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CokeOvenByProductPlant
PostedbySatyendraonJan17,2014inTechnical|1comment

CokeOvenByProductPlant
Thecokeovenbyproductplantisanintegralpartofthebyproductcokemakingprocess.Duringthe
productionofcokebycoalcarburizationinacokeovenbatteryalargeamountgasisgeneratedduetothe
vaporizationofvolatilematterinthecoal.Thegasisgeneratedovermostofthecokingperiod,thecomposition
andtherateofevolutionchangingduringthisperiodandbeingnormallycompletebythetimecoalcharge
temperaturereaches700degC.Thisgasisknownasrawcokeovengasandisprocessedinthebyproduct
plant.Thefunctionsofthebyproductplantaretoprocesstherawgastorecovervaluablecoalchemicalsandto
conditionthegassothatitcanbeusedasaclean,environmentallyfriendlyfuelgas.
Afterleavingthecokeovenchambers,therawcokeovengasissprayedwithflushingliquorsoastoreduceits
temperaturetoareasonablylowlevelandtocondensethemosteasilycondensable(highboilingpoint)
components.Therawgasiscooledbyadiabaticevaporationofsomeofthesprayliquortoaround80degCand
iswatersaturated.Thetemperatureofthegasbecomessufficientlylowsothatitcanbehandledinthegas
collectingmains.Fromthegascollectingmaintherawcokeovengasflowsintothesuctionmain.Theamount
offlushingliquorsprayedintothehotgasleavingtheovenchambersisfarmorethanisrequiredforcooling,
andtheremainingflushingliquorwhichisnotevaporatedprovidesaliquidstreaminthegascollectingmain.At
thisstagetherearetwostreamsnamelyaliquidcondensatestreamandagasstream.Thetwostreamspass
throughabutterflycontrolvalvebeforeleavingthecokeovenbatteryarea.Thiscontrolvalveissettomaintain
aslightlypositivepressureinthecollectingmaintoprovidesafeworkingconditionsinthecokeovenchambers.
Theliquidstreaminthegascollectingmainflushesawaycondensedtarandothercompounds.Thestreamof
flushingliquorflowsundergravityintothesuctionmainalongwiththerawcokeovengas.Therawcokeoven
gasandtheflushingliquorareseparatedusingadrainpot(thedowncomer)inthesuctionmain.Theflushing
liquorandtherawcokeovengasthenflowseparatelytothebyproductplantfortreatment.
Saturatedrawgascomingfromthecokeovenbatterycontainsaround46%to48%watervapour.Other
componentofrawgascontainshydrogen,methane,nitrogen,carbonmonoxide,carbondioxide,highparaffins
andunsaturatedhydrocarbons(ethane,propaneetc.),andoxygenetc.Rawcokeovengasalsocontainsvarious
contaminants,whichgivecokeovengasitsuniquecharacteristics.Theseconsistof
Tarcomponents
Taracidgases(phenolicgases)
Tarbasegases(pyridinebases)
Benzene,tolueneandxylene(BTX),lightoilandotheraromatics
Naphthalene
Ammoniagas
Hydrogensulfidegas
Hydrogencyanidegas
Ammoniumchloride
Carbondisulphide
Functionsofabyproductplant
Inordertomakerawcokeovengassuitableforuseasaclean,environmentallyfriendlyfuelgas,thebyproduct
plantmustcarryoutthefollowingfunctions.
Tocoolthecokeovengasforcondensingofwatervapourandcontaminants
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Toremovetaraerosolstopreventgasline/equipmentfouling
Toremoveammoniatopreventgaslinecorrosion
Toremovenaphthalenetopreventgaslinefoulingbycondensation
Toremovelightoilforrecoveryandsaleofbenzene,tolueneandxylene(BTX)
Toremovehydrogensulfidetomeetlocalemissionsregulationsgoverningthecombustionofcokeoven
gas.
Inadditiontotreatingthecokeovengas,thebyproductplantmustalsoconditiontheflushingliquorthatis
returnedtothecokeovenbattery,andtreatthewastewaterthatisgeneratedbythecokemakingprocess.
TypicalblockdiagramofbyproductplantisshowninFig1.

Fig1Typicalblockdiagramofbyproductplant
Tarandliquorprocessingplant
Thetarandliquorplantprocesstheflushingliquorthatcirculatesbetweenthebyproductplantandthecoke
ovenbattery.Italsoprocessesthewastewaterthatisgeneratedbythecokemakingprocessandwhichresults
fromcoalmoistureandchemicallyboundwaterinthecoal.Themainfunctionsofthisplantareasfollows.
Continuousrapidseparationofasuitableflushingliquorstream.Thisisaveryimportantfunctionsince
thisflowisneededtocoolthehotovenexitgasesdowntoatemperaturewhichcanbehandledinthegas
collectingsystem.
Separationofacleanandtarfreeexcessammonialiquorforfurtherprocessing.
Separationofacleantaressentiallyfreefromwaterandsolids.
Sincetheflushingliquorsupplyisveryimportant,standbyequipmentarenormallyprovidedforflushingliquor
decantingandrecirculation.
Theflushingliquorflowsintotardecanterswherethetarseparatesoutfromthewaterandispumpedtotar
storageforprocessingintardistillationplantorforsale.Heaviersolidparticlesseparateoutfromthetarlayer
andtheseareremovedastardecantersludge.Theaqueousliquoristhenpumpedbacktothebattery,witha
portionbledofffromthecircuitwhichisthecokeplantexcessliquororwastewater.Thiscontainsammonia
and,afterthefurtherremovaloftarparticles,itissteamstrippedinastill.Analkalisuchassodiumhydroxideis
addedinthestilltodecomposeammoniacompoundsdissolvedintheliquor.Theammoniavaporfromthestill
istheneitherfedintothecokeovengasupstreamoftheammoniaremovalsystem,orthestillitselfisoften
integratedintotheammoniaremovalsystem.Eitherway,theultimatefateoftheammoniaremovedfromboth
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thecokeovengasandthewastewateristhesame.Thestrippedstilleffluentiseitherdischargedoristreatedin
anonsitebiologicaleffluenttreatmentplanttoremoveresidualammonia,phenolandcyanides.
Gastreatmentprocesses
Thegastreatmentprocessesinthebyproductplantusuallyconsistofthefollowingplantequipments.
PrimarygascoolerPrimarygascoolercoolstherawcokeovengastoremovewatervapoursoasto
reduceitsvolume.Primarycooleraretwobasictypes,thespraytypecoolerandthehorizontaltubetype.
Inaspraytypecoolerthecokeovengasiscooledbydirectcontactwitharecirculatedwaterspray,with
thecontactcoolingwaterbeingitselfcooledexternallyinheatexchangers.Inthetubulartype,thecoke
ovengasiscooledindirectlybyflowingacrosshorizontallymountedtubesthroughwhichcoolingwateris
pumped.Inthiscase,thecoolingwaterdoesnotcomeintocontactwiththecokeovengasandsoitcanbe
cooledinacoolingtowerforexample.
Asthecokeovengasiscooled,water,tarandnaphthalenecondenseout.Thecondensatecollectsinthe
primarycoolersystemandisdischargedtothetarandliquorprocessingplant.
TarprecipitatorsAstherawcokeovengasiscooled,tarvapourcondensesandformsaerosolswhichare
carriedalongwiththegasflow.Thesetarparticlescontaminateandfouldownstreamprocessesandfoul
gaslinesandburnernozzlesifallowedtocontinueinthegasstream.Thetarprecipitatorstypicallyuse
highvoltageelectrodestochargethetarparticlesandthencollectthemfromthegasbymeansof
electrostaticattraction.Thetarprecipitatorscanbeinstalledbefore,oraftertheexhauster.
ExhausterTheexhausterprovidesthemotiveforcetoinducethecokeovengastoflowfromthecoke
ovenbatteryandthroughthebyproductplant.Theexhausterisofprimeimportancetotheoperationof
thecokeovenbattery.Itallowstheclosecontrolofthegaspressureinthecollectingmain,whichinturn
affectsthedegreeofemissionsinthecokeovenbatterylikedooremissions.Afailureoftheexhauster
willimmediatelyresultinventingtoatmosphereallthegeneratedtherawcokeovengasthroughthe
batteryflares.
AmmoniaremovalDuetothecorrosivenatureofammonia,itsremovalisverymuchnecessaryinby
productplants.Theremovalofammoniafromcokeovengasresultsintoyieldofammoniumsulfate,a
saleableproduct.Theammoniumsulphateprocessisbasicallyinvolvescontactingthecokeovengaswith
asolutionofsulphuricacid.Thedifferentvariationsincludetheuseofanabsorber,inwhichthesulphuric
acidsolutionissprayedintothegas,ortheuseofasaturatorinwhichthegasisbubbledthroughabathof
sulphuricacidsolution.Thesulphuricacidreactsreadilywiththeammoniainthecokeovengastoform
ammoniumsulphate.Thisisthencrystallizedout,removedfromthesolutionanddriedandsoldasa
fertilizer.
Moremodernprocessesforammoniaremovalincludethewaterwashprocessinwhichthecokeovengas
isscrubbedbywater,whichdissolvestheammonia,alongwithsomehydrogensulfideandhydrogen
cyanide.Theresultingscrubbingsolutionispumpedtoammoniastillwheresteamisusedtostripoutthe
ammonia.Theammoniavaporsfromthestillcanbeprocessedtoformammoniumsulphatesimilartothe
processesdescribedabove,condensedtoformastrongammoniasolution,incineratedorcatalytically
convertedtonitrogenandhydrogenwhicharethenrecycledbackintothecokeovengas.
AnotherprocessforammoniaremovalfromcokeovengasisthePHOSAMprocessdevelopedbyUSSteel.
Thisprocessabsorbstheammoniafromthecokeovengasusingasolutionofmonoammoniumphosphate.The
processproducessaleableanhydrousammonia.
FinalgascoolerFinalgascoolerremovestheheatofcompressionfromthecokeovengaswhichitgains
whileflowingthroughtheexhauster.Thisisnecessarysincetheefficienciesofmanyofthebyproduct
plantprocessesgreatlyimproveatlowertemperature.Thefinalgascooleristhereforeplacedupstreamof
waterwashammoniascrubbers.Finalgascoolerstypicallycoolthecokeovengasbydirectcontactwitha
coolingmedium,eitherwaterorwashoil.Animportantaspectoffinalgascooleroperationisthatwhen
thecokeovengasiscooledbelowtheoutlettemperatureoftheprimarygascooler,naphthalenewill
condensefromthegas.Thisnaphthalenereadilycrystallizesoutfromthecoolingmediumandwillfoul
equipmentifnotdisposedoff.Inwashoilfinalgascoolers,thenaphthalenedissolvesinthewashoiland
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asidestreamofoilissteamstrippedtoremovethenaphthalene.Ifwaterisusedtocoolthecokeovengas,
thecondensednaphthaleneisabsorbedusingtar.Thetariseitherentrainedinthecoolingwater,witha
portionoftheflowbeingcontinuouslyblowndownfortreatment,orittakestheformofatarlayer
throughwhichthecoolingwaterflows.Thetariscontinuouslyexchangedwithfreshtarfromthetarand
liquorprocessingplanttodisposeoftheabsorbednaphthalene.
NaphthaleneremovalNaphthaleneisremovedfromcokeovengasinagasscrubbingvesselusingwash
oil.Thevesselcanbeofpackedtypeoritcanbeofthevoidtypeinwhichthewashoilissprayedinto
thegasinseveralstages.Thewashoilisregeneratedbystrippingoutthenaphthalenefromthewashoil
usingsteaminastill.Insomeplants,naphthaleneremovalisintegratedwiththesimilarprocessoflight
oilremoval.Thenaphthaleneisoftenrecoveredasaheavieroilstreamwhichisthenmixedwiththetar
producedinthebyproductplant.
LightoilItisageneraltermforamixtureofsimilarchemicalsconsistingmainlyofbenzene,toluene
andxylene(BTX).ItisalsoknownasBenzoloil.Theremovaloflightoilfromcokeovengasuseswash
oilinasimilarprocesstothatdescribedfornaphthaleneremoval.Thelightoilisstrippedfromthewash
oilinastillandisthencondensedtoformcrudelightoil.Thisoilcanbeeithersoldforfurtherrefining
offsiteoritcanberefinedinthebyproductplantusingseveraldistillationstepsinthelightoilplant.The
lightoilcanactuallybeleftinthecokeovengas,whereitincreasesthecalorificvalue.
Cokeovengasdesulphurization
Thereareseveraldifferentprocessesforremovalofhydrogensulfidefromcokeovengas.Thespecific
processdetermineswhereinthegastrainitisinstalled.Themaindesulfurizationprocessesinuseare
vacuumprocess,ammoniaprocess,washprocess,sulfibanprocess,andclausprocess.
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1Comment

1.

Jan19
Mahesh
Sir
verynice&detailinformation
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