ACKNOWLEDGEMENT

I would like to thank MR. SANTOSH SINGH, for providing me with the opportunities of
studying, learning and gaining practical experience in various fields during the period of
training. His invaluable suggestions not only helped me to reach the successful completion of
the tasks assigned, but also made me learn a lot.

I would like to give special thanks to MR. DHARMADHIKARI for helping me throughout
with his wise suggestions, innovative ideas and whole-hearted help.

And finally I would like to thank the HR Department of Larsen & Toubro Limited, BSL SITE,
for giving me the opportunity to have a precious and rewarding experience of training in the
prestigious industry of L&T Limited.

Yours Sincerely

PUSHPENDU SINGH

1
 Contents
Larsen And Toubro:- ......................................................................................................... 3
Introduction:- ................................................................................................................... 3
History:- ........................................................................................................................... 3
Bhushan Steel:- ............................................................................................................... 4
Introduction:- ................................................................................................................... 4
Coke:-.............................................................................................................................. 5
Coke Oven Plant:- ……………………………………………………………………………………………………….6
Introduction:- .................................................................................................................... 6
Various sections of Coke Oven plant:-.............................................................................. 7
Coal handeling and Prepration section:- ........................................................................... 8
Coke Oven Battery:- ........................................................................................................ 9
Composition of COG:-................................................................................ ……. ………… 11
By Products of COG:- ..................................................................................................... 11
Coke Oven ByProduct Recovery Section:- ……………………………………………………………… 12
Primary Gas Coolers:-..................................................................................................... 13
Electrostatic Tar Precipitator:- ........................................................................................ 14
Exahuster:- ...................................................................................................................... 16
Scrubbers:- ...................................................................................................................... 16
Ammonia Removal Section:-.......................................................................................... 17
Final Cooler:- .................................................................................................................. 19
COG Desulphurification:- ………………………………………………………………………………………….20
Tar and Liquor Plant:- ………………………………………………………………………………………………. 21
Material Handeling Systems:-........................................................................................ 22
Belt Conveyor:- .............................................................................................................. 22
Srew Conveyor:- ........................................................................................................ 25
Conclusion:- ………………………………………………………………………………………………………………26
References:- ……………………………………………………………………………………………………………….27

2
Larsen And Toubro:-
Introduction-
Larsen & Toubro Limited, also known as L&T, is an Indian multinational conglomerate
headquartered in Mumbai, Maharashtra, India. It was founded by Danish engineers taking
refuge in India, as well as an Indian financing partner. The company has business interests in
engineering, construction, manufacturing goods, information technology and financial
services, and also has an office in the Middle East and other parts of Asia.

L&T is India's largest engineering and construction company .Considered to be the

"bellwether of India's engineering & construction sector", L&T was recognized as the
Company of the Year in Economics Times 2010 awards.

History-
A company was founded in Bombay (Mumbai) in 1938 by two Danish engineers, Henning Holck-
Larsen and Soren Kristian Toubro. The company began as a representative of Danish manufacturers
of dairy equipment. However, with the start of the Second World War in 1939 and the resulting
restriction on imports, the partners started a small workshop to undertake jobs and provide service
facilities.

Germany's invasion of Denmark in 1940 stopped supplies of Danish products. The war-time
need to repair and refit ships offered L&T an opportunity, and led to the formation of a new
company, Hilda Ltd., to handle these operations .L&T also started to repair and fabrication
shops signalling the expansion of the company .The sudden internment of German engineers
in British India, who were to put up a soda ash plant for the Tata steel, gave L&T a chance to
enter the field of installation.

In 1944, ECC was incorporated by the partners; the company at this time was focused on
construction projects (Presently, ECC is the construction division of (L&T). L&T decided to
build a portfolio of foreign collaborations. By 1945, the company represented British
manufacturers of equipment used to manufacture products such as hydrogenated oils,
biscuits, soaps and glass.

In 1945, the company signed an agreement with Caterpillar Tractor Company, USA, for
marketing earth moving equipment. At the end of the war, large numbers of war-surplus
Caterpillar equipment were available at attractive prices, but the finances required were
beyond the capacity of the partners. This prompted them to raise additional equity capital,
and on 7 February 1946, Larsen & Toubro Private Limited was incorporated.

3
Bhushan Steel Site (Meramandali, Orrisa):-
Introduction:-
Bhushan Steel is the largest manufacturer of auto-grade steel in India ,and is spending RS.
260 billion to expand its capacity to 12 million tonnes annually, from the present installed
capacity of around one million tonnes .Setting up of a 6 million tonne per annum integrated
steel plant as an expansion of its existing plant being set up at Meramandali in Orrisa.

BSL is currently implementing a backward integration project to set up an integrated steel

plant of 2.3 MTPA capacity at Meramandali, district Dhenkanal, Orissa to manufacture Hot
Rolled (HR) coils (which is the key raw material for its existing operations) / billets, so as to
guard against future increase in prices / possible shortages of HR coils for its cold rolling
facilities.

The steel plant is being implemented through Direct Reduced Iron (DRI) – Blast Furnace
(BF) – Electric Arc Furnace (EAF). The steel plant will have the capacity to manufacture 2.0
MTPA of HR coils and 0.3 MTPA of billets and power generation capacity of 110 MW. The
plant has introduced the new products – Billets And Sponge Iron.

Gross sales of Bhushan Steel grew from Rs.5 billion in 2001 to Rs.40 billion in 2007. It
earned net profits of Rs.3.13 billion in 2007 and exported goods worth Rs.12.57 billion. Its
exports include steel for both the automotive and white goods industry and the list of
countries it is exporting to includes several developed countries.

The Khopoli plant in Maharashtra was commissioned in 2004 and has been producing colour
coated sheets, high tensile steel strappings, hardened and (aluminium and zinc coated sheet)
for the first time in India. At its Sahibabad plant in Ghaziabad, Uttar Pradesh, it has a 1700
mm mill, which produces the widest sheets in India for the automotive industry. It has highly
automated systems.

At its Meramandali, Dhenkanal plant in Orissa, Bhusan Steel produces hot rolled coils and
has mills for hot rolling. Construction of the first phase is being carried out.

4
Coke:-
Coke is produced by heating the coal at very high temperature in the absence of air .This
process of production of coke is called as pyrolysis .Usually coal is heated about 1450˚C for
14 to 36 hours in absence of air .Coke has five to six higher calorific value than coal.

Coke making process is multistep complex process and variety of solid liquids and gaseous
products are produced which contain many valuable products. Various products from coal
carbonization in addition to coke are coke oven gases. coal tar, light oil, and aqueous
solution of ammonia and ammonia salt.

With the development of steel industry there has been continuous development in coke oven
plant since latter half of nineteenth century. to improve the process conditions, recovery of
chemicals and environmental pollution control strategies and energy consumption measures.

Carbonization can be carried out at low temperature or high temperature. Low temperature
carbonization is used to produce liquid fuels while high temperature carbonization is used to
produce gaseous products.

Low temperature carbonization (450-750oC):- In low temperature carbonization quantity

of gaseous product is less while liquid products are large.

High temperature carbonization (above 900oC):- In high temperature carbonization, the

yield of gaseous product is more than liquid products with production of tar relatively low.

Fig:1 Pitch Coke

5
Coke Oven Plant:-
Introduction:-
Due to the development of iron and steel industry coke oven plant has become an integral
part of iron and steel industry. Due to increasing demand of iron and steel, there has been a
considerable increase in the coke oven capacity which resulted increase output of coal
chemicals.

Two types of coke manufacturing technologies use are:-

(1)Coke making through by product recovery

(2)Coke making through non-recovery

By the year 2011-12 ,the world coking coal requirement will be about 433 million metric
tones in which India’s requirement is estimated to about 54 million tones. By product from
coal gasification plant includes coke, coal tar, sulphur, ammonia. Coal tar distillation
produces tar, benzol, cresol, phenol, creosote.

Coking Coals:Blast furnace requires coke of uniform size, high mechanical strength, and
porosity with minimum volatile matter and minimum ash. Coking coal may be dived I on the
basis of their coking properties: prime coking coal, medium coking coal, semi coking coal.
The prime coking coal produce strong metallurgical coke while coals of other groups yield
hard coke only the concentration of moisture ash, sulphur and sometime phosphorous and ash
fusion temperature are important in determining the grade of coking coal since they influence
the quality of coke produced. Low moisture, ash, sulphur and phosphorous content in the coal
are desirable for production of good quality coke.

The desired analysis of typical coal charge to coke oven is.

Ash Content : 16%-18%

Volatile Matter : 22%-25%

Moisture : 06%-07%

Phosphorous : 00%-.09%

Sulphur : 00%-.56%

Fixed Carbon : 58%-60%

Some of the other factors affecting quality of coke are rank of coal, particle size, bulk
density, weathering of coal, coking temperature and coking rate, soaking time, quenching
practice.

6
Various section in coke oven plant:-
SECTION FUNCTION
Coal Handling Plant and To prepare coal blend suitable for carbonization. various steps
Coal Preparation Section involved are unloading and storage of coal, blending of coal of
various grade, coal crushing and transport to coal storage tower.

Coke oven Batteries To convert coal into coke by carbonizing coal in absence of air.
The process steps involved are coal charging and coal
carbonization.

Coke sorting Plant Crushing and sorting of coke to suitable size for use in blast
furnace. The steps involved are coke pushing, coke quenching,
coke crushing/ screening.

Coke oven by product Collection and cleaning of coke oven gas and recovery of by
recovery products.This involves gas cooling, tar recovery,
desulphurization of coke oven gas , recovery of ammonia,
recovery of light oil.

Ammonium Sulphate Ammonium Sulphate Production. Recovery of ammonia and

Product neutralization with sulphuric acid or nitric acid in case of
ammonium nitrate/ calcium ammonium nitrate.

Waste water treatment Treatment of phenolic waste water.

7
Coal Handling Plant and Coal Preparation Section:-
Coal needs to be stored at various stages of the preparation process, and conveyed around the
coal preparation section. Crushing and screening are the important part of coal handling
plant. Crushing reduces the overall size of the coal so that it can be more easily processed and
handled. Screens are used to ranges the size of coal. Screens can be static, or mechanically
vibrated. Dewatering screens are used to remove water from the product.

Partial Briquetting:-
Briquettes of low grade coal are prepared using a binder (pitch/ pitch+tar) up to 2 to 3.0% of
charge. This partial briquette of coal is charged with coal into coke oven which significantly
improve the quality of coke.

Coal Crushers:-
The preparation of ROM coal commences the moment it is received from the mine. The
Rotary Coal Breaker crushes and breaks the coal and removes the majority of the rock
contamination.

The sized coal from the Rotary Breaker can then be fed into a Rolling Ring Crusher which
produces a finer product.

For more specific and smaller sizing of the coal, the Double Roll Crusher is generally the
preferred machine, particularly for processing the sizes required by power stations and for the
export market where tight specifications are required.

Fig:2 Coal Crusher

8
Coke oven Batteries:-
Coke oven are used to convert coal into coke by carbonizing coal in absence of air and there
by distilling the volatile matter out of coal. Coke is taken as product which is use as fuel and
as a reducing agent in smelting iron ore in a blast furnace and coke oven gas as by product is
treated for recovery of coal chemicals. The coke oven temperature is keep as high as 2000˚C.
Crushing and screening of coke is done to obtain suitable size for use in blast furnace.

Coke oven plant consists of Coke oven batteries containing number of oven (around 65 ovens
in each battery). The coal is charged to the coke oven through charging holes. The coal is
then carbonized for 17-18 hours, during which volatile matter of coal distills out as coke oven
gas and is sent to the recovery section for recovery of valuable chemicals. The ovens are
maintained under positive pressure by maintaining high hydraulic main pressure of 7 mm
water column in batteries.

The coking is complete when the central temperature in the oven is around 950-1000˚ C. At
this point the oven is isolated from hydraulic mains and after proper venting of residual gases,
the doors are opened for coke pushing. At the end of coking period the coke mass has a high
volume shrinkage which leads to detachment of mass from the walls ensuring easy pushing.
The coke is then quenched and transferred to coke sorting plant.

The control of oven pressure is quite important because lower pressure leads to air entry
while higher pressure leads to excessive gassing, leakage of doors stand pipe etc. Proper
leveling of coal is important and care is taken so that free board space above (300 mm) is
maintained to avoid choking.

Fig:3 Coke Oven Battery

9
Coke oven plants are integral part of a steel plant to produce coke, which is used as fuel in the
blast furnace. Coke oven plant produces important by product coal chemical tar, ammonia,
crude benzoyl which is fractionated to produce aromatics-benzene toluene, xylene.

In Bhushan Steel at Meramandali site, there are 146 ovens in Coke Oven Battery each having
capacity to produce .80 million tonnes of coke per annum. The temperature in these chambers
are critically from 1100˚C to1500˚C.

Total capacity of coke oven battery of Bhushan Steel Limited, Meramandali is about 300
million tonnes per annum.

10
Composition of Coke Oven Gas:-

COMPONENTS %VOLUME

Hydrogen 48.0-55.0

Methane 28.0-30.0

Carbon monoxide 5.0-7.5

Carbon dioxide 1.5-2.5

Nitrogen 1.0-3.0

Oxygen 0-0.5

Hydrocarbons 2.5-4.0

By Products of Coke Oven Plant:-

COMPONENTS

Ammonia

Hydrogen Sulphide

Hydrogen Cyanide

BTX(Benzene, Toluene, Xylene)

Tar components

Ammonium Sulphide

11
Coke Oven By product Recovery Section:-
The coke oven by-product plant is an integral part of the by-product coke making process. In
the process of converting coal into coke using the by-product coke oven, the volatile matter in
the coal is vaporized and driven off. This volatile matter leaves the coke oven chambers as
hot, raw coke oven gas. After leaving the coke oven chambers, the raw coke oven gas is
cooled which results in a liquid condensate stream and a gas stream.

The functions of the by-product plant are to take these two streams from the coke ovens, to
process them to recover by-product coal chemicals and to condition the gas so that it can be
used as a fuel gas. Historically, the by-product chemicals were of high value in agriculture
and in the chemical industry, and the profits made from their sale were often of greater
importance than the coke produced.

Nowadays however most of these same products can be more economically manufactured
using other technologies such as those of the oil industry. Therefore, with some exceptions
depending on local economics, the main emphasis of a modern coke by-product plant is to
treat the coke oven gas sufficiently so that it can be used as a clean, environmentally friendly
fuel.

In a by-product coke oven the evolved coke oven gas leaves the coke oven chambers at high
temperatures approaching 2000˚F. This hot gas is immediately quenched by direct contact
with a spray of aqueous liquor (flushing liquor). The resulting cooled gas is water saturated
and has a temperature of 176˚F. This gas is collected in the coke oven battery gas collecting
main. From the gas collecting main the raw coke oven gas flows into the suction main.

The amount of flushing liquor sprayed into the hot gas leaving the oven chambers is far more
than is required for cooling, and the remaining un evaporated flushing liquor provides a
liquid stream in the gas collecting main that serves to flush away condensed tar and other
compounds. This stream of flushing liquor flows under gravity into the suction main along
with the raw coke oven gas. The raw coke oven gas and the flushing liquor are separated
using a drain pot (the down comer) in the suction main. The flushing liquor and the raw coke
oven gas then flow separately to the by-product plant for treatment.

Duties of the by-product plant:-

●Cool the coke oven gas to condense out water vapour and contaminants.

●Remove tar aerosols to prevent gas line/equipment fouling.

●Remove ammonia to prevent gas line corrosion.

●Remove naphthalene to prevent gas line fouling by condensation.

●Remove light oil for recovery and sale of benzene, toluene and xylene.

●Remove hydrogen sulphide .

12
Sections Of Coke Oven By Product Recovery Plant:-
 Primary Gas Cooler(PGC)
 Electrostatic Tar Precipitator(ETP)
 Exhauster
 Scrubbers(BTX,NH₃,H₂S)
 Final Cooler

Primary Gas Cooler (PGC):-

The first step in the treatment of raw coke oven gas is to cool it to remove water vapour and
so greatly reduce its volume. This is done in the Primary Cooler. There are two basic types,
the spray type cooler and the horizontal tube type. In a spray type cooler the coke oven gas is
cooled by direct contact with a re circulated water spray, with the contact cooling water being
itself cooled externally in heat exchangers.

In the tubular type, the coke oven gas is cooled indirectly by flowing across horizontally
mounted tubes through which cooling water is pumped. In this case, the cooling water does
not come into contact with the coke oven gas and so it can be cooled in a cooling tower for
example.

As the coke oven gas is cooled, water, tar and naphthalene condense out. The condensate
collects in the primary cooler system and is discharged to the tar & liquor plant.

Fig:4 Primary Gas Cooler

13
Electrostatic Tar Precipitators:-
As the raw coke oven gas is cooled, tar vapour condenses and forms aerosols which are
carried along with the gas flow. These tar particles would contaminate and foul downstream
processes and would foul gas lines and burner nozzles if allowed to continue in the gas
stream. The tar precipitators typically use high voltage electrodes to charge the tar particles
and then collect them from the gas by means of electrostatic attraction. The tar precipitators
can be installed before, or after the exhauster. The usual practice in North America is to place
them immediately after the exhauster.

Fig:5 Electrostatic Tar precipitator

Tar vapour Condenses and forms aerosols. Tar particles may contaminate and foul gas lines
and Burner nozzles.

14
ETP uses high voltage electrodes, Collects Tar particles due to electrostatic attraction.

Fig:6 Cross Sectional view Of ETP

15
Exhauster:-
The exhauster is a large blower that provides the motive force to induce the coke oven gas to
flow from the coke oven battery and through the by-product plant.

The exhauster is of prime importance to the operation of the coke oven battery. It allows the
close control of the gas pressure in the collecting main, which in turn affects the degree of
emissions, for example door emissions, from the battery. A failure of the exhauster will
immediately result in venting to atmosphere, through the battery flares, of all of the raw coke
oven gas produced.

It provides the motive force to induce the coke oven gas to flow. By using it close control of
the gas pressure in the collecting main. It is placed between the ETP and Scrubbers.

Scrubbers:-
●NH₃ Scrubber (NH₃ removal)

●H₂S Scrubber (H₂S removal)

●BTX Scrubber (Benzene, Xylene, Toluene removal)

Fig:7 Scrubbers

16
●Ammonia Removal:-
Because of the corrosive nature of ammonia, its removal is a priority in coke oven by-product
plants. Historically the removal of ammonia from coke oven gas has yielded one of the more
profitable by-products, that of ammonium sulphate.

The ammonium sulphate process can take various forms but all basically involve contacting
the coke oven gas with a solution of sulphuric acid. Variations include the use of an absorber,
in which the sulphuric acid solution is sprayed into the gas, or the use of a saturator in which
the gas is bubbled through a bath of sulphuric acid solution. The sulphuric acid reacts readily
with the ammonia in the coke oven gas to form ammonium sulphate. This is then crystallized
out, removed from the solution and dried for sale typically as a fertilizer.

Nowadays the cost to produce ammonium sulphate often outweighs the revenue from the
product, however there are still very many coke plants around the world producing
ammonium sulphate.

Fig:8 modern ammonia removal method

17
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
sulphide and hydrogen cyanide. The resulting scrubbing solution is pumped to ammonia still
where steam is used to strip out the ammonia. The ammonia vapours from the still can be
processed to form ammonium sulphate 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 vapours is usually not an option in areas where
environmental laws restrict the emission of NOx and sulphur 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 mono ammonium
phosphate. The process produces saleable anhydrous ammonia.

●Naphthalene removal:-
Naphthalene is removed from coke oven gas using wash oil in a gas scrubbing vessel. The
vessel may be packed or it may be the "void" type in which the wash oil is sprayed into the
gas in several stages. The wash oil is regenerated by stripping out the naphthalene from the
wash oil using steam in a still. In many plants, naphthalene removal is integrated with the
similar process of light oil removal. The naphthalene is typically recovered as a heavier oil
stream that is then often mixed with the tar that is produced in the by-product plant.

● Light oil removal:-

Light oil is a general term for a mixture of similar chemicals consisting mainly of benzene,
toluene and xylene. The removal of light oil from coke oven gas uses wash oil in a similar
process to that described for naphthalene removal. The light oil is stripped from the wash oil
in a still and is then condensed to form crude light oil. This can be sold for further refining
offsite or it can be refined in the by- product plant using several distillation steps in the light
oil plant. The light oil can actually be left in the coke oven gas, where it increases the
calorific value. Its removal has historically been extremely cost effective, as benzene toluene
and xylene from coke oven gas were once vital raw materials for the developing chemical
industry. However these materials can nowadays be obtained at lower cost and in greater
quantities from other sources.

18
Final Cooler:-
The duty of the final cooler is to remove the heat of compression from the coke oven gas that
it gained on flowing through the exhauster. This is necessary because the efficiency of many
of the by-product plant processes, including the water wash ammonia removal process, is
greatly improved at lower temperature.

The final cooler is therefore placed upstream of water wash ammonia scrubbers if these are
installed. Final coolers typically cool the coke oven gas by direct contact with a cooling
medium, either water or wash oil. An important aspect of final cooler operation is that when
the coke oven gas is cooled below the outlet temperature of the primary cooler, naphthalene
will condense from the gas. This naphthalene readily crystallizes out from the cooling
medium and will foul equipment if not disposed of. In wash oil final coolers the naphthalene
dissolves in the wash oil and a side stream of oil is steam stripped to remove the naphthalene.
If water is used to cool the coke oven gas, the condensed naphthalene must be absorbed using
tar.

The tar is either entrained in the cooling water, with a portion of the flow being continuously
blown down for treatment, or it takes the form of a tar layer through which the cooling water
flows. The tar is continuously exchanged with fresh tar from the tar and liquor plant to
dispose of the absorbed naphthalene.

19
Coke oven gas desulfurization:-
There are several different processes for removal of hydrogen sulphide from coke oven gas.
The specific process determines where in the gas train it is installed. The main desulfurization
processes in use are:-

Hydrogen Sulphide is absorbed from the coke

Vacuum Carbonate Process oven gas using a solution of Potassium
Carbonate, then stripped out in a still

Hydrogen sulphide is absorbed from the coke

Ammonia Wash Process oven gas using a solution of ammonia, then
stripped out in a still - this process is often
combined with the ammonia removal system

Hydrogen sulphide is absorbed from the coke

Sulphiban Process oven gas using a solution of Mono
ethanolamine (MEA) then stripped out in a
still

The hydrogen sulphide is converted into elemental sulphur, using the Claus process, or it can
be used for the production of sulphuric acid.

20
Tar and Liquor Plant:-
The tar and liquor plant handles the flushing liquor that circulates between the by-product
plant and the coke oven battery. It also processes the waste water that is generated by the
coke making process and which results from coal moisture and chemically bound water in the
coal. The flushing liquor flows into tar decanters where the tar separates out from the water
and is pumped to storage for later sale. Heavier solid particles separate out from the tar layer
and these are removed as tar decanter sludge (TDS).

The aqueous liquor is then pumped back to the battery, with a portion bled off from the
circuit which is the coke plant "excess liquor" or waste water. This contains ammonia and,
after the further removal of tar particles, it is steam stripped in a still. An alkali such as
sodium hydroxide is added in the still to decompose ammonia compounds dissolved in the
liquor. The ammonia vapour from the still is then either fed into the coke oven gas upstream
of the ammonia removal system, or the still itself is often integrated into the ammonia
removal system. Either way, the ultimate fate of the ammonia removed from both the coke
oven gas and the waste water is the same.

The stripped still effluent is either discharged to a municipal sewer or it can be treated in an
on-site biological effluent treatment plant to remove residual ammonia, phenol and cyanides.

21
Material Handling Systems:-
●Belt Conveyor:-
The belt conveyor is an endless belt moving over two end pulleys at fixed positions and used
for transporting material horizontally or at an incline up or down. The main components of a
belt conveyor are:

1. The belt that forms the moving and supporting surface on which the conveyed material
rides. It is the tractive element. The belt should be selected considering the material to be
transported.

2. The idlers, which form the supports for the carrying and return stands of the belt.

3. The pulleys that support and move the belt and controls its tension.

4. The drive that imparts power to one or more pulleys to move the belt and its loads.

5. The structure that supports and maintains the alignments of the idlers and pulleys and
support the driving machinery.

Other components include:

1. Loading chute or feeder chute that organises the flow of material and directs it on the belt
conveyor.

2. Take-up-device which is used to maintain the proper tension of the belt for effective
power transmission.

3. Belt cleaner that keeps the belt free from materials sticking to the belt.

4. Tramp removal device, which is optionally used in case the conveyed material bears the
chance of having tramp iron mixed with it and subsequent handling of the material, demands
its removal.

5. Continuous weighing device for constantly measuring the load being carried by the
conveyor belt.

6. Discharge chutes to guide the discharged projectile to subsequent conveyor or other

receiving point.

7. Surge hopper and feeder, which is essential for supplying material to the conveyor at
uniform rate when the supply of material is intermittent.

8. Tripper arrangement to discharge material at different point or to other device.

22
Application:-
Conveyor belts are widely used in mineral industry. Underground mine transport, opencast
mine transport and processing plants deploy conveyor belts of different kinds to adopt the
specific job requirements. The main advantages of conveyor belt system are:-

1. A wider range of material can be handled which pause problems in other transportation
means. Belt conveyor can be used for abrasive, wet, dry, sticky or dirty material. The lump
size of the transported material is limited by the width of the belt. Belts up to 2500 mm wide
are used in mining industry.

2. Higher capacity can be handled than any other form of conveyor at a considerably lower
cost per tonne kilometre. Conveyor belts with capacity of 11000t/h and even higher can be
deployed to match with higher capacity mining machinery.

3. Longer distances can be covered more economically than any other transportation system.
A single belt conveyor or a series of belt conveyors can do this. Belt conveyors can be
adopted for cross-country laying.

4. By the use of many forms of ancillary equipment such as mobile trippers or spreaders bulk
material can be distributed and deposited whenever required.

5. Many other functions can be performed with the basic conveying like weighing, sorting,
picking, sampling, blending, spraying, cooling, drying etc.

6. Structurally it is one of the lightest forms of conveying machine. It is comparatively

cheaper and supporting structures can be used for many otherwise impossible structures such
as crossing rivers, streets and valleys.

The limitations of conveyor belt are:-

1.The loading and transfer points need to be properly designed.

2.Numbers of protective devices have to be incorporated to save the belt from getting
damaged by operational problems.

3.The belt needs higher initial tension (40-200% of useful pull).

4.The use of belt is restricted by the lump size. If the maximum diagonal of a irregular lump
is X then the belt width (B) is approximately given by:

where, B: Belt width, mm

X: Longest diagonal of irregular lump, mm

5.Conveying of sticky material is associated with problems of cleaning and discharge causing
poor productivity.

23
Belt Conveyor Types:-
Permanent: This type of conveyors is installed for the life of the mine. They are used in
main line, slope, long overland installation, preparation plants and stockpiles.

Portable: These are characterised by relative ease of assembling and disassembling to

facilitate advances and recovery in development and retreat operations in underground
mining. Portable conveyors mounted on crawler or wheels are also used in mechanised
quarries and surface mines.

Shiftable: Used in continuous surface mining this type of conveyor is mounted on skid or
supporting structures aligned together and the whole can be shifted transversely to follow the
advancing working face.

High Angle: Conveyor: These are special type of conveyor belt arrangement used for
negotiating steeper angle of inclination. Such belts can work in slope up to 70-800. Sandwich
belt conveyor is a type of such belt conveyor.

Cable Belt Conveyor: Where the belt is carried on moving wire ropes and the tractive force
is applied through the rope to the belt is known as cable belt conveyor. NALCO (in
collaboration with France) is using such system for long distance conveying of bauxite in
their mines in Orissa.

Fig:9 Level and inclined Conveyor

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Screw conveyor:-
A screw conveyor or auger conveyor is a mechanism that uses a rotating helical screw blade,
called a "flighting", usually within a tube, to move liquid or granular materials. They are used
in many bulk handling industries. Screw conveyors in modern industry are often used
horizontally or at a slight incline as an efficient way to move semi-solid materials, including
food waste, wood chips, aggregates, cereal grains, animal feed, boiler ash, meat and bone
meal, municipal solid waste, and many others. The first type of screw conveyor was the
Archimedes' screw, used since ancient times to pump irrigation water.

They usually consist of a trough or tube containing either a spiral blade coiled around a shaft,
driven at one end and held at the other, or a "shaft less spiral", driven at one end and free at
the other. The rate of volume transfer is proportional to the rotation rate of the shaft. In
industrial control applications the device is often used as a variable rate feeder by varying the
rotation rate of the shaft to deliver a measured rate or quantity of material into a process.

Screw conveyors can be operated with the flow of material inclined upward. When space
allows, this is a very economical method of elevating and conveying. As the angle of
inclination increases, the capacity of a given unit rapidly decreases.

Fig:10 Screw conveyor

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Conclusion:-
The above describes the main features of the coke oven plant at Bhushan steel Limited,
Angul. The resultant main output streams are shown in the table below. The quantities shown
are intended to be indicative only and relate to a typical facility producing 1.3 million tons
per year of blast furnace coke. Coal properties and plant design and operation influence the
actual quantities.

Typical quantities,
Stream Destination based on 1.3 million
tons per year coke
Coke Oven Gas Used as fuel gas at the coke 50 million std.cu. ft./day
oven battery and steel works

Flushing Liquor Re circulated back to the Varies with plant design

coke oven battery

Waste Water Discharged to treatment plant Varies with plant design

Tar Sold as product 29,000 gallons/day

Ammonia/ Ammonium Sold as product 12 tons/day (as ammonia)

Sulphate

Light Oil (if recovered) Sold as product 12,500 gallons/day

Sulphur/Sulphuric Acid (if Sold as product Varies with coal properties

gas is desulfurized) and local requirements

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References:-
1. Austin, G.T., “Coal Coal Chemicals” Shreve’s Chemical Process Industries Fifth Edition
Edited by George T. Austin McGraw Hill International editions1984.

2. Mukhulyonov, I.U., Kuznetsov, D., Averbukh, A., Tumarkina, E., Furmer “Chemical
Technology”, Mir Publishers Moscow,1974

3. Tirodkar, R.B., Belgaonkar, V.H. “Use of chemicals derived from coal in surface coating
industry” Chemical Business No.4, April 1991,

4. http://en.wikipedia.org/wiki/Coke_%28fuel%29

5. http://www.paulwurth.com/en/Our-Activities/Cokemaking/Coke-Oven-Plants

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