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The stamped charging of coals, developed in Europe and adopted in China and India, allows the use of high volatile poor coking coals, soft and semi soft coals as well as inerts like petroleum coke and anthracite without impairing coke quality. In this paper the development of the technology is detailed. Different type of equipmentfor cake preparation and charging are described. The operating aspects areanalyzed, including the safety against wall pressure. Blend design as practiced in European, Chinese and Indian coke plants is discussed. Coke quality indexes obtained with this technique are shown. The reasons behind the improvement in MICUM 10 and CSR are briefly addressed. A summary of current research on this process being carried out in Universities, Institutes and Research Centers is presented.
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Jorge Madias
Mariano de Cordova
metallon, San Nicolas, Argentina
A Review on Stamped Charging of Coals
Content
Introduction
Equipment and Operation
Blend Design and Coke Quality
Recent Research
Conclusions
Introduction
Drivers for this review Start-up of a pilot coke oven
with stamped charging facility at
a steel plant in Peru, with
unexpected results
Dramatic expansion of stamped charging capacity in China:
more than 100 Mtpa of installed
capacity (Dr. Q. Meng, ICSTI
2012)
Introduction
PCI calls for higher coke quality
Coking coal price volatility calls for use of poorly coking coals
One of the answers has been stamped charging
Introducing the coal blend previously ground within a steel box, as successive layers that are
rammed mechanically
The higher the density, the higher the coke quality (mostly for high volatile blends)
Introduction
Developed in Silesia and Poland in the
early XX century
Extended to East and West Europe Germany
France
UK
Czech Republic
Ukraine
Introduction
1978 First 6 m high cake, after long R&D effort
(Feuerfesten Coke Plant,
Germany)
1984 First 6 m high coke stamp charged batteries
(ZKS, Vlklingen) by Didier
and Saarberg Interplan
1989 Battery #7 in Tata Steel
1995-2013 Expansion in China and India
Introduction
Some coke plants with stamped charging Company Location Country Mta Year Builder Oven type ZKS Vlklingen Germany 1.3 2010 (#3)
2012 (#1) Paul Wurth-Saarberg Conventional
ISD Alchevsk Coking Plant Alchevsk Ukraine 2.0 1993/2006 Azovintex-VeCon Conventional Shanxi Changzhi Changzhi China 1.5 MEPC Conventional Shanxi Zhonghua Dali Village China 1.2 SPDCI Heat-recovery Zhongmei Jingda Huian China SPDCI Heat-recovery Jincheng Qinhe Qinhe China SPDCI Heat-recovery Shanxi Sanjia Jiexiu City China SPDCI Heat-recovery Shanxi Luxin Energy Group Shanxi Prov. China SPDCI Heat-recovery Xinjiang International Urumqi China SPDCI Heat-recovery Jiangsu Zhuxi Activated C. Liyang City China 0.75 SPCDI Heat-recovery Shanxi Fenyang Longquan Fenyang C. China 0.4 SPCDI Heat-recovery Hunan Loudi Xinxing Loudi China 0.6 SPCDI Heat-recovery Qingdao Steel Qingdao China 0.6 1995 Saarberg Conventional Taiyuan Gangyuan Donggaobai China 0.4 SPCDI Heat-recovery Xinggao Coking Group Gaoping China 1.0 2000
2008 SPCDI
FLSmidth Koch Heat-recovery Conventional
Tata Steel Jamshedpur India 2.0 1989/2000 Conventional Sesa Goa Amona India 0.28 Sesa Goa Non-recovery Bla Coke Arambhada India 0.25 Bla-VeCon Non-recovery JSW Steel Bellary India 1.2 Sesa Goa-VeCon Heat-recovery JSW Steel Bellary India 1.5 2008 Sinosteel Conventional JSL India 0.42 Sinosteel Heat-recovery JSPL Raigahr India 0.8 2008-2013 Sinosteel Heat-recovery SISCOL Tamil Nadu India 0.4 2007 Sinosteel Heat-recovery Lanco Ind. Ltd. Rachagunneri India 012 2005 Dasgupta-MEPC Heat-recovery Hoogly Met Coke & Power Haldia India 1.6 MEPC Heat-recovery TK-CSA Santa Cruz Brazil 2.0 2010 Sinosteel Heat-recovery
Equipment & Operation
Stamping equipment
Location Stationary (i.e. in a building below the coal tower)
In a stamping/charging/pushing machine
Densification Ramming (several layers)
Vibration (as a complement, for horizontal ovens)
Cake properties Densification
Mechanical properties
Equipment & Operation
Vertical stamping
Equipment & Operation
Horizontal stamping
Equipment & Operation
Cake preparation
Densification Required by the coking process, for coke quality
Influenced by Moisture
Grain size
Coal properties
Stamping energy
Mechanical properties Required to handle cake (critical for vertical ovens)
Compressive strength, shear strength
Favored by densification (and additives)
Equipment & Operation
Influence of moisture on cake density
Equipment & Operation
Influence of stamping energy on cake density
Equipment & Operation
Influence of moisture and stamping energy
on compressive and
shear strength
Equipment & Operation
Charging slot ovens
Equipment & Operation
Charging heat-recovery oven
Equipment & Operation
Wall pressure issues
Equipment & Operation
Wall pressure issues
ZKS Didier batteries 1 & 2
started up in 1984,
6.25 m high
Battery 3 built by Paul Wurth in 2010
Battery 1 demolished and rebuilt in 2012
Battery 2 said to be shut down in 2012
So, battery live was 28 years
Equipment & Operation
Wall pressure issues
Tata Steel Jamshedpur
Oldest stamp charged battery #7, built in
1989
Failures started in 2005
After long continuous improvement work, all
ovens came back by
2010
Equipment & Operation
These examples suggests that with the technology used for 6 m high stamp charged
batteries in the mid 80s, working life should
be around 30 years
This is less than what is expected for top charged batteries (40-50 years)
But it is the same that for non-recovery/heat recovery ovens, with or without stamped
charging
Blend Design & Coke Quality
ZKS blend
Local coal Ruhr coal Imported coal Pet coke Blend Content (%) 72 5 8 12 100* Volatile matter (%) 38.6 17.3 19.1 11.8 31-32 Dilatation (%) 100 -18 34 - 10 FSI 8 3 9 - Ash (%) 6 7 10 1 6 Sulphur (%) 0.72 0.80 0.80 0.85-1.70 Mean reflectivity 0.89 - 1.4 - 1.14
Blend Design & Coke Quality
Tata Steel
Main blend component: West Bokaro
Complemented with hard and semi soft Australian coals
Volatile matter (%) 26.7
Ash (%) 17.5
FSI 3
Maximum fluidity (ddpm) 3900
Vitrinite reflectance 0.97
Blend Design & Coke Quality
Tata Steel
Blend cost comparison
Blend Design & Coke Quality
Coke Quality (JSW Steel) Coking coal (%) 100 95 90 85 80 65 65 75 70 65 Semi soft coal (%) 0 0 0 0 0 15 10 0 0 0 Non-coking coal (%) 0 5 10 15 20 20 25 25 30 35 Coking time (h) 62 60 59 61 58 61 61 56 56 62 CRI (%) 23 24 25 24 24 25 25 26 26 27 CSR (%) 67 67 66 66 65 64 64 65 63 62 MICUM 10 (%) 5.6 5.7 5.5 5.8 5.3 5.3 5.7 5.3 5.9 5.7 MICUM 40 (%) 85 86 87 85 88 89 89 87 87 89
Blend Design & Coke Quality
China Committee of Coke and
Coal Resources of the
China Coke Industry
Association: by using
stamp charge, coking coal
and fat coal can be
decreased by 14%
So, there is emphasis on full utilization of stamp
charging installed
capacity
Blend Design & Coke Quality
China
CRI and CSR comparison (three blends)
Blend Design & Coke Quality
China
Blends with anthracite
Coal Ash (%) Volatile Matter (%) Sulphur (%) 45% anthracite 10.2 9.3 0.41 20% coking coal 7.7 18.5 0.44 35% 1/3 fat coal 8.8 33.2 0.45 Blend 9.0 21.6 0.42
Coke M40 (%) M10 (%) CSR (%) Ash (%) Sulphur (%) 85.6 6.6 62.1 11.3 0.34
Blend Design & Coke Quality
Summary
Main blend component: high volatile local coal
Use of soft/semisoft coals
Use of low volatile inerts like anthracite and petroleum coke, in some plants
For such blends, MICUM 10 and CSR improve in comparison with top charging (less porosity)
Recent Research
Technical University of Berlin, Germany
Stampability, modeling of stamping operation
Tata Steel R&D, India
Tar pitch/molasses to improve cake strength
Fluid pet coke/anthracite to decrease cost
RDTE, China
Influence of coke structure on high temperature behavior
Conclusions
With more than 100 Mtpa capacity installed, stamped charging became one of the most
applied technologies to decrease blend cost
and/or to improve coke quality
Adoption by China and to a less extent by India, suggests that further increase in
capacity may take place in the future
Some Universities, Institutes and Steel Companies are supporting this technology
with R&D efforts
Jorge Madias
Mariano de Cordova
metallon
Thank You