Summer internship report on

Coke oven and

coal chemical plant
By
R. RAGHAVENDRA RAO (12021A2502).
K. AVINASH KUMAR (12021A2543).

Introduction

Visakhapatnam steel plant is the one having shore

based steel plant in the world

Location:

26 kms south west of the city of the

Visakhapatnam.

installed capacity:
liquid steel - 3 million tones.
saleable steel - 2.656 Million Tons.

three international standards for

Quality (ISO-9001),
Environment Management (ISO- 14001).
Occupational Health & Safety (OHSAS-18001).

The plant was inaugurated formally on 20 th

January 1971 by the prime minister.

Major departments in VSP

Raw materials handling plant

Coke ovens and coal chemical Plant.

Sinter plant

Blast furnaces

Steel melt shop

Rolling mills

LMMM (Light and medium merchant mill)

WRM (Wire rod mill)

MMSM (Medium merchant and structure

mill)

CO&CCP FLOW CHART

SOLAR OIL

H2SO4

To BATTERIES ,BF SP,MILLS ,SMS

Cleaned CO Gas

FGC

Benzene
Toluene
Heavy crude benzol
Solvent oil

BENZOL
DISTILLATION
PLANT

Crude Benzol

AMMONIUM
SULPHATE
PLANT

EXAUSTER

PGC,
SEPERATOR

Ammonium sulphate
(Pushkala)

Crude Tar

Tar pitch
Light oil
Phenol
Naphthalene oil
Wash oil
Anthracine oil
HP Naptha,D N Oil

TAR
DISTILLATION
PLANT

NH3 liquor

MBC Water
Treatment
Plant

POND( Gangavaram)

Raw CO Gas
COAL YARD

COAL
PREPERATION
PLANT

BATTERY
1,2,3,4
Heating with
CO Gas

1000 c
Hot coke
0

COKE
DRY
COOLING
PLANT
1,2,3,4

1750c
Cooled coke

COKE
SORTING
PLANT

Nut coke
(10-25mm)
To Sinter plant
Breeze coke
(0-10mm)
To Sinter plant

steam

Turbine

BF coke
(25-80mm)
To Blast Furnace

(15MW power generation)

COKE SORTING PLANT

WHY COKE OVENS?

B-3&CDCP-3

B-2& CDCP-2

B-1&CDCP-1

TO CONVERT COAL TO COKE IN ABSENCE OF AIR WHICH IS USED

AS A REDUCING AGENT IN BLAST FURNACE
TAR PLANT&MBC PLANT

RECOVERY PLANT

BENZOL PLANT

CPP

Coke ovens & coal chemical

plant

The coke oven and coal chemical plant is

mainly divided into the following
department:

Coal Preparation Plant

(C.P.P)

Coke Oven Batteries

Coke Dry Cooling Plant

(C.D.C.P)

Coke Sorting Plant

(C.S.P)

Coal Chemical Plant (C.C.P)

Coal and coke

COAL:

Coal is used in the form of coke to serve the purpose of iron

ore reduction in blast furnace. It also serves as a heat source.

COKE:

It is a strong porous hard mass that is obtained by heating

of the coal in the absence of air at high temperature.

NEED FOR MANUFACTURE OF COKE FROM COAL:

Natural coal is too dense and fragile to be used as fuel.

The ASH CONTENT in coke is very low i.e.) around 10%. So it

does not arise problems of striking on the grates.

As compared to coal coke is of high quality and is highly

reactive.

As coke is a rigid hard mass it does not create the problems

of dust nuscence.

Types of coal

There are 2 types of coal:

(1) Coking Coal.

The different coking coals used in VSP are:

M.C.C

I.C.C

I.S.S.A.C SOFT

(2) Non-Coking Coal.

Medium coking coal

BENGAL, BIHAR

Imported coking coal

AUSTRALIA

Imported coking coal

-

Imported coking coal

AUSTRALIA

AUSTRALIA

In VSP coking coal is used for producing metallurgical coke where

as non-coking coal is used for producing thermal power (in boilers).

Types of coal and its

properties
s.no

Type of coal % moisture

M.C.C

I.C.C

I.S.S.A.C

23 - 25

8 - 10

1.16 1.3

SOFT

30 - 34

8 - 10

0.9 1.0

25 - 28
24 - 26

%Ash

17 22
8 10

Mean
maximum
Refluctance
0.9
1.10 1.3

Charge coal quality

S
No

Parameter

1
2
3
4
5
6

Total Moisture(%)

% -3mm fraction

Volatile Matter(%)
Ash Content(%)
CSN
MMR
Sulphur

Values
7-9
25-26
10 max
6.5-8
1.12-1.18
0.6 max

74-78

CONTENTS IN 1 TON OF COAL:

Coke

746 kgs

Crude Tar -

32 kgs

Crude Benzol -

Ammonia -

4.1 kgs

CO Gas

6.9 kgs
150

kgs

Losses

61 kgs

Coke Ovens

PURPOSE OF COAL PREPARATION PLANT:

The main purpose of this plant is to prepare the coal by
removing the foreign matter and bringing to the size suitable
for carbonization or coking process.

PURPOSE OF BATTERY :
Coal is converted into coke by high temperature carbonization
in the ovens of the battery.

COKE DRY COOLING PLANT:

After pushing the coke from the Battery with a temperature of
1050c, it is transferred into C.D.C.P for cooling purpose.

COKE SORTING PLANT:

Coke from C.D.C.P enters the C.S.P section. Here coke is
crushed, screened and later conveyed to different consumers.

Coke oven Battery

BATTERY-1

1989

BATTERY-2

1991

BATTERY-3

1992

RAW MATERIAL
PRODUCT
matter.
BY-PRODUCT

Coal blend.
Coke with 1-3% volatile

Raw coke oven gas.

Objective:- To produce good quality of

metallurgical coke.

Coke oven Battery

COKE OVEN BATTERY CONSISTS OF 67 OVENS.

These ovens are OTTO-HOFFOMENS by-product

oven type.

The total length of the battery is 100 mts.

It consists of rectangular chambers of length 16
mts,
height 7 mts

width 0.14 mts with removal door ends.

Battery has 4 machines:

Pusher car
Charging car
Door extractor car
Loco car

CHARGING CAR:

32 T of coal is charged in each oven up to a

height of 6.7 mts out of 7 mts in each oven.

levelling which is done by a leveling bar fixed to

the pusher car.

PUSHER
SIDE

COKE OVEN BATTERY:

coking period of 17-18 hrs by indirect

heating with coke oven gas or mixed gas (CO
gas + BF gas) in absence of air at 1150c.

coking process is continued until most

of the volatile matter is removed.

Coke side

COKE OVENS
MAIN PRODUCTS

BF COKE

NUT COKE

BREEZE COKE

COKE DUST
BY-PRODUCTS FROM CO GAS:

TAR

AMMONIA

BENZOL

CLEANED CO GAS

Composition of CO gas
Hydrogen: 58-60%
Methane : 24-25%
Carbon monoxide: 6-7%
CmHn: 2-2.5%
Nitrogen: 3-4%
Carbondioxide:1.5-2%
Oxygen: 0.2%
Ammonia: 8-10 gm/NCum
Benzol: 25-30gm/NCum
Naphthalene: 0.8-1.1
gm/NCum

Coal Chemical Plant

Many by products are extracted from the coke oven gas at this
department. It consists of the following sections:

Primary gas cooler.

Exhauster house.

Ammonium sulphate plant.

Final gas cooler.

M.B.C plant.

Tar distillation plant.

Benzol plant.

Benzol distillation plant.

Hydro refining.

Extractive distillation.

Primary gas cooler

PURPOSE OF PGC:
The main purpose of PGC is to cool the gas from 90c to 30c.

The cooler consists of three zones:

This is a shell and tube heat exchanger in which the CO gas
exchanges with
service water in the top two zones and
chilled water in the bottom zone.

Naphthalene and traces of tar present in the gas condense and this is collected at
the bottom of the PGC.

The CO gas from the bottom of the PGC is fed to the electrostatic precipitator.

Primary gas cooler

Gas temperature before PGC

80-95c

Gas temperature after PGC

27-30c

Service water inlet temperature

Service water outlet temperature

Gas condensate flow to each PGC

10-15 Nm3/hr

Chilled water inlet temperature

11-12c

Chilled water outlet temperature

Total number of tubes

32-33c
43c

20c
409

Electrostatic Precipitator

Electrostatic precipitators are cylindrical vessels with a

conical bottom. Each ESP is provided with a seal pot.

The CO gas enters the ESP from the bottom.

Electrodes are nothing but SS metal rods.

High voltage of about 50,000 volts is supplied to each

electrode.
Capacity

30,000 Nm3/hr

Voltage

70KV

Number of electrodes
ESP insulator boxes temperature

148
80C

Exhauster house

PURPOSE:

These are centrifugal fans Used to drive the coke oven gas from the
batteries itself to various plant like ASP.

The flow of gas is controlled by Askania valve, which is a butterfly

valve.

When the quantity of gas is low - valve is closed

when the gas quantity is high - valve is opened.

Capacity

67,000-76,000Nm3/hr
Power 1250KW

Maximum suction at inlet

500mm WC g

Maximum pressure at delivery

2700mm WC g

Ammonia Sulphate Plant

Coke oven gas from exhauster is fed to the ASP.

PURPOSE:.
To recover AMMONIA SULFATE from co gas

CAPACITY:
41,700 Ton / year

PROCESS:
The CO gas from the exhauster is fed to the preheater to preheat the gas to 60-70c. So the gas is directly fed to
the saturator. Separation of ammonia sulfate from co gas takes
place by using H2SO4 and further processing takes place.

SATURATOR:
NH3
NH4 (HSO4)

+
+

H2SO4 NH4 (HSO4)

NH3

ACID TRAP

CRYSTAL RECEIVE TANK

CENTRIFUGE

DRIER

CYCLONE

MOTHER LIQUOR TANK

(NH4)2SO4

AMMONIA COLUMN:
(NH4)2S

2NH3 +

H 2S

NH4CN

NH3

HCN

(NH4)2CO3

2NH3 +

CO2

NH3

H 2O

+ CO2

NH4HCO3
NH4HS

+
NH3

H2O

H 2S

Final gas cooler

Coke oven gas after ammonia recovery

consists of 0.8-1.12 mg/lit of naphthalene.
These naphthalene particles are removed by
using solar oil.

Temperature at the bottom of FGC

50-60c
Naphthalene in CO gas after FGC
0.4 g/Nm3

FGC tar temperature

90c
Specific gravity of FGC tar moisture

5%

80-

MBC Plant

Effluent water from coke oven and by product plant was sent to
the MBC from the two pump houses.

PROCESS DESCRIPTION:

All Inputs are collected, mixed with air in Pre-Aerators and

distributed in Tar Settling Tanks (TST).

TST works in parallel. Heavy matter and tar settle in TST and the
settled effluent overflow to collecting tank.

From collecting tanks effluent is pumped to Oil Flotators via Pr.

tanks for oil removal. Two Oil Flotators can work in series or
parallel. Oil is removed by froth flotation mechanism.

From Oil Flotators effluent overflow to Equalizing tanks by gravity.

Here P2O5 is added and pumped to 1st stage Aerotanks for Phenol
degradation.

MBC Plant

In 1st Stage degradation of Phenol take place due

to bio-oxidation by activated sludge.

Effluent Overflow from 1st stage to intermediate

collecting tank from where it is again pumped to
2nd stage Aerotanks.

Cyanide and Rhodanides are decomposed here by

similar action like 1st stage.

Effluent from 2nd stage overflow to intermediate

collecting tank and from there it is pumped to STP.

Two numbers Air blowers pumps ambient air into

the system as a source of Oxygen.

Tar
Settling
Tank

Oil Flotators
3

Heat Exchanger

PT2

PT1
7

A21

A11

10

11

Air Blower
E2

A15

A25
2
Aerotank
nd

1 Aerotank
st

P1
P2

STP.

E1

Equalizing Tanks

Process Flow
Diagram for
MBC.

EFFLUENTQUALITYATDIFFERENTSTAGESOFMBCPLANT.
Sl

Parameter

Unit

Inlet

After1stStage

After2nd
Stage

01

Phenol

PPM

400

3-5

02

Cyanide

PPM

20

12

1.5-3.5

03

Thiocyanate

PPM

400

350

10

04

FreeNH3

PPM

250

90-100

80-100

05

TotalNH3

PPM

600

500

500

06

Tar&Oil

PPM

500

30-35

25

07

TSS

PPM

100

200-300

150-200

08

BOD

PPM

1000

150

09

COD

PPM

2500

1200

300

10

PH

7-9

7-9

7-9

Equipment capacities
EQUIPMENT

NUMBER AVAILABLE

CAPACITY

TAR SETTLING TANK

230M3

FLOTATORS

270M3

EQUALIZATION TANKS

1600M3

FIRST STAGE AERO TANKS

600M3

SECOND STAGE AERO TANKS

800M3

CENTRIFUGAL AIR BLOWER

18500M3/HR

BACTERIA CULTIVATION TANKS

PURIFIED WATER COLLECTING TANK

100M3
100M3

TAR Distillation

Tar Distillation Section.

Pitch Cooling & Loading Area.

Naphthalene & Anthracene Fraction

Crystallization section (NAFC).

Tar & Oil Storage.

TAR DISTILLATION PLANT

Tar & oil storage

Decanter 1 no

Water

Reciprocating pump 2
Furnace Fist stage
no

Reciprocating pump 2 no

1st Evaporator
2 nd Evaporator
MH Pitch
Pitch Bays
For cooling

Collecting Tank

Furnace 2nd stage

Soft pitch
Reactor
Light Oil

Cutting & Bagging

Phenol
Naphthalene
Wash Oil
Anthracene I OIl

Anthracene II OIl

Distillation column

To NAFC

TAR Distillation

Tar received from FGC unit to TOS unit.

From TOS tar is pumped to Decanter in TDS unit.

After removal of water from decanter moisture content in tar reduces

to 5-6%.

Tar is heated in the first stage of furnace to a temp.of120-150 deg C

and sent to first stage evaporator.

In first stage evaporator complete de-moisturisation is done.

Tar after first stage evaporator is again heated in II stage of furnace

to a temp. of 330-350deg C.

In the second stage evaporator oil fraction is separated from top of

second stage evaporator(35-40%) and soft pitch from bottom.

The oil fraction is sent to the distillation column, where individual oil
products are tapped , cooled collected in storage tanks.

Benzol Plant
(OBJECTIVES)

To recover Crude Benzol from Benzolised Oil.

To remove Impurities from Crude Benzol.

To produce Pure Products from C.B.

Benzol Plant
(SUB-SECTIONS)
Benzol Distillation Section.
Hydro Refining Unit.
Extractive Distillation Unit.

BENZOL DISTILLATION UNIT

CRUDE BENZOL
CB-I

S
T
I

B.O

TO CFPS

COOLERS

ONE

TWO

C
O

CB-I

STEAM

U
M

LIVE STEAM

STEAM
CB-II

DBO TO SCRUBBERS

Benzol Distillation Section

To separate Crude Benzol from Benzolised Oil.

To separate HCB from Crude Benzol.

Hydrorefining Unit

To remove Sulphour Compounds from Crude Benzol.

To produce BTXS Raffinate for processing in Extrative Distillation Unit.

Extractive Distillation Unit

To separate non aromatics from benzene & tolune.

To produce pure benzene, pure tolune, Light solvent oil &still bottom oil
from BTXS Raffinate.

ANY QUERIES


U
O
Y
K
N
A
TH