Nomination for Best Technical Group Award

Submitted By
Coal Carbonization Technology Group
Research and Development Centre for Iron and
Steel
Steel Authority of India Limited

Financial Year: 2015-16

Introduction:
Coal carbonization technology group is working in the field of coal, coke
and by product of coke oven. The main functional objective of the group is
to provide technological inputs to SAIL plants to improve productivity and
quality, Introduction/Optimization of state of the art technologies in SAIL
plants, Assist SAIL plants to improve operational efficiencies by
technological services, Undertaking consultancy assignment based on
expertise developed over the year and interaction with different agencies
in coal and coke areas.
The main aim of the group is to reduce the cost of coal blend with
available resources without affecting the coke quality, Optimization of
different operating parameters of coke oven and by product, to improve
the yield of by product plants e.t.c.
Coal Carbonization Technology group consist of following Members:
1. Shri T.S. Reddy, DGM & HOG ( CCL &CCT)
2. Shri K.K. Manjhi, DGM
3. Shri S.K. Kushwaha, Sr. Manager
4. Shri P.K. Jha, DM
5. Shri P.K. Pankaj, DM
6. Shri Rahul Srivastava, AM
7. Shri Anup Kumar

Annual Target Fulfillment:

Sl.
No
1.

Parameters
Ratio of project completed per Executive
Following projects were completed in 2015-16
Reduction in specific heat consumption of
COB #8 at BSP, Bhilai ( PPI, 50:74:25), Apr15-

No
4

Ratio
0.66

March16
Improvement in coke quality by blend
formulation and optimization of operating
parameters of COB #10 at ISP, Burnpur ( PPI,
50:70:58), June14- May15
Determination of statistical relationship
between coal and coke quality and
development of coal blend optimization tool
( BR, 50:01:46), Aprl14 Mar16
Study the effect of ash chemistry on coke
quality ( SID, 50:01:45, BSP), Aprl14
Sept15

Ratio of Publications per Executive

0.33

0.16

Following publication were done

Reduction in tar moisture content

through process control,P.K.Pankaj, S.K.
Kushwaha, K.K.Manjhi, O.S.Niyogi, T.K.Das &
Ashutosh Gupta, Steel India Volume 38 , No :
1

An attempt to predict weathering

indicator (% transmittance) of coal using
ANN, P.K. Jha, T.K. Das & A.B. Soni,
International journal for scientific research
development, Oct 2015, Volume 3 , Issue 8

Ratio of patent per executive

Following patent were done

Customer Satisfaction Index (CSI)

4.9

Technology Awareness Programme ( TAPS)

Achievement beyond Annual Target:

Major Technical Services:

 Investigation for improving coke quality coke quality of COB #11,

ISP, Burnur w.r.t heating regime and deposition in coke oven gas.
Samples of deposition in reversing valve and distribution pipeline were
collected and tested in RDCIS, Ranchi laboratory. Heating regime was
studied. Charge weight per oven, free space height and temperature was
monitored. Discussion was done with the shop in charge and corrective
measures were taken. Report was prepared and submitted to RDCIS,
Ranchi and ISP, Burnpur.
Investigation on low calorific value of coke oven gas at coke oven
battery of BSL .
Heating regime of the batteries, coke oven gas line layout, charge weight
per oven and calorific value analysis at lab was studied and monitored.
Per oven charge weight was found low. Discussion was carried out with the
shop in charge and suggestions for corrective action were given.
Immediate action was taken. Report was prepared and submitted to RDCIS
and BSL. Calorific value of coke oven gas improved and CAB was obtained
RS.291 lacs.
Investigation on battery performance and scope of increasing
pushing index of COB# 1 & 2 at DSP.
Battery condition, Operational and maintenance practices, thermal and
hydraulic regime were studied and monitored. Heating regime was
analysed and flue gas sample analysis was carried out. Report was
prepared and submitted.
Investigation on heating system of coke oven batteries for
improvement in coke quality at RSP, Rourkela.
Heating regimes of all the batteries were studied. Coal samples were
collected for granulometry study. Thermal and hydraulic regime was
monitored. Battery condition, tunnel draught, gas line pressure fluctuation
etc was also monitored. Flue gas sample analysis from waste heat boxes
and chimney was done to improve the heating regime. A discussion was
carried out with the shop in charge along with the suggestion for
improvement. Flue gas sample analysis was done battery # 6 for initial
study for a new project. Report was prepared and submitted to RDCIS and
RSP.
Investigative study on the utilization of tar pitch produced at DSP
Coke Oven for road making.

A detailed report was submitted to shop for the scope of tar utilization for
road making.
A report was submitted on request from BSP, on different type of
Tar products in new TDP at BSP.
Description Finely divided black dust or powder Sp Gravity 1.9 2.1 Iodine
Absorption Value (in mg/g) 82 5 DBP Absorption Value (in mg/g) 102 5
CTAB in m2/g 82 5 Tinting strength (%) 100 2 Heat loss at 125 OC (%)
1.0.
Analysis of Naphthalene content in clean coke oven gas
As per letter Ref. No: SK/COB #11/15/184, RDCIS Team visited ISP from
19/05/15 to 22/05/15. RDCIS along with RCL, ISP Burnpur studied and
carried out Ammonia and Naphthalene test as per standard procedure
followed at ISP. It was observed that in ISP, Burnpur total ammonia (free
and fixed)is determined in the analysis sample of clean coke oven gas,
whereas all other SAIL plants determine only ammonia in the clean coke
oven gas. In other SAIL plants total ammonia is determined in ammoniacal
liquor from the outlet of ammonia stripper.

Following observation and Recommendation were given to plant:

The net result of this complex series of chemical reactions is that both
corrosion and deposition can occur simultaneously in coke oven gas
distribution systems. NH3, H2S and ammonium sulphate is main culprit for
this.

Naphthalene is not only the impurity which leads to deposition.

Other impurities like NH3, H2S and ammonium sulphate is also equally
responsible for the choking and deposition in coke oven distribution
system

NH3 in clean coke oven gas at ISP, COB #11 is on higher side. It should be
reduce further to avoid deposition and corrosion in gas pipelines
Naphthalene content in clean coke oven gas at ISP, COB #11 is behind the
limit.
ISP has Gas chromotographer in RCL Laboratory but it is not under
operation. It should be utilized for different testing purpose and will be
very useful for day to day operation.

Benefits
Certified Annual Benefit (CAB) in lakhs: 5041.04 (Annexure 1)

Involvement in Multi Area Projects

Development of an Advanced Process Control System for Coke Oven
Battery # 3 & 4 at BSL (AAPC & CCT)
Engineer Days
50

Year
2015-16

PLC based instrumentation and control system for

improvement at chasnala coal washery (P&C, AAPC, CCT)
Engineer Days
40

performance

Year
2015-16

Development of procedure for Pilot Oven carbonisation test for producing

coke having properties similar to that of commercial oven
Engineer Days
90

Year
2015-16

Evaluation of new imported coking coals through Pilot Carbonization tests

Engineer Days
100

Year
2015-16

Characterization of new indigenous coals and coal creation of coal testing

laboratory at CCSO, Dhanbad
Engineer Days
50

Year
2015-16

Studies on coke structure through image analysis.

Engineer Days
50

Award Bagged

Year
2015-16

 Shri Pradeep Kumar Pankaj received awards

engineers/material scientist by IIM Ranchi Chapter

of

excellence

for

Shri Rahul Srivastava bagged 2nd prize in Hindi poem, organized by

hindi department of RDCIS-SAIL.

Training Imparted (Other than TAP)

Around 30 students of different engineering colleges were imparted
vocational training in coal and coke area.

Timely submission of project completion report

All project completion report were submitted on time

Learning
Learning from projects handled at ISP ( Project no : 50:70:58), a new
projects were initiated at DSP ( Project no : 50:70:59)
On the basis of SID project handled at RDCIS Laboratory, utilization of
mill scale in heavy media bath at washery has been initiated.

Major implemented suggestion

Oven throughput were increased at BSL ( From 19 to 21 Ton/Oven )
Free space temperature of battery at BSL and ISP were reduced
Excess air coefficient reduced from 1.35 to 1.24 at BSP
Refractory patch work were done at reducer and regenerator face
wall at BSL
Increase in Imported soft coal at BSP.
Spindle lifting work were done in waste heat boxes to reduce CO
percentage in flue gas
Modification in tar decanter at DSP, to increase the residence time
of tar.
Oven throughput increased at DSP in COB # 3 by increasing the
number of revolution of charging hopper

 Down coming heating regime maintained as air 7 mm water column

and gas 7.5 mm water column/ air 7.5 & gas 8 mm water column at
a difference of 0.5 water column.
Vertical top pressure for BF gas heating system in coke oven battery
maintained positive from 0.2 to 0.5 mm water column.

Why the group thinks it as the Best Technical

Group

Annexure 1
Sl.
No
1

Name of project/ Technical Services

Investigation of problems in CV of CO gas at BSL

CAB in
lakhs
291.00

Study the effect of ash chemistry on coke quality

1832.53

Improvement in coke quality by blend formulation 107.04

and optimization of operating parameters of COB#10
Reduction in coke moisture in Quenching Tower #1 15.64
through modification in quenching tower spray valve
system in coke ovens

Usage of magnetized water to improve the bulk 1744.70

density and
wettability of coal blend.

Optimization of blend and performance improvement 1050.13

of COB
# 10
Total 5041.04