OPPORTUNITIES

1 Ammonia removal
More modern processes for ammonia removal include the water wash process in which the coke oven gas is scrubbed by water, which dissolves the ammonia, along with some hydrogen sulfide and hydrogen cyanide. The resulting scrubbing solution is pumped to an ammonia still where steam is used to strip out the ammonia. The ammonia vapors from the still can be processed to form ammonium sulfate similar to the processes described above, condensed to form a strong ammonia solution, incinerated or catalytically converted to nitrogen and hydrogen which are then recycled back into the coke oven gas. The incineration of the ammonia vapors is usually not an option in areas where environmental laws restrict the emission of NOx and sulfur dioxide. Another process for ammonia removal from coke oven gas is the PHOSAM process developed by US Steel. This process absorbs the ammonia from the coke oven gas using a solution of monoammonium phosphate. The process produces saleable anhydrous ammonia.

2. Dust Collectors for Air Cleaning :

The following factors determine selection of dust collection equipment: * Concentration and particle size of contaminant; * Degree of collection required; * Characteristics of air or gas stream; * Characteristics of contaminant; * Methods of disposal. Depenging on above factors, the following Canadian Air Systems dry type dust collectors can be utilized: - Cyclone Dust Collectros Cyclone Collectors are frequently applied for the removal of coarse dusts from an air stream, as a pre-cleaner to more efficient dry or wet dust collectors and / or as a separator in product conveying systems using an air stream to transport material. Principle advantages are low cost, low maintenance and low pressure drop (in order 0.75" to 1.5" WG), but this type dust collector can not be used for collection of fine particles. - High Efficiency Centrifugal Collectors

Have been developed whereby higher centrifugal forces are exerted on dust particles in a gas stream. Improvement in dust separation efficiency has been obtained by 1) increasing velocities through a cyclone shape dust collector, 2) utilizing a skimmer or other design feature, 3) using a number of small diameter cyclones in parallel and 4) placing units in series in some unusual applications. - Dry Type Dynamic Precipitators In this collector, dust is precipitated by centrifugal force on to specially shaped blades on an exhauster wheel and then conveyed through a dust circuit in the fan casing to the dust storage hopper. - Louver Type Dust Collectors Centrifugal forces can be applied to a particle by a rapid change in direction of air flow by series of plates set at an angle to the air stream. Coarse particles traverse the air stream and will project back to the dirty air side by the forces that can be produced from such an impact. - Settling Chambers Dust is ettled out in a large chamber when conveying velocities are reduced to the point where the particles are no longer conveyed. Extreme space requirements and the presence of edde currents to nullify the effective velocity mean that settling chamber type of dust collectors can be used only for removal of extremely coarse particles. - Potable Unit Collectors To fill the need for dust collection from isolated, portable or frequently relocated dust producing operations, a number of unit collector designs are availbale having capacities in the range of 200 to 1,000 CFM. Featuring small space and designed to recirculate the air, collectors of this type have been used extensively, especially in the metal working industry. A stationary Cyclone Type Dust Collector is one of the most popular choices for industrial users due to it low initial cost and simple maintenance. Cyclone dust collector provides a simple and economical means to most medium to coarse dust collection applications. The centrifugal action and gravitational forces are the basic plinciples of its operatrion. The dust laden air enters the dust collector through ahigh velocity inlet forcing the dust particles to the collector wall in spiral motion. This, together with gravitational pull, forces the concentrated dust downward and out of the dust outlet, while the cleaned air travels upward via the inner vortex and out the air outlet on the top side of the dust collector.

Cyclone dustcatcher: The existing dust catcher has to be replaced by a high efficiency ,bifurcated entry axial cyclone complete with replacable

quide vanes ,dust flow cones,nuclear level sensing device, bifurcated outlet nozzle and a dust hopper sized for 1.5 days of storage capacity. 3 The existing bischoff scrubber was replaced by with a new annular scrubber capable of handling the gas volumes and particulateloading associated with the 15% productivity increase .

4.Automatic dust dump 4.Dry type dust removal system.The generation of the electrical
powerby the top pressure recovery turbine increased by 4.5kWh/t(about 11%) and the running cost of the BF gas heater and other will reduced. 5 electric ignitor

6.Demister The gas cleaning system was completed with an upright

external demister arranged in the clean gas immediately downstream of the scrubber vessel. furnace has no isolation valve ,with this arrangement it was possible to provide the facilities required for establishing a water seal during furnace stops. The water seal is created automatically through a sequence of valve movement initiated by the PLC program when instructed by the operator. The external demister features high efficiency and is furnished with nonclogging, maintenance free internals, designed to match the life of the furnace. Helical overlapping vanes at the entry impose a swirling motion to the gas. The water droplets are centrifuged against the cell and collected at the bottom.

7. Process for treating a mud produced during gas scrubbing in a blast furnace
A process for treating mud produced during gas scrubbing in a blast furnace comprises decanting water from the mud to produce a mud concentrate which is still free flowing and adding a reducible carbon additive to the concentrate. The resultant mixture is passed to a rotary tube furnace where it is dried and then heat treated at a temperature of 900 C. to 1300 C. so as to ensure agglomeration, volatilization of zinc and lead and at least partial reduction of iron oxides in the mixture. After discharge and cooling, the material from the furnace is added to charge material for iron making.

8. The gas Cleaning Plant process equipment includes:

Axial Cyclone Compact design High efficiency dust separation (up to 85% of the total dust content) for removal of coarse (larger size) dust particles Adjustable Guide Vane Design accommodates changing furnace operation conditions Adapts to existing plants replacing the existing dustcatcher without requiring additional downcomer support Can be equipped with highly reliable Paul Wurth dry dust extraction equipment such as our GRITZKO II Dust Valves Annular Gap Scrubber High dust particle separation efficiency with minimum gas pressure loss High efficiency cooling of the gas Designed for long operational life and ease of maintenance Provided with shell protection to suit the expected plant operations and gas properties Effective moisture removal from the associated demister unit Efficient furnace top pressure control Energy Recovery Turbine High efficiency electrical power generation when used to recover mechanical energy from high pressure BF gas Results: Clean BF gas for distribution to the hot blast stoves, steam generation plant or other units with a dust content < 5 mg/Nm3 Significantly higher dry dust collection in the axial cyclone with an associated reduction of scrubber sludge by as much as 70% High efficiency of the axial cyclone dust collection results in low zinc content in the dry dust suitable for recycling to the sinter plant/furnace.

9. The old insulation of steam pipe lines was made of with Cement coating , due to aging effect
it was broken at many places and its efficiency was reduced. This insulation was replaced with insulation and Aluminium sheet cover. This has resulted in heat loss saving.

10. Since outlet gas from second venturi contains lot of moisture, the gas is taken in the cyclonic separator for removal of moisture. 11. Seal pots with sufficient dip length are provided at the bottom of the quencher, venturi and cyclonic separator to prevent gas leakage.

12. There are various digitally operated valves and pumps at various stages of gas cleaning process that can be directly operated by logically programming the PLC. The analog controllers can be used to open and close the septum valves and also it can be used for adjusting the venturi throat according to the pressure ranges. 13.