OPTIMIZATION OF SPECIFIC HEATING
CONSUMPTION OF COKE OVEN PLANT
USING FLOW METER CALIBRATION
MODIFICATION
Niranjan Mahato
PhD research schlor, Department of Mechanical Engineering Government
Engineering College, Jagdalpur, India (India).
niranjan123mahato@gmail.com - https://orcid.org/0000-0002-2849-8264
Himanshu Agarwal
Professor, Department of Mechanical Engineering, Government Engineering
College, Jagdalpur, India
himanshu.jglr@gmail.com
Jainendra Jain
Professor, Department of Applied Mathematics, Government Engineering College,
Jagdalpur, India
jj.28481@gmail.com
v
Reception: 03/11/2022 Acceptance: 05/01/2023 Publication: 04/02/2023
Suggested citation:
M., Niranjan, A., Himanshu and J., Jainedra. (2023). Optimization of specific
heating consumption of coke oven plant using flow meter calibration
modification. 3C Tecnología. Glosas de innovación aplicada a la pyme, 12(1),
243-260. https://doi.org/10.17993/3ctecno.2023.v12n1e43.243-260
https://doi.org/10.17993/3ctecno.2023.v12n1e43.243-260
3C Tecnología. Glosas de innovación aplicadas a la pyme. ISSN: 2254-4143
Ed.43 | Iss.12 | N.1 January - March 2023
243
ABSTRACT
Coke oven plant produces coke which acts as a reducing agent in blast furnaces. So,
coke is an important material which is also called as a reducing agent. Coke is
basically used for manufacturing of steel materials and extraction of metals. In an
integrated steel plant coke is a prime material for making high grade of steels. In this
present research work, the calibration of flow meter is modified. By this modification of
gas flow meter calibration coke oven gas flow reduced from 17100Nm3/hrs to
16900Nm3/hrs, such as 200 Nm3 on hourly basis saving without any extra manpower
cost. The proposed method is also cost effective as it saves Rs 6483000 every month
for producing coke. This methodology is also helpful for reducing the manufacturing
cost of coke in a recovery type of coke plant and stable oven operation and
prolongation of coke oven life. Future advancements in this technique will allow us to
minimize the need for money, which will revolutionize the nation's economy.
KEYWORDS
Coke, Coke furnaces, heating chambers, heating flues, coke rate
PAPER INDEX
ABSTRACT
KEYWORDS
ABBREVIATION
1. INTRODUCTION
2. METHODOLOGY OF RESEARCH
2.1. SEVEN METER TALL BATTERY EXPERIMENTAL DESCRIPTION
2.2. CPD OF RECOVERY TYPE OF COKE PLANT
2.3. NO. OF CHARGING / PUSHING IN A DAY
2.4. COKE OVEN GAS FLOW REQUIREMENT OF COKE OVEN GAS FLOW
ACCORDING TO PUSHING AND CHARGING
2.5. CALCULATION FORMULA OF SPECIFIC HEATING CONSUMPTION OF
COKE OVEN GAS
3. RESULTS WITH FULL DISCUSSION
3.1. MODIFICATION OF GAS FLOW METER CALIBRATION IN RESPECT OF
PUSHING/CHARGING
4. CONCLUSION
ACKNOWLEDGEMENT
REFERENCES
https://doi.org/10.17993/3ctecno.2023.v12n1e43.243-260
3C Tecnología. Glosas de innovación aplicadas a la pyme. ISSN: 2254-4143
Ed.43 | Iss.12 | N.1 January - March 2023
244
ABSTRACT
Coke oven plant produces coke which acts as a reducing agent in blast furnaces. So,
coke is an important material which is also called as a reducing agent. Coke is
basically used for manufacturing of steel materials and extraction of metals. In an
integrated steel plant coke is a prime material for making high grade of steels. In this
present research work, the calibration of flow meter is modified. By this modification of
gas flow meter calibration coke oven gas flow reduced from 17100Nm3/hrs to
16900Nm3/hrs, such as 200 Nm3 on hourly basis saving without any extra manpower
cost. The proposed method is also cost effective as it saves Rs 6483000 every month
for producing coke. This methodology is also helpful for reducing the manufacturing
cost of coke in a recovery type of coke plant and stable oven operation and
prolongation of coke oven life. Future advancements in this technique will allow us to
minimize the need for money, which will revolutionize the nation's economy.
KEYWORDS
Coke, Coke furnaces, heating chambers, heating flues, coke rate
PAPER INDEX
ABSTRACT
KEYWORDS
ABBREVIATION
1. INTRODUCTION
2. METHODOLOGY OF RESEARCH
2.1. SEVEN METER TALL BATTERY EXPERIMENTAL DESCRIPTION
2.2. CPD OF RECOVERY TYPE OF COKE PLANT
2.3. NO. OF CHARGING / PUSHING IN A DAY
2.4. COKE OVEN GAS FLOW REQUIREMENT OF COKE OVEN GAS FLOW
ACCORDING TO PUSHING AND CHARGING
2.5. CALCULATION FORMULA OF SPECIFIC HEATING CONSUMPTION OF
COKE OVEN GAS
3. RESULTS WITH FULL DISCUSSION
3.1. MODIFICATION OF GAS FLOW METER CALIBRATION IN RESPECT OF
PUSHING/CHARGING
4. CONCLUSION
ACKNOWLEDGEMENT
REFERENCES
https://doi.org/10.17993/3ctecno.2023.v12n1e43.243-260
ABBREVIATION
Table 1. Technical type Abbreviation of coke plant.
1. INTRODUCTION
Coke is produced by the proper destructive distillation of coal in coke plant.
Specially feeding coal blend comprising of the various different types of blended coals
of desired coking parameters is heated in an oxygen-free atmosphere (coked) until
the most volatile components in the coal are removed. The process is carried out in
battery, which contains twenty or more tall, wide and narrow ovens arranged side by
side. In [1] this paper during carbonization coal passes through a softening phase
when the coal particles swell and become soft. This soft mass is termed as
metaphase and said to be plastic in nature. During this transformational phase coal
releases most of its hydrocarbons, heavy oils and tar; the coal particles coalesce and
are bound together by the plastic mass. On further heating the plastic mass re-
solidifies into a porous mass called semi-coke. On further heating the semi-coke
contracts and becomes a structurally stable product which we know as metallurgical
coke or simply coke. In [2] the main function of by product plant to purified the raw
coke oven gas. The step by step procedure of purification is little complicated. Firstly
coke oven gas goes to primary gas cooler then coke oven Gas enters into the electric
type tar precipitator from its bottom, via the gas distribution plate gas is uniformly
distributed onto the whole section, then flows through high voltage electric field of the
Serial
No. Code Full form
01 C.P.D Coke making duration in hr.
02 N1 No. of ovens
03 N No. of pushing target / charging target in a day
04 C.W.T Cross chamber wall temperature
05 V Gas Flow required in Nm3/h
06 C.O.G Coke oven gas
07 C.V Calorific value of coke oven gas in kcal/Nm3
08 Q The Specific heat energy consumption in kcal/kg
09 T Periods of Gas flow in hr
10 W.B.A.D Weekly basis the average technical data
11 N.P.C.P.D No. of pushing and charging in a day
12 S.H.C Specific heating consumption of COG
13 A.S.H.C Average of specific heating consumption in (kcal/kg)
14 H.W.F.N Heating chamber wall flue No.
15 P. T Pause heating time in sec.
16 T.H.W.N Temperature of the chamber heating wall No.
17 W dry basis charged coking coal in tones
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honeycomb upward to leave electric tar precipitator and enters into the exhauster unit.
At the upper part of hydrogen sulfide scrubber, hydrogen sulfide in gas is absorbed
with enriched ammonia water from ammonia scrubbing and lean solution from de-
acidifier and ammonia stripping unit. At the same time of hydrogen sulfide removal in
hydrogen sulfide scrubber, also carbon die oxide, hydrocarbons and ammonia are
absorbed. Because the absorption process of hydrogen sulfide, CO2, hydrocarbons
and ammonia is the process of exothermic reaction, therefore both upper stage and
lower stage of hydrogen sulfide scrubber are provided with the coolers for hydrogen
sulfide circulating scrubbing solution. In [3] the primary purpose of coke ovens is to
transform coal into coke, which is utilized in the blast furnace as a fuel and reducing
agent. The entire process of creating coke is fraught with safety risks, such as being
hit by or tangled in moving machinery, getting burned, starting a fire or explosion,
falling and slipping, being exposed to dust, noise, heat, and gas, etc. The majority of
health risks associated with coke production is caused by emissions produced during
coal charging, coal carbonization, coke pushing, and coke cooling. Poly nuclear
aromatic hydrocarbons, which cause cancer, are present in coke oven emissions
along with other hazardous materials. In [4] this article of research developed a new
model for the reducing of variation in the burning of coal to coke during the coke
making process and to gain the good quality and also to proper develop the energy in
coke plant. The total length of the battery is hundred meters, consist of the rectangular
type of shaped heating chambers of length sixteen meters, the height is seven
meters, and the width 0.41 meters with removal door ends.[5]. In [6] this research
paper describes gas pressure in the oven chambers should be positive and higher
than pressure at any point of adjacent heating chamber during whole coking period. In
[7] a new design of optimum control of temperature of gas coming out of the oven into
the stand pipe is about 600-700 ℃
, and it leaves the hydraulic mains at the
temperature of 80-85℃
[8].In [9] in this system of ovens, paired vertical flues are
envisaged which are interconnected with each other with a provision for recirculation
of products of combustion. The heating chamber is divided into pairs of vertical flues.
Vertical flues of each pair are connected at the top through a window in the partition
wall [10]. In [11] coke oven gas can save 300-400 Nm3/hour by using reversal cycle
modification in coke plant [12]. The gas and preheated air are fed to the base of the
flues from where they move upwards under the influence of chimney draught.[13]the
hot products of combustion cross over to the adjacent flues and pass on the
regenerators where the checker-work absorbs most of the sensible heat contained in
the product of combustion.[14]. In this paper, the cooled gases from the regenerator
move to the waste heat flues and then to the chimney. These two currents of heat
flow, i.e. the up-current and down-current are periodically reversed in every 20
minutes to maintain uniform and state temperature condition throughout the whole
battery[15]. Readiness of coke at the end of coking period along the length, height
and width of coke oven chamber by maintain uniform temperature throughout the
length and height of heating wall all along the battery[16].The practical study was to
determine in which of the several type alternative toxic air pollution abatement
systems which affords the most economical solution to the control of at- morphemic
emissions during the charging of coal into the by-product coke plant[17]BF Coke size
https://doi.org/10.17993/3ctecno.2023.v12n1e43.243-260
3C Tecnología. Glosas de innovación aplicadas a la pyme. ISSN: 2254-4143
Ed.43 | Iss.12 | N.1 January - March 2023
246
honeycomb upward to leave electric tar precipitator and enters into the exhauster unit.
At the upper part of hydrogen sulfide scrubber, hydrogen sulfide in gas is absorbed
with enriched ammonia water from ammonia scrubbing and lean solution from de-
acidifier and ammonia stripping unit. At the same time of hydrogen sulfide removal in
hydrogen sulfide scrubber, also carbon die oxide, hydrocarbons and ammonia are
absorbed. Because the absorption process of hydrogen sulfide, CO2, hydrocarbons
and ammonia is the process of exothermic reaction, therefore both upper stage and
lower stage of hydrogen sulfide scrubber are provided with the coolers for hydrogen
sulfide circulating scrubbing solution. In [3] the primary purpose of coke ovens is to
transform coal into coke, which is utilized in the blast furnace as a fuel and reducing
agent. The entire process of creating coke is fraught with safety risks, such as being
hit by or tangled in moving machinery, getting burned, starting a fire or explosion,
falling and slipping, being exposed to dust, noise, heat, and gas, etc. The majority of
health risks associated with coke production is caused by emissions produced during
coal charging, coal carbonization, coke pushing, and coke cooling. Poly nuclear
aromatic hydrocarbons, which cause cancer, are present in coke oven emissions
along with other hazardous materials. In [4] this article of research developed a new
model for the reducing of variation in the burning of coal to coke during the coke
making process and to gain the good quality and also to proper develop the energy in
coke plant. The total length of the battery is hundred meters, consist of the rectangular
type of shaped heating chambers of length sixteen meters, the height is seven
meters, and the width 0.41 meters with removal door ends.[5]. In [6] this research
paper describes gas pressure in the oven chambers should be positive and higher
than pressure at any point of adjacent heating chamber during whole coking period. In
[7] a new design of optimum control of temperature of gas coming out of the oven into
the stand pipe is about 600-700 ℃, and it leaves the hydraulic mains at the
temperature of 80-85℃ [8].In [9] in this system of ovens, paired vertical flues are
envisaged which are interconnected with each other with a provision for recirculation
of products of combustion. The heating chamber is divided into pairs of vertical flues.
Vertical flues of each pair are connected at the top through a window in the partition
wall [10]. In [11] coke oven gas can save 300-400 Nm3/hour by using reversal cycle
modification in coke plant [12]. The gas and preheated air are fed to the base of the
flues from where they move upwards under the influence of chimney draught.[13]the
hot products of combustion cross over to the adjacent flues and pass on the
regenerators where the checker-work absorbs most of the sensible heat contained in
the product of combustion.[14]. In this paper, the cooled gases from the regenerator
move to the waste heat flues and then to the chimney. These two currents of heat
flow, i.e. the up-current and down-current are periodically reversed in every 20
minutes to maintain uniform and state temperature condition throughout the whole
battery[15]. Readiness of coke at the end of coking period along the length, height
and width of coke oven chamber by maintain uniform temperature throughout the
length and height of heating wall all along the battery[16].The practical study was to
determine in which of the several type alternative toxic air pollution abatement
systems which affords the most economical solution to the control of at- morphemic
emissions during the charging of coal into the by-product coke plant[17]BF Coke size
https://doi.org/10.17993/3ctecno.2023.v12n1e43.243-260
is an important factor for blast furnace of operation. The Some type of methodology
has been investigated in order to rectify the coke mean size.[18]. this paper, various
types of elementary of reaction which having the different steps important for coke
formation during thermal-cracking of the hydro- carbons are to be studied[19]. The
papers describes, by the petro-graphic specific technique and the semi type coking
coals or the non coking of coals to be blended and with coking coals is used to
produce BF coke.[20].
However, a there is a requirement to follow a study to reduce the specific heating
consumption by rectification of flow meter calibration in coke oven plant oven.
Generally in running coke oven plant calibration of flow meter in yearly or half yearly
which includes accuracy of flow of coke oven gas is not correct.
The main objective of the present research work is, to reduce the SHC by
rectification of flow meter calibration instead of yearly to monthly in own plant lab in
coke oven plant. The modification of flow meter is also helpful to reduce the carbon
emission which is eco-friendly to the environment.
2. METHODOLOGY OF RESEARCH
The carbon deposits on coke oven walls may not only interrupt the oven operation.
But also cause damage to the oven walls, although many studies have been made on
the properties of deposited carbons and the mechanism of their formation. There are
few on the quantitative emission of carbon formation in an actual coke oven. For the
purpose of stable oven operation and prolongation of oven life, it is necessary to
remove carbon according to the amount of carbon deposited on coke oven walls. A
flow meter is aspecial type of instrument which is used to measure the flow rate of a
gas then display the flow-reading to the instrument user via an indicator, digital
analogue or the digital type output. The Calibration of the flow meter can be achieved
in one of several ways, but generally involves the comparison of the flow meter
against a reference standard of higher accuracy. Calibration is an essential part of an
instrumentation system to ensure a line of traceability of the measurement system is
maintained. To understand the flow meter performance over a period of time, flow
meter calibration should always be conducted on “as Found” on the practical basis so
meter drift- analysis can be assessed. With the further customer agreement, a further
adjustment of the flow meter reading maybe performed to optimize the flow- meter
errors.
In this paper, it is introduced that a quantitative emission of carbon formation rate
on the wall was developed and new type SOP for regular maintenance, to optimize
the SHC by modification of flow meter calibration instead of yearly to monthly in own
plant lab in coke oven plant. The modification of flow meter is also helpful to reduce
the carbon emission which is eco-friendly to the environment. This method is also
helpful for the reducing of coke oven gas flow.
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2.1. SEVEN METER TALL BATTERY EXPERIMENTAL
DESCRIPTION
The experimental set up for 7-meter-tall coke oven battery required some technical
process and operation parameters which are shown in table1 which is given below.
There are sixty seven number of heating oven, sixty eight number of heating wall and
sixty nine numbers of waste heated boxes for transferring the waste gas tunnel to
chimney. There are three number of charging hole for feeding the coking coal into the
heating oven. Thirty-two tones of blended dried coal is charge per oven and output
coke is around twenty five tones is produced. There are total thirty two number of
heating flues out of thirty two sixteen numbers of heating flues in pusher side and
sixteen numbers in coke side. The experimental brief description is given below in
tabulation form in Table2.
Table 2. Technical parameters for experimental set up.
2.2. CPD OF RECOVERY TYPE OF COKE PLANT
2.2 describe mathematical formula for time of coking period
2.3. NO. OF CHARGING / PUSHING IN A DAY
2.3 describe the advance mathematical expression for determining the No. of
production target like pushing and charging schedule.
2.4. COKE OVEN GAS FLOW REQUIREMENT OF COKE OVEN
GAS FLOW ACCORDING TO PUSHING AND CHARGING
2.4 comprise that mathematical equation for calculating the required flow of coke
oven gas
No. of
oven
No. of
heating
walls
No. of
waste
heat
boxes
Dry
charged
coal in
tones
No. of
heating
flues in
pusher
side
No. of
heating
flues in
coke
side
No. of
heating
flues per
wall
Output
coke per
oven
No. of
charging
hole per
oven
Oven
height in
meter
67 68 69 32 16 16 32 25 03 7
C
PD =
N
1
×24
N
N
=
N
1
×24
CPD
V
=
Q*1000*N*W
C.V×T
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Ed.43 | Iss.12 | N.1 January - March 2023
248
2.1. SEVEN METER TALL BATTERY EXPERIMENTAL
DESCRIPTION
The experimental set up for 7-meter-tall coke oven battery required some technical
process and operation parameters which are shown in table1 which is given below.
There are sixty seven number of heating oven, sixty eight number of heating wall and
sixty nine numbers of waste heated boxes for transferring the waste gas tunnel to
chimney. There are three number of charging hole for feeding the coking coal into the
heating oven. Thirty-two tones of blended dried coal is charge per oven and output
coke is around twenty five tones is produced. There are total thirty two number of
heating flues out of thirty two sixteen numbers of heating flues in pusher side and
sixteen numbers in coke side. The experimental brief description is given below in
tabulation form in Table2.
Table 2. Technical parameters for experimental set up.
2.2. CPD OF RECOVERY TYPE OF COKE PLANT
2.2 describe mathematical formula for time of coking period
2.3. NO. OF CHARGING / PUSHING IN A DAY
2.3 describe the advance mathematical expression for determining the No. of
production target like pushing and charging schedule.
2.4. COKE OVEN GAS FLOW REQUIREMENT OF COKE OVEN
GAS FLOW ACCORDING TO PUSHING AND CHARGING
2.4 comprise that mathematical equation for calculating the required flow of coke
oven gas
No. of
oven
No. of
heating
walls
No. of
waste
heat
boxes
Dry
charged
coal in
tones
No. of
heating
flues in
pusher
side
No. of
heating
flues in
coke
side
No. of
heating
flues per
wall
Output
coke per
oven
No. of
charging
hole per
oven
Oven
height in
meter
67
68
69
32
16
16
32
25
03
7
CPD =
N1×24
N
N=
N1×24
CPD
V=
Q*1000*N*W
C.V×T
https://doi.org/10.17993/3ctecno.2023.v12n1e43.243-260
2.5. CALCULATION FORMULA OF SPECIFIC HEATING
CONSUMPTION OF COKE OVEN GAS
2.5 describe the mathematical equation formula for evaluating specific heating gas
This type mathematical expression for calculating in the table 3, table 4 and table 5
respectively.
It was observed that the accuracy of flow of coke oven gas is more on yearly or half
yearly calibration of flow meter. Due to this, flow meter is allowing to pass extra gases
for producing the combustion process without the recovery of the sensible heat. To
establish the reasons for the low efficiency, the calibration method of gas flow meter
have suggested. The modification of gas flow meter calibration on monthly basis with
respect to pushing and the charging and the possible modification type solution is
verified against the Standard Operating Practices and preventive and daily Schedule
jobs of Regular Maintenance). Technical data like number of pushing/charging per day
is 83 and pause time 20 second is used obtaining values express in table 3.
Table3. S.H.C before modification of flow meter calibration.
Table3 describes before modification of gas flow meter calibration coking periods is
around 19.37 hours, pause time average is around 20 second at constant production
target is 83.The average COG flow required in average pushing/charging 83 is 17100
Nm3/hr at above pushing/charging schedule. The all data is taken as on weekly basis
which is mentioned in table 3.
Q
=
V*CV*T
W*1000*N
S/No. W.B.A.D A.S.H.C N.P.C.P.D P. T C.P.D
1 1 670 83 20 19.37
2 2 670 83 20 19.37
3 3 670 83 25 19.37
4 4 670 83 25 19.37
5 5 670 83 20 19.37
6 6 670 83 20 19.37
7 7 670 83 15 18.37
8 8 670 83 15 19.37
9 9 670 83 20 19.37
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249
3. RESULTS WITH FULL DISCUSSION
3.1. MODIFICATION OF GAS FLOW METER CALIBRATION IN
RESPECT OF PUSHING/CHARGING
It was observed that the accuracy of flow of coke oven gas is more on yearly or half
yearly calibration of flow meter. Due to this, flow meter is allowing to pass extra gases
for producing the combustion process without the recovery of the sensible heat. To
establish the reasons for the low efficiency, the calibration method of gas flow meter
has suggested. The modification of gas flow meter calibration on monthly basis with
respect to pushing/charging and the possible rectification solution is verified against
the Standard Operating Practices and Schedule jobs of Regular Maintenance). Due to
additional gas consumption in coke plant at same pushing charging schedule of 83,
the coke oven gas flow is reduced 200 Nm3/hr without affecting the coke quality.
Table 4. S.H.C after modification of flow meter calibration.
Table4 describes after modification of gas flow meter calibration coking periods is
around 19.37 hours, pause time average is around 20 second at constant production
target is 83. The average on the before modification COG flow rate requirement in
average pushing and charging 83 is 17100 Nm3/hr as per above pushing and
charging target. The all data is taken as on weekly basis which is mentioned in table
3. After the medication of gas flow meter calibration, The average COG flow rate
requirement in 83 numbers pushing and charging is 16900 Nm3/hr as per above
pushing and charging schedule, which is given in the table 4.Afterthe modification of
the COG flow meter calibration, to the thermal regime of coke oven plant at randomly
at a time, the temperature of cross wall is taken at 05 numbers of heating walls. The
temperature of Cross wall is the all heating wall of the flue (means of the all the 32 no.
of heating flues) temperature recorded reading. The temperature of cross-wall data of
reading is express in table 4, 16, 17, 18, 19, and 20, respectively.
S/No. W.B.A.D A.S.H.C N.P.C.P.D P. T C.P.D
01 1 660 83 20 19.37
02 2 660 83 20 19.37
03 3 660 83 25 19.37
04 4 660 83 25 19.37
05 5 660 83 20 19.37
06 6 660 83 20 19.37
07 7 660 83 15 18.37
08 8 660 83 15 19.37
09 9 660 83 20 19.37
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250
3. RESULTS WITH FULL DISCUSSION
3.1. MODIFICATION OF GAS FLOW METER CALIBRATION IN
RESPECT OF PUSHING/CHARGING
It was observed that the accuracy of flow of coke oven gas is more on yearly or half
yearly calibration of flow meter. Due to this, flow meter is allowing to pass extra gases
for producing the combustion process without the recovery of the sensible heat. To
establish the reasons for the low efficiency, the calibration method of gas flow meter
has suggested. The modification of gas flow meter calibration on monthly basis with
respect to pushing/charging and the possible rectification solution is verified against
the Standard Operating Practices and Schedule jobs of Regular Maintenance). Due to
additional gas consumption in coke plant at same pushing charging schedule of 83,
the coke oven gas flow is reduced 200 Nm3/hr without affecting the coke quality.
Table 4. S.H.C after modification of flow meter calibration.
Table4 describes after modification of gas flow meter calibration coking periods is
around 19.37 hours, pause time average is around 20 second at constant production
target is 83. The average on the before modification COG flow rate requirement in
average pushing and charging 83 is 17100 Nm3/hr as per above pushing and
charging target. The all data is taken as on weekly basis which is mentioned in table
3. After the medication of gas flow meter calibration, The average COG flow rate
requirement in 83 numbers pushing and charging is 16900 Nm3/hr as per above
pushing and charging schedule, which is given in the table 4.Afterthe modification of
the COG flow meter calibration, to the thermal regime of coke oven plant at randomly
at a time, the temperature of cross wall is taken at 05 numbers of heating walls. The
temperature of Cross wall is the all heating wall of the flue (means of the all the 32 no.
of heating flues) temperature recorded reading. The temperature of cross-wall data of
reading is express in table 4, 16, 17, 18, 19, and 20, respectively.
S/No.
W.B.A.D
A.S.H.C
N.P.C.P.D
P. T
C.P.D
01
1
660
83
20
19.37
02
2
660
83
20
19.37
03
3
660
83
25
19.37
04
4
660
83
25
19.37
05
5
660
83
20
19.37
06
6
660
83
20
19.37
07
7
660
83
15
18.37
08
8
660
83
15
19.37
09
9
660
83
20
19.37
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Table 5. CWT average cross wall reading in a day basis.
The table number 05 describes that the temperature cross wall average data of
reading is taken in shift wise such as A, B and C shifts respectively. This represents,
after the modification of COG flow, the thermal section of the coke plant is not more
affected. The temperature of cross wall is taken in different schedule of shifts like A, B
HWFN T.H.W.N (16) T.H.W.N (17) T.H.W.N (18) T.H.W.N (19) T.H.W.N (20)
01 1170°c 1170°c 1180°c 1180°c 1170°c
02 1170°c 1180°c 1180°c 1180°c 1180°c
03 1180°c 1190°c 1180°c 1190°c 1180°c
04 1190°c 1190°c 1190°c 1200°c 1190°c
05 1210°c 1200°c 1200°c 1200°c 1200°c
06 1210°c 1210°c 1210°c 1210°c 1210°c
07 1220°c 1220°c 1220°c 1220°c 1220°c
08 1230°c 1230°c 1230°c 1230°c 1230°c
09 1220°c 1220°c 1220°c 1220°c 1220°c
10 1220°c 1220°c 1220°c 1220°c 1220°c
11 1230°c 1220°c 1230°c 1220°c 1230°c
12 1220°c 1230°c 1220°c 1220°c 1230°c
13 1230°c 1230°c 1230°c 1230°c 1230°c
14 1230°c 1230°c 1230°c 1230°c 1230°c
15 1230°c 1230°c 1230°c 1230°c 1240°c
16 1220°c 1220°c 1220°c 1220°c 1220°c
17 1220°c 1220°c 1220°c 1220°c 1220°c
18 1220°c 1220°c 1220°c 1220°c 1220°c
19 1240°c 1240°c 1240°c 1240°c 1240°c
20 1250°c 1250°c 1240°c 1250°c 1250°c
21 1240°c 1240°c 1240°c 1230°c 1240°c
22 1250°c 1250°c 1250°c 1250°c 1250°c
23 1240°c 1240°c 1240°c 1240°c 1240°c
24 1250°c 1250°c 1250°c 1250°c 1240°c
25 1250°c 1250°c 1240°c 1240°c 1250°c
26 1240°c 1240°c 1240°c 1230°c 1230°c
27 1230°c 1230°c 1230°c 1220°c 1220°c
28 1220°c 1220°c 1220°c 1200°c 1210°c
29 1210°c 1210°c 1200°c 1210°c 1210°c
30 1200°c 1200°c 1190°c 1200°c 1200°c
31 1190°c 1190°c 1190°c 1190°c 1190°c
32 1180°c 1180°c 1180°c 1190°c 1180°c
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and C, in different of timing. Comparing the table3 and the table4, it is observed that
after modification of the coke oven gas flow meter calibration, 200 Nm3/hr coke oven
gas flow is saved. This is beneficial in terms of expenditure.
Figure 1 to 5 shows that the cross-wall temps taken at the different times and
different of shifts do not affect the temp of flues. The randomly taken 5 No. ofwall, the
cross wall temp is almost same in nature.
Figure 1. Variation of temperature for heating wall/flue number.
Figure1 comprises that the heating wall no. sixteen in x axis flue number and y axis
temperature reading is taken. flue number 01 temperature is 1170 °c, flue number 02
temperature is 1170 °c, flue number 03 temperature is 1180 °c, flue number
04temperature is 1190 °c, flue number 05 temperature is 1210 °c, these temperature
reading shows that temperature is slowly increases with respect to flue wise, the
maximum temperature reading is taken in flue no.20 is 1250 °c. The last five numbers
of flues temperature reading such as flue number 28 is 1220 °c, flue number 29 is
1210 °c, flue number 30 is 1200 °c, flue number 31 is 1190 °c, flue number 32 is 1180
°c.
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and C, in different of timing. Comparing the table3 and the table4, it is observed that
after modification of the coke oven gas flow meter calibration, 200 Nm3/hr coke oven
gas flow is saved. This is beneficial in terms of expenditure.
Figure 1 to 5 shows that the cross-wall temps taken at the different times and
different of shifts do not affect the temp of flues. The randomly taken 5 No. ofwall, the
cross wall temp is almost same in nature.
Figure 1. Variation of temperature for heating wall/flue number.
Figure1 comprises that the heating wall no. sixteen in x axis flue number and y axis
temperature reading is taken. flue number 01 temperature is 1170 °c, flue number 02
temperature is 1170 °c, flue number 03 temperature is 1180 °c, flue number
04temperature is 1190 °c, flue number 05 temperature is 1210 °c, these temperature
reading shows that temperature is slowly increases with respect to flue wise, the
maximum temperature reading is taken in flue no.20 is 1250 °c. The last five numbers
of flues temperature reading such as flue number 28 is 1220 °c, flue number 29 is
1210 °c, flue number 30 is 1200 °c, flue number 31 is 1190 °c, flue number 32 is 1180
°c.
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Figure 2. Variation of temperature for heating wall/flue number.
Figure2 comprises that the heating wall no. seventeen, in x axis flue number and y
axis temperature reading is taken. flue number 01 temperature is 1170 °c, flue number
02 temperature is 1180 °c, flue number 03 temperature is 1190 °c, flue number
04temperature is 1190 °c, flue number 05 temperature is 1200 °c, these temperature
reading shows that temperature is slowly increases with respect to flue wise, the
maximum temperature reading is taken in flue no.20 is 1250 °c. The last five numbers
of flues temperature reading such as flue number 28 is 1220 °c, flue number 29 is
1210 °c, flue number 30 is 1200 °c, flue number 31 is 1190 °c, flue number 32 is 1180
°c.
Figure 3. Variation of temperature for heating wall/flue number.
Figure3 comprises that the heating wall no. eighteen, in x axis flue number and y
axis temperature reading is taken. flue number 01 temperature is 1180 °c, flue number
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02 temperature is 1180 °c, flue number 03 temperature is 1180 °c, flue number
04temperature is 1190 °c, flue number 05 temperature is 1200 °c, these temperature
reading shows that temperature is slowly increases with respect to flue wise, the
maximum temperature reading is taken in flue no.22 is 1250 °c. The last five numbers
of flues temperature reading such as flue number 28 is 1220 °c, flue number 29 is
1200 °c, flue number 30 is 1190 °c, flue number 31 is 1190 °c, flue number 32 is 1180
°c.
Figure 4. Variation of temperature for heating wall/flue number.
Figure4 comprises that the heating wall no. nineteen, in x axis flue number and y
axis temperature reading is taken. flue number 01 temperature is 1180 °c, flue number
02 temperature is 1180 °c, flue number 03 temperature is 1190 °c, flue number
04temperature is 1200 °c, flue number 05 temperature is 1200 °c, these temperature
reading shows that temperature is slowly increases with respect to flue wise, the
maximum temperature reading is taken in flue no.20 is 1250 °c. The last five numbers
of flues temperature reading such as flue number 28 is 1220 °c, flue number 29 is
1210 °c, flue number 30 is 1200 °c, flue number 31 is 1190 °c, flue number 32 is 1190
°c.
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02 temperature is 1180 °c, flue number 03 temperature is 1180 °c, flue number
04temperature is 1190 °c, flue number 05 temperature is 1200 °c, these temperature
reading shows that temperature is slowly increases with respect to flue wise, the
maximum temperature reading is taken in flue no.22 is 1250 °c. The last five numbers
of flues temperature reading such as flue number 28 is 1220 °c, flue number 29 is
1200 °c, flue number 30 is 1190 °c, flue number 31 is 1190 °c, flue number 32 is 1180
°c.
Figure 4. Variation of temperature for heating wall/flue number.
Figure4 comprises that the heating wall no. nineteen, in x axis flue number and y
axis temperature reading is taken. flue number 01 temperature is 1180 °c, flue number
02 temperature is 1180 °c, flue number 03 temperature is 1190 °c, flue number
04temperature is 1200 °c, flue number 05 temperature is 1200 °c, these temperature
reading shows that temperature is slowly increases with respect to flue wise, the
maximum temperature reading is taken in flue no.20 is 1250 °c. The last five numbers
of flues temperature reading such as flue number 28 is 1220 °c, flue number 29 is
1210 °c, flue number 30 is 1200 °c, flue number 31 is 1190 °c, flue number 32 is 1190
°c.
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Figure 5. Variation of temperature for heating wall/flue number.
Figure5 comprises that the heating wall no. twenty, in x axis flue number and y axis
temperature reading is taken. flue number 01 temperature is 1170 °c, flue number 02
temperature is 1180 °c, flue number 03 temperature is 1180 °c, flue number
04temperature is 1190 °c, flue number 05 temperature is 1200 °c, these temperature
reading shows that temperature is slowly increases with respect to flue wise, the
maximum temperature reading is taken in flue no.20 is 1250 °c. The last five numbers
of flues temperature reading such as flue number 28 is 1210 °c, flue number 29 is
1210 °c, flue number 30 is 1200 °c, flue number 31 is 1190 °c, flue number 32 is 1180
°c.
Table 6. -Comparison analysis of hot strength of coke.
Serial
no.
Weekly basis
average data
Before
modificat
ion CSR
value
After
modificati
on CSR
value
Before
modificati
on CRI
value
After
modificat
ion CSI
value
Before
modificati
on gas
flow
(Nm3/hr)
Before
modificati
on gas
flow
(Nm3/hr)
01 First week 63 63 23 23 17100 16900
02 Second week 63 63 23 23 17100 16900
03 Third week 63 63 23 23 17100 16900
04 4thweek 63 63 23 23 17100 16900
05 5thweek 63 63 23 23 17100 16900
06 6th week 63 63 23 23 17100 16900
07 7th week 63 63 23 23 17100 16900
08 8th week 63 63 23 23 17100 16900
09 9th week 63 63 23 23 17100 16900
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Table 6 describes that the hot strength of coke quality, the lab report is taken on
daily basis then after it is taken the average value of weekly basis. The lab report is
same as on the modification of gas flow meter. Before modification coke strength after
reaction(CSR) value is 63 and after modification coke strength after reaction (CSR)
value is almost same as 63. Before modification coke reactive index (CRI) value is 23
and after modification coke reactive index (CRI) value is almost same as 23.by the
modification of gas flow meter calibration, coke oven gas is saved up to 200 Nm3
onhourly basis.
Figure 6. comparative analysis of CSR and CRI Value before and after modification.
Figure 6 describes that the comparative analysis of hot strength of coke quality like
CSR and CRI, the lab report is taken on daily basis then after it is taken the average
value of weekly basis. The lab report is same as on the modification of gas flow meter.
Before modification coke strength after reaction (CSR) value is 63 and after
modification coke strength after reaction (CSR) value is almost same as 63. Before
modification coke reactive index (CRI) value is 23 and after modification coke reactive
index (CRI) value is almost same as 23.by the modification of gas flow meter
calibration, coke oven gas is saved up to 200 Nm3 onhourly basis. The saving of coke
oven gas which is shown in figure 7.
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Table 6 describes that the hot strength of coke quality, the lab report is taken on
daily basis then after it is taken the average value of weekly basis. The lab report is
same as on the modification of gas flow meter. Before modification coke strength after
reaction(CSR) value is 63 and after modification coke strength after reaction (CSR)
value is almost same as 63. Before modification coke reactive index (CRI) value is 23
and after modification coke reactive index (CRI) value is almost same as 23.by the
modification of gas flow meter calibration, coke oven gas is saved up to 200 Nm3
onhourly basis.
Figure 6. comparative analysis of CSR and CRI Value before and after modification.
Figure 6 describes that the comparative analysis of hot strength of coke quality like
CSR and CRI, the lab report is taken on daily basis then after it is taken the average
value of weekly basis. The lab report is same as on the modification of gas flow meter.
Before modification coke strength after reaction (CSR) value is 63 and after
modification coke strength after reaction (CSR) value is almost same as 63. Before
modification coke reactive index (CRI) value is 23 and after modification coke reactive
index (CRI) value is almost same as 23.by the modification of gas flow meter
calibration, coke oven gas is saved up to 200 Nm3 onhourly basis. The saving of coke
oven gas which is shown in figure 7.
https://doi.org/10.17993/3ctecno.2023.v12n1e43.243-260
Figure 7. comparative analysis of coke oven gas flow before and after modification
Figure 7 comprises that the comparative analysis of coke oven gas flow before and
after modification of gas flow meter. Firstly requirement of coke oven gas flow is about
17100 Nm3/hrs then after rectification gas flow requirement is about 16900 Nm3/hrs.
This shows that 200 Nm3/hrs coke oven gas is saving in hourly basis. On the saving
of coke oven gas by the modification of gas flow meter calibration the coke quality is
not change, quality of coke like CSR and CRI value remains constant.
Table 7. -Comparison analysis tabulation of SHC.
Table 7 shows that before and after modification of gas flow meter calibration SHC
value reduced from 670 to 660in kcal/kg. The modified COG flow (with the respect of
pushing and charging), the average saving in COG is 200 Nm3/hour. This will reduce
the production cost of coke.
Sr.
No.
A.S.H.C (kcal/kg)
before
rectification
A.S.H.C (kcal/
kg)
After the
rectification
Saving
of COG
(Nm3/hr)
COG saving
on monthly
basis(Nm3)
Monthly
Saving of the
COG
@ 4.5
rupees/Nm3
01 670 660 200 144000 648000
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Figure 8. comparative analysis between before and after calibration of flow meter
Figure 8 comprises that the experimental value of specific heat consumption with
respect to number of weeks. Specific heat consumption is directly proportional to the
gas flow requirement. Firstly requirement of coke oven gas flow is about 17100 Nm3/
hrs then after rectification gas flow requirement is about 16900 Nm3/hrs. This shows
that 200 Nm3/hrs coke oven gas is saving in hourly basis. After the rectification of
smoke pushing specific heat consumption value is reduces from 670kcal/kg to
660kcal/kg which is given in table 6.
4. CONCLUSION
By this modification of gas flow meter calibration coke oven gas flow reduced from
17100Nm3/hrs to 16900Nm3/hrs, such as 200 Nm3 on hourly basis saving without
any extra manpower cost. The proposed method is also cost effective as it saves Rs
6483000 every month for producing coke. This methodology is also helpful for
reducing the manufacturing cost of coke in a recovery type of coke plant and stable
oven operation and prolongation of coke oven life. Future advancements in this
technique will allow us to minimize the need for money, which will revolutionize the
nation's economy.
ACKNOWLEDGEMENT
All authors would like to special thanks to S K Biswas (Coke Oven HOD, NMDC
Iron & Steel Plant,Nagarnar),Arsh Pandey(AGM, NMDC Iron & Steel Plant,Nagarnar),
J Arjun Prasad (Ex General Manager I/C, iron, BSP SAIL), Chandan Bhattacharya (Ex
General Manager in Coal, Coke & Coal Chemicals, RSP, SAIL), RBK Lakra (D.G.M,
Coke Oven Operation, RINL, India) and Akurati Veera AnkaRamaseshu working in
Mecon Limited ( A PSU Under Ministry of Steel, Government of India) as a working
management committee(coke oven plant, main units)for his insights and critical
assessment in preparing this Research paper.
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258
Figure 8. comparative analysis between before and after calibration of flow meter
Figure 8 comprises that the experimental value of specific heat consumption with
respect to number of weeks. Specific heat consumption is directly proportional to the
gas flow requirement. Firstly requirement of coke oven gas flow is about 17100 Nm3/
hrs then after rectification gas flow requirement is about 16900 Nm3/hrs. This shows
that 200 Nm3/hrs coke oven gas is saving in hourly basis. After the rectification of
smoke pushing specific heat consumption value is reduces from 670kcal/kg to
660kcal/kg which is given in table 6.
4. CONCLUSION
By this modification of gas flow meter calibration coke oven gas flow reduced from
17100Nm3/hrs to 16900Nm3/hrs, such as 200 Nm3 on hourly basis saving without
any extra manpower cost. The proposed method is also cost effective as it saves Rs
6483000 every month for producing coke. This methodology is also helpful for
reducing the manufacturing cost of coke in a recovery type of coke plant and stable
oven operation and prolongation of coke oven life. Future advancements in this
technique will allow us to minimize the need for money, which will revolutionize the
nation's economy.
ACKNOWLEDGEMENT
All authors would like to special thanks to S K Biswas (Coke Oven HOD, NMDC
Iron & Steel Plant,Nagarnar),Arsh Pandey(AGM, NMDC Iron & Steel Plant,Nagarnar),
J Arjun Prasad (Ex General Manager I/C, iron, BSP SAIL), Chandan Bhattacharya (Ex
General Manager in Coal, Coke & Coal Chemicals, RSP, SAIL), RBK Lakra (D.G.M,
Coke Oven Operation, RINL, India) and Akurati Veera AnkaRamaseshu working in
Mecon Limited ( A PSU Under Ministry of Steel, Government of India) as a working
management committee(coke oven plant, main units)for his insights and critical
assessment in preparing this Research paper.
https://doi.org/10.17993/3ctecno.2023.v12n1e43.243-260
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