BSP - Innovations in Co & CCD - BSP - Op Comm Meeting - Feb 2011 at Jsw.

WELCOME
TO THE
PRESENTATION
Recent Innovations in Coke Ovens & Coal Chemicals
By: S K Ghosh, Pushpa Ambrose, B L Chandwani & Atul Goswami

1
© 2011 BHILAI STEEL COKE PLANT_ RECENT INNOVATIONS IN CO&CCD
Agenda
INNOVATIONS IN:
• COKE OVEN BATTERY AREA
• COAL AREA
• COAL CHEMICAL AREA

2
Agenda:
1. INNOVATIONS IN COKE OVEN BATTERY AREA.

3
A Glance at Coke Oven Batteries
in
Bhilai Steel Plant
4.3 metre tall Batteries 7 metre tall Batteries
(8 nos.having 65 ovens each) (2 nos. having 67 ovens each)
Batteries: 1 to 8 Batteries: 9 & 10

&
Oven Oven
Dimensions Dimensions
Length : 16 mt
Length : 14 mt
Avg Width : 407mm Avg Width : 410 mm
Volume : 21.6m3 Volume : 41.6 m3

4
TITLE OF THE INNOVATION
Redesigning and Modifying the Charging hole bricks in
Battery # 5 to address the issues related to production,
safety & environment.

5
THE PROBLEM:
During commissioning of the Battery it was found that while
opening the charging hole cover (hatch cover) for charging
the ovens with the help of magnetic lid lifters mounted in
charging car, the charging hole frame (hatch ring) was
getting uprooted and thus hindering the charging process.
At times the uprooted hatch ring got stuck with the oven top
paving also making it’s repositioning more difficult

6
This led to:
Production stoppages
Damage to CC lid lifters
Repositioning of H/R leading to time consumption
and labour wastage
Besides, Ovens remaining empty in newly rebuilt
Battery posed a threat, too.

7
THE ANALYSIS:
The bricks around the hatch ring, which is meant to hold
the ring/frame in its position, was not having proper
holding to restrict the hatch ring getting uprooted during
the hatch opening operation by the CC. 2 3
4
1

8
THE ANALYSIS (contd.):
Further in-depth analysis revealed that the bricks was not
having proper groove to support the seating of the hatch
ring. The brick design was changed by the designer !

2 3
1 4

9
INITIAL THOUGHTS……
It was decided to make a groove in all the bricks, which was
not possible as this caused cracks in the brick and its
thickness being less it further weakened the brick. It was then
proposed to replace the bricks with bricks being used in other
Batteries. But then it would take some time as the spare bricks
2 3
were not available in store.
1 4

10
In this perplexed situation …..the only ray of hope was
INNOVATION….
as, the situation demanded this problem to be addressed
2 3
adequately & most importantly……URGENTLY!
1 4

11
Innovation = Creative Idea / Invention
+
its useful application
2 3
1 4

12
INNOVATING……..THE HATCH RING BRICK DESIGN
 A frame using dia 10 mm MS rod was fabricated. In the centre

of this frame hatch ring was placed and grouted using HC
Castable powder. It was allowed to dry for 24 hours.
 Then this structure was shifted to the oven where the hatch
O N
brick had to be changed. The old hatch ring & cover were
removed, along with the bricks.
T I
V A
 After cleaning the area, 40mm thick fireclay brick lining was
laid at the surface ofO
N the area where the new casted structure
IN This was done to align the movement of lid

has to be placed.
lifters.
13
INNOVATING……..THE HATCH RING BRICK DESIGN(contd.)
Then the new structure of hatch ring was placed and
fireclay mortar was poured on all four sides to ensure proper
sealing.
N
Ounder observation for a
T
The implemented design was kept I
week for improvement if A
O V any and then the same was
N
IN
implemented for all charging hole (195 nos.) in Battery-5.

14
O N
T I
VA
NO
IN

15
HIGHLIGHTS OF THIS INNOVATION
 Quality of sealing around the hatch ring with this
modification is excellent.
N
 The new casted structure has resulted in zero
O
breakdowns for the past 8 T
I
V A months. There has been no
N O
case of hatch ring dislodgement and brick damages
IN
after changing all the bricks with new design.

16
HIGHLIGHTS (contd.)
 The modification has also been incorporated in
N
Battery No: 6, which is being rebuilt, to avoid
O
T I
A
recurrence of the same problem.
V
N O
IN
17
O N
T I
V A
NO
IN
18
O N
T I
V A
NO
IN
19
BATTERY- 5 BATTERY- 6

20
Thanks
from BSP Coke Ovens & Coal

Chemical Collective
21

BSP - Innovations in Co & CCD - BSP - Op Comm Meeting - Feb 2011 at Jsw.

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WELCOME

Recent Innovations in Coke Ovens & Coal Chemicals

By: S K Ghosh, Pushpa Ambrose, B L Chandwani & Atul Goswami

• COKE OVEN BATTERY AREA

• COAL CHEMICAL AREA

By: S K Ghosh, Pushpa Ambrose, B L Chandwani & Atul Goswami

1. INNOVATIONS IN COKE OVEN BATTERY AREA.

By: S K Ghosh, Pushpa Ambrose, B L Chandwani & Atul Goswami

Batteries: 1 to 8 Batteries: 9 & 10

By: S K Ghosh, Pushpa Ambrose, B L Chandwani & Atul Goswami

Redesigning and Modifying the Charging hole bricks in

Battery # 5 to address the issues related to production,

safety & environment.

By: S K Ghosh, Pushpa Ambrose, B L Chandwani & Atul Goswami

During commissioning of the Battery it was found that while

opening the charging hole cover (hatch cover) for charging

the ovens with the help of magnetic lid lifters mounted in

charging car, the charging hole frame (hatch ring) was

getting uprooted and thus hindering the charging process.

paving also making it’s repositioning more difficult

Damage to CC lid lifters

Repositioning of H/R leading to time consumption

and labour wastage

Besides, Ovens remaining empty in newly rebuilt

Battery posed a threat, too.

The bricks around the hatch ring, which is meant to hold

the ring/frame in its position, was not having proper

holding to restrict the hatch ring getting uprooted during

the hatch opening operation by the CC. 2 3

By: S K Ghosh, Pushpa Ambrose, B L Chandwani & Atul Goswami

Further in-depth analysis revealed that the bricks was not

having proper groove to support the seating of the hatch

ring. The brick design was changed by the designer !

By: S K Ghosh, Pushpa Ambrose, B L Chandwani & Atul Goswami

It was decided to make a groove in all the bricks, which was

not possible as this caused cracks in the brick and its

thickness being less it further weakened the brick. It was then

proposed to replace the bricks with bricks being used in other

By: S K Ghosh, Pushpa Ambrose, B L Chandwani & Atul Goswami

as, the situation demanded this problem to be addressed

By: S K Ghosh, Pushpa Ambrose, B L Chandwani & Atul Goswami

By: S K Ghosh, Pushpa Ambrose, B L Chandwani & Atul Goswami

 A frame using dia 10 mm MS rod was fabricated. In the centre

IN This was done to align the movement of lid

Then the new structure of hatch ring was placed and

fireclay mortar was poured on all four sides to ensure proper

By: S K Ghosh, Pushpa Ambrose, B L Chandwani & Atul Goswami

By: S K Ghosh, Pushpa Ambrose, B L Chandwani & Atul Goswami

 Quality of sealing around the hatch ring with this

By: S K Ghosh, Pushpa Ambrose, B L Chandwani & Atul Goswami

 The modification has also been incorporated in

By: S K Ghosh, Pushpa Ambrose, B L Chandwani & Atul Goswami

from BSP Coke Ovens & Coal

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