Coke Oven View

Coke Guide Charging Car Drawing Machine

Coke Oven View

Pyrolysis Physical Profile

Coking System

Swelling - Coking Pressure

Output of volatile material from coal and coke that is forming. Rise of pressure inside the plastic layers, which pushes the coke against the wall and compresses the coal between them and the coke does not let the gas get out completely.

Ressolidification

Cracks

Ressolidification

Contraction

Coke detached from the wall

Contraction

Coke detached from the wall

Carbonification Time

Coke Oven Plant View

Coke Oven Plant View

C o k e S i d e

P u s h e r S i d e

Coke Oven Plant View

Coke Oven Plant View

Charging car Pusher Machine Oven

Coke Charging

1-The Charging car is positionated to start

Blending

charging.

2- Coal is loaded in the oven according a standard procedure.

Leveling Bar

3- The Charge is leveled by the leveling bar.

Coke Guide

Piston

4- Completed coking process the coke oven doors are opened, the coke guide and quenching car are positioned. 5- The incandescent coke is pushed by the pusher machine.

Quenching Car

Horizontal Furnaces Battery

The walls of a coke oven are not parallel. The oven has a taper in the width of the oven, for ease of drawing operation.
Taper

(PS)

(CS)

Taper

Coke Oven Plant View

Coal Bunker
02 silos with capacity of 1500 t. Feed system that distributes coal by rotating chute in two silos. Level is controlled by the operator's control room.

Charging Car
The function of the charging car is put into the furnace the mixture of coal and control the furnace charge. The load of coal is weighed and then the car turns to an empty oven. Under the command of the operator, the car sits on the oven you want, and after the transfer of its load, returns to the Coal Bunker where is made a new weighing.

Charging Car

Coke Oven Plant Equipments

Coke Guide Drawing Machine

Charging Car

Coke Oven Plant View

Coke Oven Plant View

Coke Dry Quenching (CDQ)

Coke Dry Quenching (Giprokoks)

Comparative Between Coke Dry Quenching and Coke Wet Quenching

Parameter DI 15 - 150 Reactivity JIS Volatile Matter Porosity Average Size Distribution (mm) + 100 + 75 + 50 + 38 + 25 + 0 (zero)

CDQ 83,4 16,7 0,42 46,8 62,5 4,9 21,8 40,0 23,1 7,8 2,4

Wet 79,6 23,5 0,75 50,7 64,7 7,9 25,0 40,9 16,2 5,3 4,7

CDQ - Wet 3,8 6,8 0,33 3,9 2,2 3,0 3,2 0,9 6,9 2,5 2,3

CDQ Coke Dry Quenching

What is the Driven Force of the Coking Process:

The driven force is temperature.

Combustion is an oxidation reaction, whose processing agent is oxygen free

or combined, and has products such as CO2, H2O and heat.

The heating system can be divided in two units: the combustion chambers and regenerators (located underneath the ovens and walls of heating, recovering the sensible heat of the fumes). The combustion gas is admitted at half of these chambers and the combustion is ensured by the introduction of preheated air. An upward combustion happens in these chambers. The other half of the chamber ensures the evacuation of descended smoke.

View Coke Oven Plant

By-product Battery Combustion

The rich gas (COG) or the mixed gas (COG + BFG) are taken from the by-product of the plant and / or gasometer. The pipeline are designed to carry the appropriate volume of gas with supply pressure also suitable.

Physical Events During Cokemaking Process (coke oven plant slot)

Pyrolysis Thermal Profile

Time Curve

Cokemaking process
By-product oven
Combustion chamber Positive pressure Heating wall Free zone Coke mass

Heating wall

Horizontal front coking

Horizontal front coking Conduction Conduction

Vertical line of cleavage of coke mass

By-Products Battery

By-Products Battery Objectives: coke production with consistent high quality, appropriate thermal efficiency and low emission of contaminants in withdrawing. Appropriate conditions for achieving the goals: Homogeneous charge in terms of moisture, particle size and charge density (which highlights the importance of coal preparation and charging techniques of coal in coke oven). At the end of the coking cycle, just before withdrawing, the temperature of coke in the charge center (equidistant from the walls of heating) should be the same (around 1050 oC). In order to obtain uniform conditions of temperature inside the charge is necessary to adjust and control the vertical and horizontal temperature profiles of each and heating wall along the entire length of the battery.

Curves of Temperature Rise Within the Charge of Coke Oven

Wall Temperature (C) Middle

Coking Time (h)

Efficient Operation of Coke Battery

Stable production. Smallest possible change in production leads to an efficient operation. So it is better withdrawing stably and non-stop for shift changes, meal breaks etc.. Ovens properly completed. Leads to better production rates and lower energy consumption per tonne. It also reduces the space above the charge to the formation of naphthalene (good charging systems and adding oil helps to have well-filled ovens). Maintenance and preservation.As in any plant a good maintenance / preservation (door frames and walls) is a indispensable prerequisite. Consistency of the coal blend (formula, blending, particle size and moisture). Regulating the supply of gas so that combustion is complete and the amount of excess air is equal to the practical minimum. Correct adjust of heat to the whole heating wall in order to have uniform coking. Optimum time of reversal. There is an optimum time in order to have the best efficiency. Each battery has its optimum time.

Efficient Operation of Coke Battery Regularity of withdrawing scale. Maintaining of proper pressure balance Measurements and main controls. An important requirement for efficient operation is to measure and control the parameters that affect the process.

Efficient Operation of Coke Battery

Heating control: Various methods are used to this control, with the common goal of stable operation (coking optimization and minimization of energy consumption). Combustion control: it is essential that the products of combustion in the burnt gas be measured, especially CO and O2, if its value is known it assists in the proportion of the air/ gas for the burning and help to control the damper of the chimney. In order to achieve good control may be required individual adjustment of one or more ovens using portable analyzers.

Operational Control of Coke Battery

Temperature Control 1. Control of the heating characteristics, temperature measurement along the walls (all the wall chambers are monitored) and average temperatures of the battery (selected chambers, usually two per wall, are monitored).

Measures Objective : Distribution avaliation of the battery heating 2. Data presentation: 2.1. curve or graph of chamber temperature per individual oven. 2.2. Graphic of battery average taperature. 2.3. Battery temperature distribution.

Operational Control of Coke Battery

Heating Control 1. 2. 3. 4. Supply pressure of the heating gas. Heat imput. Heat input versus caloric value. Wobbe index versus the square root of difference pressure across the battery Combustion Control 1. 2. Quantification of burnt gas. Burnt gas analysis (O2 e CO)

Battery Average Temperature

The temperature measurement of the hundreds combustion chambers would be laborious and no practical. What do you do? Measure the temperature of some selected chambers (central chambers or fifth chambers from the coke side and pusher side of all walls except the end walls of the battery.) Optical and infrared pyrometers (focused on the bottom of the chambers in smoke, in the space between the holes of gas and air or at the base of gas burner coke oven)

Temperature Crosswall Distribution

Due the width increase of the PS to the CS oven, the temperature also increases gradually in this direction (the purpose is that coking times are similar along the entire length of the oven). The average temperature of the wall is obtained by the arithmetic average of its chambers, eliminating the measures of the extreme chambers (two CS and two PS). Taper (function of the furnace tapering) is the temperature difference between the third and antepenultimate chamber wall. The taper is achieved by regulation of sliding bricks located in inlet air and gas holes at the base of the chamber through the holes of inspection on top of the battery.

Temperature Crosswall Distribution

Temperature (C)

Battery 6m

Chamber

Temperature of Extreme Chambers

Individual control by regulating the flow of air and gas for those chambers (the end of each regenerator). The temperature of those chambers is lower for protection of metallic structures nearby, preventing formation of carbon deposit on the refractory of the doors and reducing the heat loss.

Vertical Distribution of Temperature

The more uniform distribution of temperature more uniform quality of coke. When the combustion is in only one stage (base of the chamber), the adjustment of the vertical distribution is done acting on the calorific value of gas and in the excess of air (factors that determine the height of flame). Hot top favors the formation of graphite and arising problems(difficulty of withdrawing, hanging, leaking doors, etc).

Temperature Vertical Distribution

Coking Rate Charge

Charge density of 820kg/m3 Coking heat of 400kcal/kg Moisture of 10% Wall thickness of 100mm

Coking Time (hours)

K = (/ t) (B/2)2
K = coking index

= charge density (t / m3)

B = oven width

Chamber Average Temperature (C)

Soaking Time

For more uniform the heating of the coke oven walls be, there is always irregular distribution of temperature inside the charge due the non-uniformity of charge density and differences in geometry of the oven that range from pusher side to coke side . Additional time (may be a few hours) to amortize the deficiencies in the distribution of temperature, for the charge has not temperatures significantly lower at the end of the coking cycle.

Soaking Time

As consequence, the mass of coke may not show uniform contraction and industrial practice shows lateral retraction ranged from 1 to 12 mm. If the temperature differences are really significant, part of the charge may not detach from the walls and the charge can only be withdrawing with difficulties or even stay hanged.
Charge contraction Operational security

Reasons for soaking time

Amortization of differences In charge temperature

Strength

Coke quality

Reactivity

Characteristic Curve of Vertical Coke Contraction

10

1 Coke Mass Temperature 2 - Vertical Contraction (CS) 3 Vertical Contraction (PS)

1

1000

Vertical Contraction (%)

8 2 6 2

800

600 3

400

2 1

200

10

12

14

16

Hours After Charging

Coke Mass Temperature (C)

Coke of Charge Top

Coke Oven Plant With Stamp Charge

Source: VCom, Seminrio ABM 2004

1,15 1,2 1 0,8 0,6 0,4 0,2 0 0,8 0,9 1

Charge Density (t/m3)

Top Charging

Briquette Blending

Preheating

Stamp Charging

Efficient proportioning of components coal.

Opening sequence of hoppers continuous flow, and leveling control charge.

Sampling Uniformity level Distribution of coal in the yards Stacking and withdrawing Remaining time

Appropriate and consistent routine of silos filling. Maintenance of minimum stock

Determination of coking end point.

Appropriate and consistent crushing Efficient mixing, to facilitate the interaction between the coals and avoid fluctuations in the composition of the mixture

Effective control of the quantity of water, duration of quenching and uniform allocation of water on the surface of the coke mass in the car.

Well preserveds ovens and consistent Conditions of heating.

The coke is transferred from the battery ramp to the blast-furnace.

Avaliation Parameters of Coking Coal Rota do carvo

COAL AS RECEIVED

CRUSHED COAL

MISTURE

COKEMAKING

COKE

BLASTFURNACE

Moisture Ash Volatile matter Rank Maceral composition Rank Size

Moisture Ash Volatile matter Rank Maceral composition

Moisture Ash Volatile matter Average rank index Maceral composition Mixture formule Size (80 a 85%< 7 #) Average rank index

Moisture release Volatile evolution Ash concentration Low coking pressure Suitable contraction

High carbon content Low ash content Volatile matter < 1% FUEL REDUCER Low water content. Provide carbon to pig iron.

New size

+ +

Suitable quenching

Rank

Rank

Final temperature

Low CO2

reactivity

with

Rank Maceral composition Size Plasticity

Rank Maceral composition Size Plasticity

Mixture formule Average rank index Maceral composition Size Plasticity

Coke oven dimension Load moisture Wall temperature Coking rate Coke handling

Suitable size Small size distribution Strength

Permeabilizer

Low content of sulphur, phosphorus and others elements.

Low content of sulphur, phosphorus and others elements.

Low content of sulphur, phosphorus and others elements.

Concentration of phosphorus and others elements content and reduction of sulphur content.

Low content of sulphur, phosphorus and others elements.

Not pig iron contaminant

Low content of sodium, potassium and zinc.

Low content of sodium, potassium and zinc.

Low content of sodium, potassium and zinc.

Concentration of sodium, potassium and zinc content.

Low content of sodium, potassium and zinc.

Not operation disturber.