Upload
susmitadasgupta
View
6.315
Download
3
Embed Size (px)
Citation preview
Tuesday, April 11, 2023
1
Pollution and Pollution Control Performance and
Measures in India
COKE OVENSReference: “Into The
Furnace”. CSE, Delhi.2011
Tuesday, April 11, 2023
2
Coke Ovens is complex of distinct plants
Coke Oven, By Product Plant, Effluent Treatment
Plant
Tuesday, April 11, 2023
3
Presentation of CSE Report, June 2012 on
the Iron and Steel Industry in India
Susmita DasguptaJPC, ERU
Tuesday, April 11, 2023
4
COKE OVENSPresentation I
Tuesday, April 11, 2023
5
There is a variant to this complex in the form of
Coke oven heat recovery/non recovery
type.
Tuesday, April 11, 2023
6
India has 32 million tonnes of annual coke producing capacity
Of this 23 mtpa is the by product recovery type
9 mtpa is non recovery type
Of the 9 mtpa, 6 mtpa is with the merchant coke producers. The rest 3 mtpa is with integrated plants like Bhushan Steel.
Tuesday, April 11, 2023
7
The basic processes are
• Coal is heated in Coke Oven in the absence of air to yield coke.
• Volatile matters wholly and partially combusted evaporate into CO Gas which is quenched and collected.
• Collected gas is then cooled and distilled to yield by products like tar, benzene, napthalene and clean of sulphur.
• Water from condensation and CO cleaning is collected and passed on to Effluent Treatment Plants.
• Treated water and solid waste is generated.
Tuesday, April 11, 2023
8
Three Basic Processes
Coal to coke. Coke goes to
pusher.CO oven Gas
goes to By Product Plant
Coke Oven Gas to by products.By products are
recovered through
condensation.Waste Water
goes to Effluent Treatment Plant
Effluent Treatment of
Water
Discharges water and sludge
Tuesday, April 11, 2023
9
Pollution From Coke Ovens
Coal
CO Gas
By products Water
Coke
Dust
Tuesday, April 11, 2023
10
COKE OVEN BY PRODUCT RECOVERY TYPE
23 million tonnes of annual capacity
Tuesday, April 11, 2023
11
Kinds of Pollution
Due to combustion of coal
• Particulate matter• S02• CO• Nox
Due to incomplete combustion
• PAH compounds, carcinogenic
• During distillation of by product.
• During treatment of waste water.
• May be contained both in air as well as water.
Tuesday, April 11, 2023
12
Kinds of Pollution ..
Fugitive• Unintended waste
due to leakages.• They are PAH
compounds found in air, water or sludge.
• Tar sludge, benzol sludge.
• Usually hazardous.• Incomplete
processes.• They happen due to
high pressure generated in the ovens and decanters.
Process• Generated out of
processes like water, particulate matter, solid non hazardous waste.
• Usually non hazardous.
• Completed processes.
Tuesday, April 11, 2023
13
Kinds of pollution ..
• Air• Water• Solid sludge.
Tuesday, April 11, 2023
14
POLLUTION IN COKE OVENS
Usually air emissions.
Tuesday, April 11, 2023
15
Sources of Pollution in Coke Ovens
1. Splutter when coal is placed in the heated oven, called charging emission. This contains both particulate matter and PAH compounds.
2. Due to high pressure of volatile matter inside oven during heating gas leaks out. This is diffuse emission.
3. When volatile matter is wholly burnt and coke remains, dust is emitted. This is combustion emission.
4. When coke is done and is pushed out of ovens into the pusher car, soot blows out. This is called pusher emission.
5. When Coke Oven Gas is quenched with water, water evaporates into steam with particulate matter, So2, Nox and CO. This is called quenching emission.
Tuesday, April 11, 2023
16
Charging emissions can be prevented by
• Increasing compactness in coal packing. Change from top charging to stamp charging.
• Increase the volume of coke ovens to reduce frequency of charging.
• Increasing height of chamber.
Tuesday, April 11, 2023
17
Diffuse emission can be prevented by
• Using self sealing doors.• Use of magnetic lid.• Use of screw tightened pipes.• Water sealing of ascension pipes.• Plugging charging holes.• Containing build up of pressure in
the oven through variable pressure controller.
• Increasing compactness of feed through stamp charging.
Tuesday, April 11, 2023
18
Combustion emission due to under firing of stack can
be contained through
• Arrest of dust containing PM, So2, Nox, CO and CO2.
• Having larger oven sizes through increase in chamber height.
• Stamp charging.• HPLA
Tuesday, April 11, 2023
19
When coke is done, and is pushed out of the oven into
container cars on rails, soot can be controlled by
• Having a land based stationary emission control device instead of the suction hood and bag filter attached to the mobile car.
Tuesday, April 11, 2023
20
Quenching emissions
• When water is sprayed on CO Gas to cool the fluid, water evaporates producing steam. The steam contains particulate matter, CO, So2 and Nox.
• Dry quenching with ammonia helps in reducing this type of emissions.
Tuesday, April 11, 2023
21
Emissions are of two kinds
Fugitive• Fugitive emissions
happen due to gas leaks.
• This may contain both combusted and incompletely combusted matter. Incomplete combustion has traces of PAH levels measured by the concentration of benzene pyrelene in the emission.
• Pollution control rules pertain to equipment design.
Process• Usually wholly
combusted matter in the form of dust, namely PM, Nox, So2 and CO.
• Pollution control rules pertain to emission norms and
• Pollution control devices.
Tuesday, April 11, 2023
22
The emissions from CO Plant is air emission
• We track particulate matter, So2, CO and Nox.
• We track the concentration of B(a)p, a PAH compound that contains poisonous cyanide and emanates out of improperly combusted volatile matter in coal.
Tuesday, April 11, 2023
23
Ministry of Environment and Forests have specifications for
• Emission norms and standards.• Plant design equipment.• Specification of pollution control
equipments.
Tuesday, April 11, 2023
24
Comparison of Air Emission Standards For Coke Oven Recovery
Fugitive Visible Emissions Units India Europe USA
Percentage Leaked From Doors % 55 to 10 4
Percentage Leaked from lids % 1 1 0.4
Percentage laked from ascension pipes % 4 1 2.5
Charging Emissions seconds/ charge 16 20 14
Benzo(a)pyrene in the work area Units India Europe USA
Battery area Top ug/m3 5 5
Other units in coke plant ug/m3 2 2
Ambient air standards ng/m3 10 6
Underfiring Stack Emissions Units India Europe USA
Particulate Matter mg/Nm3 50 20 50
Sulphur dioxide mg/Nm3 800200 to 500 500
Nitrogen Oxide mg/Nm3 500350 to 500 750
Carbon Monoxidekg/tonne of gross coke 3 3 3
Other Stack Related Emissions Units India Europe USA
Stamp Charging PM mg/NM3 25
Coke Pushing Emissions
gm/tonne of coke pushed 5 5
Sulphur in Coke Gas Recycled mg/Nm3 800 300
Wet Quenching Units India Europe USA
Particulate Matter from Tower
gm/tonne of coke produced 50 (wet) 25 (wet)
20 (dry) mg/Nm3
Source: CSE, June 2012
Tuesday, April 11, 2023
25
Norms Provided by the GSR 46(E) Notification dated 3.2.2006
Fugitive Visible Emissions UnitsNew Baterries for Greenfield sites
Rebuilt Batteries
Existing Batteries
Percentage Leaked From Doors % 5 10 10
Percentage Leaked from lids % 1 1 1
Percentage laked from ascension pipes % 4 4 4
Charging Emissionsseconds/ charge 16 (HPLA) 50 (HPLA) 75
Benzo(a)pyrene in the work area Units Green Field Rebuilt Existing
Battery area Top ug/m3 5 5 5
Other units in coke plant ug/m3 2 2 2
Ambient air standards ng/m3 10 10 10
Underfiring Stack Emissions Units
Particulate Matter mg/Nm3 50 50 50
Sulphur dioxide mg/Nm3 800 800 800
Nitrogen Oxide mg/Nm3 500 500 500
Carbon Monoxidekg/tonne of gross coke 3 3 3
Other Stack Related Emissions Units Green Field Rebuilt Existing
Stamp Charging PM mg/NM3 25 25 25
Coke Pushing Emissions (land based system applicable)
gm/tonne of coke pushed 5 5
Sulphur in Coke Gas Recycled mg/Nm3 800not specified
not specified
Wet Quenching Units Green Field Rebuilt Existing
Particulate Matter from Tower
gm/tonne of coke produced 50 50
not specified
Tuesday, April 11, 2023
26
(a) air-cooled self-sealing doors;(b) the hydro-jet cleaning system shall be provided for the door and door frame cleaning with a facility of hydro jet pressure of 600 kg/cm2;(c) the charging should be accomplished with hermetically sealed charging sleeves and screw feeder in charging car. The charging car should also be equipped with magnetic lid lifter and lid and frame cleaning mechanism (applicable to top charging batteries);(d) to provide aspiration through high-pressure ammonia liquor (HPLA) injection in goose neck and emission should be transferred directly to gas collecting mains;
(e) water sealed AP covers should be provided;(f) computerized combustion control and moisture control systems.
Tuesday, April 11, 2023
27
Among the pollution control equipment it specifies
• Land based stationary precipitator.
• Norms for the use of effluent treated water for wet quenching.
Tuesday, April 11, 2023
28
COKE OVEN PERFORMANCE PARAMETERS
Poor environment management also means poor economic efficiency
Tuesday, April 11, 2023
29
Fugitive Emission Standards Compliance Status 2009-10
Name of Steel Plant Battery NoComplianc
e
Vizag Steel Plant Battery 1 Yes
Visakhapatnam Battery 2 Yes
50% Battery 3 No
Battery 4 No
SAIL, Rourkela Battery 1 Yes
40% Battery 2 No
Battery 3 No
Battery 4 Yes
Battery 5 No
Tata Steel Battery 3 No
Jamshedpur Baterry 5 No
33% Baterry 6 No
Baterry 7 No
Baterry 8 Yes
Baterry 9 Yes
JSW Steel, Vijayanagar Battery 3A Yes
100% Battery 3B Yes
Battery 3C Yes
Battery 3D Yes
Neelachal Ispat, Orissa Battery 1 Yes
100%
Source: CSE 2012
Tuesday, April 11, 2023
30
Coke Oven Stack Particulate Matter Emission
Coke Oven Stack PM Emissions
2008-09 and 2009-10
Plant mg/Nm3
Vizag Steel, 4 43.2
SAIL RSP,2 46
Tata Steel, 3 83
JSW Steel 10
Neelachal Ispat 56
SAIL BSP, 1 77.7
SAIL BSP, 2 75.4
SAIL BSP, 3 66.6
SAIL, BSP 7 80.3
SAIL, BSP 8 83.3
SAIL, BSP 9 89.3
SAIL, BSP 10 94.4
SAIL, DSP, 3 132.3
SAIL, IISCO, 8 113.68
SAIL, IISCO, 9 61.45
Source; CSE, June 2012
Improve quality of coal.
Stamp charging increases bulk density.
Variable pressure controller.
Tuesday, April 11, 2023
31
Coke Oven Gas Emissions
Coke Oven Stack PM Emissions
2008-09 and 2009-10
Plant mg/Nm3
Vizag Steel, 4 43.2
SAIL RSP,2 46
Tata Steel, 3 83
JSW Steel 10
Neelachal Ispat 56
SAIL BSP, 1 77.7
SAIL BSP, 2 75.4
SAIL BSP, 3 66.6
SAIL, BSP 7 80.3
SAIL, BSP 8 83.3
SAIL, BSP 9 89.3
SAIL, BSP 10 94.4
SAIL, DSP, 3 132.3
SAIL, IISCO, 8 113.68
SAIL, IISCO, 9 61.45
Source; CSE, June 2012
High emissions indicate leakages.
Can be corrected with self sealing doors.
Stamp Charging. To improve bulk density of charge.
Increase in coke oven chamber height.
Increase in coke oven volume.
Water sealed ascension pipes.
Hydrojet cleaning.
Magnetic lid
Dry Quenching
Tuesday, April 11, 2023
32
BF to Gross Coke Yield
Company wise BF Coke Yield to Gross Coke
Plant Yield %
Vizag Steel 83.2
SAIL RSP 88.8
Tata Steel 80
JSW Steel 91.9
Neelachal Ispat 87.8
SAIL, BSP 82.5
SAIL, BSL 83
SAIL, DSP 79
SAIL, IISCO 89
India's Average 84
Global Best 92
Source: CSE, June 2012
This parameter indicates the control of the company to raw material resources especially coal.
Tuesday, April 11, 2023
33
Gross Coke Yield Improves
Company wise Gross Coke Yield 2009-10
Plant Gross Coke Yield %
Vizag Steel Plant 74.4
SAIL, RSP 74.6
Tata Steel 75.6
JSW 72
Neelachal Ispat 75.6
SAIL, BSP 74
SAIL, IISCO 76
India's Average 74.5
Global Best 81
Source: CSE, June 2012
If quality of coal is better.
Bulk density improves through stamp charging.
Coke chamber height increases.
Variable pressure monitor is installed.
Tuesday, April 11, 2023
34
Coke Oven Gas Collection Rate
Company wise Coke Oven Gas Collection Rate 2009-10
Plant Nm3/tonne of dry coke
Vizag Steel 340
SAIL RSP 318
Tata Steel 310
JSW Steel 320
Neelachal Ispat 332
SAIL, BSP 317
SAIL,BSL 310
SAIL, DSP 290
SAIL, IISCO 299
India's Average 316
Global Best Practice 388
Source: CSE, June 2012
Would improve if
Wet quenching is replaced by dry ammonia quenching.
HPLA rather than Gas Burning Chamber is installed.
Water sealed ascension pipes are used.
Coke yield in the oven improves.
Low levels of particulate matter is emitted.
Coal has low sulphur content.
Tuesday, April 11, 2023
35
Specific Thermal Efficiency
Specific Thermal Energy Consumption
2009-10
Coke Oven kcal/kg gross coke
Vizag Steel Plant 813
SAIL, RSP 786
Tata Steel 794
JSW Steel Total 885
JSW 3A and 3D 900
Neelachal Ispat 764
SAIL Bhilai Total 662
SAIL Bhilai 5 546
SAIL, IISCO 781
India's Average 764
Global Best 496
Source: CSE, June 2012
Dry quenching helps in heat recovery.
Proper sealing of doors, lids, pipes improve thermal efficiency.
Stamp charging improves thermal efficiency.
Tuesday, April 11, 2023
36
List of Clean Technologies
1. Increase in coke oven chamber height.
2. Move over from top to stamp charging to increase density in bulk.
3. Self sealed doors.4. Magnetic lids.5. Hydrojet cleaners.6. Water sealed ascension pipes.7. HPLA8. Land based ESP
Tuesday, April 11, 2023
37
Technology #1Increase in Chamber Height
• This increases the volume of the oven and reduces the need to repeatedly open the doors. Reduces leakage/diffuse emissions.
• The number of bushings is reduced. Decreases pushing emission.
• Global best practice = height of 8.3 metres.
• India’s average 4.3meters.• Volume of coke oven increases. 8.3
m height = 70 tonne of oven volume.
Tuesday, April 11, 2023
38
Technology # 2Stamp Charging
• Top charging accommodates 765 kgs/m3 volume. Stamp charging accommodates 1150kg.m3 volume.
• More coal can be pushed at a time and this reduces charging and pushing emissions.
• Stamp charging improves coke strength and this helps BF productivity.
• Combustion emissions/stack emissions are reduced due to increased coke strength.
Tuesday, April 11, 2023
39
Technology #3Self sealed Doors
• Gas pressure is kept at a minimum inside the oven so that tar sealing gaskets are formed along the doors.
• Spring loaded stainless steel doors.
• GSR 46(E) notification of 3.2.2006 specifies self sealing doors.
• Of the 45 ovens studied, only 18 have self sealing doors.
• This is 40% compliance.
Tuesday, April 11, 2023
40
Technology #4Magnetic Lid
• In order to minimise leakage/diffuse emissions, magnetic lids are prescribed.
• GSR 46(E) dated 3.2.2006 specifies magnetic lids.
Tuesday, April 11, 2023
41
Technology #5Hydrojet Cleaners
Technology # 6Water sealed ascension pipes
• Hydrojet cleaners helps clean gas exit zones to help declog.
• GSR 46(E) 3.2.206 has specified the use of such cleaners.
• Since gas tends to leak through ascension pipes due to high pressure built up in the oven, water sealed ascension pipes are recommended.
Tuesday, April 11, 2023
42
Technology #7High Pressure Liquid Ammonia
Aspirator
• This helps capture emission by reducing the pressure of gas through ammonia cooling.
• Used in dry quenching technology for gas collection.
• Used in stamp charging to reduce charging emissions.
• Very useful for capturing PAH emissions emanating out of incomplete combustion.
• GSR 46(E) 3.2.2006 notification exists.
Tuesday, April 11, 2023
43
Technology #8Land Based Stationary Air Filter
• Coke is pushed out in container cars on rails equipped with suction hood and bag filters.
• GSR 46(E) 3.2.2006 recommends the use of land based stationary precipitator for control of dust during coke pushing.
Tuesday, April 11, 2023
44
Design of Coke Ovens In India
Name of Plant Battery
Gross Coke Capacity in million tonnes per annum
Number of ovens/ batteries
Chamber Height in metres
Type of Charging
Coal Holding Capacity (dry coal) in tonnes/ oven
Vizag Steel Battery 1 0.8 67 7 top 31.6
Battery 2 0.8 67 7 top 31.6
Battery 3 0.8 67 7 top 31.6
Battery 4 0.8 67 7 top 31.6
SAIL, RSP Battery 1 0.48 70 4.5 top 17
Battery 2 0.48 70 4.5 top 17
Battery 3 0.48 70 4.5 top 17
Battery 4 0.56 80 4.5 top 17
Battery 5 0.56 80 4.5 top 17
Tata Steel Battery 3 0.3 54 4.5 top 17
Battery 5 0.5 30 4.5 Stamp 24.3
Battery 6 0.48 60 4.5 Stamp 24.3
Battery 7 0.48 54 4.5 Stamp 24.3
Battery 8 0.5 70 4.5 Stamp 24.3
Battery 9 0.5 70 4.5 Stamp 24.3
JSW Vijaynagar Battery 3A 0.38 56 4.3 Stamp 27
Battery 3B 0.38 56 4.3 Stamp 27
Battery 3C 0.38 56 4.3 Stamp 27
Battery 3D 0.38 56 4.3 Stamp 27
Neelachal Ispat Battery 1 0.8 67 7 top 17
SAIL DSP Battery 1 0.4 78 4.45 top 17
Battery 3 0.4 78 4.45 top 17
Battery 4 0.4 78 4.45 top 17
Battery 6 0.4 78 4.45 top 17
SAIL BSL Battery 1 0.57 69 5 top 20.7
Battery 2 0.57 69 5 top 20.7
Battery 3 0.57 69 5 top 20.7
Battery 4 0.57 69 5 top 20.7
Battery 5 0.57 69 5 top 20.7
Battery 6 0.57 69 5 top 20.7
Battery 7 0.57 69 5 top 20.7
Battery 8 0.57 69 5 top 20.7
SAIL, BSP battery 1 0.4 65 5 top 16.8
battery 2 0.4 65 5 top 16.8
battery 3 0.4 65 5 top 16.8
battery 4 0.4 65 5 top 16.8
battery 5 0.4 65 5 top 16.8
battery 6 0.4 65 5 top 16.8
battery 7 0.4 65 5 top 16.8
battery 8 0.4 65 5 top 16.8
battery 9 0.8 67 7 top 30
battery 10 0.8 67 7 top 30
SAIL, IISCO Battery 8 0.4 78 4.5 top 18.8
Battery 9 0.4 78 4.5 top 18.8
Battery 10 0.4 78 4.5 top 18.8
Source: CSE, June 2012
Tuesday, April 11, 2023
45
Technologies Adopted in Indian Coke Ovens
Tuesday, April 11, 2023
46
BY PRODUCT PLANTSulphur is removed, by products are retrieved
Tuesday, April 11, 2023
47
New technologies for sulphur removal
• Sulphur content in CO Gas prior to treatment is 1800-4000 mg/Nm3.
• In ammonia scrubbing, sulphur content comes down to 800 mg/Nm3.
• In wet oxidative system, sulphur content comes down to 200 mg/Nm3
Tuesday, April 11, 2023
48
Sources of Pollution in By Product Plant
• Water is generated when the CO gas condenses.
• Water may contain PAH.• Water may also contain sulphur.• Sulphur sludge.• Tar sludge• Benzol sludge.
Tuesday, April 11, 2023
49
EFFLUENT TREATMENT PLANT
Here waste water enters for treatment and cleaning. Also sludge from distilled by products are cleaned into non hazardous solid waste.
Tuesday, April 11, 2023
50
Steps in Effluent Treatment Plant
1. Tar is removed.2. Suspended solids captured.3. BOD,COD removed.4. Sludge is thickened. Water
released.5. Ammonia is removed.6. Cyanide is removed.7. Clean water flushed.8. Solid waste disposed.
Tuesday, April 11, 2023
51
Water Treatment Parameters in ETP
Waste Water Treatment Plant Parameters
Parameter Units Tata Steel SAIL, RSP JSW, Vijaynagar
pH 7.8 8.5 to 9.5 8.2 to 8.7
Ammonia Nitrogen mg/litre 150 300 to 350 120-348
Phenol mg/litre 330 400 to 450 264 to 725
Cyanide mg/litre 4.8 to 5.6 20 7.4 to 262
Oil and grease mg/litre 5 to 10 30 to 40 7.7 to 24.6
BOD mg/litre 1150
COD mg/litre 2400 1939 to 2931
Total Suspended Solids mg/litre 50 138 to 569
Mixed Liquor Suspended Solids 4000 3248
Source: CSE, June 2012
Tuesday, April 11, 2023
52
Water Consumption in Coke Oven
• Coke Ovens consume 13% of all water required in the steel plants.
• Water is used for cooling ovens, quenching off gas.
• Cleaning plant and machinery.• Water is condensed out of coal,
out of the Coke Oven Gas while recovering tar and other products.
• Also during cyanide dilution.
Tuesday, April 11, 2023
53
Dry Quenching reduces water consumption.
Coke Oven Plants 2009-10
Plantm3/tonne gross coke
Method of Quenching
JSW 0.55 dry
SAIL, RSP 0.72 wet
Tata Steel 2.3 wet
Source: CSE, June 2012
Waste Water in ETP 2009-10
Plant m3/tonne gross coke
Vizag Steel Plant 0.2
Tata Steel 0.27
SAIL, RSP 0.44
JSW 0.5
Global Best 0.3
Source: CSE June 2012
Tuesday, April 11, 2023
54
Solid waste can be
Non hazardous1. Coal dust as
spillage from carts, storage and handling areas.
2. Undersize particles of coke.
3. Spillage during coke pushing.
4. All are collected and recycled.
Hazardous1. Tar decanter
sludge from by product plant.
2. Coke activate sludge from ETP.
3. Benzol muck.4. Sulphur muck.5. Waste oil and
grease with cyanide.
Tuesday, April 11, 2023
55
Hazardous Solid Waste Generation and Disposal
c
Hazardous Solid Waste Disposal in 2009-10
Vizag Steel Plant SAIL RSP Tata Steel JSW Steel
Hazardous Solid Waste
quantity generated in tonnes
Method of disposal
quantity generated in tonnes
Method of disposal
quantity generated in tonnes
Method of disposal
quantity generated in tonnes
Method of disposal
Tar Decanter Sludge 2956 100% recycled 60 100% recycled 3180 100% recycled 300 100% recycled
Other tar wastes 77.7 100% recycled 96 waste pit
Benzol muck 468.17 100% recycled Coke Oven ETP activated sludge/tarry waste 751.37 100% recycled 8 100% recycled 47.5 100% recycled 365 100% recycled
Sulphur waste none 10
sold to authorised agencies
300 waste pit 330
sold to authorised agencies
Source: CSE, June 2012
Tuesday, April 11, 2023
56
Overall Performance of Coke Ovens, By Product Recovery
• Vizag Steel 3 leaves• Tata Steel 2 leaves• JSW 2 leaves• Neelachal Ispat 2 leaves• SAIL, RSP 1 leaf• SAIL others: non performers.
Tuesday, April 11, 2023
57
Main sources of deviation
1. COD, Nitrogen, cyanide control.2. B(a)P concentration high.3. Leakage, charging and pushing
emissions.4. Stack PM emissions.5. Hazardous waste disposal.6. CO gas collection rate.7. Dry quenching technology.8. Coke oven chamber size.
Tuesday, April 11, 2023
58
Changes Needed
Plant and equipment1. Dry quenching.2. Taller chambers.3. Self sealing
doors, magnetic lids, water sealing.
4. HPLA system.5. Variable pressure
monitor.6. Land based
stationary precipitator.
Operational1. Better cleaning.2. Better draining.3. Keener COD,
BOD practices.4. Improved tar
decanting.5. Improved solid
hazardous waste disposal.
Tuesday, April 11, 2023
59
NON RECOVERY OVENS
Tuesday, April 11, 2023
60
CO oven serves the following functions
1. Provides coke for Blast Furnace.2. Recovers by products like tar
with economic value.3. Recovers Coke Oven Gas which is
a source of heating for the steel plant.
Tuesday, April 11, 2023
61
However, the recovery type coke ovens also
produces PAH
PAH emanates due to the attempt to recover by products.PAH is carcinogenic and the US has banned the recovery oven
for future ovens.
Tuesday, April 11, 2023
62
In the non recovery coke oven
1. CO oven gas is wholly burnt without any possibility of recovery of by products.
2. Instead, more heat is recovered from the process.
3. No waste water discharge. No need for elaborate ETP.
4. PAH is negligible.5. More coal holding capacity.
Tuesday, April 11, 2023
63
But, the flip side
1. Less coke yield as coke is also burnt.
2. Air emissions tend to be high due to high pressure as the volatile matters are burnt inside the coke chamber.
3. Takes up more space.
Tuesday, April 11, 2023
64
Performance can be improved through
1. Stamp charging.2. Dry quenching.
Tuesday, April 11, 2023
65
Comparative Gross Coke Yield
Company wise Gross Coke Yield 2009-10
Recovery Coke Oven Plant Gross Coke Yield %
Vizag Steel Plant 74.4
SAIL, RSP 74.6
Tata Steel 75.6
JSW 72
Neelachal Ispat 75.6
SAIL, BSP 74
SAIL, IISCO 76
India's Average 74.5
Global Best 81
Source: CSE, June 2012
Company wise Gross Coke Yield 2009-10
Non recovery Oven Gross Coke Yield %
Visa Steel 68.3
JSPL 68.3
Bhushan Steel 72.9
JSW 71
India's Average 70.2
Global Best 76
Source: CSE, June 2012
Tuesday, April 11, 2023
66
BF to Gross Coke Yield
Recovery Ovens
Company wise BF Coke Yield to Gross Coke
Plant Yield %
Vizag Steel 83.2
SAIL RSP 88.8
Tata Steel 80
JSW Steel 91.9
Neelachal Ispat 87.8
SAIL, BSP 82.5
SAIL, BSL 83
SAIL, DSP 79
SAIL, IISCO 89
India's Average 84
Global Best 92
Source: CSE, June 2012
Non recovery Ovens
Company wise BF Coke Yield to Gross Coke
Non recovery Yield %
Visa Steel 87
JSPL 90
Bhushan Steel 90
JSW 87.6
India's Average 88.6
Global Best 92
Source: CSE, June 2012
Tuesday, April 11, 2023
67
Sources of Air Pollution in Non recovery ovens
• Stack emissions connected to Waste Heat Recovery Boilers.
• Fugitive Emissions due to charging and pushing.
• During wet quenching of coke.• All CPCB norms of air pollution
limits are the same.• No suggestions on plant and
equipment.
Tuesday, April 11, 2023
68
Other emissions
• Negligible waste water discharge.• Almost no hazardous solid waste.
Tuesday, April 11, 2023
69
Performance of non recovery coke ovens
Plant
• Bhushan Power and Steel, Odisha
• Visa Steel, Kalinganagar, Odisha
• JSPL, Raigarh
• JSW Vijaynagar
Grades
• Two leaves
• Two leaves
• One leaf
• One leaf
Tuesday, April 11, 2023
70
Major Areas of Deviances
• Unable to match up in waste heat generation.
• Unable to match up to BF coke yield.
• Unable to instal dry quenching.
• Stack emissions poor.