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Presentation On Preparation of Coke in Coke Oven Batteries: Presented By: Anil Kumar Khatai

This document provides an overview of the coke production process. It discusses: 1) The history of coke ovens and how coke is an essential material for steelmaking as it provides carbon and heat for smelting iron ore. 2) The analysis and sampling of coal, which is the raw material, to determine its composition and quality. 3) The construction and operation of coke oven batteries, where coal is heated over 12-14 hours to produce coke in an oxygen-free environment. 4) The quenching process where hot coke is cooled with water or gas to stop further chemical reactions from occurring. 5) The byproducts that are recovered during

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ANIL KUMAR KHATAI
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1K views18 pages

Presentation On Preparation of Coke in Coke Oven Batteries: Presented By: Anil Kumar Khatai

This document provides an overview of the coke production process. It discusses: 1) The history of coke ovens and how coke is an essential material for steelmaking as it provides carbon and heat for smelting iron ore. 2) The analysis and sampling of coal, which is the raw material, to determine its composition and quality. 3) The construction and operation of coke oven batteries, where coal is heated over 12-14 hours to produce coke in an oxygen-free environment. 4) The quenching process where hot coke is cooled with water or gas to stop further chemical reactions from occurring. 5) The byproducts that are recovered during

Uploaded by

ANIL KUMAR KHATAI
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Presentation on

preparation of coke in coke oven batteries

PRESENTED BY: ANIL KUMAR KHATAI


CONTENTS
 Introduction
 History of coke oven
 What is coal and coke
 Analysis of coal
 Sampling of coal
 Construction of coke oven
 Outer side of coke oven
 Charging of coal into coke oven
 Total cooking process
 Charging of coal
 Conversion of coal to coke
 Quenching
 By-Products
INTRODUCTION:-

Coke is produced from metallurgical grade coals and is


an essential part of integrated steelmaking, because it
provides the carbon to remove the oxygen from iron ore
and the heat to produce molten iron in the blast furnace.
Due to its strength and porous nature, coke is treated as
an important contributor in the formation of the permeable
bed required for the optimization of blast furnace
performance.
 Coke making represents more than 50% of an integrated
steel making’s total energy use.
 The two types of coke manufacturing technologies, which
form an integral part of integrated iron and steel plant for
commercial use are:
1) Coke making through by-product recovery
2) Coke making through non-recovery/heat recovery
HISTORY OF COKE OVEN:-

• Early coke making involved the use of beehive ovens, so


named because of their round dome shape. Later, theses
were consolidated into 2 rows, with stone(Brick) sidewalls,
called battery ovens, because many ovens, because many
ovens could be lined up along rail road sidings for loading
and unloading. When coke was made under these
situations, the byproducts were generally lost or wasted.
Since coal is a hydrocarbon, there are many toxic but useful
byproducts that can be claimed as the coke is being made.
WHAT IS COAL AND COKE ?
 Coal:-
A natural dark brown to black graphite
like material used as a fuel, formed from fossilized plants and
consisting of amorphous carbon with various  organic  and some 
inorganic compounds.
 Coke:-
Coke is a solid carbonaceous material derived from destructive
distillation of low-ash, low sulfur bituminous coal (black coal).
Coke from coal is grey, hard and porous.
Coke can be used as a fuel or as a reducing agent in blast furnaces
used for smelting of iron ore. It is generally considered to be one of
the 3 fundamental materials for producing iron, which is then used
to make steel, usually in combination with limestone and iron ore.
ANALYSIS OF COAL

 Proximate analysis:- proximate analysis of coal


is estimation of the moisture content, ash
content volatile matter content and free carbon
content.
 Ultimate analysis:- Ultimate analysis of coal is
estimation of fixed carbon, sulphur, oxygen,
nitrogen, hydrogen.
SAMPLING OF COAL

 Washing of coal decreases Sulphur & ash content and increase the
caloric value & caking property of coal which controls its ash fusibility.
 Coal comes from Australia & New Zealand.
 Imported coking coal is prime coking coal, having less than 10% ash.
Blend is approximate PCC 10%, MCC 15% and imported 75% for
batteries.
Range of analysis of Indian coals:

TYPES OF COAL ASH VOLATILE MATTER


Prime coking coal(PCC) 20 - 23% 22 - 24%
Medium coking coal 20 - 23% 25 - 30%
Imported coal 08 – 10% 20 – 23%
CONSTRUCTION OF COKE OVEN

 Coke oven are mainly construction of silica, fireclay and ordinary insulating
bricks. The coke oven battery 6.5 m height having 65 ovens each battery.
 The coke oven chimney is made of concrete lined with fireclay bricks.
 Normal life of a coke oven battery under indian condition is considered to
be 25 years.
 The heating of ovens is done both the sides in side fired batteries.
 Width of the coke oven towards coke side is slightly more than that on
pusher side to facilitate easy discharging of coke.
 Height of coke oven is limited maximum up to 7m.
 The elaborate regenerate system (of refractory bricks ) ensure good
preheating of mixed gas as well as heat recovery from flue gases.
 Time period required cooking of coal 17 to 18hr.
OUTER SIDE OF COKE OVEN BATTERY
CHARGING OF COAL INTO COKE OVEN

• At first the coal is taken in charging car from the local


tower and is charged into the empty oven.
• Each oven has three charging holes and each
charging car has three bunkers for charging of coal
into the ovens.
• With an increasing thrust towards improving
productivity and coke quality, especially with respect
to strength, a partial briquetting for coal charge has
been installed in coke ovens.
TOTAL COKING PROCESS:-

 After removing the impurities from the coal, it send to crushing(0-


3mm) after that blending.
 Then the crushed coal having size 0-3mm is send to coal bunker
where it is stored.
 The powered coal is taken in charging car from coal bunker and is
charged into the empty oven.
 Each oven have three charging holes and each charging car has
three bunkers for charging of coal into the oven.
 Then the powered coal is heating for 12-14 hr. inside the oven,
oven is heated by using byproduct gas, coke oven gas, blast
furnace gas and mixed gas (coke oven & b.f.).
 After carbonizing it is pushing out with the help of pushing car and
is collected in quenching car.
 Then it send to quenching tower where it is quenched by
means spraying water over the red hot carbonizing coal for
2.5min (is called wet quenching) or spraying inert gas(N2
gas ) over the hot coal(is called dry quenching).
 Then final product coke is collected and it send to blast
furnace for melting of rock iron.
 And some byproduct also collected from coke oven tower
during coking & it send to CCD( coke chemical department )
to separate different chemicals.
FLOW DIAGRAM OF TOTAL PROCESS
CHARGING OF COAL
QUENCHING

 The coke after being pushed into quenching


car, is quenched in quenching tower where
phenolic water is pumped @50 m3 per hr.
 Quenching time = 2.5 min.
 Quenching:-
cooling of coke after carbonizing by
means of spraying water(wet quenching)/
Nitrogen gas(dry quenching) over the hot coke.
BY-PRODUCTS :-
 Tar components
 Tar acid gases (phenolic gases)
 Benzene, toluene and xylene (BTX), light oil and other aromatics
 Naphthalene
 Ammonia gas
 Hydrogen sulfide gas
 Hydrogen cyanide gas
 Ammonium chloride
 Carbon di-sulphide
THANK YOU

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