Coke oven life prolongation a multidisciplinary approachJorge Madias
The replacement of aged batteries needs investment and will be submitted to growing environmental pressures. Hence, an important effort is carried out to make the battery last longer. In this paper, coke oven life prolongation technology is reviewed taken into account several points of view: blend design; battery heating; operational control; refractory maintenance. Also, a technique for the diagnostics of the degree of damage is presented, as a tool for follow-up, damage assessment and application of corrective actions
Coke oven life prolongation a multidisciplinary approachJorge Madias
In this presentation, the coke oven life prolongation technology is reviewed from different points of view: blend design; battery heating; operational control; refractory maintenance. A summary of major inspections in critical areas, for the evaluation of the battery conservation situation is presented. A discussion on tools for the diagnostics of the degree of damage is carried out
Reformer Tube design principles
- Larsen Miller Plot
- Larsen Miller & Tube Design
- Design Margins - Stress Data Used
- Max Allowable & Design Temperature
- Tube Life
- Effect of Temperature on Life
- Material Types
HK40: 25 Cr / 20 Ni
HP Modified: 25 Cr / 35 Ni + Nb
Microalloy: 25 Cr / 35 Ni + Nb + Ti
- Alloy Developments
- Comparison of Alloys
Manufacturing Technology
- Welds
Failure mechanisms
- Failure Mechanisms - Creep
- Creep Propagation
- Common Failure Modes
- Uncommon Failure Modes
- Failure by Creep
- Creep Rupture - Cross Section
- Failure at Weld
Actions to Take if Tube Fails
- Pigtail Nipping
Inspection techniques
Classification of Problems
- Visual Examination
- Girth Measurement
- Ultrasonic Attenuation
- Radiography
Eddy Current Measurement
LOTIS Tube Inspection
LOTIS Compared to External Inspection
Coke oven life prolongation a multidisciplinary approachJorge Madias
The replacement of aged batteries needs investment and will be submitted to growing environmental pressures. Hence, an important effort is carried out to make the battery last longer. In this paper, coke oven life prolongation technology is reviewed taken into account several points of view: blend design; battery heating; operational control; refractory maintenance. Also, a technique for the diagnostics of the degree of damage is presented, as a tool for follow-up, damage assessment and application of corrective actions
Coke oven life prolongation a multidisciplinary approachJorge Madias
In this presentation, the coke oven life prolongation technology is reviewed from different points of view: blend design; battery heating; operational control; refractory maintenance. A summary of major inspections in critical areas, for the evaluation of the battery conservation situation is presented. A discussion on tools for the diagnostics of the degree of damage is carried out
Reformer Tube design principles
- Larsen Miller Plot
- Larsen Miller & Tube Design
- Design Margins - Stress Data Used
- Max Allowable & Design Temperature
- Tube Life
- Effect of Temperature on Life
- Material Types
HK40: 25 Cr / 20 Ni
HP Modified: 25 Cr / 35 Ni + Nb
Microalloy: 25 Cr / 35 Ni + Nb + Ti
- Alloy Developments
- Comparison of Alloys
Manufacturing Technology
- Welds
Failure mechanisms
- Failure Mechanisms - Creep
- Creep Propagation
- Common Failure Modes
- Uncommon Failure Modes
- Failure by Creep
- Creep Rupture - Cross Section
- Failure at Weld
Actions to Take if Tube Fails
- Pigtail Nipping
Inspection techniques
Classification of Problems
- Visual Examination
- Girth Measurement
- Ultrasonic Attenuation
- Radiography
Eddy Current Measurement
LOTIS Tube Inspection
LOTIS Compared to External Inspection
A piping and instrumentation diagram/drawing (P&ID) is defined by the Institute of Instrumentation and Control as follows: A diagram which shows the interconnection of process equipment and the instrumentation used to control the proces
Reheating Furnace in Rolling Mill IndustriesVikas Yadav
In steel plants reheating furnaces are used in hot rolling mills to heat the steel stock (Billets, blooms or slabs) to temperatures of around 1200 deg C which is suitable for plastic deformation of steel and hence for rolling in the mill.
Rotary kilns have become the backbone of many industrial processes, with new applications being developed all the time. This presentation gives an overview of what types of processes rotary kilns are used for, as well as how both direct-fired and indirect-fired rotary kilns work.
6 Guidelines to Select Right Refractory for your Furnace.Gita Gilada
Expert Says - "Picking the Right Refractory will not only Last Longer, it also Saves the Annual Fuel Cost". Type of Furnace & Type of Fuel matters most.
A presentation on furnaces and refractories by stead fast engineerssteadfast123
A presentation on furnaces and refractories by stead fast engineers. Stead Fast Engineers Pvt Ltd one of the Leading manufacturers of Induction Furnace in India. find here Induction heater,Induction Melting furnace,
Induction heating system,Induction Billet heater for your sourcing needs.
In this file basic information regarding a sintering plant is shared.
sintering plant produce sinter for blast furnace feed.
Fine iron ore isn't usable for blast furnace .
So,it feeds to sintering plant.
Then sinter feeds to blast furnace as a charging material in addition to coke,additive,iron ore.
Non recovery-heat recovery cokemaking - a review of recent developmentsJorge Madias
This paper is an update of a previous publication in Spanish [1]. One of the current trends in the production of
metallurgical coke is the comeback of non-recovery ovens. This is driven by less interest in byproducts, smaller investment per annual ton, better environmental performance. The development took place particularly in China, India, USA, Brazil, Australia and Colombia [2]. In the USA, one important factor promoting this technology was that EPA declared it as Maximum Achievable Current technology in 1990. This technology arises from the classic beehive ovens which supplied since the XVIII century the coke for the industrial revolution. Those ovens were manually operated, with small heat recovery, just for heating the oven. Now, non-recovery ovens are modern construction, with highly mechanized operation, and automated to a certain degree. Gases generated by the combustion of the volatile matter are sent through downcomers and further burnt to heat the oven bottom and sides; in many cases, mostly when the plant is built within or closed to a steelmaking facility, the hot gas is used for vapor generation and electric power production. Main differences between conventional and non-recovery/heat recovery processes are shown in figure 1. In conventional process, the coal charged receives the heat indirectly through the furnace walls, by combustion of external gas; inside the oven, positive pressure develops. Gas generated in the coking process is sent to the
by-products plant. In non-recovery ovens, coking proceeds from the top through direct heating by the partial
combustion of the volatile matter over the coal bed, and from the bottom by heat coming from full combustion of gases escaping from the oven. In these plants, the offgas is treated and sent to the stack, in many cases after recovering sensible heat to produce vapor and electric power. Installed capacity for these furnaces was esteemed in 2005 in 22 M metric tons per year, probably including
beehive ovens [2]. In table 1, some of the non-recovery coke plants currently operating are listed. Some plants
belong to companies with coal mining as its core business; others are independent coke producers, purchasing coal and selling coke; then there is some joint ventures between coke producers and steelmakers,
and finally, captive coke plants belonging to steel companies.
Hydrogen fuel cell vehicles are zero emission and run on compressed hydrogen fed into a fuel cell "stack" that produces electricity to power the vehicle. A fuel cell can be used in combination with an electric motor to drive a vehicle – quietly, powerfully and cleanly.
classification of refractories and commonly used refractory brickssunrise refractory
Refractories act as a thermal barrier between a hot medium and the wall of the containing vessel, represent a chemical protective barrier against corrosion, ensure a physical protection, prevent the erosion of walls by the circulating hot medium and act as thermal insulation for heat retention.
Dear Readers,
In this presentation, I have tried to explain main raw material sources of iron making process. Also, with my experience, I have tried to give a concept about the plant engineering related to raw material. I hope that, this presentation will be helpful for young engineers. With this presentation they will get a broad idea about the raw material, based on which they can study more on the subject.
Regards,
Nirjhar.
A piping and instrumentation diagram/drawing (P&ID) is defined by the Institute of Instrumentation and Control as follows: A diagram which shows the interconnection of process equipment and the instrumentation used to control the proces
Reheating Furnace in Rolling Mill IndustriesVikas Yadav
In steel plants reheating furnaces are used in hot rolling mills to heat the steel stock (Billets, blooms or slabs) to temperatures of around 1200 deg C which is suitable for plastic deformation of steel and hence for rolling in the mill.
Rotary kilns have become the backbone of many industrial processes, with new applications being developed all the time. This presentation gives an overview of what types of processes rotary kilns are used for, as well as how both direct-fired and indirect-fired rotary kilns work.
6 Guidelines to Select Right Refractory for your Furnace.Gita Gilada
Expert Says - "Picking the Right Refractory will not only Last Longer, it also Saves the Annual Fuel Cost". Type of Furnace & Type of Fuel matters most.
A presentation on furnaces and refractories by stead fast engineerssteadfast123
A presentation on furnaces and refractories by stead fast engineers. Stead Fast Engineers Pvt Ltd one of the Leading manufacturers of Induction Furnace in India. find here Induction heater,Induction Melting furnace,
Induction heating system,Induction Billet heater for your sourcing needs.
In this file basic information regarding a sintering plant is shared.
sintering plant produce sinter for blast furnace feed.
Fine iron ore isn't usable for blast furnace .
So,it feeds to sintering plant.
Then sinter feeds to blast furnace as a charging material in addition to coke,additive,iron ore.
Non recovery-heat recovery cokemaking - a review of recent developmentsJorge Madias
This paper is an update of a previous publication in Spanish [1]. One of the current trends in the production of
metallurgical coke is the comeback of non-recovery ovens. This is driven by less interest in byproducts, smaller investment per annual ton, better environmental performance. The development took place particularly in China, India, USA, Brazil, Australia and Colombia [2]. In the USA, one important factor promoting this technology was that EPA declared it as Maximum Achievable Current technology in 1990. This technology arises from the classic beehive ovens which supplied since the XVIII century the coke for the industrial revolution. Those ovens were manually operated, with small heat recovery, just for heating the oven. Now, non-recovery ovens are modern construction, with highly mechanized operation, and automated to a certain degree. Gases generated by the combustion of the volatile matter are sent through downcomers and further burnt to heat the oven bottom and sides; in many cases, mostly when the plant is built within or closed to a steelmaking facility, the hot gas is used for vapor generation and electric power production. Main differences between conventional and non-recovery/heat recovery processes are shown in figure 1. In conventional process, the coal charged receives the heat indirectly through the furnace walls, by combustion of external gas; inside the oven, positive pressure develops. Gas generated in the coking process is sent to the
by-products plant. In non-recovery ovens, coking proceeds from the top through direct heating by the partial
combustion of the volatile matter over the coal bed, and from the bottom by heat coming from full combustion of gases escaping from the oven. In these plants, the offgas is treated and sent to the stack, in many cases after recovering sensible heat to produce vapor and electric power. Installed capacity for these furnaces was esteemed in 2005 in 22 M metric tons per year, probably including
beehive ovens [2]. In table 1, some of the non-recovery coke plants currently operating are listed. Some plants
belong to companies with coal mining as its core business; others are independent coke producers, purchasing coal and selling coke; then there is some joint ventures between coke producers and steelmakers,
and finally, captive coke plants belonging to steel companies.
Hydrogen fuel cell vehicles are zero emission and run on compressed hydrogen fed into a fuel cell "stack" that produces electricity to power the vehicle. A fuel cell can be used in combination with an electric motor to drive a vehicle – quietly, powerfully and cleanly.
classification of refractories and commonly used refractory brickssunrise refractory
Refractories act as a thermal barrier between a hot medium and the wall of the containing vessel, represent a chemical protective barrier against corrosion, ensure a physical protection, prevent the erosion of walls by the circulating hot medium and act as thermal insulation for heat retention.
Dear Readers,
In this presentation, I have tried to explain main raw material sources of iron making process. Also, with my experience, I have tried to give a concept about the plant engineering related to raw material. I hope that, this presentation will be helpful for young engineers. With this presentation they will get a broad idea about the raw material, based on which they can study more on the subject.
Regards,
Nirjhar.
Design and Optimization of 0.5 Ton Hr Foundry Cupola Furnace Operationsijtsrd
The work in this research comprises of the design processes and the optimization of cupola furnace operation fundamentals. The cupola furnace actually comprises of the structural components and the different zones in the working of the system. The structural components are the shell, foundation, tuyere’s, wind belt box, blower, tapping spout, charging door and chimney or stack. The zones of interest in cupola furnace are the stack zone, preheating zone, melting zone, reducing zone, combustion zone and the hearth or crucible zone. In these cupola zones are the optimization considerations. The design processes consider the appropriate shapes and dimensions of the cupola furnace premium effective furnace diameter, 300mm effective height in melting, 1000mm total height, 2100mm charge mass, 500kg. In optimizing the operation of the cupola, the blower capacity of 10 kW, 3 phase running at maximum speed at about 2900 rpm tends to produce sufficient air pressure of 0.00345N mm2 and volume of air, 96.8m2 min. to combust and suspend the charge for efficient heating and melting. It requires 112Kg of fuel charcoal to melt 500Kg of Cast Iron metal. The volume 5807 m3 of air per ton per hr and 12kg of air to 1kg of fuel charcoal are sufficient enough for complete combustion per heat of the cupola operation. Intensive air force in the system pulverizes the entire charge materials for complete combustion and a good furnace operation at tuyeres’. This enhances the melting rate and increase in tapping temperatures for cast iron metal it is in the range 1320oC to 1370oC. The optical pyrometer is used to measure the temperatures. The quantity of heat required to make a heat of 500kg is about362539.8 kJ hr or kW. The efficiency of the furnace is 92.3 . Moses C. Uzochukwukanma | Fredrick O. Okeagu | Richard U. Orji "Design and Optimization of 0.5-Ton /Hr Foundry Cupola Furnace Operations" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-7 | Issue-6 , December 2023, URL: https://www.ijtsrd.com/papers/ijtsrd60113.pdf Paper Url: https://www.ijtsrd.com/engineering/mechanical-engineering/60113/design-and-optimization-of-05ton-hr-foundry-cupola-furnace-operations/moses-c-uzochukwukanma
Webinar: 'Applying carbon capture and storage to a Chinese steel plant.' Feas...Global CCS Institute
The Global CCS Institute has recently published a feasibility study report on applying carbon capture and storage (CCS) to a steel plant in China. Toshiba was commissioned to conduct the study in collaboration with Chinese corporations.
The feasibility suggests that carbon capture in Chinese steel plants is a cost effective means of reducing carbon emissions compared with similar plants around the world. In this webinar, Toshiba presented on the major findings of this feasibility study.
'Applying carbon capture and storage to a Chinese steel plant.' Feasibility s...Global CCS Institute
The Global CCS Institute has recently published a feasibility study report on applying carbon capture and storage (CCS) to a steel plant in China. Toshiba was commissioned to conduct the study in collaboration with Chinese corporations.
The feasibility suggests that carbon capture in Chinese steel plants is a cost effective means of reducing carbon emissions compared with similar plants around the world. In this webinar, Toshiba presented on the major findings of this feasibility study.
Est group harbin urea conference 2014 pap paper v1 englishJim Novak (吉因龙)
An Improved Tube Plugging Technique for Ammonia and Urea Plant Heat Exchangers. Eliminates Welding, Reduces Downtime and Increases Reliability
We will provide details documenting the development of Pop-A-Plugs specifically for this service and how this significantly reduces the shutdown time required to seal tubes in such service. Everybody knows that welded plugs in high pressure heat exchangers in urea plants are prone to leaking problems as the proper quality of the welds is difficult to assure. Pop-A-Plug® System plugs promise a much better reliability than welded plugs.
Response to Climate Change (incl. case of Carbon Capture)Shibojyoti Dutta
The presentation contained context of Iron & Steel w.r.t. Climate Change, response of sector in India and Tata Steel. Sustainable solution offered by Tata Steel and brief discussion on Carbon Capture prospects at BF at the National seminar on “Environmental Prisnciples, Policies and Climate Change” organised by Indian Institute of Metals - Kolkata Chapter on 16 Dec 2010 at Taj Bengal, Kolkata
Connector Corner: Automate dynamic content and events by pushing a buttonDianaGray10
Here is something new! In our next Connector Corner webinar, we will demonstrate how you can use a single workflow to:
Create a campaign using Mailchimp with merge tags/fields
Send an interactive Slack channel message (using buttons)
Have the message received by managers and peers along with a test email for review
But there’s more:
In a second workflow supporting the same use case, you’ll see:
Your campaign sent to target colleagues for approval
If the “Approve” button is clicked, a Jira/Zendesk ticket is created for the marketing design team
But—if the “Reject” button is pushed, colleagues will be alerted via Slack message
Join us to learn more about this new, human-in-the-loop capability, brought to you by Integration Service connectors.
And...
Speakers:
Akshay Agnihotri, Product Manager
Charlie Greenberg, Host
Builder.ai Founder Sachin Dev Duggal's Strategic Approach to Create an Innova...Ramesh Iyer
In today's fast-changing business world, Companies that adapt and embrace new ideas often need help to keep up with the competition. However, fostering a culture of innovation takes much work. It takes vision, leadership and willingness to take risks in the right proportion. Sachin Dev Duggal, co-founder of Builder.ai, has perfected the art of this balance, creating a company culture where creativity and growth are nurtured at each stage.
Transcript: Selling digital books in 2024: Insights from industry leaders - T...BookNet Canada
The publishing industry has been selling digital audiobooks and ebooks for over a decade and has found its groove. What’s changed? What has stayed the same? Where do we go from here? Join a group of leading sales peers from across the industry for a conversation about the lessons learned since the popularization of digital books, best practices, digital book supply chain management, and more.
Link to video recording: https://bnctechforum.ca/sessions/selling-digital-books-in-2024-insights-from-industry-leaders/
Presented by BookNet Canada on May 28, 2024, with support from the Department of Canadian Heritage.
GraphRAG is All You need? LLM & Knowledge GraphGuy Korland
Guy Korland, CEO and Co-founder of FalkorDB, will review two articles on the integration of language models with knowledge graphs.
1. Unifying Large Language Models and Knowledge Graphs: A Roadmap.
https://arxiv.org/abs/2306.08302
2. Microsoft Research's GraphRAG paper and a review paper on various uses of knowledge graphs:
https://www.microsoft.com/en-us/research/blog/graphrag-unlocking-llm-discovery-on-narrative-private-data/
Software Delivery At the Speed of AI: Inflectra Invests In AI-Powered QualityInflectra
In this insightful webinar, Inflectra explores how artificial intelligence (AI) is transforming software development and testing. Discover how AI-powered tools are revolutionizing every stage of the software development lifecycle (SDLC), from design and prototyping to testing, deployment, and monitoring.
Learn about:
• The Future of Testing: How AI is shifting testing towards verification, analysis, and higher-level skills, while reducing repetitive tasks.
• Test Automation: How AI-powered test case generation, optimization, and self-healing tests are making testing more efficient and effective.
• Visual Testing: Explore the emerging capabilities of AI in visual testing and how it's set to revolutionize UI verification.
• Inflectra's AI Solutions: See demonstrations of Inflectra's cutting-edge AI tools like the ChatGPT plugin and Azure Open AI platform, designed to streamline your testing process.
Whether you're a developer, tester, or QA professional, this webinar will give you valuable insights into how AI is shaping the future of software delivery.
Essentials of Automations: Optimizing FME Workflows with ParametersSafe Software
Are you looking to streamline your workflows and boost your projects’ efficiency? Do you find yourself searching for ways to add flexibility and control over your FME workflows? If so, you’re in the right place.
Join us for an insightful dive into the world of FME parameters, a critical element in optimizing workflow efficiency. This webinar marks the beginning of our three-part “Essentials of Automation” series. This first webinar is designed to equip you with the knowledge and skills to utilize parameters effectively: enhancing the flexibility, maintainability, and user control of your FME projects.
Here’s what you’ll gain:
- Essentials of FME Parameters: Understand the pivotal role of parameters, including Reader/Writer, Transformer, User, and FME Flow categories. Discover how they are the key to unlocking automation and optimization within your workflows.
- Practical Applications in FME Form: Delve into key user parameter types including choice, connections, and file URLs. Allow users to control how a workflow runs, making your workflows more reusable. Learn to import values and deliver the best user experience for your workflows while enhancing accuracy.
- Optimization Strategies in FME Flow: Explore the creation and strategic deployment of parameters in FME Flow, including the use of deployment and geometry parameters, to maximize workflow efficiency.
- Pro Tips for Success: Gain insights on parameterizing connections and leveraging new features like Conditional Visibility for clarity and simplicity.
We’ll wrap up with a glimpse into future webinars, followed by a Q&A session to address your specific questions surrounding this topic.
Don’t miss this opportunity to elevate your FME expertise and drive your projects to new heights of efficiency.
DevOps and Testing slides at DASA ConnectKari Kakkonen
My and Rik Marselis slides at 30.5.2024 DASA Connect conference. We discuss about what is testing, then what is agile testing and finally what is Testing in DevOps. Finally we had lovely workshop with the participants trying to find out different ways to think about quality and testing in different parts of the DevOps infinity loop.
Epistemic Interaction - tuning interfaces to provide information for AI supportAlan Dix
Paper presented at SYNERGY workshop at AVI 2024, Genoa, Italy. 3rd June 2024
https://alandix.com/academic/papers/synergy2024-epistemic/
As machine learning integrates deeper into human-computer interactions, the concept of epistemic interaction emerges, aiming to refine these interactions to enhance system adaptability. This approach encourages minor, intentional adjustments in user behaviour to enrich the data available for system learning. This paper introduces epistemic interaction within the context of human-system communication, illustrating how deliberate interaction design can improve system understanding and adaptation. Through concrete examples, we demonstrate the potential of epistemic interaction to significantly advance human-computer interaction by leveraging intuitive human communication strategies to inform system design and functionality, offering a novel pathway for enriching user-system engagements.
Slack (or Teams) Automation for Bonterra Impact Management (fka Social Soluti...Jeffrey Haguewood
Sidekick Solutions uses Bonterra Impact Management (fka Social Solutions Apricot) and automation solutions to integrate data for business workflows.
We believe integration and automation are essential to user experience and the promise of efficient work through technology. Automation is the critical ingredient to realizing that full vision. We develop integration products and services for Bonterra Case Management software to support the deployment of automations for a variety of use cases.
This video focuses on the notifications, alerts, and approval requests using Slack for Bonterra Impact Management. The solutions covered in this webinar can also be deployed for Microsoft Teams.
Interested in deploying notification automations for Bonterra Impact Management? Contact us at sales@sidekicksolutionsllc.com to discuss next steps.
Dev Dives: Train smarter, not harder – active learning and UiPath LLMs for do...UiPathCommunity
💥 Speed, accuracy, and scaling – discover the superpowers of GenAI in action with UiPath Document Understanding and Communications Mining™:
See how to accelerate model training and optimize model performance with active learning
Learn about the latest enhancements to out-of-the-box document processing – with little to no training required
Get an exclusive demo of the new family of UiPath LLMs – GenAI models specialized for processing different types of documents and messages
This is a hands-on session specifically designed for automation developers and AI enthusiasts seeking to enhance their knowledge in leveraging the latest intelligent document processing capabilities offered by UiPath.
Speakers:
👨🏫 Andras Palfi, Senior Product Manager, UiPath
👩🏫 Lenka Dulovicova, Product Program Manager, UiPath
De-mystifying Zero to One: Design Informed Techniques for Greenfield Innovati...
Emission Free Coke Oven Doors
1. 134 Coking Coals and Coke Making: Challenges and Opportunities
Eco–Friendly Coke Oven
Door – A Measure to
Minimize Gas Emmission
from Coke Oven Doors
C.S.N. Sastry, C.P. Gupta and Rajeev Kumar
A B S T R A C T
The recent boom in world coke production suggests a multifold increase in greenhouse gas
emissions from coke oven doors worldwide. By the end of 2010, the world will have an annual
coking capacity of approximately 433 million tons, which corresponds to 167,700 tons of global
warming gas (CO2
equivalent) emission annually. This paper discusses the philosophy of
providing perfect gas sealing in coke oven doors and also discusses the satisfactory results obtained
at Bhilai Steel Plant of Steel Authority of India Limited and elsewhere.
Keywords: Coke Ovens, Environment, Coke Oven Doors, Gas Emissions, Sealing
INTRODUCTION
Concerns on environmental issues are getting more and more serious worldwide. Regulations
for coking facilities have become more stringent than ever in every country. Non-recovery
coke oven batteries may be a choice for this issue, however, considering the huge investments
required to replace all existing batteries by non-recovery batteries, this choice may not be
feasible. Investigations on the sources of gas emissions from existing coke batteries have
not showed any promising results in meeting the regulations and the most difficult but
probable counter-measure is to eliminate gas emissions from around coke oven doors. It
seems gas emissions from coke oven doors are still a matter of headache. In this paper, the
8
2. Eco–Friendly Coke Oven Door – A Measure to Minimize Gas Emmission from Coke Oven Doors 135
sealing capabilities of coke oven doors and requirements for perfect gas emission prevention
and report on successful results obtained at Bhilai Steel Plant (BSP) of Steel Authority of
India Limited (SAIL) and elsewhere have been discussed.
EMISSION FREE COKE OVENS
Coke Ovens (CO) Complex of BSP has been constantly striving to minimize the emissions
from coke oven doors of the coke batteries. The coke oven collective had earlier tried different
design of doors and different methods of door regulation to reduce gas emissions. During
the last 5 years, the gas leakage measured in PLD (Percentage Leaking Doors) has been
controlled below 10 per cent level with the use of asbestos ropes for sealing.
However, the continued efforts to reduce the door leakages below 5 per cent with this
technology seemed to be a herculean task. The Central Pollution Control Board (CPCB) of
India has fixed a norm of below 10 per cent PLD for a running old battery and maximum of
5 per cent PLD for a new battery.
In Battery No. 3 of BSP, all the doors have been replaced with air cooled self sealing
doors of improvised IKIO design supplied by M/S Simplex Castings Limited, Bhilai. With
this innovation the dream of achieving gas leakage of less than 1 per cent has been realized
and further efforts are being made to achieve totally emission free batteries.
This is a significant achievement, particularly, for a working battery. Following the above
success, with replacement of the present doors in the remaining batteries of BSP with new
Ikio Design Simplex Doors, the day of achieving emission free Coke Ovens is not far away,
thus contributing to the reduction of global warming.
Fig. 1 Battery No. 3 door emission – before and after installation of air cooled doors
3. 136 Coking Coals and Coke Making: Challenges and Opportunities
Battery No. 3 of BSP (Start-up year- 1962, Rebuilt- 1990, Cold Repairs- 2007, Height 4.3
m., 65 Ovens of Russian Design) started the conversion of existing doors to “Air Cooled Self
Sealing Type Ikio-Simplex Doors” in the 1st
week of April, 2008 and finished worked in the 1st
week of August 2008. Fig. 1 shows the remarkable improvement in gas emission index (GEI)
of CPCB, India along with the progress of door replacements. Fig. 2 shows a current
photograph of BSP’s Battery No. 3 with practically negligible emission.
Fig. 2 BSP’s No. 3 Battery after door replacement
M/S. Simplex Castings Ltd., Bhilai entered into a Technical Collaboration in the year
1988 with M/S. Ikio Iron Works, Japan for making Emission Free Self Regulating Air
Cooled Doors.
Coke Ovens is the area where maximum pollution is generated. Generally, Conventional
Type Coke Oven Doors are being used in Coke Oven Batteries, which are prone to heavy
leakage of hazardous gases, flames, heat and dust. Due to these reasons, Coke Ovens Complex
is considered as an unpreffered area to work, where workmen are exposed to pollution
resulting in low productivity. This is the main concern of all steel plants today.
Top managements of steel plants world over are concerned about pollution and working
conditions at Coke Oven Complexes and are continuously trying to improve the design of
Coke Oven Doors. M/S. Simplex Castings Ltd., Bhilai being a leading manufacturer of
Coke Oven Doors as per customer’s drawings and specifications, also realized the gravity
of this problem, studied the adverse impact in-depth in consultation with users, designers
and in-house studies. Various types of coke oven doors used world wide by different Coke
Oven Plants, posed the question of its suitability in design to meet the present environmental
4. Eco–Friendly Coke Oven Door – A Measure to Minimize Gas Emmission from Coke Oven Doors 137
norms, and after detailed study, M/S Simplex came up with “Emission Free Self Regulating
Air Cooled Coke Oven Doors” which here after are referred to simply as “Simplex Doors.”
ADVANTAGES OF EMISSION FREE SELF REGULATING AIR
COOLED COKE OVEN DOORS OF IKIO-SIMPLEX DESIGN
• Emission free
• Zero emission of fire between door frame and doors, PS and CS and leveler door
window
• Very less coke fall from Ovens
• Door regulation is very simple and doors are user friendly for doormen and door car
operators
• Maintenance of the doors is very simple
• Self sealing and regulation by springs (spring steel)
• Diaphragm with Knife (stainless steel sheet and high tensile flat)
• Refractory material made of silica bricks having 40% alumina content
• Fibre packing made of ceramic fibre sheet, containing alumina, silica and zirconia,
which can withstand operating temperatures of the level of 1050 °C continuously
• The door does not rest on the oven sole; instead it is hung from the door frame
hanging bracket. Hence, the door is free for automatic regulation of the Diaphragm
Knife for self sealing by springs when the temperature rises to 1050°C
• Brick retainers are of cut back design. Provision of brick compartments of 5 to 6 Nos.
for easy circulation of hot air inside the chamber, so that while circulating, gas pressure
on Diaphragm Knife is less and coal tar deposits on sealing surface and door frame
sealing face is practically negligible
• It is recommended to incorporate the door along with the door frame to maintain
surface contact of knife with sealing surface of the frame.
• High output of coke oven gas
• Production of coke of high and uniform quality with optimum yield of by-products
• The environment remains pollution-free
Tata Steel at its Jamshedpur Works has replaced all its existing doors with Ikio-Simplex
Doors in the following batteries:
• Battery No. 7, start up 1989, height 4.5 m., OTFU, 54 ovens converted from original
coke oven doors to IKIO-SIMPLEX Doors in 1991;
• Battery No. 5 start up 1995, height 4.5 m., OTFU, 30 ovens;
• Battery No. 6, start up 1993, height 4.5m., OTFU, 60 ovens;
• Battery No. 8, start up 1998, height 4.5 m., OTFU, 70 ovens;
• Battery No. 9, start up 2000, height 4.5 m., OTFU, 70 ovens.
5. 138 Coking Coals and Coke Making: Challenges and Opportunities
All its batteries have achieved the PLD within environmental norms.
Durgapur Steel Plant at its COB # 6 (height 4.45 m., OTFU, 39 ovens) has also converted
10 doors to the new Ikio-Simplex design.
Among the various international coke companies, at Lucchini-Piombino Coke Battery,
Ikio-Simplex Doors were installed during start up in June 2002 in the new battery, height 6.2
m., number of ovens 45; at SMS-Demag built Al-Nasar Coke Company, for producing Coke
& Chemicals at El-Tabbin, Helwan, Egypt, Ikio-Simplex Doors were installed in the 5.0m.
tall Battery No.3, start up in 1978, 65 ovens, BVR type, No. of doors replaced - 25 in 2007.
Recently, Rashtriya Ispat Nigam Ltd. ( RINL ), Vishakhapatnam, COB #4; ISP, SAIL,
Burnpur, COB # 10; Rourkela Steel Plant, SAIL, COB # 4; Bokaro Steel Plant, SAIL, COB #
1& 2; Jindal Stainless Steel, Jajpur, COB # 1, have all gone ahead for Ikio-Simplex doors
based on the recommendations of Mecon Limited and Centre for Engineering ( CET ), SAIL,
Ranchi.
Ikio-Simplex doors are under operation in many advanced countries like Nippon Steel
Corporation ( NSC ), JFE ( Formerly NKK & Kawasaki Steel Corporations ), Arcelor Mittal,
Battery No. 1 & 2 at Aviles COB, Imasa, Spain, China Steel Corporation, Taiwan etc. and all
are working satisfactorily for more than a decade.
From the above evidences, sealing capability of Ikio-Simplex coke oven doors has been
clearly established. For monitoring of gas emissions, five (5) week rolling average of GEI is
to be used in order to observe the trend of gas emission behaviour. Every coke plant always
has to keep this rolling average below 10.
CONDITIONS FOR MAINTAINING GEI WITHIN NORMS
It is required to fulfill the following four conditions in order to keep GEI within a favourable
range. If any of these, is not satisfied, there will be no perfect results because these four
conditions are closely interlinked with each other.
The results obtained at BSP are the examples that fulfilled these four conditions, which
are shown below:
Condition 1 : Good Door
Condition 2 : Good Door Frame
Condition 3 : Good Cleaners
Condition 4 : Good Maintenance
Coke Oven Doors
Roughly speaking there are two types of coke oven door body. One is a box shaped body
represented by the Wolf type door and the other is a skeleton shaped air cooled door (ACD)
body that originated from a Japanese engineer K. Yamasaki in 1974, when the ACD was first
put into service. Later, this door became famous worldwide by the name of “IKIO DOOR”.
6. Eco–Friendly Coke Oven Door – A Measure to Minimize Gas Emmission from Coke Oven Doors 139
Yamasaki invented this door while working for Ikio Iron Works, Japan, as Manager of Door
Development and Manufacturing. His innovation was to separate door body and plug
mounted sealing unit thermally, by providing skeleton type door body, which does not
receive heat from the coking chamber directly. Table 1, shows the differences between Wolf
door and ACD. Complete separation of body and diaphragm functions for ACD is the main
reason for the above mentioned difference. In the design of ACD, in order to minimize
thermal and mechanical bending of the door body, air gap was provided between door body
and sealing unit and at the time, enough rigidity was given to door body to enable it to
maintain its straightness while coping with the counter force generated by plunger springs.
Table 1. Differences between Wolf Door and Air Cooled Door (ACD)
Type of Door Thermal Bending Sealing Unit (Diaphragm)
of Door Body
Wolf Large Attached to door body directly. Receives
influence of thermal bending of door directly.
Fitting ability to the deformed door jamb is poor.
Air Cooled Negligible or small Well isolated from door body thermally. Receives
Door (ACD) no influence of bending of door due to the very
small door body thermal bending.
Free from influence caused by difference of
thermal expansion between door body and
diaphragm. High adjustability against door
jamb deformation.
Thanks to this design, the relative position of door and door jamb is kept unchanged all
the way and the flexible sealing unit can always keep good contact with door jamb sealing
surface. Thus, the roles of door body and sealing unit are clearly separated in the ACD
design philosophy. Since the time “Ikio door” came into the world market, many doors with
skeleton bodies appeared, but those doors, which had no distinct design philosophy,
disappeared soon and only doors with rigid bodies and flexible diaphragms have survived.
Progress in ACD Design
The first ACD Ikio door soon became famous worldwide with its better sealing capability
compared to existing knock seal type doors because of its easy adjustment to fit knife edge
to the door jamb.
Many of the door manufacturers of the world have been supplying their products with
plungers and skeleton body since then. Some of those are supplying under the license of
Ikio Iron Works, Japan.
7. 140 Coking Coals and Coke Making: Challenges and Opportunities
Kesao Yamasaki established his own company, Yamasaki Industries Co. Ltd. (YIC),
Japan in 1984 and added many improvements to ACD later. Table 2 given below, shows the
typical structural progress in ACD design.
Table 2. Typical Structural Progress in ACD Design
Generation Manufacturer Body Cross Diaphragm Sealing Unit Sealing Unit
Section Cross Section Bending Exchange or
Replacement
1st
Generation Ikio “U” shape Convex or Not available Full
1974 Corporation Flat Disassembling
after 1993
2nd
Generation YIC after “H” shape Flat Provided Full
1991 1995 Disassembling
3rd
Generation YIC “H” Shape Flat Provided Cartridge
Blue Sky
Major changes in ACD design are as follows:
1. Cross section of door body was changed from “U” shape to “H” shape, to improve
torsional rigidity by increasing section modulus.
2. Cross section of diaphragm was changed from convex to flat, because convex
diaphragm was not flexible enough, especially at door corners and as a result, fitting
capability of knife edge to door jamb was poor.
3. New function was added to the 2nd
generation design. This was to bend diaphragm
along its length to provide better fitting of knife-edge to door jamb, which generally
has considerable differential bowing on both sides of jamb frame.
It does not take much man-power to make bending adjustments. Therefore,
combination fixing of doors on ovens are not necessary.
4. The diaphragm should be replaced by a new one, after several years of service. In case
of 1st
and 2nd
generation designs, disassembling of all sealing parts was necessary for
replacement. To reduce manpower for replacement work, 3rd
generation design
introduced cartridge type sealing unit. Disassembly became no longer necessary. Total
time required for cartridge replacement is not longer than 5 hours with two well-
trained workers. The door maintained complete sealing capability, entirely similar to
the new door, only by replacing the cartridge.
By adding the above mentioned improvements to older type ACD, 3rd
Generation
ACD has been accepted as the most reliable door in the market presently.
8. Eco–Friendly Coke Oven Door – A Measure to Minimize Gas Emmission from Coke Oven Doors 141
Comparison of 3rd
Generation ACD with Wolf Type Door
Major advantages of 3rd
generation ACD over Wolf type doors are as follows:
Thermal Bowing of Door Body
Temperature differences within a door body cause thermal bowing. Wolf type door shows
the difference as much as 120°C. On the other hand, the difference is as low as 40°C in case
of 3rd
generation ACD. Bowing of Wolf type door body is easily influenced by the change of
ambient temperature. Therefore, it is impossible to maintain good sealing always.
Fitting Ability to Deformed Door Jamb
Allowable door jamb bowing range for 3rd
generation ACD is 20 to 25 mm. in total. Although
this range varies due to the actual prevailing conditions, it is much larger than that of Wolf
type doors.
Maximum Allowable Gas Pressure
When a battery operates with wet coal charge, the peak gas pressure at the bottom part of
diaphragm ranges from 150 to 300 millibar. Wolf type doors may require a lot of manpower
to cope with this peak pressure in order to maintain operation without gas emissions.
Blue Sky door keeps good sealing performance even when the gas peak pressure rises up
to 2000 mm WC. This peak is generally observed when a battery operates under coal moisture
control system.
TYPICAL EXAMPLES OF EMISSION FREE COKE OVENS
Coke Oven Battery No.1 at Sakaide Works of Mitsubishi Chemical Corporation, Japan
(Start-up: Nov.1969, Height: 6 m, Otto Design, 100 Ovens) started the replacement of its
existing doors with the most advanced Air Cooled Doors (ACD) named “Blue-Sky” in April
1999 and completed the work in May 2000. Fig. 3 shows a remarkable improvement in gas
emission index (GEI) along with progress in door replacement.
Like Sakaide Works, Nippon Steel’s Oita Works also replaced their original coke oven
doors with Blue Sky Doors for all its batteries (Battery Nos.1 and 2, Start-up: 1972, Height:
5.925 m, NSC Type, 156 Ovens; Battery Nos. 3 and 4, Start-up: 1976, Height: 6.092 m, NSC
Type, 164 ovens) and have achieved similar results. From these evidences, excellent sealing
capability of Blue Sky Door has been clearly proven with respect to operation of “emission
free coke ovens”. At Sakaide Works, following the success experienced at Battery No. 1,
recently Battery Nos. 2 and 3 ( Battery No.2, Start-up:1971, Height: 6.9 m, Carl Still Design,
100 Ovens; Battery No. 3, Start-up: 1973, Height: 6.9 m Carl Still Design, 123 ovens) also had
their earlier doors replaced with Blue Sky Doors.
9. 142 Coking Coals and Coke Making: Challenges and Opportunities
Fig. 3 Mitsubishi Sakaide No.1 Battery after doors replacement
DOOR JAMB
Bowing of Door Jamb
It is obvious that when the bowing of door jamb exceeds a certain allowable limit, we are
not able to prevent gas emission, even if we use doors with good sealing ability. However,
there has hardly been any technical paper, which elaborately discusses about the relationship
between gas emission and door jamb bowing. Discussions about gas emissions in the past,
pointed out only sealing capability of the door itself as a subject. Fig. 3 shows an example
of a door jamb bowing measured at an existing battery in operation. There is an obvious
difference in bowing between right and left frame of a door jamb. This difference is not
strange for most of the existing batteries in operation. At Sakaide’s Battery No.1, we made
bowing measurements for some number of door jambs selected by random sampling, prior
to door replacement. The results showed that, bowing of all tested jambs was within an
acceptable range. Then the new jambs were manufactured to replace existing old door jambs
with the design similar to the original Battery No. 1 doors, which were replaced by Blue Sky
Doors, without providing specially designed door jambs at all.
10. Eco–Friendly Coke Oven Door – A Measure to Minimize Gas Emmission from Coke Oven Doors 143
Prior to replacement of doors of Battery Nos. 2 and 3 at Sakaide Works, we measured
bowing of all door jambs in all the three batteries, because we found jamb bowing at Battery
Nos. 2 and 3 as worse compared to that at Battery No.1. Fig. 4 shows the measurement
results. The “d” in Fig. 4 corresponds to the maximum bowing showed in Fig. 5. Fig. 5
shows that more than 70% of total jambs have bowing beyond the limit that Blue Sky Doors
can accept. We have not clearly understood the exact reason why there is such an exaggerated
difference in door jamb bowing between Battery No.1 and Battery Nos. 2 and 3. The only
plausible reason at the moment seems to be the difference in battery designs of Otto and
Carl Still.
Replacement of Door Jamb
In order to achieve an emission free environment, we provided special shaped door jambs,
for which the bowing is shown in Fig. 4. The back of these jambs had proper contours by
which jambs could make good contact with the deformed brickwork face, behind the jambs.
The jambs with contoured back sat on the deformed brickwork correctly.
Cases where this consideration is paid for jamb replacement.
Once door jamb replacement is executed under above mentioned consideration, gas
emission due to door jamb distortion would not happen for many veary because brickwork
distortion does not progress rapidly.
Fig. 4 Door jamb bowing Fig. 5 Door jamb bowing at Sakaide Nos. 2 and 3 Batteries
11. 144 Coking Coals and Coke Making: Challenges and Opportunities
If the new jambs had been manufactured as per the original design, then the result of
jamb setting on deformed brickwork would have varied geometrically from one to another.
In other words, the new jamb would not give sealing face parallel to knife edge plane. As a
result, inspite of jamb replacement, perfect gas emission free environment would not be
realized. It seems to us, there are few cases where this consideration is taken into account for
jamb replacement.
Once door jamb replacement is executed under the above mentioned consideration, gas
emissions due to door jamb distortion would not happen for many years because brickwork
distortion does not progress rapidly.
Good cleaning of door and door jamb is a must for emission free battery operation. The
type of cleaners should be discussed in combination with the type of doors.
Door Cleaners
Generally speaking, there are two types of door cleaners. One is the mechanical type and the
other is the high-pressure water jet type. The majority of cleaners are of mechanical type
with wire brush or scraper for cleaner head. This type of door cleaners, inspite of many
modifications, has some weak points. Firstly, it cannot remove deposits on the knife-edge
tip and secondly, it imparts considerable strong force on the door diaphragm and in order
to counter the force imparted by cleaner heads, we lose flexibility of the diaphragm, which is
most crucial for sealing function.
High pressure water jet cleaner is friendlier towards the flexible diaphragm used for
ACD type doors because this cleaner does not make direct mechanical contact with the
diaphragm. Some coke plants say that, they do not like this type of cleaner because a part of
the cleaning water falls down onto the battery platform and creates secondary environmental
problems. However, when water pressure higher than 500 to 600 bars is applied, then the
required quantity of cleaning water is too small to make any impact while falling down onto
the battery platform. Excess water evaporates quickly before it reaches the battery platform.
Advantage of high pressure water jet cleaner over mechanical cleaner is that, the former
can clean not only the diaphragm but also knife-edge tip without damaging them. The latter
cannot deal with knife-edge tip with such a delicate contact. High pressure water jet cleaner
is most favourable for ACD type doors.
Door Jamb Cleaner
Only mechanical cleaners have been put into service worldwide. It is the shortcoming
common to these cleaners that they damage the jamb sealing surface while their cleaner
heads are working.
Knife-edge sealing face of Yamasaki’s ACD - Blue Sky Doors is machined by specially
designed high precision planer to ensure that it provides perfect contact with the door jamb
12. Eco–Friendly Coke Oven Door – A Measure to Minimize Gas Emmission from Coke Oven Doors 145
sealing face. If the door jamb sealing face is not in good condition, complete gas sealing
cannot be expected. Already, Yamasaki is in a position to supply high pressure water jet type
jamb cleaners.
Cleaner for Jamb Inside Surface
Some times, we see carbonaceous deposits on the lower part of jamb inside surface. When
this deposit grows up, door may not go to the right position because door plug is blocked
by the deposit. Deposit removal work today, relies only on manual operation. Although this
issue is not related directly to gas emission, we must not leave the matter as it is, when we
think about a pollution free working environment.
MAINTENANCE ASPECTS
Door
The diaphragm life of Blue Sky Doors has exceeded 7 years at Nippon Steel Corporation’s
Oita Works. Periodical off-line maintenance for each door is recommended. Main items of
this maintenance are change of worn plunger springs, careful visual check-up of the projection
piece of leveler door protector and manual removal of carbon deposit residuals on the door
diaphragm with the help of high pressure water jet. Stationary cleaning facilities for carbon
deposit residuals removal play a very important role for maintaining an emission free
environment for long. If one tries to stop gas emissions, leaving the carbon deposits as it is,
by tightening plunger screw beyond a limit to increase pressing force onto the knife-edge,
there will be permanent deformation of the diaphragm and/or knife edge. Once this occurs,
the cartridge will have to be replaced by a new one.
Door Cleaner
When water jet nozzle tips get worn out and increase their hole diameter, the water pressure
may decrease leading to a fall in the cleaning efficiency. Nozzle tips have to be kept in good
condition at every moment.
Movement of nozzle head should always be appropriately adjusted so as to cover all
areas of the diaphragm and knife-edge. Condition of wire brush or scraper of mechanical
cleaner is crucial. Conditions of the equipment have to be maintained at their best in order
to perform to their full potential. Adhesion of tar to wire brushes will cause loss of cleaning
effect within a short period. Deformation of scraper will damage the diaphragm extensively
and cause gas emission.
13. 146 Coking Coals and Coke Making: Challenges and Opportunities
Door Jamb Cleaner
When carbonaceous deposits left on the sealing face of door jamb grows up and forms hard
scab, the knife-edge cannot have direct contact with the jamb sealing face in this area. The
knife-edge and diaphragm of this area will start distorting gradually and finally cause gas
emission. The only way to avoid this undesirable situation is to always maintain the door
jamb cleaner in good condition.
M/S. Simplex Castings Ltd., Bhilai has entered into a technical collaboration with M/S.
Yamasaki Industries Co. Ltd., Japan in the year 2007, for manufacturing Blue Sky Doors.
CONCLUSIONS
• Results obtained at Coke Ovens Complex of Bhilai Steel Plant (SAIL) has proved that
complete prevention of gas emission from around the coke oven door area is possible
with the use of ACD doors made of Ikio-Simplex design.
• Results obtained at Mitsubishi Chemical Corporation’s Sakaide Works and Nippon
Steel Corporation’s Oita Works has proved that complete prevention of gas emission
from around coke oven door area is possible with the use of Blue Sky Doors.
• By replacing damaged door jambs and applying high sealing performance ACDs,
even a battery older than 18 years can be revived for perfect gas tightness.
• To fulfill the four required conditions, such as good door, good door jamb, good
cleaner and good maintenance, one has to have correct knowledge and understanding
about coke oven doors because this the right path to long lasting emission free
environment surrounding the coke oven door area.
ACKNOWLEDGEMENTS
The authors would like to express their special thanks to all senior executives of the Coke
Ovens & Coal Chemicals Department of Bhilai Steel Plant (SAIL) who directly or indirectly
contributed to the successful implementation of ACD doors of Ikio-Simplex design for an
emission free environment.
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14. Eco–Friendly Coke Oven Door – A Measure to Minimize Gas Emmission from Coke Oven Doors 147
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13. Patent Pending.