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Pollution and Pollution Control Performance and Measures in India COKE OVENS Reference: “Into The Furnace”. CSE, Delhi.2011 1 5/8/22

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Page 1: Coke oven

Tuesday, April 11, 2023

1

Pollution and Pollution Control Performance and

Measures in India

COKE OVENSReference: “Into The

Furnace”. CSE, Delhi.2011

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Coke Ovens is complex of distinct plants

Coke Oven, By Product Plant, Effluent Treatment

Plant

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Presentation of CSE Report, June 2012 on

the Iron and Steel Industry in India

Susmita DasguptaJPC, ERU

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COKE OVENSPresentation I

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There is a variant to this complex in the form of

Coke oven heat recovery/non recovery

type.

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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.

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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.

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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

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Pollution From Coke Ovens

Coal

CO Gas

By products Water

Coke

Dust

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COKE OVEN BY PRODUCT RECOVERY TYPE

23 million tonnes of annual capacity

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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.

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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.

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Kinds of pollution ..

• Air• Water• Solid sludge.

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POLLUTION IN COKE OVENS

Usually air emissions.

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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.

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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.

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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.

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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

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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.

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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.

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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.

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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.

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Ministry of Environment and Forests have specifications for

• Emission norms and standards.• Plant design equipment.• Specification of pollution control

equipments.

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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

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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

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(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.

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Among the pollution control equipment it specifies

• Land based stationary precipitator.

• Norms for the use of effluent treated water for wet quenching.

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COKE OVEN PERFORMANCE PARAMETERS

Poor environment management also means poor economic efficiency

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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

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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.

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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

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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.

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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.

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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.

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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.

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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

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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.

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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.

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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.

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Technology #4Magnetic Lid

• In order to minimise leakage/diffuse emissions, magnetic lids are prescribed.

• GSR 46(E) dated 3.2.2006 specifies magnetic lids.

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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.

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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.

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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.

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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

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Technologies Adopted in Indian Coke Ovens

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BY PRODUCT PLANTSulphur is removed, by products are retrieved

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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

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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.

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EFFLUENT TREATMENT PLANT

Here waste water enters for treatment and cleaning. Also sludge from distilled by products are cleaned into non hazardous solid waste.

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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.

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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

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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.

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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

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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.

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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

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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.

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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.

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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.

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NON RECOVERY OVENS

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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.

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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.

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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.

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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.

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Performance can be improved through

1. Stamp charging.2. Dry quenching.

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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

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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

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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.

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Other emissions

• Negligible waste water discharge.• Almost no hazardous solid waste.

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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

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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.