This document summarizes Rohit Babu's summer training project at Tata Steel's coke plant in Jamshedpur from July 9th to August 5th, 2019. The project aimed to implement a mathematical model to achieve optimal underfiring heat input in Coke Oven Batteries 8 and 9. It provides details of Rohit's guide, the certificate awarded upon completion, and thanks various colleagues who assisted with the project.

1. SUMMER TRAINING PROJECT
AT
TATA STEEL LIMITED, JAMSHEDPUR
9TH
JULY 2019 -5TH
AUGUST 2019

2. Project Title: IMPLEMENTATION OF
MATHEMATICAL MODEL TO ACHIEVE
OPTIMUM UNDERFIRING HEAT INPUT IN
COKE OVEN BATTERY 8 & 9
PROJECT GUIDE:- MR GURVINDER SINGH JAGDEV
SR. MANAGER
OPERATIONS&HEATING BATTERY 8 & 9
SUBMITTED BY:- ROHIT BABU (BTECH PRODUCTION
ENGINEERING,BIRSA INSTITUTE OF
TECHNOLOGY,SINDRI)

3. CERTIFICATE
It is certified that ROHIT BABU, VACATIONAL
TRAINEE, has successfully completed his project on
“IMPLEMENTATION OF MATHEMATICAL MODEL TO ACHIEVE
OPTIMUM UNDERFIRING HEAT INPUT IN COKE OVEN BATTERY
8 & 9
” at COKE PLANT “under the guidance of Mr. GURVINDER
SINGH JAGDEV ,SR. MANAGER,OPERATIONS&HEATING
BATTERY 8 & 9
He has worked on the above subject and successfully completed
it.
MR GURVINDER SINGH JAGDEV
SR. MANAGER
OPERATIONS&HEATING BATTERY
8 & 9

4. ON SUCCESSFUL COMPLETION OF MY PROJECT, I WOULD SINCERELY LIKE
TO THANK THE ENTIRE COKE PLANT UNIT FOR TAKING THEIR VALUABLE TIME
OUT TO GIVE ME AN OPPORTUNITY TO WORK IN AN ENVIRONMENT,
EXTREMELYHEALTHYFOR LEARNING AND DEVELOPING MY SKILLS.
I TAKE THIS OPPORTUNITYTO EXPRESS MYGRATITUDE IN THANKING MR.
GURVINDER SINGH JAGDEV SR.MANAGEROPERATIONS&HEATING
BATTERY NO # 8 & 9 , WHO STOOD BY ME THROUGHOUT MY PROJECT
PERIOD AND DESPITE HIS BUSY SCHEDULE CONSTANTLY ASSISTED ME IN
MAKING THINGS CLEAR TO ME. HE BOOSTED ME AND ALWAYS
ENCOURAGED ME IN GOING AHEAD AND ACHIEVING THE DESIRED RESULTS.
I AM ALSO THANKFUL TO MR.BIJAN KUMAR SHARMA, OF COKE PLANT
WHO PROVIDED ME VARIOUS DATA AND INFORMATION REGARDING MY
PROJECT.
FINALLY, I AM THANKFUL TO ALL THE EMPLOYEES OF TATA STEEL, WHO BY
ANY MEANS HAVE HELPED ME IN COMPLETING MYPROJECT SUCCESSFULLY.
THANKING YOU,
ROHIT BABU
REFERENCE NO: VT20193393

5. TABLE OF CONTENTS
(CTRL + LCLICK) TO GO TO A TOPIC
CONTENTS PAGE
NO
A SECTION OF TATAFAMILY TREE 6
ABOUT TATA STEEL 7-12
INTRODUCTION TO COKE PLANT 12-18
GENARAL PROCESSOF COKE PLANT IN BATTERY
8&9
18
SCP MACHINE ,CTC MACHINE,QUENCHINE
LOCO,CGT MACHINE
18-25
WHAT IS A MATHEMATICAL MODEL 26-29
REGENERATOR 30
INTRODUCTION 31
ASSUMPTIONAND MODEL 32-38
RECOMMENDATIONS 39
CONCLUSION 40
BIBLIOGRAPHY 41

6. A SECTION OF TATA FAMILY TREE
GoToCONTENTS

7. ABOUT TATA STEEL
Established in 1907, Tata Steel is the world's 6th largest steel company
with an aggregate of annual crude steel production capacity of around 28
million tones having approximately 74,000(2017) employees across the
four continents. It was Asia's first steel company and remains India's
largest integrated private sector steel manufacturer. With investments in
Corus, NatSteel and Tata Steel (Thailand), Tata Steel is the world's second
most geographically diversified steel producer, with operations in
24countries and commercialpresence in over 50 countries.
The Company plans to grow and globalizes through organic and inorganic
routes. To fulfill its objective of Growth & globalization, the six million tons

8. per annum (MTPA) Jamshedpur Works is gearing up to double its capacity.
The Company is making steady progress on its three Greenfield steel
projects in the Indian states of Jharkhand, Orissa and Chhattisgarh, to add
23 Million tones to its present capacity. It also plans to set up steel making
capacities in Vietnam and Bangladesh. Through investments in Corus,
Millennium Steel (renamed Tata Steel Thailand) and NatSteel Asia,
Singapore, Tata Steel has created a manufacturing and marketing network
in Europe, South East Asia and the Pacific-rim countries. Corus, which
manufactured 18.3 MT of steel in 2006, has operations in the UK, the
Netherlands, Germany, France, Norwayand Belgium. Tata Steel (Thailand)
is the largest producer of long steel products in Thailand, with a
manufacturing capacity of 1.7 MT. NatSteel Asia produces about 2 MT of
steel products annually across its regional operations in seven countries.
Tata Steel, through its joint venture with Tata BlueScope Steel Limited, has
also entered the steel building and construction applications market. It has
also set up joint ventures for the development of limestone mines in
Thailand, to procure low ash coal from Australia and coking coal from
Mozambique, for the development of iron ore deposits in Ivory Coast and
for setting up of a deep-seaport in coastal Orissa.
Tata Steel is one of the few steel companies in the world that is Economic
Value Added (EVA) positive. It was ranked the "World's Best Steel
Maker", for the third time by World Steel Dynamics in its annual listing in
February, 2006. Tata Steel has been conferred the Prime Minister of India's
Trophy for the Best Integrated Steel Plant five times.

9. Products
Tata Steel's products include hot and cold rolled coils and sheets,
galvanized sheets, tubes, wire rods, construction re-bars, rings and
bearings. In an attempt to 'discommodities' steel, the company has
introduced brands like Tata Selenium (the world's first branded Cold Rolled
Steel), Tata Shakti (Galvanised Corrugated Sheets), Tata Tiscon (re-bars),
Tata Pipes, Tata Bearings, Tata Agrico (hand tools animplements) and
Tata Wiron (galvanized wire products). The Construction Solution Group
explores new avenues for steel utilization by techniques that are
economical, use less natural resources and energy. Tata Steel has also
developed "gal annealed" cold rolled steel with technical assistance from
Nippon steel & Areole for high-end auto applications.
Tata Steel is a global player with a balanced presence in developed
European and fast growing Asian markets and with a strong position in the
construction, automotive and packaging markets. Its Jamshedpur steel
works produces hot and cold rolled coils and sheets, galvanized sheets,
tubes, wire rods, construction rebars, rings and bearings. In an attempt to
'discommodities' steel, the Company has introduced several branded steel
products, including Tata Selenium (the world's first branded Cold Rolled
Steel),
Tata Shakti (Galvanized Corrugated Sheets), Tata Tiscon (rebars), Tata
Pipes, Tata Bearings, Tata Structure, Tata Agrico (hand tools and
implements) and Tata Wiron (galvanized wire products). In the financial
year 2016-17 revenue from the sale of these branded steel products was
36% of the company's sales revenues.

10. PRODUCTS
Corus' main operating divisions comprise Strip Products, Long Products
and Distribution & Building Systems Division. Combining international
expertise with local customer service, the company supplies a range of
long and strip products to demanding customers worldwide in markets
including the construction, automotive, packaging and engineering sectors.
The NatSteel group produces construction grade steel such as rears, cut-
and-bend, mesh, presage bore pile, PC wires and PC strand. Tata Steel
Thailand produces round bars and deformed bars for the construction
industry.
COATED COIL
WIRE RODSTUBESREBAR
HOT ROLLEDCOLD ROLLED

11. Regarded globally as a benchmark in corporate social responsibility, Tata
Steel's commitment to the community remains the bedrock of its hundred
years of sustainability. Its mammoth social outreach program me covers
the company-managed city of Jamshedpur and over 800 villages in and
around its manufacturing and raw materials operations through uplift
initiatives in the areas of income generation, health and medical care,
education, sports, welfare and relief.
Tata Steel’s vision is to be the global steel industry benchmark for “Value
Creation and Corporate Citizenship”.
ETHICS OF TATA STEEL
Ethical behaviour is intrinsic to the way Tata Steel conducts business and it
is part of the Group’s legacy from the founder Jamsetji Tata, who believed
that business must operate in a way that respects the rights of all its
stakeholders and creates an overall benefitfor society.
Tata Steel believes in adopting the best practices in terms of corporate
governance that have been and continue to be developed. The company
conducts all aspects of its business with full transparency and
accountability

12. Business Ethics and The Tata Code Of Conduct
The values and principles, which have Governed Tata Steel’s business for
over a century, have been deployed through the implementation of the Tata
Code of Conduct (TCOC, often referred to as the 'Code' ), which was first
formally articulated in 1998. This was intended to serve as a guide to each
employee on the values, ethics and business principles expected of him or
her in personal and professional conduct.
Human Rights
The Tata Steel Group is proud of its longstanding reputation as a fair and
caring employer, and respects all human rights both within and outside the
workplace. The Tata Code of Conduct stipulates that all employees have a
personal responsibility to help preserve the human rights of everyone at
work and in the wider community.

13. GoToCONTENTS
INTRODUCTION TO COKE PLANT
Coke is the main source of energy for the Blast furnaces for hot metal
production. Coke plant is engaged in production and supply of coke and
coke oven gas to steel works. Coking coals of different grades are blended,
conveyed, crushed and then charged into the Ovens for carbonization.
After the carbonization period the charged coal becomes the coke. During
the carbonization of coal, coke oven gas is generated. Coke, the main
product of coke plant is screened and conveyed to blast furnaces. In the
Blast Furnace coke is mixed with iron ore (sinter) and charged to the blast
furnaces. The Coke ovengas is the energy source for heating the furnaces
of Mills and power houses for power generation. Part of the coke oven gas
is used by the coke plant
Key activities of Coke Plant
• Blending
• Coal preparation
• Stamping of coal & cake making
• Carbonization of coke (battery #’ operation)
• Wharf management
• Sizing of coke
• Dispatching of coke to blast furnace

14. Coke plant comprises of following areas:
 Stamp charge Battery
 By productplant
 Coal handling plant
 Coke handling plant
Coke plant converts naturally found coal into coke, which is suitable for
use in the Blast Furnaces. There are seven batteries in operation with a
total of 444 nos. Stamp Charged ovens. Battery # 5,6& 7 has 144 Ovens,
Battery # 8 & 9 - 140 Ovens and Battery # 10 &11 - 160 Ovens
COKE DISPATCH TO CUSTOMER
Coke plant is an essential part of an integrated steel plant. Cokingprocess
consist of heating of coal (pyrolysis) in absence of air at temperature
ranging 9500
C to 12000
C in oven made up of refractory materials for 20
Hrs. The coal undergoes physical and chemical changes producing volatile
chemicals in the form of complex mixture of vapour and gases. At the end
of the process a hard-porous mass remains, which is coke. Quenching with
water-cools the lump coke. The coke is further crushed and screened.
During carbonization about 23-25% (by weight) of the initial charges of the
coal spews out as mixed gases and vapors, which pass from oven to
collecting mains. Byproducts are recovered from these gases and vapors.

15. COAL CARBONIZATION OR COKING
When coking coal heated in the absence of air they become plastic and
soft over a temperature range of 3100
C to 5000
C. The coal particle
agglomerate into a coherent mass, which swells and solidifies again to form
a porous structure known as coke.
When coal is charged in the hot oven, the temperature of oven refractory
wall being at about 11000
C to 15000
C, the portion of the coal in immediate
contact with hot wall is heated very rapidly to a high temperature; a thin
layer softens, becomes plastic and melts. This layer of plastic material
travels towards the center of the oven and some of the gaseous product
force their way out of the plastic materials, as the temperature ofthe charge
is raised. On the wall side, the plastic layer hardens into a cellar residue
and the volatile matter left in the coke is driven of gradually as the
temperature rises during remainder of the coke period. Thus, in an oven,
during initial stage of coking, the coal exists side by side in several phases,
e.g. coke, semi coke, a plastic mass and granular coal.
The phenomenon of conversion of coal to coke may be started in a
simplified way as follows:
 Evaporation of the moisture in the temperature range up to 1000
C.

16.  Release the volatile matters in the temperature range of 2000
C to
6000
C, most of the volatile matter is released between 3000
C to
6000
C.
 Softening and solidifying zone remains in the temperature range of
3000
C to 6000
C.
 Plastic zone up to 4500
C.
 Sami coke in the range of 4500
C to 6500
C.
 Release of hydrocarbons up to 8000
C.
 Above 8000
C only hydrogen is released, and coke cake becomes
hard.
Time Duration for Coking
 Minimum coking time 19 Hrs. 45

17. Min.
 Maximum coking time 20 Hrs. 45
Min.
Figure1.0Schematic Diagram of COKE Plant
IMPORTANT DIMENSIONS & PARAMETERS
Oven:
 Length 13760 mm
 Height 4570 mm
 Average Width 460 mm
(Ram side 450 mm, Middle 460 mm, Coke
side 470 mm)
 Oven Taper 20 mm
(From Ram side to Oven
side)
 Oven to Oven Centre Distance 1200 mm
Heating chamber:
 Length 13760 mm
 Height 4570 mm
 Average Width 740 mm
 Thickness of Stretcher Wall 95 mm
(5 mm more that old Batteries)

18. The Battery 8 and 9 of the TATA STEEL is the state of the art battery with
world’s best technology achieving the quality parameters of the world class
coke as well as meeting 100% of the environmental norms. These are
OTTO DESIGN, Stamp Charge battery with 70 ovens in each battery. Its
heating system is twin flue, under jet firing type, double stage air, and
compound ovens. It can be operated in B.F. (Blast Furnace) Gas or C.O.
(Coke Oven) Gas according to requirement. So it is called compound
ovens. The capacity of both the batteries combined is one million tons per
annum.
GENERAL PROCESSES OF COKE PLANT IN BATTERY
8 AND 9
Coal is carbonized in oven chamber by heat received form heating walls on
both sides. After coking time 20 hrs., it turns into hard, porous cake of blast
furnace use. Blended coal is taken from coal bunkers to stamp charging
and pushing machine and stamped into a dense coal cake in stamping box
and charged in empty oven through SCP machine side door. Charging
emission is eliminated using a CHARGING GAS TRANSFER CAR with a
help of HIGH PRESSURE LIQUOR ASPIRATION SYSTEM. This is a
unique feature of battery 8 and 9.
GoToCONTENTS
Oven Machines:
The machines used in Battery operation are:

19. 1. S.C.P. machine- Stamping, Charging and Pushing Machine.
2. C.T.C. machine- Coke TransferCar.
3. Quenching Loco.
4. CGT Car-Charge Gas Transfer
Figure 2.0 General Process of Coke Plant Battery 8 & 9

20. STAMP CHARGING AND PUSHING (SCP)
MACHINE
Stamp charging and pushing (SCP) machine is one of the most essential
equipment for any modern Coke Plant. Most of the operations of the Coke
Plant are being done with the help of this machine. The machine is
electrically powered having electronics and PLC control. The actual
functions are carried out by mechanical components and almost critical
movements are by hydraulic system.
Figure 3.0 Stamping Charging & Pushing Machine
Coal Hopper
Operator’s
Cabin
Geared
Motor
Stamping
Unit
Plate feeder
Gea
r
Box Pusher
UnitGea
r
Box
Diesel
Engine
Hydraulic
Unit
Gear
BoxDiesel
Engine Charging
Unit
Long Travel
Gear Box
Spillage
Conveyor
Gear box
Compressor
Electrical &
PLC Cabin

21. SCP machine is existed in Coke Plant to perform many functions. It takes
crushed coal from the coal tower, presses it to make a cake, charges them
into the ovens and pushes them finally to quenching car after some hours
when coal is converted into the coke. Between the processes, the machine
is performing various important and critical operations. Most of the
operations are performed with the hydraulic system interfaced with
electrical and electronics. Automatic operation is performed with the help of
PLC. Interlocks are provided to avoid to wrong sequencing of the operation
and also to save the machine and the oven to get any type of damage.
Operations performed by hydraulic system have been explained along with
their hydraulic circuit and their functions.
COKE TRANSFER CAR (CTC) MACHINE
CTC machine is used in the oven top of the Batteries coke side area. It has
its two nos. long travel drive arrangement on coke side bench level and
other two nos. long travel drive arrangement on the girder side. It is single
spotting machine and with a single positioning of machine all the function
carried out.Most of the operations are performed with the hydraulic system
interfacedwith electrical and electronics. Automatic operation is performed
with thehelp of PLC. Interlocks are provided to avoid to wrong sequencing
of theoperation and also to save the machine and the oven to get any type
of damage. Operations performed by hydraulic system have been
explainedalong with their hydraulic circuit and their function.

22. QUENCHING LOCO AND QUENCHING CAR
The Quenching Car is used to transfer the hot coke form the coke oven to
the wharf. The hot coke is transferred from the coke oven to the carthrough
CTC machine. This hot coke is then carried to the QuenchingTower where
quenching is done with cold water and the temperature of the coke is
brought down from 11000
C to about 1500
C.Now this quenched
coke is carried by the car and dumped into the wharf. From this wharf with
the help of plough extractor and conveyor belt it is sent to the high line
C
O
K
E
G
U
I
D
E
F
R
A
M
E
C
L
E
A
N
E
R
D
O
O
R
E
X
T
R
A
C
T
O
R
PANNEL
ELECTRICAL
ROOM
OPERATOR
ROOM
HYDRAULIC
ROOM
LUB. PUMP
DEISEL
ENGINE
COMPRESSOR
LT
BOGIE
LT
BOGIE
SCHEMATIC DIAGRAM OF CTC MACHINE

23. bunker for blast furnaces. The Quenching Car is run by a Quenching Loco
with a speed of approx. 12.4 km/h.
CHARGING GAS TRANSFER (CGT) MACHINE
CGT machine is used in the oven top of the Batteries. When moist coal is
charged in the hot Oven, charging gas is generated immediately and these
gases are dealt with effective gas handling system so called Charging gas
transfer system. CGT machine transfers the gas coming out during
charging oven(N) to other charged oven(N+2
) to gas collecting main through
QUENCHING CAR & LOCO
HYD.
ROOM
OPERATOR
CABIN
LT G/B
CENT. LUB.
PUMP
QUENCHING LOCO QUENCHING CAR
FLAP#1 FLAP#2
LT BOGIE LT BOGIE
LT
BOGIE
LT
BOGIE

24. its ‘U’ tube arrangement. In the end of the last two ovens gas is transferred
to charged oven (N-2
) and these gases are taken to By- product plant
through an almost complete close system. For these operations strong
suction is required, and these suctions are created by spraying High
pressure liquor aspiration system (HPLA) and gas Exhausters.
Main function of CGT Machine
1. Travelling and positioning of Machine
2. Machine ready for Charging / Transferring process
3. Start of Charging / Transferring process
4. End of Charging / Transferring process
The function sequence system of CGT machine begins with the positioning
of CGT machine. In addition of CGT car function a strong suction was
created through HLPA system. These gases are transferred to gas
collecting and from there they are fed to gas exhausters.
To start the sequence SCP and CGT machined are positioned at oven too
be charged. THE position of SCP machine, CGT machine and CTC
machined is checked by co-ordination programmable logic control (CO-
PLC). After positioning CGT machine lower downs “U” Tube into mini stand
and closes both air flooding pipes of “U” Tube. Cover lifter system lifts mini
stand cover by fingers of charged and transfer oven. SCP machine sealing
frame is applied to stop gap between coal cake and oven to prevent intake
of oxygen. When the charging process starts, HPLA also starts to create
suction and charging gas is transferred the charged transfer oven. After
competition of charging Ovendoor is closed by SCP machine, CGT

25. machine release and close mini stand covers. Then “U” Tube is lifted to
complete the charging process
Figure 6.0 Diagram of Charged Gas Transfer Car
Most of the operations are performed with the hydraulic system interfaced
with electrical and electronics. Automatic operation is performed with the
help of PLC. Interlocks are provided to avoid to wrong sequencing damage
of the operation and also to save the machine and the oven to get any type
of damage.
HYDRAULIC
ROOM
&
ELECTRICAL
ROOM
U
T
U
B
E
U
T
U
B
E
MINI
STAND
LT G/B
FERVAL GREASE
PUMP
OPERATOR
CABIN
Schematic Diagram of Charging Gas Transfer Car of
Battery 8 & 9

26. GoToCONTENTS
AIM:- IMPLEMENTATION OF MATHEMATICAL
MODEL TO ACHIEVE OPTIMUM
UNERFIRING HEAT INPUT IN COKE
PLANT BATTERY 8&9
 WHAT IS A MATHEMATICAL MODEL?
A MATHEMATICAL MODEL IS A
DESCRIPTION OF A SYSTEM USING
MATHEMATICAL CONCEPTS AND
LANGUAGE.
IT MAY HELP TO EXPLAIN A SYSTEM
AND TO STUDY THE EFFECTS OF

27. DIFFERENT COMPONENTS, AND TO
MAKE PREDICTION ABOUT BEHAVIOUR.
A TRADITIONAL MATHEMATICAL MODEL
CONTAINS MOST OF THE
FOLLOWING ELEMENTS
1) GOVERNING EQUATION-__IT DESCRIBES HOW
THE VALUE OF THE UNKNOWN(DEPENDENT)
VARIABLES CHANGE WHEN ONE OR MORE OF
THE KNOWN(INDEPENDENT) VARIABLES CHANGE.
2)SUPPLEMENTARY SUB-MODEL-__
a)DEFINING EQUATIONS-__ IT DEFINES NEW
QUANTITIES IN TERMS OF BASE QUANTITIES.
b) CONSTITUTIVE EQUATION-__ IT IS A RELATION
BETWEEN TWO PHYSICAL QUANTITIES THAT IS
SPECIFIC TO A MATERIAL OR SUBSTANCE AND
APPROXIMATES THE RESPONSE OF MATERIAL TO
EXTERNAL STIMULI.
3)ASSUMPTIONS AND CONSTRAINTS-__

28. a) INITIAL AND BOUNDARY CONDITIONS-__ INITIAL
CONDITION IS A VALUE OF EVOLVING VARIABLE AT
SOME POINT OF TIME DESIGNATED AS INITIAL
TIME. BOUNDARY CONDITIONS ARE SIMILAR TO
INITIAL CONDITIONS. IT HAS CONDITIONS SPECIFIED
AT EXTREMES OF THE INDEPENDENT VARIABLEIN
THE EQUATION.
b) CLASSICAL CONSTRAINTS AND KINEMATIC
EQUATION-__ A CONSTRAINT ON A SYSTEM IS A
PARAMETER THAT THE SYSTEM MUST OBEY.FOR
EXAMPLE A BOX SLIDING DOWN A SLOPE MUST
REMAIN ON THE SLOPE.
KINEMATICS DESCRIBES THE MOTION OF
POINTS,BODIES,AND SYSTEM OF BODIES WITHOUT

29. CONSIDERING THE FORCES THAT CAUSE THEM TO
MOVE.THE EQUATIONS WHICH REPRESENT THE
MOTION OF OBJECT ARE KNOWN AS KINEMATIC
EQUATION
 INTHIS PROJECTWE HAVETO FORMA MATHEMATICAL MODEL OF
BALANCED INPUTOF MIXED GAS SO AS TO OBTAINREQUIRED
TEMPERATURE INSIDETHEREGENERATOR.
PROPERTIES OF VARIOUS HEATING GASES
COKE OVEN
GAS
BLAST
FURNACE
GAS
CONVERTER
GAS
SOURCE COKE OVEN
BATTERY
BLAST
FURNACE
CONVERTER
INPUT COAL COKE AND
IRON ORE
PIG IRON
OUTPUT COKE PIG IRON STEEL
HYDROGEN% (50-70)% 5% -
METHANE% (25-30)% - -
CARBON
MONOXIDE%
(4-5)% 20% 60%+
CALORIFIC
VALUE
4100-4300
KCAL
800-900
KCAL
1700-1800
KCAL

30. REGENERATOR IN A COKE OVEN
REGENERATORS ARE USED IN COKE OVEN FOR EXTRACTING
HEAT FROM THE HOT PRODUCT OF COMBUSTION(MIX GAS)
AND USING THAT HEAT FOR PREHEATING THE GASES BEFORE
USING.
IN ORDER TO OBTAIN UNIFORM DISTRIBUTION OF AIR OR GAS
THROUGH THE REGENERATOR NECESSARY FOR MAXIMUM
EFFICIENCY OF THE REGENERATER, IT IS IMPORTANT THE
PORTS BE SO DESIGNED THAT THEY PRODUCE A RESISTANCE
TO FLOW INVERSELY PROPORTION TO THE VARIATION IN
PRESSURE ALONG THE LENGTH OF THE OF THE FLUE DURING
UPFLOW AND DOWNFLOW PERIODS OF OPERATIONS.

31. INTRODUCTION
COMBUSTIBLE WASTE GASES ARE BY-PRODUCTS OF MANY
TECHNOLOGICAL PROCESSES. THEY VARY IN THEIR CALORIFIC
VALUE AND ARE USED TO DECREASE THE USAGE OF GAS
WHOSE CALORIFIC VALUE ARE HIGHER.
DEPENDING UPON PROCESS HEATING VALUE, GASES CAN VARY
BETWEEN 1.2 MJ/Nm3
AND 18 MJ/Nm3
. GASES WITH
HEATING VALUE ABOVE 4MJ/Nm3
CAN BE CONSIDEREDAS
INDEPENDENT FUEL.
COKE IS PRODUCED FROM COAL IN AN AIRLESS PROCESS AT
12000
C.REGENERATIVE HEAT EXCHANGER ALLOWS TO
DECREASE SIGNIFICANTLY THE CONSUMPTION OF COKE
OVEN GAS AND HENCE INCREASE THE EFFICIENCY.
THE OPERATION CYCLE OF THE REGENERATIVEHEAT EXCHANGER
CONTAINS HEATING UP PHASE OF THE HEAT EXCHANGER
FILLING AND COOLING PHASE OF HEAT EXCHANGER FILLING
.TO TAKE UNDER CONSIDERATIONVARIATION OF THE
PARAMETERS OF INFLOWING GASES WITH TIME A SINGLE
PHASE OF OPERATION CYCLE IS DIVIDED INTO A NUMBER OF
TIME PERIODS.

32. ASSUMPTIONS
GoToCONTENTS
1.THE REGENERATOR IS DIVIDED INTO ZONES , THE
ZONE k=1 IS THE HIGHEST TEMPERATUREZONE.
2.THE REAL FILLING OF REGENERATOR IS REPLACED BY
PLATE FILLING.
3.THE SUBSITUTE PLATE FILLING IN THE ZONE OF
REGENERATOR IS DIVIDED INTO LAYERS THE LAYER
j= Y IS SITUATED ADJACENTTO THE SURFACE OF THE
PLACE.

33. 4.THE WORKCYCLE OF THE REGENERATOR (HEATING
AND COOLING PHASE) IS DIVIDED INTO TIME
INTERVALS.
5.THE TEMPERATUREOF THE BLAST AT ITS INTAKE TO
THE FILLING OF THE REGENERATOR HAS CONSTANT
VALUE TA.
6.THE THERMALPROPERTIES OF THE GASES AND
FILLING INSIDE THE REGENERATOR ARE CONSTANT
WITHIN THE RANGE OF GIVEN ZONEAND TIME
INTERVAL.
7.THE TEMPERATUREOF THE GAS IS EQUALIZED
ACROSS THE VERTICAL SECTION IN RELATION TO ITS
DIRECTION OF FLOW.
8.THE HEAT CONDUCTS IN THE FILLING PARALLELY TO
THE GAS FLOW HAS BEEN LEFT OUT OF
CONSIDERATION.
THE HEAT TRANSFER IN ZONE (k) AND TIME INTERVAL (l)
--- IS DESCRIBED BY THE FOLLOWING EQUATIONS.
HERE,

34. Tl
k
---temperature of the gas(k)
l
k
--- temperature of the filling(k)
(Mcp)l
k
--- thermal capacity of the gas(J/kmal.K)
cl
k
---thermal capacity of filling material(J/kcal.K)
l
k
---convective heat transfer coefficient(W/m2
.K)
 l
k
--- thermal conductivity(W/m.K)
k--- density of the filling (kg/m3
)
HK,FK--- height and surface area of the zone.
▲k--- half the thickness of the subsitute plate of the
filling.
x,z--- co-ordinates
--- time(s)

35.  THE ENERGY BALANCE IN THE GAS SPACES`
 FOURIER KIRCHOFF’S EQUATION FOR
SUBSITUTE PLATE FILLING.
THE CONVECTIVE HEAT TRANSFER CO-EFFICIENT IS
CALCULATED FROM INDIVIDUAL ALGORITHM
BELONGING TO THE MATHEMATICAL MODEL.

36. _FOR TEMPERATURE OF GAS
Tk
l(0, ) =Tdk
l
()
where Tdk
l
() – temperature of gas supplying to the zone
_FOR TEMPERATURE OF GAS
k
l
(x,0) = 0
l
(x)
where, 0
l
(x) – distribution of temperature in the zone at the
beginning of the process.
of the second kind in the symmetry plane of the
substitute plate filling

37. of the third kind in the symmetry plane of the
substitute plate filling
WHERE
IN CASE OF SPECTRAL DISCRETE
TRANSFORMATION(DST) METHOD, THE SET OF
DIFFERENTIAL EQUATION IS TRANSFORMED INTO A
SET OF INDEPENDENT DIFFERENTIAL EQUATION.

38. HAVING GOT THE SOLUTION AND AFTER
RETRANSFORMATION WE OBTAIN EQUATION
WHICH DESCRIBES THE CHANGE OF TEMPERATURE
IN TIME OF THE DIFFERENTIAL ELEMENTS OF THE
FILLING IN THE GIVEN ZONE AS WELL AS THE
TEMPERATURE OF GAS LEAVING THE ZONE OF THE
REGENERATOR.

39. SIMULATION OF VARIOUS ENVIRONMENT(i.e
THERMAL ANALYSIS BY VARYING THE
COMPOSITION OF VARIOUS FLUE GAS AS WELL
AS AIR).
THE SIMULATION COULD BE DONE IN ANSYS
OR ANY OTHER SIMULATING SOFTWARE.
THE OBTAINED RESULT SHOULD BE
IMPLEMENTED IN THE PLANT AND THE
PRODUCT SHOULD CHECKED FOR ANY QUALITY
ISSUE BEFORE ACCEPTING THE OBTAINED
TERM BY SIMULATION.
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40. IN THIS PROJECT WE GOT TO LEARN MANY THINGS ABOUT THE COKE PLANT
IN TATA STEEL. MAINLY THE WHOLE PROCESS OF COKE MAKING FROM THE
COAL. IT WAS A GREAT EXPERIENCE TO EXPLORE HOW THE WHOLE PROCESS
WORKS SEAMLESSLYTHROUGH AUTOMATION WITH THE HELP OF THE PLC.
MOREOVER , KNOWING THAT TATA STEEL UTILIZES A HUGE PERCENT OF ITS
FLUE GAS AND ITS CONTINUOUS EFFORT TO INCREASE THE EFFICIENCY OF
THE PLANT MADE ME REALISE THE IMPORTANCE OF CONTINUOUS
IMPROVEMENT IN MAINTAINING ONE’S POSITION.
IN THIS PROJECT THE DIFFERENTIAL EQUATIONS FORMED FOR THE HEAT
MODEL WILL HELP TO SAVE THE ENERGY AND THUS REDUCE COST.
HOWEVER THE RESULT OF THE DIFFERENTIAL EQUATIONS MUST BE
MATCHED WITH A SIMULATION SOFTWARE BEFORE APPLYING.
ALL THESE MADE ME MUCH MORE CURIOUS. ALSO, IT’S THE INDUSTRIAL
EXPERIENCE THAT MADE EVERYTHING GOOD. IT WAS A GREAT EXPERIENCE
TO LEARN SUCH NEW THINGS AND I HOPE ALL THIS WILL ADD TO MY SKILL
AND ABILITY AND WILL BE HELPFUL IN MY FUTURE.

41.  BOOKS AND SOURCES
MANNUALS OF COKE PLANT
HEAT AND MASS TRANSFER SOLUTION
https://www.researchgate.net
www.wikipedia.com
SOME DRAWINGS MADE IN THIS PROJECT HAS BEEN MADE IN
AUTOCAD
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