Package – 3 (By-Product Plant)

Introduction:
The purpose of By Product Plant is to clean the raw coke oven gas generated in batteries with removal
of tar, ammonia, hydrogen sulphide and naphthalene to the extent. The coke oven gas after cleaning
in the BPP will be distributed to various other units of the plant through IPPL (Inter Plant Pipe Line)
network.

In order to make raw coke oven gas suitable for use as a fuel gas at the coke oven battery and
elsewhere in the steelmaking facility the by-product plant must:

i. Cool the coke oven gas to condense out water vapor and contaminants
ii. Remove tar aerosols to prevent gas line/equipment fouling
iii. Remove ammonia to prevent gas line corrosion
iv. Remove naphthalene to prevent gas line fouling by condensation
v. Remove hydrogen sulfide to meet local emissions regulations governing the combustion of
coke oven gas.

In addition to treating the coke oven gas, the by-product plant must also condition the flushing liquor
that is returned to the coke oven battery, and treat the waste water that is generated by the coke
making process.

TECHNICAL PARAMETERS UOM VALUE

Total coke oven gas generation Nmᶟ/h 83,560
Type of byproduct Recovery type
Elements for recovery Coal tar, H2S & Naphthalene
Temperature of cooled co gas °C 80-85
Dry coal charged into two batteries t/h 261
Yield of coke oven clean gas Nm³/t 261
Desired pressure of co gas MM or WC 800
Coke oven gas per battery Nmᶟ/h 41780
Co gas required for each battery
Nmᶟ/h 19450
heating
Net calorific value of co gas KCal/Nm³ 4300
Oil,greese & tar Mg/L 150-200
Purity of naphthalene & sulphur % 99
Yield of crude tar Kg/t 40
Yield of sulphur Kg/t 1.09
Yield of naphthalene Kg/t 0.17
Description:

1. Raw Materials:
Solar Oil, Caustic Soda, Catalyst and chemicals required for Effluent Treatment Plant.

2. Output:
Tar, Naphthalene and Sulphur.

3. Other technological facilities for By Product Plant:

The By-product plant along with Effluent Treatment Plant will consist of following technological
units:

 Primary Gas Cooler:

Primary gas coolers are intended for primary cooling of coke oven gas to about 23°C, entering
into it from gas collector at about 80-85°C temperature.

The first step in the treatment of raw coke oven gas is to cool it to remove water vapor 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 recirculated 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.

 Gas Condensation Plant (GCP) / Tar Removal Plant (TRP)

i. Coarse Condensation Plant (CCP): The coke oven gas in gas collecting main will be
cooled to 80-85°C by spraying flushing / Ammonia cal liquor. The coal fines mixed with
tar & flushing liquor is known as sludge. Tar, sludge and ammonia cal liquor will be
separated by gas condensation. Sludge being heavier, settle at bottom of the decanter,
then tar settles down at bottom and liquor flows from top.

ii. Fine Condensation Unit: In fine condensation unit, cooling tower & chilled water
(Vapour Absorption Machine) plant will be used for catering the requirement of
primary gas cooler & other heat exchangers. Electrostatic Tar Precipitator is used to
remove the remaining tar fog of gas.
iii. Exhauster Unit (EU): Electric motor driven exhauster will suck the coke oven gas
leaving electrostatic precipitator.
 iv. Tar Storage Unit (TSU): Crude tar from immediate tank of tar is pumped to large crude
tar storage tank.

v. Deterring Ammonia Liquor Unit: Excess ammonia cal liquor will be used as part of
scrubbing liquor in H2S/NH3. Mechanical deterring gravel filters will used for deterring
the liquor.

 Electrostatic Tar Precipitator (ETP)

Electrostatic tar precipitators are intended to remove the tar from coke oven gas
continuously to bring the tar at the battery limit to meet the design basis.

 Exhauster
The exhauster will be designed to cater total gas load to be generated from the coke oven
batteries as well as fluctuation of battery gas make load. Suction pressure of exhauster will be
suitable to meet the requirements of proposed coke oven battery.

 Coke Oven gas desulphurization

There are several different processes for removal of hydrogen sulfide from coke oven gas. The
specific process determines where in the gas train it is installed. The main desulfurization
processes in use are:
i. Vacuum Carbonate Process
ii. Ammonia Wash Process
iii. Sulfiban Process

The hydrogen sulfide is converted into elemental sulfur, using the Claus process, or it can be
used for the production of sulfuric acid.

 Final Gas Cooling & Naphthalene Removal Plant

The Coke Oven Gas heated at gas exhauster will be cooled in Final Gas Coolers which is similar
in construction as Primary Gas Coolers. Final Coolers & Naphthalene scrubbing unit will be
separate and independent for 2 batteries i.e. gas from 2 batteries will be treated
independently into 2 separate streams.

 Naphthalene Stripping Plant

Naphthalene enriched solar oil is taken continuously from enriched solar oil tank into this unit
for separation and subsequently recovery of naphthalene from solar oil.

 Ammonia & H2S Removal & Recovery Plant

 Removing of Ammonia & Hydrogen Sulphide from coke oven gas is technological &
environmental necessity. Coke oven batteries after removing of impurities will be used as fuel
in the Integrated Steel Plant as well as for heating of coke oven battery. This unit consists of:
 i. Ammonia & H2S scrubbing unit: Scrubber is intended to remove NH3, H2S, HCN &
Naphthalene etc. The scrubbers will ensure gas tightness.
ii. Ammonia stripping & Deacidification/Dissociation Unit: The dissociator / deacidifier
will strip of NH3, H2S, CO2, HCN from the rich solution received from H 2S/NH3 scrubber
by means of steam.
iii. NH3 removal by cracking & Sulphur Recovery Plant (SRP): The vapour coming form
dissociator will enter to Claus kiln for burning. The process gas leaving the catalytic
oven reactor enters to Waste Heat Boiler system for cooling down the process area.
The process gas leaving the boilers is directed to the Claus Reactor.
The Claus reactor as part of the sulphur recovery system is just one example of where
high performance materials are used. Sulphur needs to be solidifying; hence liquid
sulphur will be pumped to mechanized sulphur solidification unit.

 Effluent Treatment Plant (ETP)

ETP is one type of waste water treatment method which is particularly designed to purify
industrial waste water for its reuse and its aim is to release safe water to environment from
the harmful effect caused by the effluent. Effluents generated from BPP and coke oven
battery is contaminated with toxic pollutants which needs treatment prior to reuse in plant.

 Chilled Water Plant (CWP)

A water-cooled chiller uses the refrigeration process. The refrigerant vapor is used to chill
process water in the evaporator and then the vapor enters the compressor of the chiller. The
condenser contains a source of cooling water from either a nearby local water source or a
cooling tower.

 Heat Exchangers
The heat exchangers will be of shell & tube types, and are designed to exchange or transfer
heat from one medium to another. Within the industrial sector, cooling tends to be the more
prevalent function in order to prevent equipment or volatile substances from overheating.
Heat exchangers may also be used to capture and transfer steam or heat exhaust that is
released as a byproduct of a process or operation so that the steam or heat can be put to
better use elsewhere.

 Static Mixer
Static mixer will be installed on the Ammonical liquor feed line leading to Ammonia column.
The purpose is to mix thoroughly Ammonical Liquor and Caustic Soda solution before feeding
to Ammonia column where fixed ammonia from excess flushing liquor is removed.

 Surface Aerator
Mechanical surface aerators are widely used for many applications in modern waste water
treatment. They transfer atmospheric oxygen to the liquid by surface renewal and exchange.
  Storm Water Drainage
Storm water drainage will consist of well designed open surface drains network so that all the
storm water is efficiently drained off without any water logging. Design rainfall intensity will
be taken as 100 mm/hr.

4. Design Basis

Dry coal charge to each battery : 130.5 t/hr (Approx)

Yield of coke oven clean gas : 320 Nm3/t of dry coal
Raw COG for each battery : 41780 Nm3/hr
Clean COG for each battery heating : 19450 Nm3/hr

Following overload design factor will be considered in finalizing the capacities for individual
equipment:
Gas Condensation Plant : 1.15
Other units of By Product Plant : 1.07
Gas Velocity in gas pipe : 10-12 m/sec.

5. Impurities & Net Calorific Value

Impurities in Raw & Clean COG (in gm/Nm3):

Impurities Raw Coke Oven Gas Clean Coke Oven Gas
Tar 100-120 0.02 (max)
Benzol Hydrocarbons 30-36 -
Hydrogen Sulphide 3-4 0.50 (max)
Ammonia 10-12 0.03 (max)
Naphthalene 8-10 0.05 (max)
3)
Net calorific value (in Kcal/Nm
4300 (indicative) 4000

6. Quality of finished product

i. Crude Tar-
Moisture Content : 4% (max)
Specific Gravity at 40°C : 1.18
ii. Sulphur : Elemental sulphur (minimum 99% purity)
iii. Naphthalene
Purity : 99% (minimum)
Dew Point : 50-50°C
Melting Point : 80-82°C
Boiling Point : 218°C
 Oil Content : 1% (max)

7. Yield of Product (depends on raw COG quality)

i. Crude Tar : 40 kg/t dry coal
ii. Elemental Sulphur : 1.09 kg/t dry coal
iii. Naphthalene : 0.17 kg/t dry coal

8. Transportation
Tar, naphthalene and sulphur will be loaded into tankers and transported by road/rail.

Conclusion
The above describes the main features of the byproducts plants. The resultant main output streams
are shown in the table below:

Stream Destination
Coke Oven Gas Used as fuel gas at the coke oven battery and steel works
Flushing Liquor Recirculated back to the coke oven battery
Water Waste Discharged to treatment plant
Tar Sold as product
Ammonia/ Ammonium Sulfate Sold as product
Light Oil (if recovered) Sold as product
Sulphur/Sulphuric Acid (if gas
Sold as product
is desulphurized)