Since the oven top space is a high temperature atmosphere 1,100 to 1,200k, the coal carbonization gas is subject to thermal decomposition there, causing carbon to deposit on the surface of the refractory bricks that make up the coke oven chamber. Cokeoven wall repair types and methods journal article. You may need a pdf reader to view some of the files on this page. Coke oven furnaces coke oven european environment agency. Pdf combustion control system for coke ovens embedded with. The coke ovens exhaust the combusted hot flue gas, which must be cooled and environmentally treated, into a series of refractorylined manifolds to collect the gas. Coke is the only solid material remaining below the cohesive zone in the blast furnace refer figure a for various zones of operation in blast. Prototypes convert coal to coke used as fuel by many. The heating of ovens is done from both the sides in side fired batteries. The beehive coke oven design emanated from the charcoal kiln process practiced earlier. Coke oven emissions cancercausing substances national. From coking coal to coke perspectives for met coke.
Operations poducts coal emoval desulphurization emoval coke 6 1 3 6 5 1 3 2 5 6 1 3 2 6 1 3 2 4 6 1 3 6. Physical coke properties a high quality coke is characterized by a definite set of physical and chemical properties that vary within a narrow limit thereby ensuring consistency in the quality. Alfa laval has a long history of helping coke producers meet their challenges with our solutions for heat transfer and separation. Coke oven and quench tower with larry and quench cars kit. The entire cokemaking operation is comprised of the following steps. The oldest of nippon steels operational coke oven batteries is 43 years old. Us20020084210a1 method of inhibiting deposits in coke. After the 1920s, the dunlap coke ovens lay dormant for over a half century. The process also includes the processing of coke oven gas to remove tar, ammonia usually recovered as ammonium sulfate, phenol, naphthalene, light. Built in the early 1900s, the facility consists of five batteries of 268 beehive ovens, which operated under various companies until the early 1920s. The material remaining is a carbon mass called coke. Fabric filter applications on coke oven pushing operations james e. For many years, coke ovens have been built in large batteries of, for example 25 80 plus, immediately adjacent oven chambers varying in height from 3 7 meters and up to or exceeding 15 meters deep. These operations will be discussed in greater detail for the.
A key operational requirement is to sustain target draft at the interface between the fgd and the oven batteries to maintain the required operational draft at the ovens. The residual risk analysis described in this report addresses four coke plants subject to the 1993 coke oven mact standards 40 cfr part 63 subpart l and estimates potential risks due to haps emissions from facilities involved in coking operations. The emissions are complex mixtures of dust, vapors, and gases that typically include carcinogens such as cadmium and arsenic. It is an important industrial product, used mainly in iron ore smelting, but also as a fuel in stoves and forges when air pollution is a concern the unqualified term coke usually refers to the product derived. Cokenergys waste heat recovery steam generators hrsgs, arranged four per oven battery, receive and recover heat from the coke oven exhaust gas, producing powergrade steam and. This ho structure is right at home in your steel works operations, but theyre also operated at mines and as freestanding operations.
This volatile matter leaves the coke oven chambers as hot, raw coke oven gas. Trainees shall observe the operation of a coke oven battery as it pertains to method 303, including topside operations, and shall also practice conducting method 303 or similar methods. Higher capacity of the coke oven chamber is an important parameter for byproduct recovery type ovens. Supply the endless appetites of the furnaces for fuel with the highly detailed coke oven and quench tower with larry and quench cars from cornerstone. Bf operator faces dilemma either buy coking coal for own coke plant or buy coke on free market. These tests are used to evaluate how coals and coal blends will perform in byproduct coke ovens in terms of ease of pushing of the coke mass from the oven, coking pressure, and resultant coke quality. As larger amount of coal is held in an oven, it significantly reduces the number of pushings per day and hence emissions per ton of coke. Typically, a single ton of coke generates approximately 360 m 3 cog. The firms traditional products are fireclay bricks and silica bricks for coke oven plants. The ovens are now listed on the national register of historic places, and are maintained by the sequatchie valley. The byproduct cokemaking process results in the recovery of salable crude by product materials including cokeoven gas, ammonia liquor, tar and light oil. Stamp charged coke making technology facilitates reduction in volume of voids between the coal particles from almost 40% in usual top charging operations to less than 20%. Coke oven temperature measurements application note. It is made with coke bricks arranged in a 3x3x3 solid cube and rightclicking on a central block of any face with an engineers hammer.
We provide heat exchangers for the most demanding duties involving. Risk assessment document for coke oven mact residual. The blended coal is charged into a number of slot type ovens wherein each oven shares a common heating flue with the. Coke oven pushing emissions containing quantities of tars and dust require new approaches to adapt fabric filter collectors.
A world class blast furnace operation demands the highest quality of raw materials, operation, and operators. Coke is one of extremely important raw materials for ironmaking. A method of inhibiting andor removing deposits from coke oven gas handling equipment is disclosed which comprises the addition of a treatment combination of a heterocyclic nitrogenous compound such as quinoline and 2butoxyethanol to the. The coke ovens are nonrecovery type, which combusts the coke oven gas in the ovens as it is generated. Pdf combustion control system for coke ovens embedded. Santanu chakraborty, in treatise on process metallurgy. Coke manufacturing industry description and practices coke and coke byproducts, including coke oven gas, are produced by the pyrolysis heating in the absence of air of suitable grades of coal.
Our innovative technology produces highquality coke in the larger sizes preferred by blast furnace steel customers. Coke oven gas renaissance of a fuel in the 19th and the first half of the 20th century coke oven gas was one of the main sources of energy for urban households. Operation of cuttingedge coke oven having all of durability. It is normally used in coke oven battery heating, heating in other furnaces of the steel plant, and for power generation. In the process of converting coal into coke using the byproduct coke oven, the volatile matter in the coal is vaporized and driven off. It is an important industrial product, used mainly in iron ore smelting, but also as a fuel in stoves and forges when air pollution is a concern. Considering the complexity and importance of flue temperature control in coke oven heating process, the control method of combining the. Because ihccs metallurgical coke ovens continuously operate, generating flue gas 24. Ensuring reliable operation of your coke oven gas plant is more important than ever in securing a stable supply of clean fuel for your steelworks. The plants coke oven batteries will be located on a southwest to northeast line within approximately 100 feet of the eastern property line of the project site.
Normal life of a coke oven battery under indian condition is considered to be 25 years. Cokenergy preventive maintenance and operations plan. But the impurities it contains make it unsuitable for use as fuel or feedstock. The jmh emission control system uses a reverse jet bag filter unit to remove the dust from the high temperature gases. Adams ii department of chemical engineering, mcmaster university, 1280 main st. Suncoke energy our business coke business advanced. Fabric filter applications on coke oven pushing operations. Oct 18, 2015 coke ovens are mainly constructed of silica, fireclay, high alumina and ordinary insulating bricks.
Coke oven and quench tower with larry and quench cars. New coal charging car at arcelormittal zenicas coke battery duration. Prepared coal is heated in an oxygenfree atmosphere coked until most volatile components in the coal are removed. Coke oven gas cog is highly rated as a valuable byproduct of coal carbonization to produce coke in the steel industry. Coke is created by heating metallurgical coal to around 2,000 degrees fahrenheit. It was used for gas lamps, for heating and cooking. Coke is the most important raw material fed into the.
The fds coke plant is designed to charge of total of 2. To reduce costs, improve yields and treat gas in an environmentally responsible way, alfa laval provides highly efficient solutions for refining from primary gas. Coke oven emissions come from large ovens that are used to heat coal to produce coke, which is used to manufacture iron and steel. Before carbonization, the selected coals from specific mines are blended, pulverized, and oiled for proper bulk density control.
The coke oven byproduct plant is an integral part of the byproduct cokemaking process. The coking process takes about 12 to 36 hours in the oven to complete, according to the world coal association. Faced with this situation, the company has developed and applied a variety of coke oven repair technologies, from such simple repair methods as gunning and hot spray. In order to improve the level of control and management of coke oven, the research on intelligent control system is carried out. New coal charging car at arcelormittal zenicas coke battery. The throughwalls separating adjacent ovens burn coke oven gas generated by the coking process to heat the ovens to the coking temperature. During that time, the volatiles of the coal are driven into the offgas and a pure carbon form called coke remains. Industry profile draft report prepared for daniel c. Coke oven gas forms a major component in the energy balance of the steel plant. Coke is a key ingredient in the production of steel. Its structure is growing decrepit, and this is more or less true of all the other batteries. The following discussion does not include such purely inplant problems as coal dust incident to the grinding and.
While a blast furnace is operating, the stop of supplying the raw material is not allowed, and very. In many parts of the world the population was supplied with purified coke oven gas as town gas. Indiana harbor coke company ihcc metallurgical coke plant, consisting of four batteries of 67 coke ovens each to produce coke for ams blast furnaces. The plants coke oven batteries will be located on a southwest to northeast line within approximately 100 feet of. Optimization of coke oven gas desulphurization and. The emissions produced during the coking process contain a mixture of complex and toxic particles, including vapors, coal particles, gasses, tars and other carcinogenic substances. A method for cyclical operation of a coke oven facility which includes an even number of coke oven banks which in turn include an even number of coke oven chambers is shown. As larger amount of coal is held in an oven, it significantly reduces the number of pushings per day and hence emissions per ton of coke produced. The majority of coke produced in the united states comes from wetcharge, byproduct coke oven batteries figure 1.
Illinois, and international operations in vitoria, brazil, and odisha, india. The coke oven is a multiblock structure added by immersive engineering. Jan 17, 2019 in the coke oven, the coal is heated to 1,800f for up to 18 hours. The coke oven managers yearbook 224 gas as it is generated, and also to have a reliable continuous supply of flushing liquor to quench this coke oven gas.
Prototypes convert coal to coke used as fuel by many industries. Us2179635a us251295a us25129539a us2179635a us 2179635 a us2179635 a us 2179635a us 251295 a us251295 a us 251295a us 25129539 a us25129539 a us 25129539a us 2179635 a us2179635 a us 2179635a authority us united states prior art keywords heating wall heat oven coke prior art date 19390117 legal status the legal status is an assumption and is. The commercial cokemaking process can be classified into three. Its made by heating metallurgical coal in largescale, speciallydesigned ovens to more than 2,000 degrees fahrenheit, which leaves behind a carbonrich product called coke. Us20110253521a1 method for a cyclical operation of coke. Optimization of coke oven gas desulphurization and combined cycle power plant electricity generation lingyan deng, and thomas a. The coke oven managers yearbook 224 gas as it is generated, and also to have a reliable continuous supply of flushing liquor to quench this coke oven gas to a reasonably low temperature. The ovens are also computermonitored so operators can remotely assess each oven to finetune the coking process. In the coke making process, bituminous coal is fed usually after.
Conse quently, paul wurths jumbo oven battery concept. Coke is manufactured by heating coal to very high temperatures in a large refractory oven, known as a coke oven. This involves the incorporation of all necessary mechanical equipment on the machine with no requirement for an operator or benchman. Coke oven gas is an abundant byproduct of coverting coal into coke used in steel production. This paper deals with the wheelabratortaisei precoat filter systems being used on coke oven pushing operations. Coke ovens are mainly constructed of silica, fireclay, high alumina and ordinary insulating bricks. Cokenergy llc preventative maintenance and operation plan page 1 table of contents abbreviations 2 1. The dunlap coke ovens are the remnants of a coke production facility near dunlap, in the u. Our business unit process technologies supplies chemical plants. The emissions produced during the coking process contain a mixture of complex and toxic particles, including vapors, coal particles. West, hamilton, ontario l8s 4l7, canada corresponding author. Our coke also has consistently high values for coke cold strength and coke strength after reaction. Learn more about the jmh coke oven machinery technology in the john m henderson brochure pdf. Pdf coke oven intelligent integrated control system.
John m henderson coke oven machines have been designed for fully automated manless operation. Exposure to coke oven emissions may occur for workers in the aluminum, steel, graphite, electrical, and construction industries. Operations poducts coal emoval desulphurization emoval coke 6 1 3 6 5 1 3 2 5 6 1 3 2 6 1 3 2 4. Coke oven immersive engineering feed the beast wiki. By the 1980s, all that remained of the dunlap operations were the ovens, a slate pile and coal washer ruins, two company houses drastically modified, and the clubhouse. Sole heated oven sho tests done in the sole heated oven evaluate the contraction or expansion. Environmental protection agency innovative strategies and economics group md15 office of air quality planning and standards oaqps air quality standards and strategies division research triangle park, nc 27711 prepared by research triangle institute. After being taken out of the oven, the coke is cooled with water or air to before it is either placed into storage or is put directly to the blast furnace. John m henderson pusher machines are at the cutting edge of coke oven equipment technology.
Coke oven gas can be used as such or can be mixed with the blast furnace gas before being used as fuel in a furnace. Coke oven gas treatment tar, liquor, ammonia by keith wright. The coke oven chimney is made of concrete lined with fireclay bricks. Located downstream of the coke oven banks are boiler facilities which drive turbines with the hot waste gases from the coke oven banks.
Beehive process is a self heating process where the volatile matter is burnt over the coal charge under restricted and directed air supply, and the radiant heat bounces back to the charge from its arch shaped roofs. Chronic longterm exposure to coke oven emissions in humans results in conjunctivitis, severe dermatitis, and lesions of the respiratory system and digestive system. Coke is a grey, hard, and porous fuel with a high carbon content and few impurities, made by heating coal or oil in the absence of aira destructive distillation process. Oven conditions considered while a repair is made are hot idle, hot operating and.
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