COKE

PLANT

AND

COAL

CHEMICAL

ORIGIN OF COAL:
Coal originated from the arrested decay of the remains of trees, bushes,
mosses, vines and other forms of plant life, which flourished in huge swamps
and bogs millions of years ago, during prolonged periods of humid, tropical
climate and abundant rainfall. Streams into the swamps and lake basins to
form the coal beds carried an enormous amount of vegetations. Owing to
pressure, the streams have generally been crushed to an elliptical section and
formed coal.
USE OF COAL IN VSP:
Coal is used in the form of coke to serve the purpose of iron ore
reduction in blast furnace. It also serves as a heat source.
TYPES OF COAL:
There are 2 types of coal:
(1) Coking Coal.
(2) Non-Coking Coal.
In VSP coking coal is used for producing metallurgical coke where as noncoking coal is used for producing thermal power (in boilers).
COKE:
It is a strong porous hard mass that is obtained by heating of the coal in
the absence of air at high temperature. It is a reactive fuel and satisfies the
need for blast furnace.
FUNCTIONS OF COKE:
1. It acts as heat producer in blast furnace

2. It acts as reducing agent by carbon reduction in blast furnace with

oxygen reaction.
3. It gives a permeable bed and also as a slag carrier.
CARBONIZATION OF COAL:
Heating of coal in the absence of air at high temperatures to produce
residue coke, coke oven gas is called CARBONISATION OF COAL or
DESTRUCTIVE DISTILLATION. Its main purpose is to produce coke and
the by-product known as coke oven gas from which various products are
obtained and this is used as fuel of high calorific value.
NEED FOR MANUFACTURE OF COKE FROM COAL:
1. Natural coal is too dense and fragile to be used as a fuel in the furnace.
2. Coal is not strong enough to withstand nearly 25 mts of burden lying
on it inside the furnace.
3. Coal is nearly VOLATILE MATTER FREE so it does not create
problems of hot shortness and coal shortness.
4. As compared to coal coke is of high quality and is highly reactive.
5. Coke is highly porous mass and it equalizes the blast coming from the
bottom of the charge.
6. As coke is a rigid hard mass it does not create the problems of dust
nuscence.
7. The ASH CONTENT in coke is very low i.e.) around 10%. So it does
not arise problems of striking on the grates.
The coke oven and coal chemical plant is mainly divided into the following
department:
1.
2.
3.
4.
5.

Coal Preparation Plant (C.P.P)

Coke Oven Batteries
Coke Dry Cooling Plant (C.D.C.P)
Coke Sorting Plant
(C.S.P)
Coal Chemical Plant
(C.C.P)

6.

COAL PREPARATION PLANT

PURPOSE OF COAL PREPARATION PLANT:
The main purpose of this plant is to prepare the coal by removing the
foreign matter and bringing to the size suitable for carbonization or coking
process.
PROPERTIES:

VOLATILE MATTER: 20-25%.

MEAN MAXIMUM REFLUCTANCE: 1.12-1.14.
CRUSING INDEX:% of -3mm size particles which should be
around 70% - 75%
FIXED CARBON:
The carbon left behind after the removal of the volatile matter is
fixed carbon.
ASH CONTENT: Around 17-22 in Indian coking coal & 8-10 in imported
coking coal.
TOTAL MOISTURE:
The amount of total moisture present in coal. There lies some
internal moisture also.
COAL PREPARATION
SECTIONS:

PLANT

CONSISTS

OF

FOLLOWING

Foreign material separation section

Dogimeters.
Selective crushing sections.
Pneumatic separation.

The coking coal is taken from coal yard by using bucket elevators on the
conveyors. Then it is sent to foreign material separation section.

PROCESS:
First the suspended iron separators separate the iron particles in the
coal. After it is demagnetized, the separated coal falls on self-unloading
suspended separators. it works for 19 seconds. After that coal is separated into
+150 mm & -150 mm sized particles in rotary screens. +150 mm sized
particles fall in the chute and are sent back for crushing. Where as -150 mm
particles are transferred to reversible conveyors. There are further connected
to shuttle conveyors for filling the bins. There are a total of 16 bins, equally
divided into 2 rows. The capacity of each bin being 800 T and a height of 20
mt.These are arranged under each bin for blending the coal to produce quality
of coke. Mixing of different coals depending upon blend composition does
blending of coal. Blended coal is send to selective crushing section for
crushing of coal from -150 mm to -3mm size. In selective crushing section
there are 3 primary crushers and 2 secondary crushers for crushing the coal.
The separation and collection of required size materials by utilizing air
pressure is known as pneumatic separation. The crushed coal is subjected to
pneumatic separator. There by -3mm coal is transferred to coal towers at
battery. There are 2 coal towers each with capacity of 4000 T of coal. There
are junction houses, which maintain the elevation of conveyors of different
sections.

COKE OVEN BATTERIES

Coal is converted into coke by high temperature carbonization in the ovens of
the battery. There are 3 batteries working and the Battery 4 is being
constructed for more production of hot metal.
CONSTRUCTION:
The total length of the battery is 100 mts. It consists of rectangular chambers
of length 16 mts, 7 mts high and 0.14 mts width with removal door ends.
Coke oven battery is a combination of ovens and heating chambers in
alternatively. There are 67 ovens and 68 heating chambers in a battery. The
oven walls are lined with silica bricks of high thermal conductivity.
Battery has 4 machines:
1) Pusher car

2) Charging car
3) Door extractor car
4) Loco car
PROCESS:
Coal is transported from coal preparation plant to coal tower above the
battery. a charging car travels on the battery and under the coal tower. 32 T of
coal is charged in each oven up to a height of 6.7 mts out of 7 mts by charging
position in each oven. After complete carbonization, coke oven gas is
collected by hydraulic main that is connected to the ovens, which are sent to
recovery plant for cleaning of gas. Later it is sent to recovery plant for
cleaning of gas.

COKE DRY COOLING PLANT

After pushing the coke from the Battery with a temperature of 1050c,
it is transferred into C.D.C.P for cooling purpose. The C.D.C.P technology is
adopted only in VISAKHAPANAM STEEL PLANT only because in wet
cooling the strength of the coke is reduced.The coke is cooled with N2 gas.
The advantages of DRY COOLING are:
1) Waste heat recovery (by producing steam)
2) Pollution control (done by closed circuit)
3) Better Coke strength (there is no thermal shock as in wet cooling)

COKE SORTING PLANT

Coke from C.D.C.P enters the C.S.P section. Here coke is crushed, screened
and later conveyed to different consumers.

PROCESS:
In C.S.P dust will be removed from the coke with the help of
dedusting fans. After that coke is sent to crushing section to crush into 80mm
size particles.
a) B.F coke (25-80mm) - Sent to Blast Furnace.
b) BREEZE COKE(0-10mm)- conveyed to Sinter Plant.
c) NUT COKE(10-25mm)- to Blast Furnace.
COAL CHEMICAL PLANT
Many by products are extracted from the coke oven gas at this department. It
consists of the following sections:
1. Exhauster house.
2. Final Gas Cooler
3. Ammonium sulphate plant.
4. M.B.C plant.
5. Tar distillation plant.
6. P.C.L.A
7. Naphthalene fraction crystallization.
8. Benzol plant.
Benzol distillation plant.
Hydro refining.
Extractive distillation.

Exhauster House
a)PRIMARY GAS COOLER:
The coke oven gas from the separator is fed to the PGC from the top. The
cooler consists of three zones. This is a shell and tube heat exchanger in
which the CO gas exchanges with service water in the top two zones and with
chilled water in the bottom zone the tubes are inclined in all the zones. The
main purpose of PGC is to cool the gas from 90c to 30c.
During this cooling process the naphthalene and traces of tar present in
the gas condense and this is collected at the bottom of the PGC. Tar
at
a
temperature of 90c is flushed from the top of the cooler to remove the
condensed naphthalene on the tubes. The tar is then collected at the bottom in
the seal pot.
b)ELECTROSTATIC PRECIPITATOR:
The CO gas enters the ESP from the bottom. Electrostatic precipitators
are cylindrical vessels with a conical bottom. Each ESP is provided with a
seal pot. A round disk having electrodes in suspended state is present inside
the precipitator. Electrodes are nothing but SS metal rods. Due to high voltage
the fine and foggy tar get sticked to the walls of the electrodes and they fall
down due to gravity.
Capacity
30,000 Nm3/hr
Voltage
70KV
Number of electrodes
148
ESP insulator boxes temperature
80C
c)EXHAUSTERS:
These are centrifugal fans necessary to drive the gas from the batteries
itself to various plants like ASP. Exhauster sucks the CO gas from the
batteries. The pressure at the suction side of the exhauster is -350mm WC and

the discharge side is +2500mm WC. Due to increase in the pressure the
temperature is increased to 55-60c.

AMMONIUM SULPHATE PLANT

Coke oven gas with a pressure of 2500mm WC from exhauster is fed to the
ASP. Ammonia present in the CO gas is recovered in ASP as ammonium
sulphate fertilizer.
PROCESS:
The CO gas from the exhauster is fed to the pre-heater to preheat the gas to
60-70c.
a)SATURATOR:
The CO gas enters through the bubbler hood which is dipped in the bath. The
gas rises through the mother liquor. During this period, the ammonia present
in the gas reacts with the sulphuric acid in the liquor(mother liquor contains
4-5% of sulphuric acid)

NH3

H2SO4

NH4 (HSO4)

NH3

NH4 (HSO4)
(NH4)2SO4

Ammonium sulphate thus formed settles at the bottom of the saturator.

Pure nitrogen is purged into the saturator through N 2 rings at 4-5 kg/cm2. N2
purging increases the crystal growth.
b)ACID TRAP:

The outlet gas of the saturator carries some acid mist. In order to remove
the acid mist, the gas is sent to the acid trap.

C)CRYSTAL RECIEVER TANK:

Ammonium slurry from the bottom of the saturator is pumped to the
crystal receiver tank with conical bottom. The ammonium sulphate crystal
settled at the conical portion of the tank, which is wet with liquor. The mother
liquor from the top of the receiver is fed to the saturator. The slurry from the
bottom is fed to the centrifuge.
d)CENTRIFUGE:
Crystals present in the slurry are separated by the centrifugal force .Hot
water is sprayed into the centrifuge to wash of the free acidity that is the acid
layer on the crystal. And then they are dried.

FINAL GAS COOLERS

Coke oven gas after ammonia recovery consists of 0.8-1.12 mg/lit
of naphthalene. These naphthalene particles are removed by spraying tar.
Temperature at the bottom of FGC
Naphthalene in CO gas after FGC
FGC tar temperature
Specific gravity of FGC tar moisture

50-60c
0.4 g/Nm3
80-90c
5%

a)GAS PRE-COOLER:
The gas at 30-35c is fed to the pre-cooler, which is indirect contact
cooler. The gas is cooled by chilled water (150c), which passes through the
tubes. The gas is cooled to 25-27c so that any particles condensed are
received in the seal pot.
b)SCRUBBERS:
Scrubbers are long towers consisting of aluminum packing or
wooden sheets provided with three layers. The CO gas from the gas precoolers is sent to the first benzol scrubber at the bottom. Solar oil or debenzolised oil is used for scrubbing the gas to recover benzol.

MECHANICAL BIOLOGICAL AND

CHEMICAL TREATMENT PLANT
PROCESS:
Toxic effluents generated in various sections of coke oven and byproduct plant are collected and pumped to the treatment plant from two pump
houses.
Major Pollutants in Coke Oven Effluent Water:
Phenols

Rhodanides ( Thiocyanates)

Cyanides

Ammonical Nitrogen

Oil and grease

Suspended solids

a)Flash Unit: Flash unit (FU) is used for cooling of effluent delivered to MBC at
around 85C and is cooled to 70-75C.
b)Heat Exchangers:
Outlet water from flash unit enters a series of heat exchangers for further reduction
of temperature. Here the temp reduces by 5-6C.
c)Pre-Aeration Tanks:
Different sources of effluents are mixed with the help of air supplied from
blowers.
d)Tar Settling Tanks:
Effluent from pre-aeration tanks is distributed equally among 5 tar settling tanks
for treatment from course dispersive insoluble impurities including heavy tar
and oil.
e)Phenolic Water Collecting Tanks:

Ferrous Sulphate solution is added in these tanks for the decrease of effluent
toxicity and increase in the efficiency of treatment of the same from oil. Addition of
ferrous sulphate favours enlargement and sedimentation of oil particles. Mainly
ferrous sulphate converts volatile cyanides into non-volatile and non-toxic ferrocyanides.
f)Oil Floatators:
Effluent from phenolic water collection tanks enters into oil floatators through
pressure tanks. Flotation method is based on the ability of suspended solids to
stick together molecularly with finely dispersed bubbles of air and then float up
as oily foam.
g)Equalizing Tanks:
Equalizing tanks are also called as averaging tanks. it is mixed compressed air
and averaged in temperature and pH .Phosphorous feed is added as a nutrient to
bacteria in the form of ortho phosphoric acid.
.
h)First Stage Aero Tanks :
Here partial treatment of phenols by culture of phenol destructive bacteria
(Pseudomonas Putida) is carried out. By these bacteria, the phenol present in
effluent gets converted into carbon dioxide and water in the presence of air
(aerobic).
C6H5OH +7.O2
3H2O + 6.CO2
i)Second Stage Aero Tanks :
Effluent in this stage is treated by rhodanide destructive bacteria (Thiobacillus).
Oxidation of cyanides and rhodanides takes place
NH4CNS +2.O2 +2.H2O
(NH4)2SO4 + CO2
2NH4CN + O2 + 4.H2O
2(NH4)2CO3
j)Third Stage Aeration Tanks:
Nitrosomonas and Nitrobacter are used for conversion to nitrites and nitrates
respectively which is called nitrification process.
k)Fourth Stage Aeration Tanks:
Aeration tanks of additional treatment are designed for COD decrease and
increase of treatment degree from ammonia, phenols and nitrites after the third
stage

TAR DISTILLATION PLANT

Tar is a viscous fraction obtained by the cooling of coke oven
gas with ammonia liquor. It consists of large chain aromatic compounds,
which can be distilled into light oils, phenols, naphthalene oil, wash oil and
pitch. Coal tar in coke oven gas is collected from CPH and final gas a cooler
of benzol recovery is transferred to tar and oil storage. From there it is
pumped to mechanized decanter in tar distillation plant.
COMPOSITION OF COAL TAR COMING TO TDS:
Light oil
Phenol fraction
Naphthalene
Wash oil
Anthracene oil
Moistur4e
Pitch

0.5%
1-1.5%
5-6%
8-9%
18-19%
5-6%
55-60%

PROCESS:
The tar from the condensate pump house is fed to the tar and oil
storage of the TDP. The tar to the tar distillation section is fed from the tar and
oil storage tanks. This tar contains 5% of moisture, which can be removed in
the decanters.
DECANTERS:
The tar is fed to the decanters. It is provided with a scraper conveyer
to remove the sludge collected at the bottom and transferred to a bunker in the
decanter small quantities of water and flushing liquor collects at the top of
layer which are continuously removed.
The tar from the decanters flows through two strainers to remove
suspended matter to a common suction header of liquor plunger pumps for

first stage. A plunger pump consists of three piston, suction and delivery
valves, which pump with high pressure. Tar initially consists chloride salts
and acid, which causes corrosion and damages the piping present in the
furnace and the plant. To prevent the soda ash solution of 8% concentration is
injected at the suction side of the pumps.
2NH4Cl
H2O
2HCl
CO2

+
+

Na2CO3
Na2CO3

-------------------

2NaCl
2NaCl

2NH 3
+

+
H2 O

CO2 +
+

The ammonia formed from the above reactions vaporizes along with
water vapor and light oils.
FURNACE:
It consists of two zones one is convection zone and the other is
radiation zone. Furnace is having four burners where CO gas is used as fuel.
Air draught is taken from the bottom of the furnace. The tar from the filter is
pumped to convection zone, which is at the top of the furnace. Here the
temperature increases to 120-130c. Controlling the airflow can control the
flame length more the air longer the flame and vice versa. This arrangement
helps in controlling the temperatures of tar in both the zones.
In radiation zone dehydrated tar is circulated which is pumped from
second stage plunger pumps. The temperature of the tar is increased to 400c.
The temperature of the tar should not increase beyond 400c as this cause the
formation of B.F grade pitch.
The flue gas from the furnace is sent to the atmosphere through the
chimney. It is provided with a baffle plate in order to assure complete
combustion of the gas.
I STAGE EVAPORATOR:
Evaporator is a cylindrical vessel having baffle plates, which
change the direction of gases. Evaporator is designed for the evaporation of
water and light oils from the crude tar, which are fed at the middle of the
evaporator. The temperature of the tar at the inlet is about 120-130c. Due to
this temperature, the moisture in the tar is evaporated. These vapors from the
top of the evaporator are fed to the twin condensed coolers. From the bottom

dehydrated tar having less than 2% moisture is fed to the dehydrator tar tank
and pumped to the radiation zone of the furnace.
Pressure in the evaporator
Temperatures of vapors
Temperature of DTT
Baffle plates
Spilling plates

0.3 kg/cm2
102-105c
<110c
3
2

DEHYDRATED TAR TANK:

Tar from the evaporator is fed to the DTT tank, which is used as a
intermediate storage. The tank is always maintained 100% and the over flow
tar from the DTT is fed to the decanter4. Tar is fed to the II stage tar pump
from the bottom of the DTT. The pump discharges this tar to the radiation
zone of the furnace where it is heated up to 380-400c. This tar is fed to the
second stage evaporator at the rate of 10 m3/hr.
II STAGE EVAPORATOR:
In second stage evaporator oil vapors and pitch are separated.
Dehydrated tar from the radiation zone is fed to the evaporator. Two baffle
plates are arranged below the vapor inlet and five above the vapor inlet. Four
bubble cap trays are also arranged at the bottom of the evaporator. This
arrangement completely separates tar fraction form pitch. A protective plate is
also installed as in first stage evaporator. The oil vapors from the top of the
evaporator are fed to the distillation column. The tar at the bottom of the
evaporator is called as pitch and is supplied to the pitch cooling section.
Pressure in the evaporator
Number of bubble cap trays
No. of baffle plates
Temperature of the fractions

0.5 kg/cm2
4
7
400c

DISTILLATION COLUMN:
Fractionating column is designed to separate different fractions
from tar. The column is provided with 59 trays out of which 56 are bubble cap
trays and the remaining three baffle plates. Each tray has 42 bubble caps.
Mixed oil vapors from the top the second stage evaporator are fed to the third
tray of the fractionating column at a temperature of 360-380c.

As the vapors rises to the top of the column different fractions are
obtained from different trays. Initially vapors enter at about 360-400c. Pure
light oil is supplied as reflux to the top plate rectification column to maintain
top temperature of the column. Reflux is fed as the top temperature increases.
All the fractions are continuously drawn from the column. The vapors, which
are not condensed are collected from the top of the column and fed to the twin
condenser cooler of the second stage.
LIGHT OIL:
Light oil is obtained from the column, which is lighter than all of
the fractions the top temperatures of the column are maintained at 100c. The
light oil consists of phenol and phenol containing water (PWC). The light
vapors are cooled in twin condensed coolers and fed to the separator II.
PHENOL:
Phenol fraction obtained is not in pure state at 160-180c. It
contains 22% phenol and 10-15% naphthalene. Three tapings are provided on
44.46 and 48 trays.
NAPHTHALENE:
Naphthalene fraction can be trapped from 24, 26, 28 and 30 trays. It
is obtained at a temperature of 190-200c. Steam jacketed lines are provided
because decrease in temperature results in crystallization of naphthalene.
WASH OIL:
There 5 tapping for wash oil on 12, 14, 16, 18, and 20. Normally
wash oil will be tapped at a temperature of 280-290c. It is tapped from 6 & 8
trays. Anthracene II is heavier than all fractions. So it is obtained from 1 st or 2
nd
trays at 320-330c.
TWIN CONDENSED COOLERS I & II STAGES:
These are shell and tube heat exchangers to condense the vapors.
First stage coolers condenses the gas coming from I stage evaporator and the
II stage cooler condenses the gas leaving the column. The vapors pass through
the shell and service water is used to cool the vapor passing through the tube
side. The vapors of I stage cooler are cooled from 102-50c. The vapors of
second stage coolers from 100-40c. After condensation the vapors from both
I & II stage condensers enter into separators I & II respectively.
SEPERATORS I &II:

Separators are used to separate light oils from other fractions (NH 3
water and phenolic water) obtained form the top of the first stage evaporator
and distillation column in separator I & II respectively. Light oil obtained
from the top the two separators flow to light oil tanks by gravity. At the
bottom of the separator I ammonia water will be settled and a the bottom of
the separator II phenolic water will be settled. Both of them are removed
through dip tubes to prevent light oil mixing with them.
SUBMERGED COOLERS:
Submerged coolers contain a coil inside the coolers through which
the fractions from the column are passed. This coil is submerged in the water.
The vapors are cooled from 80-50c are sent to the collected tanks.
START UP TANK:
During initial starting of the plant, the temperature of the tar does
not reach up 400c in second stage evaporator will be diverted to start up tank
until it reaches the temperature of 290c similarly column bottom liquid will
also be diverted to start up tank until the temperature of the column reaches to
330c.

PITCH COOLING AND LOADING

AREA
Pitch is a mixture of resins and straight chain aromatic compounds
and oils. Pitch from the bottom of II stage evaporator is fed to the storage a
tank of PCLA . Air is injected through the bubbler, which is provided with a
ring having small holes. As the air passes through the pitch, it entrains any oil
present in the pitch. This process produces three grades of pitch :
1. Pitch creosote mixture
2. Medium hard pitch
3. BF grade pitch
The main consumers are BALCO, NALCO, and INDALCO & HINDALCO.
This pitch is mainly used in manufacturing electrodes in aluminum industries.

BENZOL PLANT
Benzol plant is provided in order to produce pure benzene,
toluene, and solvent naphtha. Benzol plant consists of three sections:
Benzol distillation plant.
Hydro refining unit.
Extractive distillation unit.
Crude benzol recovered from the coke gas is fed to the benzol distillation
plant. Various chemicals in the benzol are recovered by distillation.
In the benzol distillation plant, the benzolised oil from final
absorption is pumped to the storage tanks of the benzol distillation. The BO is
then stripped of with steam to get the crude benzol and debenzolised oil. The
temperature of the BO fed to the stripping column is about 130-135c.
STRIPPING COLUMN:
Pre-heated BO from the exchangers is fed to the 17 th tray of the
stripping column. The column consists of bubble cap trays. Low pressure of
steam at a temperature of 180c and 3.8kg/cm2 is injected through DBO at the
bottom of the column.
Crude benzol in the BO is recovered by steam distillation. Steam
distillation is done so that the partial pressure of the benzol decreases and
easily get vaporized. LP steam injected at the bottom not only maintains
temperature of the column but also decrease the partial pressure of the crude
benzol. The partial condensation removes any higher fractions present in the
vapors which further increases the purity of the vapors. Three sets of
dephlegmator are provided, two sets for oil and one for water. The vapors are

cooled to 92-95c in oil dephlegmator by pre-heating the feed to the stripping

column and further cooled to 84 c in water dephlegmator. The condensate
collected in the heat exchanger is called PHLEGMA. The phlegma from the
exchangers, which contains water, is collected in a separator. Water is
separated and phlegma over flows to the phlegma collecting tank from this
tank phlegma is sent to stripping column as reflux.
REGENERATOR:The continuous circulation of DBO forms some
polymer due to heating and cooling which must be removed from the DBO
by regeneration. Regeneration is a hollow tank in which steam coils are
arranged medium pressure steam is circulated through these coils due to the
pressure CB vapors are collected at the top, which are in turn sent to the
stripping column. The bottom liquid from the regenerator is pumped out and
stored in Crude and Finished Product Storage.
Top temperature
Bottom temperature
No. of trays
Feed tray
Pressure in the column

110-115c
120-130c
23
17 th tray
0.3-0.35

CRUDE BENZOL COLUMN I:

Here the the crude benzol is separated to heavy crude benzol and
light crude benzol. Crude benzol mainly consists of LCB, HCB and polymer.
Lighter fractions like benzene, toluene, and xylene are present in LCB and
HCB is similar to that of heavy polymer, which is used as furnace oil.
The column consists of 16 bubble cap trays. Simple distillation is carried out
in this column. A reboiler provided at the bottom of the column supplies the
necessary heat. MP steam is used as heating media.
CRUDE BENZOL COLUMN II: CB II consists of 6 bubble cap trays. The
bottom product of the CB I which mainly contains HCB with small amount of
LCB is fed to the CB II column. To recover the LCB the liquid is to be
distilled.
DEBENZOLISED OIL: The DBO from the bottom of the stripping column is
pumped through oil-oil heat exchanger to DBO cooler. In DBO cooler it is

cooled to 45-50C. Due to high temperature exposure, part of solar oil

decomposes which is removed by decantation (to maintain absorption
efficiency).

DECANTER: Small amount of water is fed to the decanter which provides

better removal of sludge or muck form of oil. Water settles at the bottom
carrying sludge with it. Muck or sludge layer is formed the water layer. Oil
layer is formed above the muck layer.
EMULSION BEAKER: This is a horizontal cylindrical vessel provided with
insulation. Medium pressure steam is fed through a coil into the beaker.. Due
to heating of emulsion, oil and water get separated which is called as Deemulsification.

HYDRO REFINING
In this unit using hydrogen gas purifies the light crude benzol.
Hydrogen is recovered from coke oven gas and LCB from benzol distillation
plant.This consists the following sections. They are,
De-fronting section
Reaction section
Purification section
DE FRONTING SECTION:
In this section, carbon disulphide is removed from the crude benzol
and this is called as de-fronted crude benzol.
Distillation column consists of 30 bubble cap trays of which 17 th
tray is the feed tray. Steam is fed into the reboiler, which heats the bottom
product recycled to the column.. Simple distillation is carried out and due

to heating CS2 vapors rise in the top and these are condensed in a water
condenser.
REACTION SECTION:
This section consists of reactors and evaporators. Here the hydro
refining takes place in the reactors provided which removes the oxygen,
nitrogen and sulphur content in DCB.
PURIFICATION:
This section consists of a stripping column in which the sulphur
content as H2S and any dissolved gases in the DCB are removed.

EXTRACTIVE DISTILLATION UNIT

In this unit, the BTX raffinate is processed to separate benzene, toluene
and xylene solvent. Further benzene and toluene are also separated. Using
Extractive Distillation in which N-formylmoropholine (NFM) is used as
solvent does separation of BTX into BT and X. Non aromatic compounds
present in BTX are removed by pressure distillation solvent is recovered in
solvent recovery column. Benzene and toluene are separated in BT separation
column.
The total heat required for the unit is supplied from various means
pressure distillation receives heat from hot oil. Aromatic separation column
and solvent recovery column receives heat from the vapors of the pressure
distillation column. The BT column receives heat from the LP steam.
The unit consists of the following sections:

Pressure distillation section

Extractive distillation section
Solvent recovery section
Aromatic stripper
BT separation section
Xylene solvent section

a)Pressure distillation section:This section consists of a distillation column in

which the BT & X solvent are separated by simple distillation from reffinate.
b)Extractive distillation column :ED column serves for the separation of nonaromatics contained in the feed, which is not possible under normal
distillation conditions. This means that non-aromatics originally with boiling
points higher than aromatics, becomes low boiling non-aromatics which can
be with drawn at the top of the ED column while the aromatic substances
dissolve in the NFM is yielded at the bottom of the ED column.
c)Solvent recovery column:The column is used for separation of nonaromatics yielded at the top of ED column from the residual carried over
solvent contents.
d)Stripping column:The product yielded at the bottom of the ED column
consists of NFM in which the extracted aromatic substances are dissolvedIn
this column the pure aromatics are separated from the NFM.
e)Benzene toluene seperation column:BT separator is a normal two-phase
distillation for pure aromatics.