AN INTRODUCTORY

PRESENTATION ON COKE
OVEN PLANT
Prepared By:
Shreenath M Kalyane
(2010A1PS403G)
Rohit Vijayavargiya
(2010A1PS356G)

INTRODUCTION
Coke Oven processes the coking coal and
converts it into coke in large batteries in a process
called COKING.
This process consists of heating coking coal
in the absence of air to drive off the volatile
compounds; the resulting coke is hard but porous
carbon material that is used for reducing the Iron
in the Blast Furnace.
The Coke Ovens recover volatile chemicals in form
of
Coke Oven Gas, tars and oils.

Coke Oven Complex at BSL

As required coking coal is not available
in India , it is imported by shipping from
Australia.
This coal is processed in RMH unit. It is then
charged in the BATTERY unit to produce coke.
The volatile matter which contains coke oven
gas, tar and oil is very important.
These are called as by-product and are
processed in BY-PRODUCT unit. By-products like
tar, crude benzol are expensive and so they are
recovered and sold.

Basic flow chart

Raw Material Handling Unit (RMHS)

Need for raw material handling

Bhushan steel with an existing steel

production capacity of approx. 2 million tons
per annum is one of the pioneer in steel
making industries. The integrated steel plant
has three phases:
Phase 1 of 3 MPTA, phase 2 of 5 MPTA and
phase 3 of 7 MPTA capacity.
The project of this magnitude requires a raw
material handling technology that is
engineered to provide long life and is low on
maintenance services.

 Who took the project of raw material

handling?
When it came to installation of Wagon
Tippling equipment, BSL trusted Metso Wagon
Tipplers and found one stop solution for all its
need for moving the raw materials.
The main requirement of the RMH unit was to
load off raw material like iron ore, fluxes ,
coal etc. that are received from open top
railway wagons.
Metso proposed Rota Side Tippler (Hl-Lift XL)
with a Side Arm Charger as a part of the

 Why Metso Wagon Tipplers?

Metsos material handling technology

besides performance and efficiency focuses a
lot on safety operations.
They have been designed to avoid all types
of damages to man, machine and accessories.
It is also very environmental friendly because
they come with a built in water spray system.

Functions of RMH unit in Coke Oven

In RMH, coal is sorted according to its quality.
VM% of coal has to be maintained as
per requirement and it is done in RMH unit.

Because of BSLs captive raw material supply,

BSL has been a key beneficiary of the RMH unit.
It helps a lot in improving the efficiency and
performance of following processes.

Battery unit
Battery unit is
the main
function unit of
coke oven
complex.

Recovery type coal

: forms by-product with
coke
Non recovery type coal: forms coke only

Battery is the unit where all the processing takes place.

It converts raw coal to coke.
Two methods uses for coke making: a) using B/F gas
b) using COG
Battery consists of following sections
Charging car
Pushing car
Quenching car
Guiding cars
Ovens

 Process of coke formation

Crushed and blended coal from RMH unit is

taken as input. Size of coal is -3 mm. Required
amount of moisture is added because input is
basically dry coal and in order to form cake
moisture is added. Input is now stamped and
coal cakes are formed. These cakes are then
charged into the batteries. They are baked for
40 hrs. and when the VM content of coal is
removed output is coke.

 Functions of different cars

Charging car is used to charge the coal cake

in the battery.
Pushing car is used to take out formed coke of

the oven.
Quenching car is used to lower the
temperature of coke.
Guide cars are used to guide the process.

 Construction of battery

Each battery consists of 64 ovens and 65

heating valves. In order to sustain high
temperatures, batteries are lined internally
with refractory bricks. On an average 39
ovens in each battery are being used. Heating
material used is coke oven gas.
Heating takes place in absence of oxygen
through heating valves.

Schematic diagram of coke oven

plant

Battery unit

 Capacity of Coke Oven Batteries

0.85 MTPA(phase 1)
1.00 MTPA(phase 2)

By-product unit
What is a Byproduct?

A byproduct is a secondary product

derived from
a manufacturing process or a
chemical reaction. It is not the primary product
or service being produced. A byproduct can be
useful and marketable or it can be considered
waste. They are called so because they
generate revenue.

Preparation of coke leaves behind ash, moisture

and VM. Ash being of no use is dumped and VM is
processed in by-product unit.
VM contains tar, naphtha, ammonia, sulfur, benzol
and coke oven gas. This VM is removed using
different processes and purified coke oven gas is
used in other units like Blast Furnace, SMS, Sinter
plant. This COG is again used in coke oven complex.
Byproduct unit mainly retains tar, crude benzol,
ammonium sulfate and sulfur. Tar and crude benzol
are be sold.

 Facilities at by-product unit

Gas-Liquid separator
Primary gas cooler(PGC)
Electrostatic tar precipitator (ETP)
Exhauster
Decanter
Crude benzol plant
Desulphurization plant
Different storages
Cooling water tower

Coke oven gas containing VM is

extremely hot and has a temperature around
900c. Ammonia liquor is sprayed in in order
to cool it to 80c. This gas is then sent to GasLiquid separator.

Process of retaining byproducts

Gas liquid separator
Due to cooling some amount of
gas condenses to liquid, which
is processed in gas-liquid
separator. It consists of a
vertical tower. Gas being
lighter is taken out form the
upper chamber and liquid is
drained from the lower pipe.
Liquid consists of tar, ammonia
and sludge
Liquid contains 95 % of the
total tar content the gas
initially had. Gas consists of
COG ,tar, benzol etc.

Processing of gas from GLS

Primary gas cooler(PGC)

Gas from GLS is processed

here. Temperature of the gas
is further lowered using
chilled water from cooling
towers. Temperature of the
gas now is 22 c. Around 3%
tar is removed in this process.

 Electrostatic tar precipitator(ETP)

Around 2 % tar is removed here. Electrodes are

used in ETP to attract the negatively charged tar
and precipitate it which is removed .
The gas is now almost
free of tar. Very few
traces of tar which do
not cause any effect in
further processes
remains. The gas is
sent for further
processing.

Processing of liquid from GLS

Mechanized ammonia water settling tank
Liquid portion from GLS is
processed here. Basically
gravity separation takes
place. Ammonia being
lighter is at top. Tar in the
middle and sludge in the
lower part. Ammonia and
tar are sent to their
storage tanks. Sludge is
removed from lower part
and can be used in coke
formation.
This section can also be
called as DECANTER.

Different
Storages

 EXHAUSTER

Exhauster or blower
is the heart of coke
oven plant. All the
gas movements in
different sections
take place with the
help of exhauster.

Flow chart of by-product unit

Major milestones of coke oven

collective
Commissioning of Coke Oven Battery #2 on

3rd dec. 2011.

Commissioning of crude benzol plant on 27 th

dec.
Completion and total commissioning of BOD

plant with effluent treatment facilities.

Commissioning of Desulphurization plant.

Journey of coke oven complex

Within three months of commissioning
Battery#1, the production level rose above
95% of the rated capacity.
Battery#2 was commissioned on 3rd
December 2011 and so far no problem
regarding stamping have been experienced.
The Battery is currently being operated at
70% capacity level.

Since commissioning of the first battery CO

gas worth Rs. 25 crores was supplied to the
plant grid, while crude tar worth Rs. 24 crores
was sold. Additional revenue of Rs. 25 crores
per month will be available on account of
crude benzol. Use of surplus COG to other
areas is also being implemented in phases.

As coke is a major contributor to the cost

of steel, the coke oven team intends to, in
coming days, maximize production with least
fluctuation in quality at the minimum cost,
and most importantly by adopting green
practices

Conclusion

THANK YOU