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COKE OVEN
Introduction: In JNIL there is non-recovery type coke oven is present which is used for making metallurgical coke. Specification: Non recovery type No of oven- 11 Ovens per Battery No of battery- 04 Nos. Working hour - 60 To 66 hour Input Raw Material: Coking coal: it is the type of coal which is used for the production of metallurgical coke. When metallurgical coke is heated in the absence of air it forms hard mass. Coking coal is found in almost different countries: 1) Australia (almost 80%coking coal sells) 2) Other countries( canada ,USA,newzealand,russia,china)-(sells rest 20% coking coal) In India coking coal contains 22% ash where as in foreign countries it contains 9% ash. Therefore coking coal of India is called low grade where as outside countries it is called high grade. Types of coking coal: 1) Prime 2) Medium 3) Blend or poor coking coal Properties of coking coal: MMR( maximum mean reflectance) Coking coal contains vitrinite mineral which tells the prepartion ofcoking coal. Higher reflectibility indicates better coking coal. MMR- less than0.85= non coking coal 0.85- 1.15=medium coking coal 1.15- 1.35=prime coking coal 0.85-1.0= soft coking coal >1.35= anthracite CSN(crusible swelling number):

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For prime coking coal= 8-8.5 For semi prime coking coal= 6-6.5 Fluidity : This is measured by dial division per minute(DDPM). For good quality of coking coal the fluidity should be around 10. Volatile material Maximum VM in coking coal Prime=20-25% Medium=25- 30% Soft= 28-34% If VM is 22-24% then coal is good. As the age of coal increases MMR increases where as other properties like CSN,VM,fluidity decreases. Maximum coking coal is imported from Australia. Operation : Coke is extracted from coal by heating it in a closed chamber of temp of approx. 1300C for 60-66 hours for removing all the volatile material present in it. Coking coal Paste(at 400C)

Volatile material vapours(600C)

Totally dry and compact(1000-1300C)

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Product Metallurgical coke-It is used as reducing agent of iron ore and supplying heat for the reduction process and its hardness supports the burden load . In JNIL its capacity is 2 lakhs per annum. Raw Material Handling: (Coal Route)
VF3 3 VF4 VF5 K1A VF2 K1.1 K1.2 PRIMARY CRUSHER VF1 K1 SEC. CRUSHER K2 HM1

HM2

CT1

CT2

Coal Yard Coal yard is used for storing of coal. Coking coal is imported from foreign countries by ships and via train and stored in coal yard.

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Blending yard: Here coals are blended with a fixed proportion and sent to hopper. Prime coking coal=45% Medium coking coal=40% Poor coking coal= 15% Over ground bunker-In which mixed coking coal from the blending yard which come through the tippler fall down on the over ground bunker. The coal travels with the help of belt conveyor to the hammer mill or coal crusher mill. Sizeof coal incoming is 80mm. Coal crusher and hammer- For coal crushing our plant have 2 roots. 01 one root having primary and secondary type hammer crusher, in which coal is fed primary to secondary crusher and then after k3 belt. 02 this have two hammer crushers for crushing the coal to -3mm output. Coal tower-The coal tower having 2 bunkers of capacity of 150tph . Coal travels from hammer mill to coal tower bunker with the help of k3 and k4 conveyor belt. ProcessingStamping machine-Stamping machine having one mobile hopper 150 ton capacity. The coal first is discharged through bunker to mobile hopper . These hopper has gate for discharging coal to the sole plate with the help of telescope. The coal layer is properly sprayed over sole plate , then two stamping head stamp the coal to make proper cake. Total three layer of coal and 4times stamping is done . For 45ton coke moisture is 9-10% maintained and time 50-60min. is required. Pusher cum charging carThis is used for pushing the coke in quenching car and charge a new coal cake in oven with the help of pusher ram. Oven-Total 04 nos. battery and each have 11 ovens of non-recovery,heat recovery SSIT China design.Additional advantage of SSIT China design non-

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recovery stamp charge battery over bye-product recovery coke ovens are as follows Non recovery coke making is a negative pressure technology,carbonization by continuous operation under negative pressure,ambient air is being pulled into the coke oven at any available intake point and thus eliminating any potential fugitive leaks. No wastewater generated from the process.The coke facilities are a net user of water. Quenched water does not contain any toxic elements, unlike in Bye-product recovery ovens which contain no. of toxic elements like phenol,cyanides,sulphides& tar etc. Particulate matter which is allowed to be settled in settling tank & removed as sludge. Clean water obtained from settling is reused in the process.

Since all conventional bye products are burnt during the coking process, no waste water streams are generated as in case of recovery type of coke oven. Stamp charging with heat recovery coke making is ecologically friendly process which reduces charging emissions considerably. Negligible particulate matter emissions during pushing of coke because the coke mass slides to quenching car platform. Sensible heat of hot flue gas is available for recovery and generation of electric power. No consumption of steam,heating gases,compressed air etc.Hence no noise pollution. Life of equipment,structure etc.is more due to non-corrosive atmosphere .

The coal charged in oven remains for 60-66 hours . In this oven controlled combusion is done with the absence of oxygen . The gas are generated by burning of volatile matter which are present in coal.

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The gas are generated by burn of VM in the furnace upto40hour. After 45hours have soaking period. Temp. And Pressure Of Battery: Carbonization- 800-1300 Temp.(-0 To -10 Press.) Combusion HeaderChimney1000 To 1300 Temp. (-5 To -10 Press.) 700- 1050 Temp.( -8 To -4 Press.) 600- 1050temp.( -23 To -28 Press.)

Quenching tower-By quenching car coke reaches thequenching tower where the quenching is done by three steps with water spray. 01- 90 SEC. 02- 60 SEC. 03- 30SEC. 3 MIN. STOP 3 MIN. STOP STOP QUENCHINGPROSSES.

Coke wharf-- This is used store the hot coke which is received from quenching tower after this coke goes for screening. Coke wharf:This is used to store the hot coke which is received from quenching tower after this coke goes for screening. Coke cutter :After screening (-60 mm) coal directly goes to the screening and +60 mm to -100mm go to the coke cutter. This cutter cut the coke into80mm size and discharged on the vibro screen , after screening +10mm size coke goes the blast furnace and -10mm size goes for sinter plant.

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Coke route:
WHARF

KC1 KC2 GRIZZLY

COKE CRUSHER

KC3
VIBRO FEEDER

KC4 COAL BUNKER 1 COAL BUNKER 2

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COKE OVEN ELECTRICAL:MOTORS INSTALLED IN COAL ROUTE:Conveyor no. K1A K-1 K-2 K-3 K-4 1.1 KW 37 22 37 22 7.5 7.5 RPM 1470 1500 1470 1460 1475 1435

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OTHER EQUIPMENTS Old primary crusher Old hammer crusher Primary hammer crusher Secondary hammer crusher Vibrating feeder-1 M1 Vibrating feeder-1 M2 Vibrating feeder-2 Primary crusher V/F Coal bunker gate-1 Coal bunker gate-2` Primary crusher V/F M1 Primary crusher V/F M2 New V/F1 M1 New V/F1 M2 New V/F2 M1 New V/F2 M2 New V/F3 M1 New V/F3 M2

KW 37 90 132 180 0.22 0.22 1.1 0.18 3.7 3.7 1.1 1.1 1.1 1.1 1.1 1.1 1.1 1.1

RPM 1470 1480 1481 1487 1500 1500 1430 3000 1440 1440 1430 1430 1430 1430 1430 1430 1430 1430

STAMPING MACHINE:EQUIPMENTS Stamping oil station1,M1 Stamping oil stn1,M2 Stamping oil stn2,M1 Stamping oil stn2,M2 Stamping oil stn3,M1 Stamping oil stn3,M2 Stamping M/C crosstravel KW 55 45 45 45 11 11 11 RPM 1480 1490 1480 1460 1460 1460 965

PUSHER CAR:EQUIPMENTS Pusher ram Coal charging box(sole) Pusher car long travel M1 Pusher car long travel M-2 KW 185 240 52 52 RPM 588 591 910 910

QUENCHING CAR:EQUIPMENTS Quenching car long travel M1 Quenching car long travel M2 KW 75 75 RPM 975 975

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COKE ROUTE:EQUIPMENTS Scrapper -1 Scrapper-2 Grizzly screen M1 Grizzly screen M2 Coke cutter M1 Coke cutter M2 KW 7.5 7.5 3.87 3.87 22 22 RPM 960 960 950 950 1460 1460

WATER PUMPS:EQUIPMENTS Quenching water pump 1 Quenching water pump-2 Telpher grab Telpher travel M1 Telpher travel M2 KW 132 132 7.5 0.75 0.75 RPM 987 987 925 885 885

THE MAIN ELECTRICAL EQUIPMENTS USED IN THE STAMPING M\C IS AS FOLLOWS:PLC (Programmable Logic Controller) : As the stamping m\c is completely based on the automation so the PLC is used. The specification of PLC is given as SIEMENS SIMETIC S7 300 CPU-314 24V DC 3 Digital input card of 16 bit 2 digital output card Motor: As we know that the stamping m\c work on hydraulic system so the separate hydraulic system for separate pressure head and floor hydraulic is used. Hydraulic power pack 1&2: For the pressure head 2, there is a hydraulic power pack having two motor of 45KW and 55KW. As the pressure head has the three movement as FAST DOWN, SLOW DOWN and FAST UP so the 45 KW motor is used for FAST DOWN and FAST UP and the 55KW motor is used for SLOW DOWN. Same as for the pressure head 1 but in the hydraulic power pack 1 there is one more motor of 7.5 KW for

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telescope movement and for coal slide plate open and close. The detail of motor is as follow:EQUIPMENTS KW RPM Power pack1 55 1480 Power pack1 45 1490 Power pack2 55 1480 Power pack2 45 1490 Power pack2 7.5 1410 Stamping m\c C.T: for the C.T motion of the m\c there is a motor used which is control by the drive MICROMASTER 440. Thruster brake: thruster brake is used for the breaking system for the C.T movement of the stamping m\c. Limit switch and sensor: the limit switch and the sensor are the important device for the automation purpose and also protect the system for any accident .if the system is moving then it move up to the limit then the sensor is sense the object and give the signal to the PLC and system is stop. The detail of proxy sensor is as follows: 1. Coal discharge gate open position 1 no 2. Coal discharge gate close position 1 no st 3. Coal charging 1 layer position 1 no nd 4. Coal charging 2 layer position 1no rd 5. Coal charging 3 layer position 1no th 6. Coal charging 4 layer position 1no st 7. Pressure head up in 1 layer position 1no nd 8. Pressure head up in 2 layer position 1no 9. Coal pressing in beginning position 1no 10. Coal pressing position 1no 11. Coal pressing in end position 1no Total 11no The detail of limit switch is as follows 1. Trolley back off end limit switch 1no 2. Trolley march end limit switch 1no 3. Coal box side plate open limit switch 1no 4. Coal box side plate close limit switch 1no 5. Pressure head 2 up limit switch 1no th 6. 5 layer position limit switch 1no 7. Pressure head 1 up limit switch 1no Total 7no

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Pressure switch: as the pressure head having the 3 motion that is FAST DOWN, SLOW DOWN and FAST UP so for this purpose the pressure switch is used in both the pressure head so the 4 MPA is used for the FAST DOWN and FAST UP and the 16 MPA pressure switch is used for SLOW DOWN. Interlocking: to protect the system from any hazard the various interlocking is given as follows: System healthy: Selection in auto mode Coal distribution auto Coal pressing auto Emergency stop release Coal box side plate close Trolley travel overload Trolley movement: Trolley back off end limit switch Trolley march end limit switch Coal discharge gate close Both pressure head up limit switch THE MAIN ELECTRICAL EQUIPMENTS USED IN THE PUSHER CAR IS AS FOLLOWS:The pusher car is a system used to push the coke to the quenching tray and to charge the coal cake to the oven. The pusher car has the three important systems 1. Pushing ram 2. Sole plate 3. Door lifting system

The working of pusher car is as follows: After stamping process completed the sole plate is taken reverse back from the stamping area. Then the door lifting system is open the door of the oven and kept in up position When quenching tray come in position, then the pushing ram pushes the coke to the tray Then the L.T move and the sole plate come in position Then after the sole plate charges the coal cake to the oven And at last the door lifting system closes the door of the oven As the Pusher Car is moving system So power supply is given by the D.S.L Line through the 600A Current Collector then the Panel Bus Bar is charged by This Current Collector through the cable.

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Ram and the sole plate are the two important system so the motor used for this system is slip ring induction motor. The motor detail are as follow: Equipments KW RPM RAM 185 588 SOLE PLATE 240 591

The resistance box is used for both the ram and sole plate is to increase the torque of the motor because the motor require high torque for this system The pusher car door lifting system and trolley locking is operated by the hydraulic system so there are two motor used in the hydraulic system. One is operated at the time and other is as standby, the detail is as followEquipments KW RPM M1 30 1470 M2 30 1470 L.T motor: for the long travel movement of the pusher car the two induction motor used operated by the drive MICROMASTER 440 separate drive for separate motor the detail of motor are as given: Equipments KW RPM LT MOTOR1 52 910 LT MOTOR2 52 910 As the cake is made in the stamping area the support is given from all side of the cake. To support from the pusher side is given by the back buffel which is on the sole plate.It is moving through the trolley motor.The detail of the motor is as follow:Equipments KW RPM TROLLEY MOTOR 2.2 1490 Limit switch and sensor:As the pusher car is operated by the PLC system is given so different interlocking is given to protect the system from any hazards and to stop the system at their position as require without any over movement. So different limit switches and sensors are used to protect this system. The working supply through this limit switch and sensor is 24 V dc The detail of limit switch is as follow; 1. Sole plate forward position limit switch 2 no One limit switch is given through the PLC and other is given direct to the line of forward contactor as the double protection is given as one is fail other is operated. 1. Sole plate reverse position limit switch 1 no 2. Ram forward position limit switch 1 no 3. Ram reverse position limit switch 1 no 4. Door lifting back position limit switch 1 no 5. Door lifting forward position limit switch 1 no

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6. Door lifting up position limit switch 7. Back buffel back position limit switch Total

1 no 1 no 9 no

If by chance the limit switch and the sensor fail by any problem then to protect the over movement of the ram and sole plate the rotary limit switch is operated. 1. Rotary limit switch for ram 1 no 2. Rotary limit switch for sole plate 1 no Total 2 no The other device used in pusher car is as follow Thruster brake is used for the braking system for the Ram, Sole plate, L.T motor. So total thruster are used as 1 for Ram 1 for Sole plate and 1 for each L.T motor so total 4. Master controller is used for operate the movement of the Ram, Sole plate and L.T car so the 4 step master controller is used for each so total 3 master controller. THE MAIN ELECTRICAL EQUIPMENTS USED IN THE QUENCHING CAR IS AS FOLLOW:Quenching Car is used to take the coke in the receiving tray then after quenching process is completed then tilt the coke to the wharf as that the quenching process is occur on the receiving tray therefore this system is known as the quenching car. The quenching car has the two important system 1. Door lifting system 2. Receiving tray The working of quenching car is as follow The door lifting system is used to open the door of the oven. Then after the receiving tray is come to the position and move the tray to the forward position and kept the tray at exact position. Then the pushing ram pushes the coke to the receiving tray. After that the door is closed by the door lifting system. Then the L.T is move and quenching car goes to the quenching area. Then after quenching process is completed the tray is tilt the coke to the wharf. As the quenching car is moving system so the power supply is given by the D.S.L line through 600A current collector then the panel busbar is charged through the current collector through cable. As the door lifting system and the receiving tray are completely operated by the hydraulic system so there are two motors used in the hydraulic system one is operated at a time and other is as standby. The detail of the motor are as follow Equipment KW RPM FLC 1.Hydraulic motor 1 45 1480 77.2 2.Hydraulic motor 2 45 1480 77.2

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L.T motor: for the long travel movement of the quenching car the two induction motors are used operated by the drive MICROMASTER 440 separate drive is used for the separate motor the detail of the motor is as follow Equipment KW RPM FLC L.T motor 175 975 128 L.T motor 275 975 128 Limit switch 1.L.T end position limit switch 1no As the quenching car is moving at the wharf side so to protect the L.T for over travel or to stop the car at the tilting position this limit switch is used. Sensor 1.Door lifting system in forward position 1no 2.Door lifting system in backward position 1no 3.Receiving tray in forward position 1no 4.Receiving tray in backward position 1no Total 4no As to protect the L.T movement of the quenching car theinterlocking is given as follows: Door lifting system in back position Receiving tray in back position The other device used in the quenching car is as follows: Thruster brake are used for the braking system for the L.T motor so total thruster used as 2 one for each motor Master controller is used for the L.T movement of the car so the master controller are used as the 3 step master controller.

COKE OVEN MECHANICAL SECTION:S.NO. EQUIPMENTS SUBASSEMBLY Charging device Pushing PUSHER CUM device CHARGING Door device CAR LT device FUNCTION CAPACITY COMPONENTS QTY. No. of power packs Door lifting cylinder Door moving cylinder Troly locking cylinder 1 no.

Coal cake charging in 45MT oven Hot coke pushing 45 MT from oven Oven door opening 5 MT and closing Pusher car travelling

1 no. 2 no.

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Hyd. device

Hyd. Cylinder operating in door Lifting moving and trolley locking

15 MPA

Gear boxes

5 no.

120LPM 45 m No. of packs Stamping cylinder power 3

Side buffing Coal cake buffing device

Coal collect Coal storage and coal 35 m and laying distribution Travelling of machine For body operating

CT device

110 MT

Telescope cylinder Side locking cylinder Slide gate

cylinder 15 MPA

STAMPING MACHINE

Stamping device Coal cake making 45 MT Stamping head Gear boxes Coke receiving device Door device COKE RECEIVING CUM QUENCHING CAR Hot coke receiving during pushing 45 MT No. of packs 2 1 power 1

Door opening closing Car travelling Hyd. Cylinder operating

and 5 MT

Tray moving 2 cylinder Tilting cylinder 3

LT device Hyd.device

250 MT 15 MPA

Door moving 1 cylinder Door cylinder lifting 1

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QUENCHING PUMP Hoist

Red hot coke quenching Bucket lifting lowering Travelling Coke fines collecting For dedusting

1260m/hr

and 1.5MT

GRAB BUCKET

CT device Bucket

1.5MT 1.5 M 100m/hr

RINSING PUMP SCRAPPER MACHINE

Coke scrapping from wharf to kc1

COKE HANDLING SYSTEM KC1, KC2, Conveyor KC3,& KC4 Grizzly feeder Cold coke handling 100 TPH

Coke screening (80mm)

20 TPH

Coke cutter

Coke cutting upto 80 mm

50 TPH

Rotor with pulley

teeth ring Vibro screen Coke screening (20mm & -10mm) 100 TPH Wire deck 20 & 10mm

19 2+2 nos.

COAL HANDLING SYSTEM Vibrating feeder Coal feeding hopper 25TPH to K1 & K1.1

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Primary crusher Vibrating feeders Air compressor K-1, K-2, K-3, K-4 Hammer mill Hammer mill Coal tower

Coal crushing -60 to - 25TPH 10/20mm 75TPH 100TPH For oven cleaning Coal handling duct 15ltr 7.5kg/cm2 150TPH

Rotor with pulley Grinding jib

Coal crushing 20mm 50TPH to -3mm (90%) 100TPH Coal collecting & 150MT feeding in stamping machine BATTERY/OVENS PROPER Flue gas flowing to 500 mt. chimney actuator 2 no.

Branch pipe,Header pipe Bridge pipe

For connection of oven to branch pipe flue gas passing Controlling oven suction and temp.

88 no.

Up-take valve

88 nos.

Primary valve Secondary valve

air air

Air controlling Controlling air and temp. To support and tie ovens refractory during expansion/contraction To support and tie buttrus walls during expansion/contraction

Buck stay and transverse tie rode Longitudinal tie rode

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Upper door

oven

To help sealed oven during coking To help sealed oven during coking

lower oven door

Other points on mechanical section: Oil used in all most all cylinders are of grade HLP68. Pin bush coupling are used for coupling, they act as a safety device as they break out in case of any problem without damaging the motor or the gearbox. Rack and pinion arrangement is applied for transmission of rotational power to the linear motion of the pusher ram. Pusher ram is a hollow structure having rack gear on its lower side and a pushing plate at its front side. Chain drive is used for transmitting greater power and torque hence can carry larger load. Chain drive is used to carry sole plate after charging to oven.

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