analys1s (A STM); and rank determines whether a coal falls “1111c '

However coals.
W M
below Ill—percentvolanle matteridry, mineral-matter- .
‘ 'Also,attl1_e_ offier enEl, coals of extremely high vol
 matter either will not coke or will malte a poor quality coke and will be low In
proximate fixed carbon content. Although this Is arbitrary possibly 38- percent volatile _...I
y part'of matter could be considered the upper limit.
These limits are only part of the characteristics of coking coals, as de-
oals.t he scribed In this manual, but they can help to rule out many coals. Incidentally '
I' sistttlns the ideal volatile content for making a good coke Is in the_r_ange_~of 28 to 3_0_
sincoal : percent for St (lard, byproduct‘slot-type_ oyens. As few conlsare within this
, '.ually the‘ Ideal range of volatIlt, InatIer. coal blendtng comes into the picture. Although
l\' p r e s e n t i n
the above range is not binding”;siri'ce' local availabIlIty may be the end deter-
e hydro- mining factor, many coke oven operators will aim for a final mix having a
volatile content in this_range._ ‘
‘f sulfur in , The ash content is of vital importance, as this likewise determines the
II- .the s u l f u r
“effective carbon" available. The trend is naturally toward requiring lower /‘
inte nt. Sinc e 2 ash coals for numerous reasons. Many U . S. A. coking coals are in the range of ‘
s». .isim por- S to 8 percent. Worldwide, the range is much higher, going in some cases to
p Licle s.The more than 12 percent (dry basis). '
s l and 2. An Increase in ash increases the coke rate and slag _volume In a _blast
{7 \als, itis . Although the flox-ing ability of some coal ash enters into the reac- /J,IJ.:
I"Iiacoal. In
»._. eported as blast furnace productivity from 2m 3 percent. The actual economics vary, but ,.
it ..2520 .The' ~ _ some contracts provide a penalty of $1. 00 to $2.00 (U. S. )for a 1-percent ash ‘3

‘3 .
IllsilPSIems, increase over the contraCt specifications [ 9 , 1 0 , 1 1 , 1 2 ] .
:1" '53. in calories Sulfur In coal enters the coke at a rate of abOut 80 to 85 percent of the coal,“
sulfur content and 15 even more detrimentaLto blast fumgegmration tharrthe
s -.._Ie adiaba tic . ash level. It has been estimated by some that a pound of sulfur will decrease
d ..i‘is is what is

;
‘blast furnace capacity b y 25 percent more than a pound of ash. This 15 due to '
w :ue.." This is the Increase in slag volume required to slag out the sulfur to keep It out of the
e” 'fr'equired to .Iron. Figure 4 illustrates the permtssxble sulfur and effect on the coke rate. " .
:The upper limit for sulfur In coal for coking purposes is generally placed at Sofie-I.
a} exact proce- lpercent; however, some higher sulfur. coals can b e used if they are blended -', _«f’ '
o... "0t one ends

A
with low- sulfur coals to reduce the average. Some authorities state that an
cribed by the :. n'eiease of 1--peIceIit s'ulfur could inc Lase the coke rate as much as 71 pounds ;.—. '.
I
_I per net ton of hot metal [10,311].
' Some metallurgical coal contracts may place a penalty of $0. 60 to $1. 00
(U. S.) for each 0.10-percent increase in sulfur content over. the contract
specifications. Obviously, with the economic values placed on these two
‘Iete‘nsus _ingredients'In the coal, the levels of ash and sulfur must be care-
innina tion for _illy Considered. '
' "rnpor tant bear- " Metallurgical coal buyers have generally set limitations o n the moisture
~ 3 coal by“tlIe ---‘ content of the coal Although this varies with local condItIons and transporta-
coal falls into “ii... lion distances, the preference is for a maximum r_a_I_Ige of- 6-. to 8--percent
far as coke--making_is concerned, requires
urface mOIsture Since i_t is_inert §____s
, - t o classif y the Eat to evaporate -_and_lowers t_lic bulk. density of the coke ombarge, the
Sinc ecarb on is . lower the moisture__content, the better. On the oth_e_r hand extremely dry“coal“
\tter is largely . presents dust problems In handling; this also must be takeninto consideration.
her percen tage of Recentpractice In sortie-of the newer coke oven installations Is to preheat the
coal directly ahead of charging. This system is new and expensive, b u t o n the
..eral -rnatt er-fre e ' o t h e r hand, increases coke oven capacity considerably.
:ly high volat ile

C hemical analyses
‘
n
u
=
.
u
‘l. .
u
s
_ m
- p ‘
,,
p
.
E
.0m
P
' v

0'
.

f terms of Jdrogen carbOn. nitrogen, bxygen, and stilfur , on an ash-free basis

The percentage of carbonates 1s freqUenl included 1n this analysis. It mafi be
1 desirable to present the phosphorus and ctrme contents of the coal'1n tlhis
1
1‘ grouping. -
 The chemical analyses described'111 the previous chapter constitufie basic
1nformat1on_required for all 001115, They are essential 1n evaluating the?qualit'
of the coke produced find its reaction in the bi3st furnace. :1;

. < .- . . -_ _ _, .. tests bnefly, the mrportant oneswrll be tre3téd_ 111 more deL3i ..
. ~ . . _ _ .1 - :' A s mmary list of the physmal tests 15 given below.

-.1.-.m..5
. - 1. .- Althoughd etennmatto n of the s1zes of c031 to be treated'15 more apt to p: -'.1.,.'..4.._11‘m_1
l _. ' ‘ , . .. . 1 _ _ to coal preparation plant studies ancl design coal sizes are importaniii

For. exernple, 1110'st coking c031 Users wish to receive coal 111 3 51:"
below 35 to 50 millimet ers (mm); in addition, some of their contractsfil
:‘amourit of 11131111131 below 0 . 5011111110 perhaps 20 to 25 percent. , ' -f
 . a m - . - “ - 'v

The actual sizes‘pr’oduced from core “or channel samples are not truly
indicative of coal sizes through a preparation plant. These have to be reconsti-
tuted to produce sizes more comparable to actual plant product. The Austra-
lians have probably done more w o r k 'in this area than others by developing
pretreatment of samples by a wet—tumbling technique before final sizing and
testing [15].
Sizing tests are described'in ASTM and U . S. Bureau of Mines (U_SBM)
manuals [1, 2]. '
The coal sizes finally charged to coke ovens haveto be carefully regulated
to control bulk density and homogeneity. GeneLLlnefore charging, the coal
_15 crushed to pass 9QPercent t h r o u g haw3. 3-mm _(%1_-inch) semen
The sizing of coal, including the normal degradation, is affected by the
softness or relative hardness ofthe coal, including cleavages, moisture con-
tent, type ofimpurities and soforth. The most common methods of determin-
ing indices f o r hardness are by “ d r o p shatter" tests and the "Hardgrove
gn'ndability” test. Both are fully described by the ASTM [2].
, titute basic
.The drop— shatter test is not generally applicable; except in relation to
-'- m... the quality
rotary breaker design for coal. but is frequently used for measuring the
; strength of coke—especially foundry coke The Hardgrove gn'ndability index
it assortment of is of considerable Value, however, a n d i s o n e of t h e test requirements for
"'her countries
editing coal. '
I "e,ltavingbeen
"He most of these
“,H‘LRDGROVE GRINDABILITY INDEX

_ ' _itlyses)
ardgrove grinding m a c h t n e This percentage is given 'an index number; the
-_l_1_igl_1_'er the number, the Softer the coal, or the easier_it is to” g g ' _ 1 1 d _ _ _ ‘
Generally, the rank of a coal may b e indicated _by the Hardgrove index.

ore apt to pertain methods to which the constituents of a coal sample are separated at various
important in the relative densities and the quantities are determined at these densities (along
with various analyses of these fractions), are used basically for preparation
:11 in a size range plant design. Methods are described in References l and 2.
21' c o n t r a c t s limit the These washing characteristics are very importantfor evaluating the coking
“cent.
for
properties of coals, “they not _only determine the ash and sulfur lev els that

Physical rests
 .1

Pter 5), it is known that some sizes (as well as certain density fractions)
etter coking characteristics than other sizés, and that size is related to
1 :1 tiness of these fractions. ,-
~55 rain hthotxgesw are_ hhander than vitrain types of coalhandmthe
Mbe .
" 1:1is of oorer cokmg ab1l1ty Sometimes this harder variety of coal can.
“ 2.
~ - 1-
U)
'— <
1 ——sov
4 >-
_ 1::
‘“ - fl
' co
:“ g
”4.5m
111
r “ x
_ o
o
1e and can be used 1n the field to make a Brelumnary sepagation
«40 oh—colung coals and to provide some measure of relative
St1cs. It does not reflect
NM. such
,.._ essential
.1." f .1... cokulg charactensttcs
L131 colt; eength and 511011111 be use
~22 _
5—35

611111 poWer and/or cakilng power_9f_ the coal Lfino swellmg occurs the coal:
on a glomcrating. The profile of the coke button, if any, is measured
rarious coal bulk .5. .

’1dicesfrom 58
. Figure 8. Standard profiles (full scale) and, corresponding Free-Swell:

u
g _ Index (FSI) numbers. From AS TM D-720-]972'(reprmled by permzsswn)

w
u
.
.
.
m.
.
.
,
n
'
_ mmmgtheeakmg and coking propei'ties' 'o‘f coals [I] *‘It s

.
'l'tfie free-swelling index previously describ d: ‘‘

.
.
mrcélain nifiii

'
1 ng saméfile

.
,
$1511 machmeu(sect-ISO:Raga
test) and 15 indexed accordmgly . 1 .

I'- G1eseler Plastometer

Since coking coals are coals which. when heated m an absence of ,air to
sufficiently high temperatures, pass through successive transient s t a g e ; .51; 1
softening . tl1e_n_§_welli_n_g__. then_be¢oming plastic or semiplasticzflfl and finally;
sol1d1fy1ng into coke), it is apparent that a device for n1e‘a3—tfir1‘ng these changes.
would be of considerable value 1n evaluating the coking characteristics of a
coal or blend of coals. . '1
It 15 essential that coals melt and become fused into coke. This permitsthe
flu1d constituents to combine with the non-melting fractions to form a strong
coke. (It can be likened to the blending and fusing of cement and aggregafie 111

coma PEEERTIES 01-" COALV

 making" concrete.) Some coals may nave too little plasticity; others may be too

.
fluid in either case. a combination, or blendmg, of these coalsis required. in
fact, very few coals are ideal in themselves to make a high-grade blast furnace

a
coke. A knowledge of a coal' s plasticity enables one to arrive at the proper
blend of various coals.
ThewG1escler plastometcr is described by“the “ASTM, currently as D- 2639-

-
74. The onginal testing equipment was manually operafT(D-1812-69)1 and
. some laboratories still use this equipment. Much greater accuracy is obtained

n
with the constant--torque automatic apparatus. developéd'1n conjunction with
Commercial Testing & Engineering Co. of Chicago (CT &E) The Japanese .
Yoshida automatic apparatus is similar. The details of the apparatus and 1 -

a
testing procedures are fully described by the ASTM 1n Reference 2.

torque“on a stirrer placed o n a crucible m t o which the coal

w
constantly applied
.nc.m .
'_js charged The rucible 1s immersed 1n a bath :and the temperature is in:
- . . w...«Flume-'1'." A . ‘ N m - ' 4 .-— .nuwda—w—w—u -.——.w-\
Jeased uniformly.

.
The stirrer measures the resistance of the coal particles in the receptacle. It
.is attached with a hysteresis brake, adjusted until a 40--gram weight is h e l d 1n
' . . _

.
suspension- An electric- heated furnace ‘with automatic controls is provided ‘ .'
- 0.1°C per minute, on an overall basis, with no
so that a heating rate of 3. 0 ° +

- .
d ’
+ 1. 0°C for any given minute can be maintained over a tem-
more than 3 .__0°
\- 1 Eire-Swelling ' erature range from 300°. to 550°C.
at..‘}11'ssion). As the coal'is heated under prescribed conditions, it begins to soften, and f

.
‘ gal‘s caking : n t is measured b y a pomter-and—dial arrangement. As the coal becomes ‘

-.
the standard

.
.13 :arance and

.
recs of agglom-

1' :‘st for_ deter-

.
a" hat similar t o
)_ -'-pesh sample
its-111111 crucible
:ing sample is
he ISO Roga

.. .ace of air to _ men t o the fluidity measurements the temperature ranges of plastic- ,
' ntstages_(fi rst “the actual temperatures during this period are equally important, as - ' ' 3'
'1, and flnally theseghave to be taken into- account to ensure the blending of other coals
19, these changes ’ unnE this period of fluidity and temperature. Obviously, the longer the
1ctcristics,ol a __of plast1c1ty 1s , the wider the potential for blending with other coals will

"his permits the Although there are' some similarities between the Gieseler fluidity mea-
'form a strong urements and the ISO Audibert-Amu or Ruhr dilatometcr tests, particularly
and aggregate in ' wegiard to plastic range and temperature, there is no direct correlation be-

Physical test:
 Table 4 Piasticléropertie's of Coats
, ‘ 5 _' - i _ Western - 6 Eastern 1"
‘ < ' ' _ < Coal Blend ‘ CotzEIBlend

Free-swelling index I. 41/4. . ‘I

Agglutinating value 5.3 $9

Gieseler-plastonieter" ’ . '. ~ .1
. Initial softening temp.. “C 370 34.7
Fusion temp.. °C 424 464
Temp. of maximum fluidity. °C 437 , ‘ 43,8
Solidification temp.,“?C 463 . 43‘s
I Maximum fluidity, ddpm‘ - 16I . 93510

AudibertI—Arriu dilatometer
Contraction,% - , 3S
Dilatation. %, é ‘ - 6
Softening temp.~, °,CI ' 353
Temp- of maximum contraction, °C 411
Tempéot‘maximum'dilatation,°IC . y :43],

Source: ReIt'” ences .175"and 1.8

tIer [20,I21] Generally,

ut- there is a wide vanauon in th6 higher volatile IcoalIs (11146. t
weathering a n other factors - .

dibert- A r n u -D1latornete1"

' '1‘he Audibert-Am u dilatometer test [ 12 17-, 18,19-,App Ali-S an Intematlonal

' standardflSO 359111111115 measure of ‘
used as _a____ 1 6 “ n and/or .
coals. I t 15 common
plastic properties of cokingw in Eumpe '11 other parts of =
the world,’ although" it is just recently beginning to be usedtn'the U . S. A:- As .
explained in the previous subsection, although similar to Gieseler 1n thatithe.
plastic temperature ranges are approximately the same the fluidities (dilata- :
tion) measure different coking coal properties“
A pencil made of powdered coal'is inserted 1n a narrow calibrated tube and
topped b y a steel rod (piston) which slides'1n the tube as the coal is heated in
‘ accordanc e with prescribed conditions. By making regular readings of the
displacement of the piston as a function of the temperature and expressing the
displacement observed 111 percentages of the original length of the pencilha
curve of the typeIshown in Figure 10 can be plotted

COKINGIII’RIOIPERTIES OF COAL
 "ha-tum
(ml Blend

'3 103
8.9

' 347 >:

. 404 L“.
» .133 9.
433 D
‘ 0 2 .J
. 9300
‘L 2
2 ‘5
.3 c1
2
2i0 X
4
356
2
00
467
101

. " 1m) directly,

cafe compari- ’ " 10°

u ’ibert-Arnu ,_ I6 17 18 19 _2o 21‘ .22. 23 24
"y0LAT1LE MATTER PERCENT.- DRY. MMF
:1 11151211111: mat— . e 9. Relationship of Gieseler maximum fluidity _of low- a n d medium-
e the greater lardePocahontas seam coals to their volatile matter content: (rank) From
e -oals d u e to er'cnce 17. '
. I

1
1‘

I’T1=. Temperature at which piston has moved 0.5 mm (softening

nntnternational temperature).
1' ; ‘ gandjpflr '1 Tu = Temperature at which piston reached its lowest point (contrac-
I. 1erpartsof
' - tion. temperatu re).
13e.S.A. As T1.“ = Temperature at 'which piston reaches its highest point (tempera
:- ‘r in that the
‘ .ture of maximu m dilatation)...
u1u1ties (dilata- = Dilatatio n. in percent '
‘— Contraction in percent. If, after contraction has tairen. place.
1. .ed tube and the piston does not return to its original level, the dilatation'1s
r ‘ l is heated in calculated from the difference between the final level and the
" "-‘.ings of the original zero level, but repot ted as negative (see Figure 10).
expressing t h e
the pencil. a '- .-_ I t should be mentioned that this test i539" designed to indicate pressures
M.._.-M~ .mh‘....pry- ur-
exerted on the walls of industrial coEe ovens” ”MW
“ a t -—..‘~.-o—......, '

Physical tests
 c;
I111 DlSPLACEMENT

__.—_.._._.__....._._.__

Figure 10. AudiberI—Arnu dilarameter curve. From Reference 3.

. 5;

I n View of the fact that the detailed information for this ISO testis not
readily available in the U . S . A. , the latest ISO Standard(349- l975)'1s included
in this manual as Appendix A. '' '
_ . m.ISO
Although the A11d‘bcneéfifig test is thestandard test and 1s commpnly V
‘:-:-—-
used, some natififiipgefer the Lhr dilatometer. This IS particularly true in
Gemiany and of the British Standards Institution [4]. The principles are the
same, but t h e r e '13 some variation in equipment and procedures. The Ruhr
dilatometer is German Standard DIN-51—739 [22] and'IS given in detail in
Appendix B. I t 'IS believed by many that the Ruhr method produces a more
accurate reproducibility of results and it is used 1n the determination oi the
calculated “ G ” factor in indexing coking coals versus volatile matter.- ’
Sorne refeiences a1e given in the literature to the Hoffmann dilatometer
test, b u t it is based u p o n the same principles as the tests discussed earlier.
Figure 11 shows a relationship developed by the Japanese between
Audibert—Amu dilatometer dilatations and volatile matter. and indicates the

coxmc; moraines or COAL : '

 ) t a m é i e
, ,7 Blath/e"positions of various cents. The ideal blend is shown‘ in the cross-
etched area [9].

D i l u
t/KGRAY-KING TEST
‘The purpose of the Gray~King.coke test [3, 6], one of the parameters adopted
for the International Classification of Hard Coal: by Type by the United
Nations Economic Commission for Europe, is to' asses s ETIEEEEiyg propeftjgs'
~uop---'IU~--‘- .

e. '0

.
J A P - HV

.. OYuburi

.
\1' '" 230
AMERICAN " M V

.
l . -« 260
. m AMERICAN- HV‘ ”Mike 240
K l :
I g;- ‘1
. OPiedmond /
1' ‘ I Rowland ‘ . - .1 22°
l‘; AMERICAN-My
_.a_______. / '
" 200
\ / ' .
. OKeppuston
. ORussel forte ' I‘Iubarl
-
oLnncnshire / ORodn UPE -
l ‘ v T . tToitoshirno ‘ lBO
t , .L - - ' — IGO
Harman »'1
t I

- b I Str. New river ' 0Kettermon ' ._

Std. Dou ' In: E222 «Pittston i . . I"

. .g.‘ 8 5 Blend A A . —
__.‘.__..__V_
Oshw'anae ~ ' _‘ ._

new OF EL Ewoé'opau rag 06K: MAKING ..

'10 test is not
" T) is included ' "Gttrnlcnn OBorehole ,t -
~ea'iatxfrlce e. ' . oNewdeIl .
1-5 . immonly _ oMoura Liddeil ‘ ‘
:.
: .
. ieJlariy true in
cipies are t h e . 53.144
1.5.I'I‘he Ruhr ' 6 q ct”!
‘ ":1 in detail i n
AUS. CAND._ AUS. CANQ-Mv JUS. JAP. __ "
'-"'-‘!uces a more W M ~—---—- 3. AFRICAN 31!
mutation of the
l I i i 1 J
matter. ' 35 4O 45
20 . 25 30
. dilatometer
V. M. ( d . a . f . "/o)
ssed earlier.
,se between
:1 indicates the
of a coal or blend of coals by carboni'zntiog'pnder standard conditions. There
is no test comparable to the Gray- King test; it should nbt be confused With'
or regarded as an alternative to the ROga test, which also measures eaking
properties
The Gray-n res} is a laboratory assay;method of carbonizing a : Ema“;
finely ground sample of coal under certain standard condmons _up to .-1flnal_
temperature of 600_°C. It has been used most frequently 1n Great Britain.
This test is International, standard ISOJO‘L 1974(E) a n d 'ts described in
detail 1n Appendix C.
T___h__e__coke residue from the carbonization assay is class1f ed by comparison
with a series of standard coke types, grading from A to _G. The grades G and
G- l to G— 8 represent coking coals, w1th C- gbéing the most strongly coking
O n e can make a rough comparison between FSI (crucible-swelling
number) and Gray-King as follows:

Crucible—Swelling No. - Gray-King Coke Type - '

l _,...»..' '. ' A toB .
M """ ' . C toD ,.
"2t02‘fz ' '_" ‘ D t p E i
. 3 1 ‘ 131q_ S:
410 41/: ”(if “S .j
510511
61/1197
2 G-Sorhigher
. .G-s '-‘1 ‘., " '“i r'
1 9 . 9'8 5

ROGA'T'ES (is'o)
The Roga test of the ISO [3 _6', 7], originally developed 111 Poland, is a 11161
for determining the eaking power of coal ii'rid‘e'r' the standard conditio_11's'"se't
forth in its' description It is also usedm 11161110 standard classrficatton of ha'r'd
coals. (See Figure ' 2 of this m a n u a l ) , ~
The testis somewhat simi__la_r_t'_o__'t_l_'1'e_ USBM agglutinaung teat, except. that
instead of silicon carbide, a certain grad ' of anthracdekis mixed with the

Loguct. Anthracite' is found to be better than silicon carbide because i t (iii

fuse with the bituminous coal t e s t e d - See Appendix D for proceduresii
A Roget index of 45 indicates a coking coal with an .F-SI of about 3k: t_o 4 the
-m:.*...,..
stro'nge'r coking coals have Rog'a-indices above 45 "~ 31’4"-‘ '

SH ATTER 'I"'EST '(ASTM)

The shatter ml for coke, although not used as frequently as the tumblei: test,
is often referred to and is generally used 1n determining the strength of foundry
coke. It'is described in the ASTM procedures [2]. Required per test tire SE
pounds of plus--2-in coke. The cok‘e'1s classified by measuring its resistance tr
breakage when dropped from a standard height onto a steel plate. Althougi
the tests are repOrted as to the percentage retained o n 2- l - , 1 — , a n d . %--111

COKING P'ROPERTISS OR COAL

 E4}? Hchlfi [MN-ids, "HUI -8340CY£
MECON LIMITED, RANCH-834002

PETROGRAPHlC ANALYSIS OF COAL

Petrology deals with study of rock strata which is made of minerals of inorganic substances,
coal petrology is a specialized division dealing with organic rock known as coal.

Normal rocks are constituted by minerals of inorganic substances. However, in case of coal.
a term ‘maceral' is used to describe microscopically distinct organic entities.

To determine these entities (macerals), they are observed under a microscope. For
petrographic analyses, the coal sample is first crushed to pass through 20 mesh (850
micron) sieve and then mixed with an epoxy-resin binder and then is molded to 25 mm
diameter briquette and the circular surface is polished. Which is then observed under a
microscope at 400 magnification.

The method of Iobservation is called reflected light method. This is accomplished by reflecting
a beam of light off the polished surface of the prepared coal sample.

From the above analysis, various“ different types of macerals constituted by several micro
components have been identified. These are classified as follows:

Macerals Groups Micro com onents

Vitrinite Collinite
Telinite '
Semi Vitrinite‘ ' Semicollinite
Semi telinite
_ Mixinite

Fusinite Semifusinite
Micrinite
Fusinite
Sclerotinite

Leiptinite (Exinite) Sporinite

Cutinite
Resinite

Alginite ‘ Algdcollinite
Algotelinite

Minerals Clay minerals,

lron'sulphides.
Carbonates,
Other mineral

Sheet 1 of;
 @9 HQ)” K‘HHdS, “UH-834002
.W, MECON UMl‘l’ED,RANCHl-834002
A great deal of work has been ddne to determine the coking behavior of different maceral
groups. To determine the coking behaviour of maceral groups following are measured in
petographic analysis.

a) Quantity of macerals
b) Reflectance of these macerals

For quantitative measurement a microscope having 400 magnification is used. The quantity
of maceral groups are determined by “point count" system. 2000 points are counted on each
sample and group of maceral is identified for each maceral and then based on the
observations, percentage of each maceral group is calculated. As the percentage of each
maceral Is based on point count system the calculated percentage Is on volume % basis and
not on weight % basis.
of
. Similarly for measurement -of reflectance fleach point Is carried out by reflecting a beam of
light at each point and maximum reflectance of each point of each maceral'Is determined and
then the mean value of reflectance of each maceral Isdetermined.

There is a wide variation in reflectance value of each macerals. This reflectance is termed as
R0 and is measured in percentages 'of 0.1 increment. that is 0.1. 0.2, 0.5, 0.6. .'.....
1.0......1.5. ........ etc. _ .

It has been found that reflectance of coal varies With it's rank. A lessmature coal, that Is
high volatile coal will have low reflectance value and a more matured coal that'Is low volatile
coal will have high reflectance value.

To simplify the description of reflectance value of each maceral, the term ‘type‘ is used in the h
following manner.

Each type is represents a value in the range of 0.1 reflectance. For example Type 1 ~
_ indicates a reflectance Value between 0.1. & 0.2. Type 6 indicates a reflectance value
between 0.6 to 0.7 etc.

Based on studies regarding coking behaviour _of each maceral groups & types following.
general classification has been made.

General categories Maceral Group Macerai types & minerat

Vitrinites Reactive Vitrinoid V6 to V1.8
Inert Vitrinoid V0 to v5 & V19 to V70
Reactive Semifusinoides - . SF 0 to SF21
Leptinites Exinoides Reactives E0 to E15
Resinoides — do - R0 to R15
lnertinites ' Micrinolds inert M18 to M70
Fusinoides - do - F40 to F70
inert Semifusnoids - d0 - SF22 to SF40
Minerals Sulfides lnert- Pyrite, Marcasite
Carbonates - do - Calcite, Siderite
Silicates — do — lilite. Kaolinite etc.

Sheet 2 01:3

35
 5g; «mm immcs, \IWI'WWA
V MECON UMITEDBANCHl-BMOOZ
in «>e
Here, the M‘Reactive' means. those fractions of coal, which melt and then resolidify
during carbonization process. One the other hand inerts do not melt and remains solid
during carbonization. -

it has been found that only reactives do not produce good coke and require inerts in proper
proportion to produce proper coke. The strength of coke depends upon strength of the inert
7 grains and the strength of bonds. between inert grain created by reactive fractions.

10. it has been found that each reactive type has an optimum ratio of reactives to inerts. Any
reactive type will produce best coke at a 'given ratio between reactives to inerts.. The
enclosed figure gives a curve indicating reactive type vs optimum reactive/inert ratio.

11. The 2nd factor which controls the strength of coke is the average reflectance of vitrinites.
Higher the reflectance (or rank) better would be the strength of coke. For example let there
be two samples A & B; each having optimum ratio of reaCtive/inerts. But suppose A is of
higher rank than B. In such a case, strength of coke produced by sample A will be better
than the coke produced by sample B The 2'“ figure indicates the relative strength factor
variation with respect to reflectance of coat.

a . Sheet 3 o f 3

56
 .§ . . . 3
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COKINGPROP ERTIES 0F COAL

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for reactive maceral; with given quantities ofinerts. From Rafe:

\ : \ \ \
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mm1 : .

INERTS, VOLUME PERCENT

is strength chart : Relat
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m . RANK . . max
5 Figure 23. Relationship betwe'en maximum fluidity and mean maximum re—
‘E fleclance. From Reference I 2.

Petrogmplu'c ahalyses 65
 A TECHNICAL TALK
’ ON
COAL HANDLING AND COKE SORTING PLANT

I. COAL HANDLING PLANT

a. FUNCTION

i. TO PROVIDE LARGE STOCK OF COAL ENSURING MINIMUM

INTERRUPTION TO COKE MAKING UNIT DUE TO
IRREGULARITY IN RECEIPT CAUSED BY EXTERNAL FACTORS.

ii. T0 ACT AS A BUFFEF BETWEEN COAL SUPPLY SOURCE AND

PROCESSING UNIT 1.e COKE OVENS.

iii. TO HOMOGENISE LARGE QUANTITIES OF COAL HAVING

DIFFERENT CHARARCTERISTICS.

iv. THE CONCEPT OF HOMOGENITY APPLIES TO ENSURE

CONSISTENCY IN THE QUALITY OF BLENED COAL TO
PRODUCE METALLURGICAL COKE.

b. SIZE AND CAPACITY ‘ °

1. THE SIZE AND CAPACITY OF COAL HANDLING PLANT IS.

DECIDED CONSIDERING FOLLOWING FACTORS:

B._F. COKE (25—80mm) ANNUAL PRODUCTION

ii. B.F COKE YIELD (68% OF COAL CHARGED APPROX.)
iii. - -HANDLING LOSS (2.5% APPROX.)

iv. .. STOCK CAPACITY (15 DAYS TO 45 DAYS)

BLENDING BUNKER’S FOR 24 HOURS STOCK

vi. COAL TOWER FOR 24 HOURS STOCK.

CONVEYOR STEAM AND CAPACITY

THE NO. OF CONVEYOR STREAM AND ITS CAPACITY IS

DECIDED ON THE FOLLOWING BASIS.

i. COAL TO BE HANDLED PER DAY

11. - WORKING HOUR OF SINGLE STREAM SHOULD NOT
EXCEED I6 HOURS/DAY

iii. . 6-8 HOURS TIME TO BE RESRVED FOR MAINTENANCE

OF THE PLANT AND EQUIPMENT.

4H?
b. PLANT ORGANISATION

THE COAL HANDLING PLANT COMPRISES FOLLOWING MAIN V

SECTIONS:

i. COAL RECEIPT AND STORAGE SECTION

ii. . COAL RECLAIMING AND STORAGE IN BLENDING BUNKERS
iii. COAL BLENDING AND CRUSHING AND STORAGE IN COAL
TOWERS
iv. 4 CONTROL SYSTEM FOR EACH SECTION

FACILITIES IN DIFFERENT SECTIONS

SECTION-I : COAL RECEIPT AND STORAGE SECTION

MODE OF COAL RECEIPT:

- BY RAILS IN WAGONS

- BY ROAD IN TRUCKS/DUMPER

COAL UNLOADING FACILITIES:

i. MECHANICALLY BY RO'I. ARY TYPE WAGON TIPPLERS

CONSISTING OF 2 NOS. RECEIVING HOPPERS OF RCC AND
FITTED WITH RACK AND PINION GATE FOR CONTROL I
DISCHAGE ON TO CONVEYING SYSTEM

ii. “MANUALLY CONSISTING-OF TRACK HOPPBRS OF RCC AND

FITTED WITH RACK AND .PINION GATE FOR CONTROL
- DIS CHAGB ON TO CONVEYING SYSTEM ..,
iii. CONVEYOR SYSTEM FROM WAGON TIPPLER/TRACK
HOPPERS TO COAL STRORAGE YARD '

iv. ' THE COAL RECEIVED IN COAL YARD IS STACKED LONG-

ITUDINALLY IN FORM OF FILES WITH THE HELP OF EITHER
OF THE FOLLOWING EQUIPMENT:

- REVERSIBLE TRAVELLING TYPE TRIPPER '

- REVERSIBLE TRAVELLING TYPE WING TRIPPER
- REVERSIBLE TRAVELLING TYPE WING TRIPPER
- REVERSIBLE TRAVELLING TYPE SLEWING STACKER
- STACKER CUM RECLAIMER M/C

SECTION-II : COAL RECLAIMING AND STORAGE IN BUNKERS

THE COAL FROM THE STOCKYARD IS RECLAIMED WITH THE HELP

OF FOLLOWING EQUIPMENT FOR ONWARD STORAGE IN
BLENDING BUNKERS : .

4’2.
 i. _ RAIL MOUNTED RECLAIMERS
ii. RAIL MOUNTED STACKER CUM RECLAIMERS
iii. RAIL MOUNTED BUCKET WHEEL RECLAIMERS
Iv. RAIL MOUNTED HARROW TYPE CHAIN SCRAPPERS
v. PAY LOADERS

THE RECLAIMED COAL IS CARRIED TO, THE TOP OF THE BLENDING

BUNKERS AND DISTRIBUTED IN VARIOS BUNKER (ALLOTED FOR
DIFFERENT TYPE OF COALS) WITH THE HELP OF FOLLOWING
EQUIPMENT
i. REVERSIBLE TRAVELLING TYPE TRIPPER
ii. - REVERSIBLE SHUTTLE CONVEYORS

SECTION-III : COAL BLENDING AND CRUSHING'AND STORAGE IN

COAL TOWERS

AS PER PREDETERMINED BLENDING RATIO, VARIOUS

COMPONENTS OF COALS ARE WITHDRAWN FROM VARIOS
GROUPS OF COAL WITH THE HELP OF 'AUTOMATIC BELT WEIGH
FEEDERS WHICH DIS CHARGES ONoON A BELT CONVEOR IN
LAYERS WHICH ARE SENT TO FINAL CRUSHIG STATION.

IN FINAL CRUSHING STATION,-THE 'COALS ARE CRUSHED IN '

REVERSIBLE HAMMER MILLS TO 80% -3mm SIZE AND FINALLY
SENT TO TOP OP COAL TOWERS THROUGH BELT CONVEYORS.
THE COAL TOWER TOP IS PROVIDED WITH 2 NOS. RAIL MOUNTED
REVERSIBLE SHUTTLE CONVEYORS FOR DISTRIBUTION OF COALS
_ TO DIFFERENT POCKETS OF COAL TOWER.(ALL RUSSIAN AND
' T GERMAN DESIGN COAL TOWERS) .' .

WHERE COAL TOWERS HAVE NO POCKETS AND ACTS AS A

SINGLE BUNKER , THE COAL IS DISCHARGED FROM TOP THROUGH
A SINGLE REVERSIBLE SHUTTLE CONVEYOR MOUTED ON A
REVOLVING PLATFORMIDSPIIISCO).

BELT CONVEOYR SYSTEM '

THE BELT CONVEYOR SYSTEM CONSISTS OF FOLLOWING PARTS:

- i. AENDLESS BELT
ii. DRIVE PULLEY
iii. TAIL PULLEY
iv. CARRYING IDLERS
v. IMPACT IDLERS
vi. RETURN IDLERS
vii. TRAINING IDLERS ;
viii. TENSIONING UNIT ‘

4’3
 ix. . SNUB AND BEND PULLEYS
DRIVE UNIT(GEAR BOX,COUPLING AND ELECTRIC MOT OR)
xi. SAFETY SWITCHES (PCS, BSS AND ZSS)
xii. LOADING CHUTES '
xiii. DISCHARGE CHUTES
xiv. JUNCTION HOUSES
xv. CONVEYOR GALLERIES/BRUDGES/TUNNELS
xvi. BELT CHANGING UNIU

STANDARD SIZES OF JUNCTION‘HOUSES, (m x m) :

4x4, 5x5, 6x6, 6x75, 6x9, 9x9, 9x12

PARAMETERS FOR BELT CONVEYOR DESIGN

i. - CONVEYOR DESIGNATION
ii. CAPACITY, tph .
iii. BELT CONVEYOR LENGTH, m
iv. HEIGHT 0F LIFT OF MATERIAL, m
v. ' BELT SPEED, m/s
vi. CHARACTERISTICS OF MATERIAL TO BE CONVEYED
VIZ. SIZE, TEMPERATUREABRASIVENESS

. IMPORTANT SPECIFICATION OF BELT CONVEYOR _

EQUIPMENT/ STRUCTURES

i. BELTING:

STANDARD WIDTH OE CONVEYOR'BELTS (m)'

400,500,650, 800, 1000, 1200, 1400,1600AND2000
TYPE OF CONSTRUCTION. . '
COTTON/COTTON, NYLON/NYLON, COTTON/NYLON ' '

COVER GRADE: M17, M24, HR/SHR GRADE

ii. PULLEYS SIZES: (OD x FACE WIDTH)

‘ DIAMETER (mm): 250, 315, _400, 500, 550, 630, 800, 1000,1250.

FACE WIDTH (mm):

UPTO 1000mm BELT W:IDTH BELT WIDTH + 150 mm
ABOVE 1000 mm BELT WIDTH: BELT WIDTH + 200 Inm

SHAFT :
DIA (mm): 65.80.90.100.110.120/125,140,160,180,200.22025-0
MATERIAL OF CONSTN: STEEL, C40/C—45

iii. TENSIONING DEVICE

44
 SCREW TAKE—UP
HORIZONTAL TAKE-UP .
VERTICAL GRAVITY TAKE-UP
iv. [DLERS ' '
- CARRYING IDLERS:
TYPE: 2-ROLL, 3-ROLL, OR MULTI
' _ ROLL TYPE
TROUGHING ANGLE: 20%%D, 30%%0, 35%%O,45%%o
ROLL DIA.Mm: -114,127,140,152.4.219
-RETURN mLERs: SINGLE ROLL FLAT TYPE
SHAFT: . , . , '
D1A(mm): 65.80.90.100.110.120/125,140,160,180,200.220250
MATERIAL OF CONSTN: STEEL, C40/C-45.

TRANSFER CHUTES

MATERIAL m m : 6/8/10 thk MS PLATES '

VALLEY ANGLE : 955-60%%D minimum for INDIAL COALS
60-65%%D minimum for IMPORTED COALS

CHUTEE LINNING MATERIAL: CARBON STEEL C—30/35, SAILHARD/

SAILMA/TISCRAL/SS 409M, POLYMER SHEETS. ‘

MAINTENANCE FACILITIES

OVER HEAD CRANES : 20/5 T CAP. IN WAGON TIPPLER HOUSE

UNDER SLUNG CRANES: CAP. 5T, 7.5T, 10T‘
7 ‘- ELECTRIC HOIST CAP. 1T, 2T, 3T, 5T, 7.5T, I'OT, 12T.
MANUALHOISTS: ‘ CAP. 1T, 2T, 3T, 5T,7.5T

STORAGE BUNKERS/ HOPPERS

S NO. ‘ PUPOSE 'CONSTN LINING MATERIAL

i. WAGON TIPPLER HOPPERS RCC . SAILHARD/ POLYMER! '

RUBBER/8830258409
_ii. TRACK HOPPERS RCC -DO-
iii. BLENDING BUNKERS RCC POLYMER/SS4-09/SS302

4/5
II. . COKE SORTING PLANT

ORGANISAATION
i. COKE WHARF (for wet quenching system)
ii. COKE CRUSHING STATION
iii. COKE SREENING STATION
iv. COKE BREEZE BUNKERS
V. ‘ EMERGENCY COKE STORAGE YARD

BRIEF DETAILS ,OF UNITS '

i. THE WHRF '

CONSTRUCTION: RCC SLAB, SLOPE 28 DEG.
LINING MATERIAL. FIRECLAY BRICKS/HR GRADE C.I. SLABS,
SIDES AND DISCHARGE LIPS FITTED
WITH C.I.PLATES WITH BOLTS.
COKES ARE RETAINED ON WHARF WITH MAUAL GATE(MS)

SPOT QUENCHING FACILITIES FOR QUENCHING OF RED HOT COKE

PIECES
» ii. COKE CRUSHING STATION 1 °
EQUIPMENT USED : ‘i. ' 80 MM DISC GRIZZLY/
. VIBRATING SCREENS
11.. Z—ROLL TOTHED CRUSHRS
iii. COKE SCREENING STATION
EQUIPMENT USED. i. 25 MM DISC GRIZZLY/ '
. .. - VIBRATING SCREENS
a 25mm CHECK VIBRATING
, SCREEN
WAGON LOADING FACILITIES OF B.F. COKE
COKE BREEZE BUNKERS

QTY 1 UNIT CONSISTING OF 2 BUNKERS 1 FOR 10 25

mm NUT COKE AND 2“D FOR 100 BREEZE COKE

EQUIPMENT USED: 2 NOS 10 mm vibrating Screens

WAGON LOADING AND CONVEYOR LOADING FACILITIES

CONTROL/DESPATCHER ROOM

'4—é
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 mono/33w ON 9110

. 111 K15'_ son 40 IpII 1.3m/s 1

W W 9 K14 500 40 tph 1-3m/9 1
. 5 K15 I100 40 lg): 1.3m]: 1
7 K12 1200 225 1911 1.5m/1 1 Iva/1:151: ‘
,......, 6 K11 1200 2251p): 1.5m/a ‘l
I 2: 5 K9 «K10 1400 250 tph 1.3m/s 2
'r-4 4 x7 a: KB 1400 250 Iph 1.3m/s 2 -
\ YI 3 k5 & Ice, 1400 25mph L3m/a 2
:69 03 ® 92 2 2 K: A: H 1400 251mm 1.3m/o 2 °
: k ® 1 ® K é 1 K1 .1: k2 11100 2001» 1.7m]: 2
. @ 0 \® (9 3 2%' no.
SL DESIGNATION “In?“
- . cmcmr 295:0
T 01v REM.
- g a .LISI’ or BELT CONVEYORS

W E
so mm GRIZZLY SCREEN 6 " “ x'gruggfigofifiggfipgfifiw 25 1 FlL SUPPLY
~ 911mg “JA_M_M_IN_G_ QEIEQ'm_R___ ___ ______w .......... .30.. EIL_SUERL\E....__.. ..
'" :BUNKER LEVEL 551150115 In sum: HOP-
.- PERS 7 COKE BREEZE auans 2‘2 KW- SUPPLY
g uoromszo sscmn GATE ron aunms 2-
. MANUAL szcmu CA1: IN DHUI'E IN con 1 “'- SUPPLY
i‘TRAVELLING‘TRI‘PP‘ER QN_CQW 11-13 225 I m SUPPLY " .1
I MOTORISED RACK a PINION CAVE - 2" FI'L SUPPLY -
;g ELECTRONIC
' BELT
~ suLE_
- - 0—100
040° ‘1- SM:
5W! UNDER NINL» I.‘-
1 MOIORISED rum CAI: 11 FIL SUPPLY ‘
@ (9 ® ® 310mm'v13. SéRtfiN .5"60 2‘ ”§&Y_MG-
0 - ' fzsrhm CHE'CKNSCIIEEN- .' ‘ 85" I» I'wm‘mw-Y. mac. 5"
I25mm GRIZILY scaEEN' 250 2' fiaE-..supPLv
U ; . - .
2-RoLL TOOTHED CRUSHER - 150 2 5mm SUPPLY 3‘ .
. 80mm GRIZZLY SCREEN 25a 2 my: supm
' I NAME or EOUIPMEN‘! ' 13’}: ON REMARKS
W E S ? fi . .
EOUIPMENI
a \ LIST OF MAJOR .FACILITIES
10mm VIB.SCRE£N -

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10—15mm O—IOmm
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wxzon LOADING A
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MECON LIMITED —

A
““'°”
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“”‘U’
1 “ l
COKE OVEN COMPLEX
A
- DES'ENZD an. PM"
A A an,“ m COKE SORTING PLANT .
A cuzcxto TECHNOLOGICAL FLOW DIAGRAM
- mo , . ‘
WWII-IE9

INA - SIG. I'JLII~ III-R up]

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 DESIGN / CLASSIFICATION OF COKE OVENS

BY-PRODUCT RECOVERY COKE OVENS

BASED ON REFRACTORY CONSTRUCTION "

a) ALL SILICA CONSTRUCTION

b) ' SILICA CUM FIRECLAY CONSTRUCTION

' BASED ON FLOW PATTERN OF FUEL/ WASTE GASES

a) TWIN FLUE WITHOUT WASTE GAS RECIRCULATION

b) TWIN FLUE WITH WASTE GAS RECIRCULATION .
c) ‘ TWIN FLUE SYSTEM WITH STAGED AIR SUPPLY SYSTEM
d) HALF DIVIDED WALL SYSTEM
6) FOUR DIVIDED WALL SYSTEM
I) CROSS OVER FLUE SYSTEM

iii) BASED ON HEATING GAS SUPPLY SYSTEM

a) UNDER JET SYSTEM

b) GUN FLUE SYSTEM(SIDE FIRED)
iv) ' BASED ON EUEL HEATING SYSTEM
' a) SINGLE GAS HEATING SYSTEM
_ b) COMPOUND HEATING SYSTEM
V) BASED ON COAL CHARGING SYSTEM

' 21) TOP CHARGE BATTERY

b) STAMP CHARGE BATTERY
vi) BASED ON SIZE AND CAPACITY OF OVENS
a) SMALL SIZE OVENS (LESS THAN 4 m/ 15 m3 VOL)
b) MEDIUM SIZE OVENS (4 TO 6 m/ 15 TO 35 m3 VOL)
(2) HIGH CAPACITY OVENS (MORE THAN 6m] 35 m3 VOL.)
vii) BASED ON THE WIDTH OF OVEN
a) NARROW OVENS (UPTO 500 mm)
b) WIDER OVENS (MORE THAN 500 mm)

55
CALCULATION OF USEFUL VOLUME

USEFUL VOL.= (LENGTH BETN DOORS) X (HEIGHT—3 00mm) X AVG WIDTH

NORMS FOR DESIGN OF BP' COKE OVENS- BD

OVEN AVG USEFUL DESIGN BULK DENSITY FOR DRY COAL;

HEIGHT WIDTH VOLUME COKING t/m3
m ' mm m3 TIME,h 100% 100% 50% IMP
IMP ' INDIAN COAL
COAL COAL _
2.5 450 11.6 18.5 0.73 0.75 0.74
4.3 _. 407 ‘ 21.6 16.0 0.74 7 0.76 _ 0.75
4.45 ' 450 23.8 18.5 0.74 0.76 0.75
4.5 400 21.6 16.0 0.74 0.76 0.75
5.0 410 27.3 ’ 16.0 0.74 0.76 0.75
5.5 410 32.3 16.0 0.75 . 0.77 0.76
6.0 410 38.1 ' 16.0 0.75 0.77 0.76
7.0 410 41.6 16.0 0.76 '. 0.78 - 0.77
GROSS COKE YIELD=100 -VM % +1

CALCULATION FOR GROSS' COKE PRODUCTION

N = N0.0F OVENS
V = USEFUL VOLUME/ OVEN, n13 -
BD = BD OF DRY COAL CHARGE, m3 ,.
CT = COKING TIME, 11 . , "
YLD = % GROSS COKE YIELD ‘
GCP = GROSS COKE IYBAR, 1/y1‘

GCP=(N X v X BD) X (24/CT) X (YLD/l 00) X 365

CO GAS YIELD
’ CO GAS YIELD IN VM = 25 % VM = 24 %
Nm3lt OF DRY CHARGE .
4.5 AND 5.0 m OVENS 310 300 -
7 m TALL OVEN - 320 310
 NORMS FOR DESIGN OF BP COKE OVENS- BF COKE YIELD
OVEN AV-G USEFUL DESIGN BF COKE YIELD OF GROSS COKE
HEIGHT WIDTH VOLUME COKING 25-80 mm 25-60 mm 15-60 mm
m mm m3 TIME, h
2.5 450 11.6 18.5 85.0 84.0 85.0
4.3 407 21.6 16.0 88.0 87.0 88.0
4.45 450 23.8 18.5 88.0 87.0 88.0
4.5 400 21.6 16.0 88.0 87.0 88.0
5.0 410 27.3 16.0 88.5 87.5 88.5
5.5 410 32.3 16.0 88.5 87.5 88.5
6.0 410 ' 38.1 16.0 89.0 88.0 89.0
7.0 410 41.6 16.0 91.0 ‘ 90.0 91.0
NOTEz-WITH CDCP YIELD SHALL BE CONSIDERED 1 ”/0 MORE

NORMS FOR DESIGN OF B1) COKE OVENS- M 10 VALUES

OVEN USEFUL M 10 VALUE

HEIGHT VOLUME 100% IMP 100% INDIAN .50%1M1>
m m3 ‘ COAL COAL COAL
. wO DC WQ DC ' WQ DC
'25 11.6 11.0. 9.0 - 12.0 10.0 . 11.5 9.5
4.3- 21.6 10.0 8.0 11.0 9.0 10.5 8.5
‘4.45 . 23.8 10.0 8.0 . 11.0 9_0, 10.5 8.5
4.5 21.6 10.0 8.0 11.0 9.0 10.5 8.5
-5.0 . 27.3 ' 10.0 8.0 . 11.0 9.0 10.5 8.5
5.5 32.3 9.5 8.0 10.5 8.5 10.0 8.0
6.0» 38.1... . 9 . 5 8.0 10.5 8.5 10.0 8.0
7.0 41.6 8.5 7.0 ' 9.5 8.0 .. 9.0 .7.5
UTILITY CONSUMPTION
UTILITY UNIT CONSUMPTION
WATER
MAKE-UP FOR QUENCHING _ CuM/ t 0P COKE 0.5
WATER SEALED A P CAPS CuM/h 10.0
HYDROJET CLEANING CuM/h 5.0
SPOT QUENCHING CuM/ t OF COKE 2.0
VAPOUR SPRAY CuM/h 25.0
OTHER MISC CUM/h 2.0
COMPRESSED AIR CuM/h 150 .—300 (INTERMITTENT)
STEAM TONNES/h 0.2 To 0.4.
POWER Kt t 0F COKE 2.0 T0 30
FL. LIQUOR CuM/ T OF DRY 5.0 T0 6.0
COAL
SPECIFIC HEAT
CONSUMPTION >
WITH C O GAS HEATING Kcal/Kg OF WET 530 To 540
(C v 4200 Kcal/NmB) COAL (7 %) .
WITH MIXED GAS Kcal/Kg OP WET 580 TO 595
HEATING ° COAL (7 % )
(C V 1000 Kcal/Nm3) '
 By - Product Recovery Ovens Non - Recovery Ovens

DESIGN l CLASSIFICATION OF COKE OVENS

BY—PRODUCT'RECOVERY COKE OVENS
Byproduct recove1y type coke ovens a1e classified depending upon the type of refiactory
construction heating system. coal charging system and size of ovens. Basic classifications based
”

on these considerations are gi1 en below.

m
m

Classification Based on Refractory Construction

A ll silica construction .
01 en 11 a1‘15 and whole regenerator above bus flues 11reinitide of silica bricks. Bus ‘lues me made
of fire clay bucks.
»

S ilica-crun—fire clay construction

.

111 this case oven walls and a part of regenerator (upper zone only) are made of silica bricks. The -
.

lower portion of regeneratm s and bus flues are made of fire clay b1 lCLS
.
1

Classification Based on Flow Pattern of Fuel and Waste Gases

The coke ovens are classified depending upon the flow pattern of fuel gases and waste cases as
described below '.

Twin flue system without waste gas recirculation ' ~ '

in this system (refer figure 3) oven walls are di1ided into a number of waits of m i n flues
depending upon the w idth and length of ovens. 111 each pair fuel gas and air for c o .11Huq111m enter
in o n e leg and it is combusted (combustion taking place 111 11p11va1d dire: tion). and in 11111311131
cmnbustion p1oducts move downward. Direction of flow of fuel 01s. air and Combustion-
products are reversed by a reversing mechanism at a predetem‘tined reversal 11mg This 11 1.1 111 1c;
co111111o1111v' used in a modem coke oven battery design. 0110, MECCAi and some ves of Roma
design are examples of this type. .
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 Table 01-2
(Sheet 1 of 2)

TECHNOLOGY COMPARISON OF BP & NR OVENS

B.P. RECOVERY ‘ NON-RECOVERY

COKE OVENS ' W ‘
BYPRODUCTS (GAS, * NO RECOVERY OF BY
TAR, AMMONIA, PRODUCTS. CLEAN HOT .
NAPHTHALENE, BENZOL) GAS IS ONLY
RECOVERED.- HIGH VALUE BY-PRODUCT
BUT ENVIRONMENTALLY
DIFFICULT
NO COKE BURN OFF: * ABOUT 3 TO ”5% OF COKE LOST '
POLLUTION NORMS MET * LESS POLLUTION DUE TO NEGATIVE
WITH NECESSARY ADDED OVEN PRESSURE AND
MEASURES. COMPLETE COMBUSTION. -
SPECIFIC COAL BLEND.; * WIDER COAL BLEND.
Low CRUSHING. I, * HIGH DEGREE OP CRUSHING IN SOME
' DESIGNS. ' -
LOWER FLEXIBILITY. , _ .. .I-.* — ~ HIGH FLEXIBILITY
HIGH GESTATION PERIOD,‘ ‘ i3 . ‘ " MEDIUM GESTATION.
COMPLEX BRICKS * SIMPLE BRICKS

SPECIAL CLEANING EQUIPMENT *. No SPECIAL CLEANING

ARE REQUIRED FOR DOORS, EQUIPMENT REQUIRED
_ FRAME CLEANING, ETC. ‘ -

SELECTION OF TECHNOLOGY 433%

5?
 ASS
in?

TABLE 01~2
1 - (Sheet 2 01'2)
B.P. RECOVERY NON-RECOVERY
COKE OVENS COKE OVENS
" * COAL EXERTS PRESSURE ON * ‘NO PRESSURE ON SIDE
WALL. WALLS SINCE COAL EXPANDS
UPWARDS
* * EXPLOSIVE GAS HANDLING * ,NO EXPLOSIVE GAS HANDLING
, * STICKERS ARE OBSERVED * NO STICKERS ARE OBSERVED
- . I HIGH RESISTANCE WHILE * Low RESISTANCE WHILE
PUSHING PUSHING.
* . LARGE AMOUNT OF ~ . * NO OVEN TOP/ OR LESS .
,3 OVEN TOP EQUIPMENT EQUIPMENT AT OVEN TOP.
L.» * HEAT RECOVERY IS VERY * HEAT RECOVERY IS
DIFFICULT _ STRAIGHT FORWARD.
-, * PUSHING INTER LOCKING SYSTEM * PUSHING INTER—LOCKING
I Is REQUIRED. SYSTEM IS NOT REQUIRED AS OTHER
. SIDE IS VISIBLE.
\ 1 . I v

* OVEN MACHINES ARE * OVEN MACHINES ARE

I . _ ~. COMPLICATED ' -_ ' LESS COMPLICATED ' ,
‘ E CARCINOGENS ARE OBSERVED * N0 CARCINOGENS ARE
' a IN THE PLANT. OBSERVED AS THEY ARE
. BURNED IN THE OVENS.
" * OPERATIONS ARE HAZARDOUS DUE * SAFER OPERATIONS DUE
1 To HIGH TEMP. FLAMMABLE GASES TO LESS COMPLEXITY AND
‘ AND OVERALL COMPLEXITY. CLEANER OPERATION
A i

w l

SELECTION OF TECHNOLOGY 465%

g o
 COKEOVENFLA/v73 /A///1/D/,4 DESIGN
P/anl cob OVENS M M
HSP 1A 35 ’ 13.59X4.50X0.40 (21.6) - MECON
1B 35 13.59X4.50X0.40 (21.6) - MECON
2A 35 13.59x4.5oxo.4o (21.6) MECON
; 213 35 13.59X4.50X0.40 (21.6) MECON .
3A 35 13.59X4.50X0.40 (21.6) ‘ MECON
3B 35 ’ 13.59X4.50XO.4O (21.6) MECON
4A 40‘ 13.59X4.50X0.40 (21.6) OTTO
4B 40 13.59x4.5ox0.4o (21.6) OTTO
5A 40 13.59X4.50XO.40 (21.6) MECON
513 40 13.59x4.5ox0.4o (21.6) MECON
DSP .1 A 39 13.59X4.45X0.45 (23.8) OTTO
- 1 1B 39 13.59x4.45xo.45 (23.8) OTTO
2A 39 13.59X4.45X0.45 (23.8) ‘ MECON
2B 39 13.59X4.45X0.45 (23.8) MECON
3A 39 13.59X4.45X0.45 (23.8) OTTO
3B 39 13.59X4.45X0.45 (23.8) OTTO
4A 39 13.59X4.45X0.45 (23.8) MECON
4B 39 13.59X4.45X0.45 (23.8) MECON
5A 39 -13.59X4.45X0.45 (23.8) MECON
6A 39 13.59X4.45X0.45 (23.8) OTTO
BB 39 13.59X4.45X0.45 (23.6) OTTO

~85)” 1 65 14.08X4.30X0.407 (21.6) GPK

I 2 65 14.08X4.30X0.407 (21.6) GPK
3 65 1‘4.08X4.30X0.407 (21.6) GPK
4 65 14.08X4.30X0.407 (21.6) _ OTTO
5 65 -14.08X4.30X0.407 (21.6) GPK
6 65 14.08X4.30X0.407 (21.6) GPK
7 65 14.08X4.30X0.407 (21.6) . GPK
8 65 14.06X4.3ox0.407 (21.6) ‘ GPK
9 67 16.00X7.00X0.41 (41.6) MECON/GPK .
1o 67 16.00X7.00X0.41 (41.6) 1 MECON

BOKAHc 1 69 15.04x5.00x0.41 (27.3) GPK

2 69 15.04X5.00X0.41 (27.3) GPK
3 69 15.04x5.00x0.41 (27.3) GPK
4 69 15.04X5.00X0.41 (27.3) GPK
5 69 15.04X5.00X0.41 (27.3) GPK
6 69 15.04X5.00X0.41 (27.3) GPK
7 69 15.04X5.00X0.41 (27.3) GPK
8 69 15.04X5.00X0.41 (27.3) GPK

VSP 1 67 16.00X7.00X0.41 (41.6) MECON/GPK

2 67 16.00X7.00X0.41 (41.6) MECON/GPK
3 67 16.00X7.00X0.41 (41.6) MECONIGPK
4 67 16.00X7.00X0.41 (41.6) MECON

KMCZ 1 67 16.00X7.00XO.41 (41.6) MECON

10F2
61
A our): U V E / V HLA/V/b‘l/V/N/J/A DESIGN
Han! cob OVENS Oven Dim”.(Vofl

”500, 8 78 13.59X4.45X0.45(23.8) OTTO

I 9 89 13.59X4.45xo.45(23.8) MECON
10 78 13.59X4.45X0.45(23.8) so
7 72 13.59X4.45X0.45(23.8) NOT IN OPERATION

DPA 1 30 13.59x4.50xo.40(21.6) OTTO

2 so 13.59x4.50x0.40(21.6) OTTO
3 29 13.59x4.50x0.40(21.48) NOT IN OPERATION
4 29 13.59x4.50x0.40(21.48) NOT IN OPERATION
5 4o 13.59x4.50x0.40(21.6) OTTO

m 74 1 54 13.59x4.45x0.45(23.81) NOT IN OPERATION

2 54 13.59x4.50x0.40(21.48) NOT IN OPERATION
3 54 13.59x4.50x0.40(21.48) OTTO
5 30 13.76x4.57x0.48(23.5) OTTO
8 80 13.78x4.57x0.45(23.5) OTTO
7 54 13.76x4.57x0.46(23.5) OTTO
8 7o 13.76x4.57x0.46(23.5) OTTO
9 70 13.76x4.57x0.46(23.5) OTTO

20F2 :
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 Table 01-3
. my)
COMPARISON OF SALIENT DESIGN FEATURES
OF JEWELL THOMPSON, KCC, PACT1 OVENS

SL. DESCRIPTION JEWELL KCC . PACTI/

NO. THOMPSON (AUSTRALIA) THYSSEN STILL
(USA) OTTO
1. Heating System Sole heated & Sole heated Sole heated, Secondary
‘ secondary air air pre-heated in incine-
. ration chamber
2. Oven size

L. 15.24m 10.0m 14.1m

W. 3.65m 3.0 m 3.8m

Height of charge 0.65m 0.60 to 1.25m . -

Oven height 5.1m - -

from the sole of
the oven to the
CI‘OW11

3. Dry coal through 3956‘: 13.2 to 36.3t 24.4t

put per oven per ,-
charge -
4. Coking period 48h 24 to 48 11 33h
5. Dry coke ‘7'? ’"5 50,000 t/yr 33,000 t/yr " 47,000 t/yr
production . -- : - ~. - .
from 10 ovens ‘
6. Crushing of coal 80% (-) 3mm - 80%(—) 3mm
7. Maximum temp. 1370 °C - 1300 °C
achieved in
coking chamber
8. Coal quality used Medium VM Bituminous coking . Medium VM
‘ coal

SELECTION OF TECHNOLOGY ; 0158

éS
 Table 02-3
(Sheet 2 of 2!

SL. DESCRIPTION JEWELL KCC PACTI/ .

NO. ”" THOMPSON (AU STRALIA) THYSSEN STILL
(USA) . OTTO
9. ‘ Refractories Silica & FC, High Alumina Silica & castable _
V ' Fire clay castable '

10. Hot‘gas Planned Planned Planned

- Recovery

‘ 11. Charging From door by metal Top charging by From door or top
conveyor charging car
7 12. Pushing Conventional side Pusher machine Conventional side
a ' pushing by pusher- pushing by pusher
7 cum- charging cum charging
r machine machine
- 13. Quenching Quenching Car Quenchirg Car Quenching Car

SELECTION OF TECHNOLOGY 191$

66
EMISSION NORMS TO BE ACHIEVED AS PER THE GAZETTE OF INDIA

Sl.No. Parameter _ Standards

- New batteries Existing batteries
1. Fugitive Visible emission

a) Leakage from door 5 PLD 10 PLD

b) Leakage from changing lids 1 PLL 1 PLL
o) Leakage from AP cover - 4 PLO 4 PLO
d) Changing emission 16 ' 50
(second/charge) (with HPLA) (with HPLA)
2. Stack emission of Coke Ovens

a) 30x (mg/Nm3) 800 800

b) NOx (mg/Nm3) 500 500
c) SPM (mg/Nm3) 50 50

3. a) SPM emission during 25 25

charging (stack emission) ' -
mgl3 ,
b) SPM emission during coke 5 5
pushing (stack emission)
' - gm/ton of coke. . _
4. Sulphur in Coke Oven gas used 800 800
for heating-(mglB) _
5. . Emission for quenching 50 50
. operation (particulate matter gm
. IMT of coke Produced)
6.’ Benzo - Pyerine (BOP)
; Concentration in working zone a
‘is (ug/m3) . .
1 Battery area (trip of battery 5' 5
T - Other units in coke oven 2 2
plant ' -
- Ambient standards (ng/m3) 1O 10.

65?-
 MECON LIMITED ted
REFRACTORIES IN COKE OVEN BATTERY

INTRODUCTION :

Refractory consists of the major portion of tonnage of a Coke Oven Battery proper. It consists of
mainly Silica, Fireclay & Insulation quality. The quality of refractory used in the construction of
coke oven depends upon the operating requirements of the battery. Indicative tonnage & number
of shapes required for various designs of batteries are indicated in the enclosed Annexure-I.

Based on the experience the quality of refractory, used'1n different zones of a coke oven Battery,
are as below: —
Brickwork Zone Type of Refractory

> Bus Flue/ Sole Flue - — Fireclay

> Regenerator - - Firec lay at the lower portion
- Silica at the upper portion
> Inclined Flue, Vertical Flue - Silica
& Vertical Flue Roofing . .
> ‘ Oven Roof ' - Silica at the lower portion
- Fireclay at the upper portion

Insulation bricks are used to reduce the heat loss from the brickwork. Mainly it is used in
insulating the following areas —
i) 'Sole Flue Paving
ii)' Buttress Wall
iii) Oven Roof

CHARACTERISTICS OF DIFFERENT REFRACTORIES : I'

l

I. Fireclay: It has less thermal expansion, thus can take care‘of the thermal shock & attack of
moisture. Due to this property it is used to the area where the temperature is low
as well as in areas where fluctuations'in temperature 1s very high

II. Silica : Silica consists of the major portion of coke oven refractones due to the following
reasons —
i) Better load bearing capacity at higher temperature.
ii) Better thermal conductivity
iii) Better corrosion resistance against C.O / B.F gas at higher temperature.

Consideration while designing the silica bricks for coke oven -—

i) Working temperature of silica should not be less than 350° C.

ii) Cutting or grinding of working face of silica brick during erection is not
allowed.
iii) Due to high thermal expansion proper passage or expansion joint has to be
provided.
iv) Strong anchorage is required to take care of the high thermal ‘expansion
load, otherwise the joint between the bricks will open up.

by Mr. Barun Kr. Pg. 1 of3

66'
 ' an
MECON LIMITED
Precautions to be taken while inspecting the silica bricks —

i) The chemical composition. of the brick should strictly follow the

specification.
ii) Hair line cracks, broken edges, cavities, laminations are not allowed in
silica bricks.
iii) Size & shape of the brick should be strictly as per drawing.

Due to all of the reasons mentioned above special care is taken to design silica
bricks for coke oven. In case of any mismatch noticed in the site it will lead to
stoppage of the erection work as the cycle time to manufacture a silica brick is -6
weeks.

III. Insulation Brick: Insulation brick consists of lot of pores inside, which act as a bad
conductor of heat, thereby prevent the heat loss from the brickwork.

IV. Mortar : The refractory bricks are placed into position with the help of mortar. Three
types of mortar are used for the coke oven brickwork-
a) Silica mortar for the Silica bricks
b) Fireclay mortar for the Fireclay bricks,
0) Insulation mortar for the Insulation bricks

PROPERTIES OF REFRACTORY BRICKS :

The following tests are carried out for "the inspection of the-refractory bricks —

i) Bulk Density (B.D)

ii) ' Apparent Porosity (AP)
iii) Qold Crushing Strength (C.C.S)
iv) . Refractoriness Under Load (R.U.L)
v) Pyrometric Cone Equivalent (P.C.E)
Vi) . Thermal Conductivity at specified temperature
vii) Spalling Resistance
viii) Permanent linear 'change after heating
ix) Sieve Analysis

For mortar apart from‘the above the following tests are also carried out—

i) Workability test
ii) Bonding strength
. iii) Drying & Firing Shrinkage

Basic Considerations for zone wise Refractorv brick shape design for Coke Oven Battery :

i) Bus Flue — It is the base of the battery brickwork which takes care of the entire weight of
the brickwork, coal charge & machines above it and has to sustain maximum thermal
shock. Due to differential pressure of upstream air and downstream waste gas the joints of
the brickwork are designed With proper interlocking. High dense fireclay bricks are used
in this zone. Base of the sole flue is lined with insulation bricks to protect the heat transfer
. to the concrete deck slab. .

by Mr. Barun Kr. Pg.2of2

Col
 . - ”LE“
MECON LIMITED ‘ | Mi
Regenerato — Walls of the regenerator consist of either totally silica bricks as in the case
of 5m & 7m design or half fireclay and half silica bricks as in the case of 4.5m design.
This variation in the design is due to the operating temperature of the battery. Regenerator
bricks are designed to have better stability as the width of the wall is less but the height is
more. The dividing wall of the regenerator is a single brick construction, hence four side
locking are provided in the brick shapes. (Refer sketch 2.07)

To recover the' heat from the waste gas checker bricks are provided in the regenerator
chambers. Due to regular heating & cooling the quality of the checkers are low density
fi‘reclay bricks. Checker bricks are designed to have more surface area per ton of brick for
better heat regeneration. (Refer sketch 2.04)

111) Sliding joint — To take care of the differential expansion cf the silica & fireclay bricks
sliding joints are provided between fireclay & silica layers.

inclined Flue Zone '— This is the solid mass of brickwork which contains all the port
openings (56-64 openings/ heating wall) of the upstream of gas/ air and the downstream of
waste gas. To take care of the expansion along battery expansion joints are provided at
each oven pitch This zone of brickwork exerts maximum load on the buttress wall at both
sides. Due to the above factors design of this zone becomes very critical. The quality of
V

brick used'rs silica only. -

V

Vertical Flue/Heating Wall Zone: - This'is the most important area of brick work because
V

it has to do the following activities ~

V

> Transfer the heat of burning gases to coal mass for carbonization
> Taking out the high volume of product of combustion from heating flues
V

> Sustain the coal pressure during swelling of coal.

V

> Take care, the vertical stresses and bending stresses of oven roof loads.
> Transfer of load from one end to other end of heating wall through flash plate.
Due to above the quality of bricks used here are high’dense silica bricks. Proper design of
brick shape is done to take care of the various pressures and cross leakage across up
stream and down stream gases. (Refer sketch 2.08)

Oven Roof Zone : This zone consists of charging hole,.gas off take holes & inspection
holes. Bottom portion of oven roof is made-up of silica bricks to take care of high
temperature and high load. Upper portion is lined with fireclay bricks. While designing the
brick shapes care is taken to prevent cross "leakage across the various openings. Sliding
joint is provided between silica & fireclay layers in the fireclay area sufficient quantity of
insulation brick is provided to reduce the oven top temperature. Oven top layer rs of high
strength fire clay brick.

‘ Zone of brick work other than batten proper -

> Oven Door Lining

Stand Pipe Lining
Flash plate Lining
Temporary Stove Lining
Waste gas tunnel Lining
Chimney Lining
Quenching Tower Lining

by Mr. Barun Kr. Pg.3of3

 Annexure - I

NO. OF BRICK SHAPES FOR DIFFERENT COKE OVENS

Zone of brickwork No. of Shapes - Tonnage

' BSL - 5 RSP - 1 VSP-4 BSL - 5 RSP - 1 VSP-4

A. SILICA '
- Regenerator 49 72 54 2821 817 ' 4158
- Oven Sole 4 102 .
- Inclined Flue 144 117 156 1562 1096 2012
— Vertical Flue ‘ 146 222 133 3212 3252 5584
( Incl. Banana Bricks) . -
- Vertical Flue Roofing 69 71 1453 1676
- Walls at Buttresses . ' . 44 10 . 20
- Oven Roof 37 50 ‘ 20 552 464 425
- Standards 4 2 3 343 241 223
Total 453 507 447 10045 5870 14098

B. FIRECLAY ~ -
- Sole Flue/ Bottom Flue 75 71 82 857 1220 1027
- Grate Bricks , 3 °12 105 39
- Regenerator 19 70 14 88 ”1600 222
- Oven Sole _ 16 1 65 1
' - Inclined Flue 5 . 1 6 ' 18 7 ' 13
- Checkers 1 4 1 1382 1433 2283
- Vertical Flue 7 ' 48
- Oven Roofing 101 58 102 924 - 578 908
- Standards ’ 4 5 9 1000 658 575
,-" - Oven Door 20 24 120 247
- Stand Pipe 10 7 5 '67 ’ . 86 56
Total 218 264 251 - 4439 5806 5380

'1}— '
by Mr. Barun Kr. (
INTERLOCK BONDING..9: REGENERATOR,
MAM WALL AND DIV DIN-(j WALL.

“ii—2, ' -
 COKE OVEN BATTERY HEATING-.UP AND COMMISSIONING
_ OBJECTIVE:

Removal of moisture from brick work

To raise the battery temperature to self'1gnition temperature of the gas to facilitate

normal under firing (say about 750°c) ’

To raise the temperature of the battery to a point where charging of coal'1s

possible (say 1050 to 1100c)

Controlling of battery temperature & brick work expansion to ensure intactness of

brickwork

GENERAL

'1. The thermal / technical control of the followings:

I Control over Thermal regime
' Control over Brickwork expansion I °
I . I

Control over Anchorage & other related equipment

. Drying and preheating of coke oven battery is carried out by. the heating agent
(products of combustion) prepared in temporary stoves, which is then supplied
into coking chambers, withdrawn through heating walls, regenerators and fines
- to be exhausted into atmosphere through chimney.

During drying and pre heating of brickwork, the heating up procedures should be
strictly followed as per the calculated schedule of temperature-raise and gradient
by SUPplyinethe heating.#8911229?sPersim-
70 to 75 % of total brickwork expansion occurs within 100 to 300 C.

Critical temperatures - 117 °C, 163 °C, 180 “C TO 270°C, 573 °C -

. Actual maximum expansion of brickworks in all the three zones should not
exceed 0.035% per day.

. In case of such an eventuality the rate of temperature raise should be slowed down
accordingly.

. .During heating up temperature of top of regenerator should be about 95% at the

beginning and 80% at the end of heating as compared to the average temperature
of vertical flues

(I. one» '

 9. For bus flues these temperatures should correspond to about 70% and 40%
re3pectivel'y.

10. At the end of first stage heating up before switching over to normal under-firing
. the temperature of extreme verticals should not be lower than 600°C

11. Change over from heating to under firing 1s to be effected when the temperature
of the vertical fines is not lower than 750 "C This change over is carried out
during day time.

TEMPERATURE REGIME CONTROL DURING BATTERY HEATING UP.

Zones of temperature control / measurements

' Vertical flues

I
Regenerator top/bottom

' Bus flue

Heating of brick work throughout its length and height is_ controlled by means of
temperature measurements ingheating, walls, regenerators and bus flue.

Temperatures in heating walls are measured in four lines of verticals: . _

Control verticals - one for P/S and one for C/S

End verticals- P/S & C_/S .

Temperatures of Regenerators are measured at top of regenerators at control flues on

IP_IS
8; 0/8 .through inserted thermocouples

Bus flue temperatures are measured atBus flue mouth or at Waste Heat Boxes

Control verticals are 8‘h for P/S and 24th for 0/8 (Typ)
Control Heating walls "—46, 11,16,21,26,31,36,4l, 46,51,5_6,6] , 66 (Typ)

The average of the temperatures of the' control Hues/verticals of the control heating walls
represents the battery temperature.

Temperature raise per day is determined based on the reported temperature in C shifts

Besides above, temperatures are measured in all the above four verticals of three end
heating walls say 1,2,3 & 68,69,70. and at buttresses, but they are not to be taken for
averaging. -

we.
" ‘ (08 of lo)
During heating—up, the regenerator bottom, sole flue temperatures should be maintained
as per schedule to avord condensation of water vapor in regenerator o'r sole flues. If
moisture condensation takes place, then the excess air to be increased.

SHIFT DUTIES
1. To ensure battery temperatures as per schedule given-by heating up in-
charge
2. Heating gas pressure to be set & controlled accordingly
‘ 3. Flame watching
4.. Temperatures & heating parameters measurement
5. Ensuring proper functioning of seal pots
, 6. Ensure safe working
Starting & Stopping‘of gas burners
Starting of gas burners:
I Ensure ventilation / draft and no residual gas in the area. ~
iI Introduce flame torch in front-of the burner
I Open Gas cock slowly and ensure burning of burners
I Withdraw torch
In case of extinguishing of burners,
I Close the gas cock
I Allow sufficient time for ventilation and ensure purging of residual gases
I Light the burners as above. . I

SL.NO‘ ' "‘“REQUIREMENTI : ACTIONS TO'BE TAKEN

CONDITION '
1 To increase control vertical Increase heating gas supply and draft
temperature as per requirement

2 Control vertical temperature Reduce heating gas supply

Increasmg (1‘30l Increase excess air

3 _ .To Increase/ decrease sole Increase/ decrease draft

' flue temperature
. 4 To increase / decrease Decrease/ Increase draft
Vertical top pressure

jig .
(8’ of: to)
. Fuel Gas control

Medium of heating-up
Coke oven gas
LPG
Producer gas
Natural Gas
’ Coal

Gas control:
Pressure of incoming gas - 200 — 300mmWC / 500-7'00mm WC
Control pressure in the side mains -— 50 to 200mm WC
Each burner is provided with orifice plate. to control the flow.
To increase/ decrease of gas supply increase / decrease the gas pressure.
When the Control Gas pressure goes beyond 180 mm WC, then the burner
orifice size is changed to next higher size. For the same flow of gas, the
control pressure value comes down.

EMERGENCY INSTRUCTIONS

SL. TYPE OF MEASURES TO BE TAKEN -' -

N0 EMERGENCY

1 StOppage of Heating due‘to ' Close all the stop cocks

I} Close the fire gates
' Gas failure
I Close. the' side / main dampers
-' Gas pressure falling I In case gas pressure drops below
below 50 mmWC 50mmWC purge the line with steam
/N1trogen
' Fire in Gas line
I Open the bleeders.
' Heavy leakage of Gas . In case of gas leakage or fire, close the
side/main gas gate valves

EH (A of: to}
SL.- TYPE OF - .‘ MEASURES TO BE TAKEN
NO EMERGENCY

Starting of Heating I Open the bleeder

I Open side valves partly
I Purge the gas lines
I Check the gas sample for Oxygen
content .
I If safe, Open the dampers,
'I Open fire gates ‘
I Start lighting the burners ensuring gas
pressure in the main and close the
bleeders
I Maintain the required pressure.

Heavy wind . I I. Close the fire gates onlthe windward

side

I Reduce'the draft accordingly on the

windward side

:m»
 PARAMETERS AND FREQUENCY OF MEASUREMENTS DURING
HEATING-UP

TEMPERATURE MEASUREMENT
Up to 200°C BY THERMOMETERS
200 TO 750 °C BY THERMOCOUPLES .
ABOVE 750 0C BY PYROMETER (OPTICAE / INFRA RED)

IN SHIFTS

' SL.NO ' DESCRIPTION FREQUENCY / SHIFT

1 CONTROL VERTICAL TWICE IN EVERY SHIFT
TEMPERATURES

2- MIDDLE FLUES/ CROSS WALL ONCE IN EVERY SHIFT

TEMPERATURE -

3 REGENERATOR'TEMPERATURES ONCE IN EVERY SHIFT

4 BUS FLUE TEMPERATURE . TWICE IN EVERY SHIFT

HEATING PARAMETERS .
SL.NO _ _ PARAMETERS FREQUENCY
.1 " - 1N COMING COKE OVENGAS PRESSURE: EVERY TWO HOURS
2. CORE OVENGAS PRESSURE PUSHER ' EVERY TWO HOURS
SIDE -
3 COKE OVENGAS PRESSURE COKE SIDE EVERY TWO HOURS
4. GAS FLOW EVERY Two HOURS _
5 DRAFT IN SIDE FLUES EVERY TWO HOURS
6 DRAFT 1N WASTE HEAT BOX ONCE IN A SHIFT
7 VERTICAL TOP PRESSRE ONCE IN A SHIFT

_—:¥-8
(6 0419
. GENERAL SHIFT MEASUREMENTS

SL'.NO ‘ ‘ DESCRIPTION . FREQUENCY

1 . BATTERY EXPANSION MEASUREMENT TWICE IN A WEEK _
2 SERVICE BENCH COLUMNS TWICE IN A WEEK
VERTICALITY
3 BUTTRESS VERTICAIITY TWICEINAWEEK
4 REGULATION OF HOLDING DOWN DAILY
BOLTS ‘ ' '
5 CHECKING OF FLASH PLATE LIFT DAILY
' 6I MEASUREMENT AND REGULATION OF DAILY-
CROSS TIE RODS & BOTTOM TIE RODS
7 1 REGULATION OF INTERMEDIATE ° DAILY
SPRING UNITS : '
8 'LTR RGULATION ' ' TWICE IN A WEEK.
9 BUCK STAY DEELECTION DAILY
10 MEASUREMENTOF GAP BETWEEN . TWICE IN. A WEEK
_- FLASH PLATE &.BRICKWORK ' .-

' COKE OYENBATTERY COMMISSIONING

Preconditions
l . The battery temfierature Shall be around 1100 C
N

All the oven machines are to be in tested and trial run condition
All the oven top gas off take system should have been aligned
Flushing liquor system should have been trial run for more than 72 Hrs.
All the oven dOOrs are to be installed and regulated
The bye product is ready to receiveand process coke oven gas
Coal & Coke handling plant are to be ready.
Instruments and electrical systems are readiness

'(Tr 0‘1 to)

J
9. Gas collecting Main, suction main and by product system are to be filled with
purging medium Nitrogen or steam
10. Protocol detailing the activities and responsibility should be drawn and approved
by competent authority.

Commissioning

. About 16 nos of identified ov'ens are charged with two charging cars
within two hours
On completion of charging of all the ovens, the» gases are sent to Gas
Collecting Main from all the 16 ovens and pushed‘ towards by-product. .
. While cxhauster is taken in line, GCM pressure is- to be controlled
manually in close coordination with exhauster operation, so that the GCM
pressure is always kept positive.
After getting clearance from By—product, further ovens are charged as per‘
schedule. .
Parameters in heating and hydraulic regime are maintained as per
requirement
The coke is pushed after a minimum coking period of 24 Hrs after
checking coke readiness

000' (gr @6110)

 GAS HANDLING & 'SAFETY
Gas Hazards:

a) Asphyxia/ Suffocation
b) Gas poisoning '
- c) Fire
(1) Explo'sion

Asphyxia I Suffocation:
Due to reduction in Oxygen content in the atmosphere
Gas poisoning
Due to presenceof Carbon Monoxide gases in the atmosphere.
CO is colorless, odorless tasteless
Symptoms of gas poisoning is headache, vomiting, weakness I
Up to 50 PPM it is safe to work.
3200 PPM death in 30 minutes exposure
6400 PPM death Within 15 minutes of exposure
Fire
Conditions

Presence of combustible Material

Air or Oxygen
. Source of Heat . i . ' ' '

Explosion
Rapid combustion of fuel mixture in a confined closed Space causes sudden
pressure rise in and in the absence of any pressure releasing mechanism result in tearing
the close space or shell etc. with a loud sound is called explosion.
Conditions
Presence of combustible Material
Air or Oxygen to make air fuel mixture
Source of Heat/ ignition
Confined or closed space

(0t 0% to)
Typ'ical Analysis and properties of gases

_ Constituents I properties B.E.Gas Coke Oven. Gas

Carbon Monoxide 25% 6- 7%

Hydrogen . 1-2% 54 — 58%

Methane <1 % V 24 — 28%

Carbon dioxide 18% 2-3%

Nitrogen 54% 3.5%

CnHrn -. V 2~3%

Oxygen 0.5% 6.4%

Ignition Temperature 600-650 C 550 — 600 C ’ -

Explosive range _ 4s — 7o % 7'— 30%

V Calorific Value (K Call Nm3) 700 —- 800 . 4200 - 4500

Precautions
g
I

. Before charging gas in to a system, the Gas mains & equipment should be purged
with inert gases like Nitrogen or Steam._ . _.
' The gas should be allowed to escape through the bleeders till the Oxygen content in _-
the gas is less than 1%
- The systems when charged with gas should be checked for any gas leakages, if
detected to be rectified immediately.
. The gas mains should always be under pressurized condition. If the pressure inside
the system goes below 50 mm WC, then the gas main should be purged and recharged
again.

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Coal Conversion Processes

Low temp. carbonisation (< 750°C)

Associated with production of smokeless domestic
- ‘ Carbonisation fuel ‘

High Temperature carbonisation (For production of

coke for metallurgical process)

Gasification to produce low, medium & high calorific value gas

_Coal liquefaction to produce synthesis crude oil

Carbonization

Carbonisationl Destructive distillation! pyrolysis are all terms used to describe the ‘
heat treatment of 003! In absence of air. This heating decomposes the Substance
into a solid residue (Char) liquid products and gases.

Low Temp carbonisatio n

Four basic products are produced by low temperature carbonisation

- Semi coke
Tar, consisting largely of liquid hydrocarbon
Gas
Aqueous

TYP'icalyield/tofcoal . .. '
Semi coke : 680 -— 700 Kg

Tar ' z. :68 — 72 Kg

Liquor : 150 - 180 liters

Gas : 240 — 060 Mm:

Typical Composition of Gas

C02 : 9.40 - 12.80 ‘

CnHm : 1.40 - 2.20

02 : 040 ~ 0.80

CH4 : 21.90 — 25.90

CO :' 11.60 - . 13.60 ‘

(374/ I , Slows ~l
H2 : 40.70 - 46.70

N2 3.04 ~ 6.20

Broad classification of LTC process, based on heating system.

Internally heated (directly heated)

Externally heated (Indirectly heated)

Retorts are used for production of LTC coke

' Retorts are of different type. which is classified as

\

' Fixed vertical Retort - Batch process, coal is charged from top & coke is
removed from bottom
-

Continuous vertical Retort - Coal is charged continuously at the top and

product is removed at bottom. This is a most-
popular
—

Fixed horizontal Retort! - Long steel vesseis- normally cylindrical. heated

Continuous horizontal . directly or indirectly, Rotated/Fixed with a slop
Retort for movement of coal.

.LTC Plants in India

Location Capacity : Facility ‘

. " "*Naively Lignite corporation 5 2560 tld Lignite Briquettes 9 nos ? ' '
of Lurgi Spul gas '
carboniser operating
since 1965
2. M/s Singareni Coal Co. Ltd
Naspur, Adilabad (AP) .900 tld 3 nos. of internally
heated retorts (Mls
RRL. Hyderabad)

3. Coal india Limited

_

Dankuni. W.B 1500 tld - 100 nos of cont.

vertical retorts
4. Bombay Gas Company 300 tld - 192 horizontal retort
with slight indination .
Not working presetly
due to availability of
Natural gas

{95 . Sim} «2'.

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 .
Utilisation of Cool by Gas ifica tion

fi
.
ASl-lOK K U M A R " S. N . WAZIR,*‘ D R . S. R PRAMANIK**‘°

as a’t can faint azirmairm m. mar-”lime With the increasing consumption of oil, India's not

.
humans art-50% is tenant 3mm venetian export earnings to the tune of 50% are being used for ' "
nuns militant snarb m as actuation importing crude petroleum oils and its products. There-
%l‘m tight (at In finial—acct {III w a s n a t fi fi fore. utilisation of our coal resources through gasi-
fication needs to be considered on a national level.
-

scrim ail fl m fi fl qt inn firm arm fafirq Complete gasification of coal which has a very high
awhilfisas Wish admins aht air; can win,

-
coal conversion efi‘ieie‘ncy can be considered for the
fir‘hhsmsuaa‘in. qrgaszfizr gamma-61min manufacture of a large number of fuels and chemicals"
" . Winnie : 7* fair ionizer finals RENEW such as industrial and domestic fuel gas of various
-m
"""fiҤ~;".fiqiq % fat cat mm Emit Innis Faa calorific values, synthetic liquid fuels, reducing gas for
film set: =r- Rial“ r e mix 51% agents emit ar‘rz 'metallurgical purposes, synthesis gas for the produc—

.
tartan is l‘axfin stat amnesia infirm (faith

_
tion of fertilizers and synthesis gas of various composi-
am a strain 1% at mains an Hfim%)i‘i art tions as a feed stock for the manufacture of varied

fi
»
it famfim an arm E I numbers o f chemicals.

an faint fi' faint: finlm-nfm rafi it gnaw ea“ III this paper an attempt has been .made to review
'maam sienna an aura fir-III mu El inn it and critically examine the various gasification pro-

.
tan-m qfifisqfiezihfi$ film an «Til afimafim cesses. Practical aspects of adopting these processes
TU“ii in? an airmail at ms at naive Emir-[REE in the Indian Scenario to meet the requirement of
@T‘I i‘fia‘e fiume mmrb ' various sectors of industries have also been highlighted.

‘
J I l H E world- wide energy crisis which broke- out Coal: Conversion through Gasification .Route
in early seventies has made it clear that oil and
Coal is ‘a solid fuel of non-uniform composition
gas will no longer be available freely and at
and varying properties and its use in solid form .has

.
low cost. - I t i s generally accepted that coal must

.
many limitations. Direct utilisation of coal Is only T
play an important and a greater role in our country

—
by combustion which is applied commercially in
' as our: oil reserves are not only limited “but“ quite
thermal coal fired power plants. For other uses
insignificant compared to our requirements. India‘ s

,
coal reserves of around 112, 000
coal must be convened into gas which is the most
million tonnes

. ..
convenient form of energy and raw material to meet
including lignite reserves of 2268 million tonnes,
w

our industrial requirement. Coal gasification pro-v

.q
‘ .
non-coking 'c'oal of about 86,000 million tonnes are
cess has high coal conVersion efficiency and it can
likely to last for a couple of centuries even after .: .9
offer:
providing for greater use of non-coking coal.
“.

1. Medium CV l”uel gas for industrial and domestic

'7

Even though the capital cost for coal based plants use. '
u m

as compared to oil based plants will be higher, the 2. High CV pipeline gas of various calorific
saving i n terms of recurring foreign exchange needed values including S N G .
. ‘

for Import o f Naphtha and crude oil will more than Reducing gas for metallurgical purposes,
o

all set this disadvantage. Moreover it is only a Synthesis gas of varying compositions as a
'

Question of time when coal based industry will be- feed stock f or fertilizers and various chemicals.
b

come a must for want of oil as has happened in 5. Liquid hydrocarbon either directly or by
u

South Afric a. further processing of synthesis gas.

n

’..4sslt Engineering Manager MECON. Ranchi

w

" General Manager, MECON, Ranchi

”‘ Direciar. MECON. Ranch!-

14

e3
w
 The basic principle which features in the gasifica- products, residence time of Coal particles, and re-
tion pro.esses is to react coal with steam in a con: action temperature (as shown in fig. l‘”). Another
trolled way and this being an endothermic reaction criterion for classifying the gasification processes is
‘ some oxygen is added in the system for partial ‘com- on the basis of Operating pressure used. At elevated
' bustion o f coal. In certain cases this heateould pressure the rate of gasification is enhanced and it
be provided as either electric heat or nuclear heat. tends to produce gases that are richer in methane‘
thereby obviating the necessity Of subsequent me-
. Types of Gasifiers thanation and gas' compression; should these be
needed for any specific duty.
'Types of the gasifiers/gasification processes which
could be considered would naturally depend on the The gasification processes are also characterized by
' type of reacting fuel available and the product desired. the mode of supply of heat to sustain endothermic
Basically the gasifiers can be classified as: gasitieation reactions. Examples are partial com-
bustion of coal/char with air/O, in the case of Lurgi
. i) Fixed bed gasifiers pressure, K-T, winkler ,gasifiers etc.; agglomerated
ii) Fluidized bed gasifiers . ash as solid heat carrier in the case Of Union carbide
iii) Entrained bed gasifiers process; molten salt or slag or molten iron in the
iv) Molten media gasifiers case of Kellog process, CGS process etc.; chemical
v) Tumbling bed ga'sifiers.~ - reactions in the case of con-acceptor process; electric
heat or nuclear heat in the case of Bergbauforschung
.While developmental work on molten media and process. Mode of ash removal also characterises.
tumbling b_ed gasifiers has not yet sufficiently advanc- the coal gasification processes“ _
ed the first three types of gasifiers have been com- '
mercially proved. They differ mainly with respect‘
to size of the feed coal, flow of reacting elements and Status of Gasification Processes

Table-1'”, *1” indicates the status of various gasi-

fication processes. Conventional air/steam producer
FIX ED BED - COUN TERCURREN’I'
gas generators are available indigenously mostly on
the basis of collaboration agreements entered into by
C OM. GAS
various parties; the only exception being MECON ,
_ design single stage producer gas generators (fig. 2) of
upto 3 metre dia, which are being offered on total
indigenous basis. For KT entrained. bed gasifiers,
. technical collaboration exists between the Fertilizer
‘ 5 “ son 10cc 1»- l ! )
Corporation of India and M/s Krupp Koppcrs
No other technical collaborations are reported avail-
FLUlDlZED BED able in India in respect of other gasification pro-,
.cesses- even though the Indian offices and agents of
. various foreign firms are in a position to offer the
same. Fixed bed gasifi'ers operate under pressure
1 with steam and oxygen, as compared to the con:
ventional producer gas generator. These are
run we rc'r
generally denoted as Lurgi gasifiers as M/s Lurgi
were the originators. The limitations of using theSe
ENrRAINEo FLOW generators lie in the caktng properties of coals ash
content beyond 35 %, size range below 5 mrn. Biggest
size fixed bed generator in Operation is 4 m dia. A
typical cross section of Fixed bed pressure gasifier
is shown in Fig. 3‘“.

Fluidized bed gasifiers are generally denoted as

sag race use: «'1 Winkler gasifiers. In India Winkler gasifiers have
SLAB
been Operated on South Arcot L'ignite. Quite a bit
Fl£:l TYPE OF BLSWlER
of develOpmental work has been undertaken on
fluid bed gasifiers. High and medium pressure

15

S’W é
'64
Li.

L“ l
S E C T W H 0(-

.17 2 l
I GRATE
ZGRATE DRIVE SYS‘IEH
\. J-FUEL.FEED|NG SYSTEM
4 STEAM DI! UM
. ‘ 5 '
S ' A S N PAN
. \ |
SHORM WHEEL
T-ELSE P L A T E
5 - “ 0 L LER S U P P O R T
Le ' . ‘ -' 4 9 POKER H O L E

I
e
I .

FIGl—v GENERAL kRRANGEMEhH C-F MECON-DESIGN .Pnoo’ucta GAS GENERATOR

I.__

application along with multi-stage fluidized bed have

been developed: Various firms have undertaken
work on fluidized bed and today fluidized bed gasifiers
like Winkler, HYGAS, Synthane gas, U—Gas, C02—
FEE? CON.
Acceptor process, GOGAS, Westing house process,
Union Carbide‘s ’Agglomerat'ed ash coal gasification,
Hydrane process, High temperature nuclear "heat
reactor process, At—gas and Tri-gas are known to be
under various sta es of deVelopment. 'Fig. 4""3
shows the cross section of a fluidized bed reactor.

Entrained bed gasifiers have been developed by

M15 KOppers-Totzek. lndia has one of the biggest
size gasifiers in this variety Operating at Ramagundam
and Talcher. Others )Vho have entered the field
with "their own variations. are+Texaco, Shell-
Koppers, Bi-Gas', and Saarberg-Otto. Of these
Texaco process is nearing commercial application.
Shell-Koppers, Bi-Gas and Saarberg—Otto processes
are under developmental stage. The most successful
entrained flow gasificr system (the Koppers-Totzek
gasifiers) have been operating on commercial scale
since 1952. This gasifier is shown in Fig. 5*?2

(rm Lunal P a s s s u n t msmgn Generated Gas Quality

This basically depends on the inpnt quality and the

18
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 COKE OVEN BATTERY
CONSTRUCTION & REPAIRS

The coke oven plant is essential units of an integrated steel plant .lt' supply
metallurgical coke of desired specification to the blast furnaces and gas as a fuel
to various other units of the steel plant

There are different designs of batteries but the aim of all design are as
follows:--

1. Production of coke of high and uniform quality with optimum of By-

.products.

2. High'output of coke oven gas

3. Low resistance in heatingsystem

Maintenance of hermetic sealing and compactness of brick work for long

life of the battery

5. Minimum consumption of fuel.

Broadly coke oven battery proper can be divided into three zones:—

1. Heating zone

_ 2. carbonisation zone

3. Gas off take zone

HEATING ZONE

Heating zone consists of CO &‘ BF gas mains, isolation and reversing cocks,
Reversing mechanism, Reversing machine, waste heat boxes, CO 935 pre-
heater, air inlet boxes and distribution pipes with its connecting parts. This unit
control 'the supply of‘gas and air to the heating chambers for proper combustion.
The gas mains are erected with great care with respect to its position levels and
slopes so that all the connecting parts can be erected for its proper and smooth
operation.

CARBONISATION ZONE

Carbonisation zone mainly consists of anchorage system. During heating up of

the ovens the refractory bricks eXpands. Anchorage is provided to prevent the

Page i of 6
\w-zzvsumfinasttopoe (CR).dbc

€18
damage of the brickwork during heating up and helps in controlling the stress
occurring to the brickwork it also helps in reducing the influence of-mechanical
load on the brickwork during charging and pushing of the ovens

Various elements of Anchorage:-

a) Armour plates
b) Main buckstays
c) Auxiliary buokstays
d) Set of spiral springs
e) Bottom and cross tie rods
1‘) Longitudinal tie rods

The upper portion of the coke oven battery from oven sole to oven roof is
reinforced on PIS &CIS by armor plates which are installed firmly to the brickwork
of end verticals of heating walls Buckstays are erected vertically along the height
of the heating wall close to the flash plates on both sides. At the top a pair of tie
rods interconnects the PIS & C/S buckstay. At the bottom the buckstays are fixed '
with bottom tie rods from the nozzle deck Load is applied on the Buckstays by
loosening or tightening of the nuts against the springs provided on the tie r°ods.
AuXIlIary regenerator walls are anchored with the help of small anchorage, the
loads from which are transferred to the main buckstays.

Besides the Icad of anchoring the brick work the buckstays also take the load 'of
Gas collecting main and its service platforms. The buckstays on 0/8 & PIS also.
periodically take the load of Guide car and pusher beam while pushing of coke

Ovens are closed by brick lined [door bodies supported on the door frames which
are fixed with the flash plates by ‘T' bolts. Ceramic ropes are used In the grooves
. of the door frame to avoid leakage.-

Longitudinal tie rods (5 nos.) arelaid on the; oven “top above cross tie rods.
Springs and washers are provided on each tie rod from the side of the buttress
walls

GAS OFF TAKE ZONE.

Gas off take system consists of AP, ‘Gooseneck, bend, isolation valve. gas
collecting main, cross over main & suction main. These are located on the oven
top. For cooling down of the raw gas generated from the oven ammonia liquor is
spread continuously in the gooseneck.

. Page 2 of 6
\\P-7275\shan'ng\SKG_COB (CR).doc

as
Repairs:-

A coke oven battery need to be nurtured carefully during its entire life. Prescribed
norms'for operation and maintenance are strictly adhered to. Timely maintenance
and utilisation of correct techniques of repairs greatly contribute to the life of a
coke Oven battery. '
Compared to other countriesthe expected life of coke oven batteries in india has
been much less mainly due to the following factors:-

1. Lack of high standard of iaboUr discipline affecting the normal working of

batteries to the desired level of production.

Absence of clearly defined planned maintenance.

Erratic working of batteries resulting in irregular Working schedules causing

disturbance in thermal and hydraulic regimes. . .

Factors influencing the life of coke oven:-

1.' industrial relations - Labdur lndiscipline has contributed to premature failure

of coke ove’ns throughout the world

Operating conditions - The degree of attention to various rules of operation

of coke ovens plays a vital role” in the life of coke ovens. A neglected
flaming door can damage the anchorage in a very short time. The most
important factor which influences the life' of coke ovens is the neglect of
regular cleaning of doors, door frames, oven top equipment and preventive
planned maintenance of oven machinery. Ovens get pressurised due t o .
choking of gas passages resulting in early damage to the oVen brickvvd'r'ki':_" ‘
Undercharging of ovens effects in deterioration of the brick work. in order
to avoid high temperature in free space, cracking of gas, excess roof
carbon ovens are charged upto the desired level. '

Quality of construction - There should be strict control on the quality of

materials and workmanship for. better life of coke ovens.’ During
.' construction the brick joints to be filled properly in order to have minimum
leakage possibilities. ' - -

Routine maintenance & Repairs — Timely repair and maintenance of

refractory lining and as well as the reinforcing equipments is very important
for prolong life of the coke ovens. Neglect to repair in time may lead to
premature and major repair to ovens. As per Russian standard 7% of the
total invested cost to be ploughed back for maintenance from 5th year of
operation of the battery. The condition of the battery is periodically

. Pagc30f6 ' ‘
\\P-7Z75\sharing\SKG_éOB (CR).doc

lov
 inspected and defects located in time and schedule to be made for
elimination of the defects at the earliest.

Regularity of schedules - A coke oven battery has to be operated under

strict technological regime; These should be minimum fluctuations in the
production schedules of the battery. Frequent changes in the production
schedule results in disturbance of thermal regime and leads to changes in
periods of carbonisation & effecting the refractory brickwork. it is always
advisable to avoid sudden and abrupt changes in cocking period In order
to avoid the thermal shocks on the refractories

Quality of Coal - The coal blends used in another factor. which influences
the life of a battery. All coal blends are tested for its physical and chemical
properties before use. Their V.M and ash content should be well within the
limits. The crushing should be uniform & confirm to the required limits.

Quality of Fuel ga - High dust content’in B.F. gas results in choking of

regenerator checkers effecting the production. Similarly low C.V. gas
causes improper coking 'of coal. CO gas not washed properly carries Tar
and Napthalene with it which results'In choking the gas pipe lines.°

Efficiency of Thermo-Technical Regime - The dynamics of gas and airflow

in the heating system play a very important role in the up keep of coke
ovens. A good thermal and hydraulic regime not only prolongs the life of
coke ovens but also gives good quality coke and gas.

Stage of Repairs:-

Depending upon the extent of damage the repair can be classified into following
categories

Routine (running) maintenance & repairs

Hot repairs
Capital repairs (cold repairs)
Rebuilding

Routine maintenance- This'Is done from the date of commissioning of the battery
and continued throughout its life span.

This involves following jobs.

i) Pointing, patching and spraying of oven ends

- ii) Packing, tightening of door frames and sealing of gaps between the flash
plate and jam bricks
iii) Filling up of empty joints pits cracks etc. in coking chamber
iv) Sealing of Heating plugs

~ ~ Page 4 of 6 a
\\P-7275\sharing\SKG_COB (CR).doc

lot
 v) Packing and patching of regenerator face walls and Bass flues.
vi) Regular adjustment of loads on cross tie rods.
vii) Blowing of regenerator checkers. '
viii) Replacement of gooseneck standpipes, valve boxes, charging hole frame
, ' and lids, tie rods, door frames, etc.
ix) Patching upof cracks developed in the'end portion of brick work.
x) Ceramic welding of silica bricks inside the oven.
xi) Relining of oven’top.
xii) Replacement of bumers, bananas, first sole bricks.
xiii) Replacement of fused checkers.

Any defect noticed in the brick lining, however insignificant it may- be has to be
eliminated without‘delay. Failure to do so will result in accelerating the wearing out
of the adjacent area of lining thereby reducing the over all life of the whole
complex.

Based on the experience of operation standards, certain norms can be developed

for establishing the approximate life span of each element. After having completed
this life each component should either be replaced or repaired.

Hot regal - When the basic dimensions of the battery and oven the battery
reinforcement go out of line due to creeping of brickwork on both sides, such
repair becomes inevitable. In such condition it becomes necessary to carryout the
alignment of Buckstay & Flash plate in order to achieve the battery dimensions
within the workable limits. Further due to ageing of the battery wider cracks
develop invariably in the end flue region. in this stage it becomes necessary to
repair oven ends intending from two to four flues or oven beyond four flues: by
keeping rest of the chambers hot

Capital repair/cold regaiI—r After a course of time when the damage gets intended‘ .
to regenerator level also and even the full wall of few ovens, it is advisable to
carry out repairs by cooling down the ovens in blocks or whole battery under
controlled conditions. Such repairs are known as cold repair] capital repair and ‘
are undertaken keeping in view the techno-economic feasibility vis-a-vis rebuilding
of the battery.

,_ Rebuilding — When the extent of damage spreads to almost all 'areas of oven
complex, and it is feltthat no amount .of repair will help to sustain the battery,
rebuilding "plans have to be undertaken.

The rebuilding of a battery is done underfollowing conditions.

i) The number of ovens in circulation are so less that it becomes unsafe to

operate the battery because of lack of inadequate pressure in the 6.0.
mains leading to the possibility of formation of explosive mixture.

Page. 5 of 6 ' ' '

\\P-727 SkharingBKd_COB (CR).doc

tol—
 A number of ovens have to be kept empty forbad condition of walls. This
may result In wide fluctuations in thermal and hydraulic regime leading to
dangerous operating condition

There are extensive cracks in the regenerator wail or the checkers have
got completely fused beyond any economic repairs.

The battery has become sufficiently aged wherein it is impossible to

maintain an effective thermal regime in the flues due to dangerously high
temperature.

The foundation of.battery collapses.

vi) Damage to the nozzle decking & Buttress walls due to severe and
extensive cracks -

vii) When the cost of operating the battery and repairing the same is
disproportionately high and rs not adequately compensated by the return In
the form of sufficient and good quality coke & gas

Page 6 of 6
\\P-717S\sharing\$KG_COB (CR).c

(03
 COKE DRY COOLING PROCESS INf'egIIEF a. SALIENT FEATURES

After carbonization. hot coke from coke oven is pushed into specially designed bucket
kept on coke car. Coke bucket car with hot coke Is hauled to coke dry cooling plant with
help of electric loco and is lifted to the top of a refractory lined steel vessel called
cooling chamber. This coke'Is charged into the chamber through coke charging device
where coke is cooled by circulating inert gas media in a closed circuit through cooling
'

chamber dust collecting bunker, waste heat boiler dust cyclones mill fan blowing
a

device and circulating ducts (as shown in Fig. 1') during the counter-current flow of hot
coke & cirCulating gas. Charging of hot coke into chamber and discharging of cooled
-

coke is carried out with the help of charging & discharging devices located at top &
u

bottom of the chamber respectively. Cooling of hot coke is facilitated by circulating the
inert gas by mill fan through above said gas track by introducing cold gas at the bottom
‘

of cooling chamber through blowing device. Transfer of heat takes place from hot coke
to circulating gas in counter current-flow and gas gets heated up while coke gets cooled.
The hot gas leaving cooling chamber is taken to dust catching bunker to remove coarse
dust (size 3-6 mm), then the gas passes through water cooled forced circulation waste
heat boiler for transfer of heat from gas to water to produce steam The cooled gas is
circulated back to cooling chamber after- remOval of fine dust from gas (0--3 mm) in dust
cyclones with the help of mill fan. Charging-and discharging take place in batch process,
A typical sectional view of a coke dry cooling plant (Fig. 1‘)‘ is enclosed.

Salient Features of a typical Coke Dry Cooling Plant operating in India

1. Each battery Is provided with one CDCP. -"

2. Each CDCP has four cooling chamber capacity 52 t/h each
3. Incoming coketemperature:1000°C-105 0°C , .
4. ‘ Cooled coke temperature: 150° 0 - 200°C ‘ . ' ‘gW‘ -
5.. Temperature of circulating gas before boiler: 780° 0 - 800° C
6. Temperature of circulating gas after boiler. 150° C-180°-C
7. Circulating gas pressure after mill fan: 350'mmwc
8. Steam pressure: 40 atm
9. Steam temperature. 440° C
10. Steam flow: 22-25 t/h
11. Circulating gas composition:

COz : 6—12%
02 : max. 1%
CO : 6-14%
H2 Z 3-5%
N2 : rest

12. Power generation: 11~12 mw (approx.)

Page 1
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