COKE AND COAL CHEMICAL PLANT

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.

The coke oven and coal chemicals department is one of the major

departments in Visakhapatnam steel plant. The coke oven unit of the plant is

dedicated to produce metallurgical coke required for Blast Furnace. This coke-

making unit has four batteries each having 67 ovens.

The process of coke making is a high temperature carbonization in 7-meter

tall oven. The coke oven gas collected at gas collecting main is cooled by spraying

circulating Ammonical liquor. The cooled coke oven gas along with excess liquor

goes to GAS RECOVERY PLANT.There 1.crude tar 2.ammonia liquor(moisture of coal)

3.crude benzol and 4.ammonia will be separated from raw coke oven gas

.After separation of above 4 items ,the cleaned coke oven gas will be send to all

batteries for heating of ovens.

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.
The different coking coals used in VSP are:
1) M.C.C - Medium coking coal - BENGAL, BIHAR
2) I.C.C - Imported coking coal - AUSTRALIA
3) I.S.S.A.C - Imported coking coal - AUSTRALIA
4) SOFT - Imported coking coal - AUSTRALIA

In VSP coking coal is used for producing metallurgical coke where as non-coking coal is
used for producing thermal power (in boilers).

TYPES OF COAL AND PROPERTIES:

S.NO. TYPE OF COAL % MOISTURE % ASH MEAN

MAXIMUM
REFLUTANCE
1. M.C.C 25-28 17-22 0.9
2. I.C.C 24-26 8-10 1.10-1.3
3. I.S.S.A.C 23-25 8-10 1.16-1.3
4. SOFT 30-34 8-10 0.9-1.0
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. Coal Preparation Plant (C.P.P)

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

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.

COAL BLEND COMPOSITION:

1. M.C.C - 15%
2. I.C.C - 40%
3. I.S.S.A.C.C - 35%
4. SOFT - 10%

PROPERTIES:
  VOLATILE MATTER:
It is the matter which is unstable at high temperature and converts itself into
gaseous state like tar, benzene compounds etc. it is around 20-25%.
 MEAN MAXIMUM REFLUCTANCE:
It is a coal ranking. It decides the properties of coal. It is around 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:
The % of ash present in coal. It can known by testing in the laboratory. It is
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.

CONTENTS IN 1 TON OF COAL:

1. Coke - 746 kgs
2. Crude Tar - 32 kgs
3. Crude Benzol - 6.9 kgs
4. Ammonia - 4.1 kgs
5. CO Gas - 150 kgs
6. Losses - 61 kgs

COAL PREPARATION PLANT CONSISTS OF FOLLOWING SECTIONS:

 Foreign material separation section

 Dogimeters.
 Selective crushing sections.


1. FOREIGN MATERIAL SEPERATION SECTION:

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

In foreign material separation section the following equipment exists:

1. 2 Cylindrical screens.
2. 2 Suspended iron separators.
 3. 2 Self unloading suspended iron separators for separating the magnetic particles in
the coal.

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. All the odds like 1, 3, 5, 7, 9, 11, 13, 15 & the evens 2, 4, 6, 8, 10, 12, 14, 16. The
capacity of each bin being 800 T and a height of 20 mts.

Specifications of cylindrical screen:

Inclined angle - 8°
Feed end length - 1.5 m
Discharge end length - 0.8 m
Mesh size - 150 mm

2. DOGIMETERS:
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.
In the old dogimeters the doors at the chute were operated and coal discharge was
controlled. There occurred some jamming of coal. So vibrators were used to clear the
jamming which is removed now. In the new dogimeters the chute is made uniform and
“RATE OF DISCHARGE IS EQUAL TO SPEED AT WHICH THE ROTOR OF THE
CONVEYOR ROTATES”

3. SELECTIVE CRUSHING SECTION:

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. First coal is crushed in primary crushers.
Then crushers are connected from 6.6 KV motors via variable speed coupling and gear
box. Speed of motor is controlled from 1000 rpm to 400 rpm by variable speed
coupling in order to avoid the breakage of crushers and sudden stoppage of crushers. In
primary crushers there are 88 hammers in 12 rows of universal crushing.

Specifications of crusher:

Total no. of crushers - 5

Primary crushers - 3
 Secondary crushers - 2
Cap. of primary crusher - 400 T/hr
Cap. of secondary crusher - 600 T/hr
No. of hammers - 88(12 rows)
Wt of each hammer - 19.7 kgs
Wt of arm - 6.0 kgs
Length of arm - 45.0 kgs
Material of construction - Nickel Chromium Steel
Rotations of hammer - 400 rpm

4. PNEUMATIC SEPERATION:

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.

COMMISSION DATES OF BATTRIES:

BATTERY-1 - 06/09/1989
BATTERY-2 - 31/10/1991
BATTERY-3 - 30/07/1992

RAW MATERIAL - Coal blend.

PRODUCT - Coke with 1-3% volatile matter.
BY-PRODUCT - Raw coke oven gas.
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. These ovens are OTTO-HOFFOMEN’S by-product oven
type. On the roof there are metal lids for the sake of charging purpose. The width of the
coke discharge side is slightly more than the pusher side for easy transport of coke outside.
Heating flues are arranged in the walls between the ovens. There are regenerators
underneath the battery. The oven walls are lined with silica bricks of high thermal
conductivity. There is no shrinkage in the refractory walls. These bricks ensure long life.
All doors are sealed with refractory clay and water mixture.
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. Since the
coal drops by gravity, it should be leveled which is done by a leveling bar fixed to the
pusher car. After leveling all lids and doors are replaced and coking process is continued
until most of the volatile matter is removed. This process takes a coking period of 17-18
hrs by indirect heating with coke oven gas or mixed gas (CO gas + BF gas) in absence of
air at 1150°c.

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. After cleaning CO gas is recycled back to the battery
for heating purpose. The product is 1-3% moisture contained coke. Yield of coke by HIGH
TEMPERATURE CARBONIZATION at 900°c - 1200°c is 65-75%.

Calori3fi3c value of di3fferent gasses used for heating purpose:

 CV of Coke oven gas - 4200 K Cal /Nm3
 CV of Blast furnace gas - 750 K Cal /Nm3
 CV of Mixed gas - 1000 K Cal /Nm3
The walls start after 5 m level. Until 5 m level it is called the regenerator. The
regenerators serve the purpose of recovering heat by heat exchange between hot
flue gasses and bricks. The air coming in. thus air gets preheated in the regeneration
section takes this heat. In the first cycle fuel gas flows through one set of flues and
flue gas goes out through other set of flues. There are 136 waste heat boxes through
which air is supplied form one section and flue gas leaves through other section.
 As hot air is of low density and by the density difference suction is created by
which flue gas rises up out of the chimney. Checker bricks made of silica are placed in the
regeneration section so that the contact area and time for regeneration increases and
maximum heat is recovered.

SPECIFICATION:
 Total no of Batteries - 3
 No of ovens in each Battery - 67
 Heating walls - 68
 Height of each oven - 7 mts
 Length of each oven - 16 mts
 Width of each oven(P/S,C/S) - 38.5 / 43.5 mm
 Heating wall thickness - 0.105 mts
 Coal charging in each oven - 34 ton’s
 Output coke from oven - 25 ton’s
 No of vertical flues - 32
 No of waste heat boxes - 136
 Heating gas used in Battery 1&2 - CO gas
 Heating gas used in Battery 3 - CO + BF gas in 1:9 ratios.
 Coking period - 17-18 hrs
 Coke temperature - 1050°c
 Coke fluidity temperature - 400-500°c
 Capacity of battery - 97 pushing/Battery/day
 Coking Period Determination (C.P.D)

No of ovens x 24 67 X 24
C.P.D = -------------------------= ------------ = 1608 hrs
No of pushing’s per day 100

COKE DRY COOLING PLANT

After pushing the coke from the Battery with a temperature of 1050°c, 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 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)

PROCESS:
 Coke form Battery falls into loco on the coke side, which is brought into C.D.C.P.
The loco is lifted up and coke is charged into the cooling chambers. Later the chambers are
closed by lid and N2 gas is passed inside through a temperature of 55°c by a mill fan. The
hot coke is cooled from 1050°c to 180°c-200°c. There occurs no chemical reaction, as N 2 is
an inert gas. The heated gas is utilized for producing steam in boilers. These boilers are
water tube boilers, which are of capacity 25 T/hr. the temperature and pressure of the
steam, are 440°c and 40 Kg/cm2. Cooled coke i3s convey6ed to C.S.P and the steam is
used to run back pressure turbine station for producing power of 15 MW.

SPECIFICATIONS OF C.D.C.P:
 No of C.D.C.P - 3/3 Batteries
 No of chambers - 4 Chambers/each C.D.C.P
 Capacity of each C.D.C.P - 50-52 T/hr
 Coke temp before cooling - 1050°c
 Coke temp after cooling - 180°c-200°c
 Coolant used - N2 gas
 Dry coolant temperature - 55°c

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. There B.F coke (25-
80mm) is separated through 14- roll screen and sent to Blast Furnace. The remaining 0-25
mm fractions will be sent to vibrating screen. Here 0-10 mm particles called BREEZE
COKE is conveyed to Sinter Plant and 10-25 mm called NUT COKE to Blast Furnace.

COAL CHEMICAL PLANT

1.GAS RECOERY PLANT
 .SEPERATORS
 .EXHAUSTERS.
 .PRIMARY GAS COOLERS
 .ELECTRO STATIC PRECIPITATORS
 ..FINAL GAS COOLERS
 .DECANTERS
 .M.B.C plant.

2. AMMONIUM SULPHATE PLANT

  SATURATORS
 CRYSTALIZER
 DRIER
 PACKING

3.BENZIL DISTILLATION PLANT

 Benzol distillation plant.
 Hydro refining.
 Extractive distillation.

4. TAR DISTILLATION PLANT

 .REACTORS
 .DISTILLATION COLUMN
 P.C.L.A
 Naphthalene fraction crystallization

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 inclination is maintained at 15° with the
horizontal. This provides any naphthalene condensate to drain easily. The main purpose of
PGC is to cool the gas from 90°c to 30°c.
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. The liquid collected at the bottom
is sent to the seal pot by gravity. The level in the seal pot should be maintained constant as
this acts as a seal to the gas in the cooler.
Tar at a temperature of 90°c 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.
Tar and naphthalene from the seal pot is fed to the storage tank of the CPH. The CO gas
from the bottom of the PGC is fed to the electrostatic precipitator.

Gas temperature before PGC 80-95°c

Gas temperature after PGC 27-30°c
Service water inlet temperature 32-33°c
Service water outlet temperature 43°c
Gas condensate flow to each PGC 10-15 Nm3/hr
Chilled water inlet temperature 11-12°c
Chilled water outlet temperature 20°c
Total number of tubes 409

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. Three are present at the top of precipitator, which supplies the necessary
power to each ESP. high voltage of about 50,000 volts is supplied to each electrode. Due to
high voltage the fine and foggy tar get sticked to the walls of the electrodes and they fall
down due to gravity. The liquid thus collected at the bottom is fed to the seal pot. Each
electrode is covered to prevent the connection between any two electrodes.

Capacity 30,000 Nm3/hr

Voltage 70KV
Number of electrodes 148
ESP insulator boxes temperature 80°C

EXHAUSTERS:

These are centrifugal fans necessary to drive the gas from the batteries itself to
various plants like ASP. Benzene recovery and finally to the main header of the coke oven
gas. 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 55-60°c.
The flow of gas is controlled by Askania valve, which is a butterfly valve. The
function of this valve is to control the flow of gas to the exhauster. When the quantity of
gas is low then the valve is closed and when the gas quantity is high valve is opened. If any
condensate is collected and when the gas lines and sent to the storage tank of the
condensate pump house.

Capacity 67,000-76,000Nm3/hr
Power 1250KW
Maximum suction at inlet 500mm WC g
Maximum pressure at delivery 2700mm WC g

CONDENSTE PUMP HOUSE:

Flushing liquor separated from the separators is fed to the condensate pump house.
This consists of decanters and storage tanks. The tar and flushing liquor collected from the
exhauster house is stored in the storage tanks.

DECANTERS:
 Decanters are used to settle the flushing liquor by gravity. These are mechanical
decanters provided with scraper mechanism. This scraper is a chain like arrangement
provided at the bottom. The flushing liquor is fed at the middle of the decanter. In
decanters due to density difference, flushing liquor, tar & sludge form as three layers from
top, and the flushing liquor is then sent to the storage tanks.
A telescopic valve provided to the decanter removes the tar settled in the middle
layer. The valve works on the principle of ‘U’ tube manometer. Sludge removed by scraper
mechanism provided at the bottom of the decanter. The scraper then dumps the sludge into
a bunker provided at the end of the scraper. A motor provided with a gearbox runs the
scraper. The sludge from the bunker is removed periodically.
Tar collected from the flushing liquor decanter is stored in the tar storage tanks.
Then it is pumped to tar decanters. The tar from the tar decanters contains less moisture
and sludge. Flushing liquor from the decanter is stored in the storage tank and again
pumped to batteries. If the flushing liquor is excess then 60% is sent to excess flushing
liquor tanks.

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-
70°c. But according to our atmospheric temperature, this temperature is obtained after the
exhauster. So the gas is directly fed to the saturator.

SATURATOR:

Saturator is a cylindrical vessel with conical bottom. It is provided with a bubbler

hood, which is duct prolonged to the middle of the saturator. The duct has a hood at the
bottom provided with vanes like arrangement. Another ring like structure with small
openings is provided at the conical portion, which is used for nitrogen feeding. Hot water
rings are provided at the top of the saturator. Saturator is always maintained with acid bath
called mother liquor, which contains 4-5% of sulphuric acid.
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.

NH3 + H2SO4 NH4 (HSO4)

NH4 (HSO4) + NH3 (NH4)2SO4

Ammonium sulphate thus formed settles at the bottom of the saturator. Pure nitrogen
is purged into the saturator through N2 rings at 4-5 kg/cm2. N2 purging increases the crystal
growth. Pure sulphuric acid (98%) is fed to the saturator to maintain the acidity in the
saturator. The gas collected at the top of the saturator is fed to the acid trap. As the gas rises
up, some of the crystals may be carried with the gas and they get stacked to the walls of the
saturator at the top. Then the hot water is sprayed to the rings provided. The crystals
attached to the walls of the saturator are washed away. When hot water is sprayed the
concentration of the liquor decreases. So inlet acid concentration is increases to 6-7% at
that period. After the reaction mother liquor is continuously drawn to the circulating tank
provided at the side of the saturator. This acts as a seal for the saturator. From the
circulating tank, mother liquor is fed to the mother liquor tank. The crystals collected at the
bottom are fed to the crystal receiver tank by using pump.

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. It is a hollow cylindrical vessel. The coke oven gas
from saturator enters tangentially to the trap. Due to the centrifugal motion, the acid mist
gets separated. The acid collected a the bottom is fed to the circulating tank. The CO gas is
fed to the Benzol recovery.

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.

CENTRIFUGE:

Centrifuge is a horizontal cylindrical structure having two drums inside it. One drum
moves with rotary motion and the other in reciprocating motion. The feed enters at the
center of the rotation drum through pipe known as cone pipe. Crystals present in the slurry
are separated by the centrifugal force of the rum. Hot water is sprayed into the centrifuge
to wash of the free acidity that is the acid layer on the crystal.
The cleaned crystal is discharged into the outer drum which is reciprocating. The
reciprocating drum pushes the material into the discharge chute. The liquor seper4ated is
then sent to the saturator. The discharge chute of crystals opens onto a conveyor.

DRIER:

Drier is fluidized bed type. The principle is based on the loose materials property to
acquire fluidity in the airflow under a definite air velocity. The crystal from the centrifuge
contains some amount of moisture. To remove this moisture crystals are to be dried. The
drier is provided with a screen at the bottom, ceramic rings are arranged at the bottom of
the screen. The drier is provided with forced draught fan and air, heated in the duct. A
spreader at the feed chute of the drier spreads the feed in all directions.
Forced draught fan sucks the atmospheric air and feeds to the drier. The
discharge chute of the fan is divided into 2 sections. One for hot air and the other for cold
air. The hot air duct is provided with a steam heater. The air is heated to 120-150°c by
using steam and this hot air is fed form the bottom of the screen. The ceramic rings
distribute the air in all directions and allow the crystals in fluidized state. The temperature
of the air is sufficient the moisture of the crystals. At the discharge end of the drier, cold air
is passed which cools the crystals.

When the pressure level of the fluidized bed reaches the set point (300-400
mmWc) an automatic discharge feeder discharge the dry ammonium sulphate to the bucket
elevator .The elevator discharges the dry product into the bunker, which in turn feeds the
product to the bagging machine. The zone above the fluidized bed is kept under 5-10
mmWc in order to avoid carryover of the ammonium sulphate particles out of the dr4ying
unit to the dust catcher.

CYCLONES:

The air form the drier is sucked by the suction fan and fed to the cyclone
separators. Cyclone separators separate fine ammonium sulphate crystals in the air and
feed to the bunker. The air from the cyclones is fed to the dust collecting tank which
contains flushing liquor up to certain level. The dust – laden air is then fed to the bottom of
the tank. The crystals then dissolved in the water and the air is vented into the atmosphere.

MOTHER LIQUOR TANK:

The excess liquor from the saturator enters the mother liquor tank. Each saturator
is provided with two mother liquor tanks. One is vertical and the other is horizontal. First
the liquor enters the horizontal tank. As the liquor has less density than the tar it floats.
Then the clear mother liquor from the bottom is fed to the vertical tank. Form the bottom
of the vertical tank mother liquor is fed to the saturator through the pumps provided. The
concentration of the liquor is maintained 10-12%. If the concentration decreases, the
density of the liquor decreases and it may be contaminated. Then crystals may become
back.

AMMONIA COLUMN:

During carbonization of coal ammonia gets vaporized and flows along with
flushing liquor in gas collecting mains, a little amount of ammonia gets absorbed in
flushing liquor. The excess ammonium liquor after separation of tar, containing free and
fixed ammonia, phenols, pyridine bases and cyanides, rodents are pumped to the fourth
plate of the ammonia column for distillation of free ammonia.
The column consists of 24 bubble cap trays. 40% of liquor level is maintained
in the column. Steam is injected at the bottom by steam coils. The purpose of steam is to
supply the necessary heat required for distillation. As the liquor is distilled, free ammonia
present in the flushing liquor evolves and rises tot the top of the column. The distilled
liquor from the bottom of the column is fed to the pitch tank. Certain level of the flushing
liquor is maintained in the tank and the over flow from the tank is fed to the M.B.C Plant
for treatment. The pH of the flushing liquor at the discharge end of the column should be
7-7.5 and the free ammonia should be less than 50 PPM.

(NH4)2S 2NH3 + H2S

 NH4CN NH3 + HCN

(NH4)2CO3 2NH3 + CO2 + H2O

NH4HCO3 NH3 + H2O + CO2

NH4HS NH3 + H2S

The ammonia vapors collected at the top of the column are fed before primary gas
coolers. The gases are not fed to the saturators directly as the temperature of the vapors is
high and secondly the vapors contains not only ammonia but also some traces of
rhodonides and cyanides. These chemicals should not be present in the ammonium
sulphate fertilizer. To remove some content of fixed ammonia in the liquor, dilute NaOH
solution is injected at the inlet of the ammonia column. The NaOH reacts with the fixed
ammonia compounds and forms as ammonia gas.

Capacity 25m3/hr
Total trays 24
Types of trays Bubble cap
Working pressure 0.5 atm
Steam pressure 6 atm
Flow rate of liquor 25m3/hr
Ammonia content before column 4 g/lit
Ammonia content after column 50 mg/lit
Temperature of vapors at outlet 105°c
Level in the column 40-50%
Steam flow rate 3-3.5 ton/hr
PH of liquor after column 7-7.5

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 50-60°c

Naphthalene in CO gas after FGC 0.4 g/Nm3
FGC tar temperature 80-90°c
Specific gravity of FGC tar moisture 5%

GAS PRE-COOLER:
The gas at 30-35°c is fed to the pre-cooler, which is indirect contact cooler.
The gas is cooled by chilled water (150°c), which passes through the tubes. The gas is
cooled to 25-27°c so that any particles condensed are received in the seal pot.

SCRUBBERS:
Scrubbers are long towers consisting of aluminum packing or wooden sheets
provided with three layers. The main draw back of wooden sheets is that it requires large
cross-section and more height, while aluminum is efficient. But the condensate should not
have muggy materials, which stick to the plates and scrubbing cannot be done efficiently.
The CO gas from the gas pre-coolers is sent to the first benzol scrubber at the
bottom. Solar oil or de-benzolised oil is used for scrubbing the gas to recover benzol.
Large amount of the benzol is absorbed in the first scrubber. At the bottom of the first
scrubber a certain level of benzolised oil is maintained. CO gas from the top of the first
scrubber is fed to the bottom of the second scrubber in which it comes to contact with fresh
de-benzolised oil, which removes the traces of benzol remaining in the gas. The benzol
free CO gas is sent to customers.

Capacity 58,000Nm3/hr
Oil flow rate 150m3/hr
Benzol content in gas after benzol scrubber 3 g/Nm3
Specific gravity of solar oil 0.8428
Molecular weight of solar oil 230
Flash point 132°c
Initial boiling point 270°c

OIL CYCLE:
The DBO from benzol distillation unit is fed to the top of the second scrubber.
Benzolised oil from the bottom of the second scrubber is pumped to the top of the first
scrubber through the distribution nozzles. The benzolised oil collected at the bottom of the
first scrubber is sent to the benzolised oil tank from where it is pumped to the benzol
distillation section.

COMPRESSOR HOUSE:
 Compressor house provided in the recovery plant is used to supply the plant
air and instrument air.

PROCESS:

Air from the atmosphere is fed to the suction side of the compressor through
filters for removing the dust particles.

COMPRESSOR:

Reciprocating compressors are used to compress the air up to 6 kg/cm 2. This is

double acting piston type, which consists of low-pressure side and high-pressure side. A
motor drives the compressor. An inter cooler is provided between the LP side and the HP
side. An after cooler is provided to cool the air.

Air initially fed to the low-pressure side where it is compressed to 2 kg/cm 2.

Due to compressor the temperature of the air is increases and it is cooled in the inter cooler.
This avoids decrease in the compression efficiency on the high-pressure side. Air is
compressed up to 6 kg/cm2 in the HP side. The compressed air is fed to the after cooler.
The purpose of this cooler is to remove the moisture in the air. The air from the after cooler
is fed to air receiving tanks. Air in the receiving tanks contain moisture and oil particles. So
this air cannot be used for instruments. This air is used for cooling and other purposes.

In the compression of air the lube oil is used for compressor bearings. In this
process, some oil is mixed with air. To remove this oil the air is fed to the oil filter. The air
is then fed to the coke filters where coke layers are placed. This removes moisture and dust
particles in the air. Then the air is fed to the dryers in which a bed of activated alumina is
placed. This eliminates complete moisture and from dryers the air is fed to the candy filters
in which very fine particles of moisture and dust is removed. Then the air is again fed to
the buffer vessels, which is an intermediate storage. The dried air is supplied to the
instruments and its pressure is in the range of 4 kg/cm2.
 MECHANICAL BIOLOGICAL AND CHEMICAL
TREATMENT PLANT
PROCESS:

Toxic effluents generated in various sections of coke oven and by-product

plant are collected and pumped to the treatment plant from two pump houses. One at
ammonium sulphate section and the other at tar distillation section. Excess flushing after
removal of ammonia in ammonium stripping unit is also fed to this treatment plant. The
combined effluent contains large amount of tar and oils and toxicants like phenol, cyanide,
thiocyanides etc.

The effluent plant is designed to remove tar and oils with the help of
mechanical separation methods followed by biological treatment at effluent namely two
stage activated sludge process to remove other toxicants.

Phenolic effluent from two phenolic water pump houses located in CO & CCP
are directly fed to pre-aerators of tar settling plants. Excess flushing liquor ammonia
stripping is also pumped to the same pre-aerators to the double pipe heat exchangers where
it is cooled from 90°c with the help of recalculating cooling water. Water inlet temperature
is 34°c and outlet temperature is 45°c. Mixed effluent at a temperature of about 50°c is
distributed in equal positions in tar settling tanks by gravity. In pre-aerators effluent mixed
thoroughly with the help of air. The tar settling tanks are provided with steam heating coil
and scrapper mechanism at the conical hopper bottom. Tar collected at the bottom of each
tank is pumped out in the tar collecting tanks ones in 3-5 days time. Tar settling tanks are
provided for removing tar and oil form the effluents. Oil floated on the surface of water
and tar settles down in the conical bottom. Floated oil removed with the help of scrapping
device and flows to oil collecting tanks by gravity.

Over flow from the tar settling tank is collected in vertical steel tanks named
phenolic water collecting tanks from where it is pumped to the oil flotation tank through
pressurized head tank. Air (5% by volume of water) is injected in the suction line of the
pumps before it is pumped to the pressures tank. In the flotation tank air bubbles through
the water as the water is depressurized and the oil is entrained by air bubbles and floats at
the water surface. The entrained oil is skimmed with oil skimmer mechanism of the
flotation tanks and collected to the oil discharge to a tank called tar and oil collecting tank.
After oil flotation tank, water goes to the second phenolic water collecting tank, with the
help of pump collected water is send to second flotation tank to pressurized tank. Tar and
oil from the collecting tank are finally pumped to tar acid utilization plant.

After removal of tar and oil the effluent is collected in averaging tank. The
averaging tank consists of two chambers and each chamber is having one over flow tank.
In this tank adding ortho phosphoric acid and bacteria nutrient. 73% strong ortho
phosphoric acid at the rate of 20 g/m 3 of water to be purified. From these tanks effluent is
pumped to aeration tank of first stage purification through shell and tube heat exchangers
to maintain effluent temperature between 35-38°c. Cold circulating water is used for this
purpose. In this first stage purification is done with the help of phenol destruction bacteria.
To maintain their vital activity, compressed air from the air blower is applied to the
aeration tank.

Phenolic water after the first stage of purification is collected in a tank from
where it is pumped to aeration tank of second stage purification. In second stage of
purification rodents and cyanides are destroyed with the help of rodents destructing
bacteria. With each aeration tank (both 1 & 2 stage) of purification sludge settling tank
regeneration are attached. The over flow from each tank first goes to the settling tank
where sludge settles down and the super latent water overflows to the collecting of first
stage purified water collecting tank.

The settled sludge then flows to the attached regeneration from where it is
recycled back to the aeration tanks with the help of air lifting pump. Volumetric flow rate
of sludge in each tank it’s about 80% of the volumetric flow rate of water being purified, to
treatment unit for further treatment. Inlet to the treatment plant as well as excess sludge is
taken from the bottom of the settling tank and taken to sludge disposal facilities having
sludge-drying beds. Treatment effluent from the second stage of purification is collected on
a tank from where it is pumped to fecal sewage treatment plant for further treatment and
dilution. Further culture of bacteria their accumulation two separate bacteria culture tanks
requisite facilities are also provided which can be utilized and when required.

Two MS tanks each of capacity 800m3 are provided as balancing tanks. Water
can be pumped from any of the equipment, provision is there to take this water back
treated water from the collecting tank after second of purification can also be directed to a
balancing tanks.
 TAR DISTILLATION PLANT

Tar is a viscous fraction obtained by the cooling of coke oven gas with
ammonia liquor. During this cooling coke dust particles mixed with liquor and forms coal
tar. 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 0.5%

Phenol fraction 1-1.5%
Naphthalene 5-6%
Wash oil 8-9%
Anthracene oil 18-19%
Moistur4e 5-6%
Pi3tch 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 from the TOS 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 that soda ash solution of 8% concentration
is injected at the suction side of the pumps.

2NH4Cl + Na2CO3 ---------- 2NaCl + 2NH3 + CO2 + H2O

2HCl + Na2CO3 ---------- 2NaCl + H2O + 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 120-130°c. 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 400°c. The temperature of
the tar should not increase beyond 400°c 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 120-130°c. 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 0.3 kg/cm2

Temperatures of vapors 102-105°c
Temperature of DTT <110°c
Baffle plates 3
Spilling plates 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 380-400°c.
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 0.5 kg/cm2

Number of bubble cap trays 4
No. of baffle plates 7
Temperature of the fractions 400°c

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
360-380°c.
As the vapors rises to the top of the column different fractions are obtained
from different trays. Initially vapors enter at about 360-400°c. 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 100°c. 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 160-180°c. 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 190-200°c. 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 280-290°c. 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 320-330°c.

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 102-50°c. The vapors of second stage coolers from 100-40°c. 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 at 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 80-50°c are sent to the collected tanks.

START UP TANK:
During initial starting of the plant, the temperature of the tar does not reach up
400°c in second stage evaporator will be diverted to start up tank until it reaches the
temperature of 290°c similarly column bottom liquid will also be diverted to start up tank
until the temperature of the column reaches to 330°c. Tar then overflows to the decanters.

USES OF DIFFERENT TAR FRACTIONS:

LIGHT OIL:
It can be further processed to produce crude tar basis can be used to prepar4e
pyridine and heavy basis. Light oil can be fractionized to produce small amounts of
benzene, toluene, xylene and heavy solvent naphtha.

PHENOL:
 It is mainly used in plastic industry.
 In thermosetting resins made with formaldehyde.
 In pesticides preparation.
 Insecticides and pharmaceuticals.
 Dye stuffs and carpolactum for fibers.

NAPHTHALENE:
 Used in manufacturing of pthallic anhydride.

ANTHRACENE:
 It is purified to produce pure anthracene.
 It is used to produce carbozole and phenanthracene.

PITCH:
 Pitch cake.
  Industrial pitches.
 Road tar.
 Refined tar.

PARAMETERS:

TEMPERATURES:

Tar in decanters 75-80°c

Tar after first stage furnace 120-130°c
Tar after DTT 100°c
Vapors from first stage evaporator 105-110°c
Tar after II stage furnace 380-400°c
Vapors after II stage evaporator’s 300-330°c
Pitch after II stage evaporator 330-350°c
Distillation column top temperature 100°c

FLOW:

Tar in first stage 9-10 Nm3/hr

Tar in second stage 10 Nm3/hr

ANALYSIS:

Water content in I stage tar 5-6%

Water content in II stage tar <1%

PRESSURES:

Tar after I stage pump 2.3 kg/cm2

Tars after II stage pump 4.5 kg/cm2
CO gas before furnace >100 mm WC
I stage evaporator top 0.14-0.5 kg/cm2
I stage evaporator bottom 0.24-0.25 kg/cm2
II stage evaporator top 0.35 kg/cm2
II stage evaporator bottom 0.4 kg/cm2
Distillation column top 0.04-0.06 kg/cm2
Distillation column bottom 0.28-0.3 kg/cm2
 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 by gravity
mainly produces.

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.

PITCH CRESOTE MIXTURE:

The pitch from TDS is stored in the storage tanks. The softening point of this
pitch is about 65-70°c. Anthracene oil, wash oil and pitch are mixed in respective
proportions in PCM tanks. Initially, anthracene and wash oil are mixed in 1:1 ratio. The
tank is filled up to 1.8m with this mixture and the soft pitch is filled up to 4m heights. Then
the mixture is allowed to mix properly by keeping in continuous circulation through a
pump from bottom. This PCM is used as fuel in CRMP section, which produces refraction
bricks in VSP.

MEDIUM HARD PITCH:

The softening point of the soft pitch is 65-70°c. To increase the softening point
of the pitch up to 95-110°c the pitch is fed to a series of reactors.

REACTORS:

Reactors are cylindrical vessels with conical bottom. A bubbler is provided

inside, which is fed with air at a pressure of 5 kg/cm 2. An outlet provided at the top
removes the air injected. A cylindrical small vessel on the top of the reactor is provided
with baffles to remove any heavier particles present in the vapors. The vapors mainly
contain anthracene and wash oil fractions.

PROCESS:
 Initially the pitch at 360°c from TDS is fed to the middle of the first reactor.
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. The overflow from

the first reactor is fed to the second and similarly to the third. Aeration is done in all the
three reactors to increase the softening point up to 110 °c depending on the requirement.
Airflow to all the reactors increases up to 400°c. The MH pitch after obtaining the required
softening point is fed from the third reactor to electrode pitch tank. From ETP the tar is
pumped to the overhead tanks. All the ETP and overhead tanks are provided with steam
coils to keep the pitch in liquid state. The pitch from overhead tanks is pumped to the bay,
which is a large rectangular area where the pitch is allowed for atmospheric cooling. After
complete cooling the pitch in small pieces is packed in bags.
The vapors from all the reactors and storage tanks contain some entrained oil
particles. The vapors are first condensed in a shell and tube heat exchangers (water in tubes
and vapors on shell side). The condensed vapors are sent to the washer. In the washer, the
vapors are scrubbed with the light oils. The condensate collected called pitch distillates are
fed to the pitch distillate tank. The washer is provided with steam jet ejector at the top to
draw the oil free vapors and is let out to the atmosphere.

CHEMICAL PROCESS DURING ARERATION:

Pitch is a mixture of high polymers, straight chain organic compounds and oils.
Due to aeration and effective mixing in the reactor, the polymer oil bond breaks and resin
bonds progressively increase causing softening point elevation. Due to effective agitation,
new polymeric bonds formation and bond breakage large amount of heat is evolved. This
increase in temperature leads to the formation of optically sensitive isomers i.e. optical
isomers; which causes the pitch increase in optical activity. The increase in aeration in the
reactor increases the softening point of pitch to required levels and increases the porosity,
which will effective the strength and binding properties of the pitch. The aluminum
industries require various concentration of resin in the pitch, which plays main part in the
bonding property of pitch. Quinilene insoluble and benzene insoluble determine this.

BF GRADE PITCH:

BF grade pitch is used for preparation of BF mass for Blast Furnace tapping.
This requires high softening point of 170-180°c. So it is prepared separately in fourth
reactor. Initially, pitch from TDS is charged for three and a half hours and air is injected
through bubbler at the rate of 150 Nm3/hr for 10-12 hours. After softening point is attained
to the bay by gravity for cooling purpose.

PARAMETERS:

Pressure Temperature Air flow

(mm HG) (°C) (Nm3/hr)

Reactor 1 300 325 50

Reactor 2 310 330 80
Reactor 3 320 340 120
Reactor 4 ---- 280-330 150

NAPHTHALENE FRACTION CRYSTALLIZATION

Naphthalene fraction obtai3ned from the distillation column is 75-80% pure.

This is purified up to 99% in NAFC section. Crystallizing out naphthalene from the melt
obtained from TDP does this purification.

PROCESS:

Naphthalene oil from tar distillation plant at 70-80°C is pumped to the overhead
tanks of the NAFC section. The tanks are provided with steam coils. The temperature of
the naphthalene oil is maintained at 85-90°C. One tank receives oil from TDS and the other
from melting pot. The naphthalene oil is then fed to the drum crystallizer.

DRUM CRYSTALLIZER:

Drum crystallizer is a hallow cylinder with ribbed surface over its entire
perimeter. The drum is rotated at a rpm of 0.3 by an electric motor and reducer. The
rotating drum is partially submerged in oil bath. Two jackets are provided at the bottom of
the drum one for naphthalene oil and the other for hot water. The oil form the over head
tank is fed to the oil jacket. Hot water is circulated under the oil jacket to prevent the
solidification of naphthalene. Inlet and outlet to the service water is provided to the side of
the drum.
Service water is circulated inside the drum to cool the naphthalene layer formed
on the surface of the drum. Knifes are provided on the surface of the drum to cut the layer
formed on the drum. The flakes are then collected in a screw conveyor and fed to the press
mixer.

Capacity 25 T/hr4 of fr4action

Rotation per minute 0.3
Temperature of hot water in jacket 90-100°c
Cooling water temperature 18-20°c
Temperature of fraction in bath 80-90°c
Naphthalene temperature 60°c

HYDRAULIC PRESS:

It consists of a mixer and a press. Flakes from the conveyor are fed to the
mixer in which agitator mixes the crystals homogeneously. The temperature in the mixer is
maintained at 60-65°c by circulating hot water in the jacket.
PRESS:

It consists of three filters mounted in a rotary table. This system is operated by

hydraulic pressure at a pressure of 160 kg/cm 2. Oil is compressed and fed to different parts
of the press. The press consists of squeezing device, pushing device and table stopper.
Squeezing device is provided with shift to compress the naphthalene into a cake. The
filters are at an angle of 120 ° to each other. The naphthalene mass from the mixer is fed to
the filter through the charging neck of the mixer the press is operated by six operations.

CLAMPING:

The filter coincides with the axis of charging neck of the mixer. The mixer
discharges the feed into the filter. Then the table rotates.

SQUEEZING OR PRESSING:

After clamping the filter moves to the squeezing device. The squeezing device
consists of two cylinders, which compresses from top and bottom with 160-180 kg/cm 2
pressure. The oil present in the cake will be separated from the holes provided in the filter.
This is collected at the bottom. Then the cake is formed.

PUSHOUT:
This operation is done after squeezing. a cylinder from the bottom of the filter
lifts the cake forward up.

PUSH OFF:
An arm like device pushes the cake into a chute. At this position, the lifted
cylinder is in the same position. Push out and push off operations is done in the third
position of the filter.

RETURN STROKE:
In this operation all the cylinders return to their original position.

TABLE ROTATION:
After all the cylinders reach to their original positions, the table rotates so that
the filter again comes to the first position i.e. charging position. All these operations are
done automatically by gear mechanism. The temperature inside the filter is maintained by
supplying steam. All these six operations are completed in three & a half minutes.
The naphthalene cakes formed are conveyed to the jaw crushers. The weight of
the cake form is about 40 kgs and 98% pur4e. The jaw crusher crushes the cakes and the
crusher pieces are conveyed to the bagging machine through a chain conveyor.
Naphthalene bags weighting 50kg each are stored in the godow.

PRESSED OIL:

The oil separated from the filter is further processed to recover naphthalene
present in the oil as the oil contains 60-65% naphthalene. This pressed oil collected in the
ground floor is pumped to the overhead tank. This oil is processed in mechanical
crystallizes.

MECHANICAL CRYSTALLIZERS:

These are horizontal cylindrical vessels with the shaft running through the
crystallizer. The shaft is a propeller type agitator, which is fixed with a number of vanes.
The shaft is run by a motor, which connected by a gearbox. There is a provision for
spraying of water on the drum. The water is collected in the water jacket under the drum.
The de-naphthalene oil from the overhead tank is fed to the mechanical
crystallizer. Half of the volume of the crystallizer is fed with the DN oil. Due to slow and
continuous agitation of the shaft, high retention time and slow cooling the oil in the
crystallizer thickness. Small nucleuses of the crystals are formed and the oil forms as the
slurry. Constant agitation of the melt results in the breakage of weak small crystals
originally formed which then act as nucleus to new crystals. Cooling is done by natural
convention by atmosphere for 16 hours. After 16 hours of atmospheric cooling, 8 hours
water-cooling is done by spraying water on the drum. After the completion of
crystallization, the valve open and the slurry is transferred to mixer through screw
conveyor.

MIXER:

The slurry enters into the mixer through a filter, which filters any suspended
particles in the slurry. Mixer is a horizontal cylindrical drum provided with agitator. Mixer
acts as a storage drum as well as maintains the uniform mixture by agitating the slurry.
Then the slurry flows by gravity to the centrifuge by controlling the valve.

CENTRIFUGE:

The centrifuge used in the NAFC is of basket type. It is a batch wise centrifuge
operating at a rate of 400 liters of naphthalene slurry per batch. The retention time of each
is 2 minutes. The centrifuge consists of a basket rotated by a motor. Feed enters through a
feed chute, which aids provided with an automatic valve. There is a knife arrangement,
which collects the naphthalene powder into a basket type chute. The slurry is discharged
from the rotating basket tangentially through the holes arranged. The centrifuge does three
operations.

CHARGING:
 During this period (20seconds) the material is fed into the basket after a flow
rate of 400 liters, the valve is closed.

DRYING:

The power is separated from the slurry and the basket is rotated without slurry
for about 1 minute. The naphthalene powder is allowed to dry during this period.

DISCHARGE:

After the material is dried, the knife collects all the powder into a chute that is
fixed to the door.
The oil separated contains 40-60% of naphthalene. The soil is again recycled
till its concentration reaches below 30%. After this DB oil is pumped to the tar and oil
storage section. The naphthalene powder so obtained is about 98-99% pure and this fed to
the melting pot through a belt conveyor.

MELTING POT:

This is a horizontal cylindrical drum, which consist of steam coils inside it. LP
steam is circulated in these coils. The naphthalene powder gets melted due to high
temperature and the liquid thus obtained is fed to the main naphthalene friction overhead
tank to increase the purity of the naphthalene oil coming from the distillation section.
 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. This DBO is again pumped to the
benzol recovery section. Makeup solar oil is added continuously to compensate for the
losses in the equipment. The benzolised oil is initially pre-heated in three pre-heaters,
which are shell and tube heat exchangers. Pre heating is first done in oil dephelegmators,
then oil-oil heat exchanger and finally in steam pre heaters. The temperature is slowly in
order to prevent chemical decomposition of benziolised oil. The temperature of the BO fed
to the stripping column is about 130-135˚c.

Tube side Shell side

Oil dephlegmator vapors of stripping column BO
Oil-oil exchangers DBO from stripping column BO
Steam pre-heaters medium pressure steam BO

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 180°c 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 crude benzol vapors along with
steam from the top of the column are fed to the oil dephlegrmators. The DBO from the
bottom in which crude benzol is recovered is pumped to the decanter through oil-oil heat
exchangers.
 The crude benzol vapors are partially condensed in the oil dephlegmator.
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 92-95°c 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. This polymer must be removed from the DBO by regeneration. Regeneration is a
hollow tank in which steam coils are arranged MP steam is circulated through these coils.
Part of the stripping column is fed to the regenerator. Due to the pressure CB vapors are
collected at the top, which are in turn to the stripping column. The bottom liquid from the
regenerator is pumped out and stored in Crude and Finished Product Storage.

Top temperature 110-115°c

Bottom temperature 120-130°c
No. of trays 23
Feed tray 17 th tray
Pressure in the column 0.3-0.35

CRUDE BENZOL COLUMN I:

The vapors containing crude benzol from the top of the stripping column is fed
to the crude benzol column I through water dephlegmator where 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.

A CB vapor at a temperature of 80-85°c is fed to the 6 th tray of the column.

The lighter components are vaporized and these are collected at top of the column, which
are then condensed in a condenser by water. The condensed vapors are then fed to the
separator where the moisture present in the vapors is separated and the LCB obtained is
stored in CB1 tanks. Part of the LCB is fed as reflux to the CB1 column. The bottom
product obtained from CB1 column is fed to the CB II.
 Top temperature 70-80°c
Bottom temperature 115-120°c

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. The LCB vapors obtained from the top of CB II is fed to
the CB I column as reflux. The bottom product obtained from the CB II is called as Heavy
Crude Benzol (HCB).

Top temperature 120°C

Bottom temperature 140°C

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 45-50°C. Due to high
temperature exposure, part of the solar oil may get decomposed. This decreases the
absorption efficiency of the solar oil. To remove this decomposed matter DBO is fed to the
decanter.

DECANTER:

It is a horizontal cylindrical tank unlike mechanical decanters DBO is fed to

the decanter at a temperature of 45-50°C. 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. The residence time in the decanter is three to four hours. Water is
continuously drained from the decanter. Oil after 3-4 hours is fed to the DBO tank. Muck
from the decanter is drained and sent to the emulsion beaker. Due to contact of oil, water
and muck oil-water emulsions and muck-water emulsions are formed. These emulsions
float on the surface of the water, which is fed to the emulsion beaker along with muck.

EMULSION BEAKER:

This is a horizontal cylindrical vessel provided with insulation. Medium

pressure steam is fed through a coil into the beaker. Residence time for setting the oil,
muck and water in the beaker is 2 hours. Due to heating of emulsion, oil and water get
separated which is called as De-emulsification. Emulsion thus formed is broken and muck
will float on water. This muck is fed to the muck tank and the water is drained. The
temperature inside the beaker is 80-90°C.
 HYDRO REFINING & EXTRACTIVE DISTILLATION
In this unit using hydrogen gas purifies the light crude benzol. Hydrogen is
recovered from coke oven gas and LCB from benzol distillation plant.
LCB consists of benzene, toluene, xylene, solvent naphtha, non-aromatics and
residue. Initially, the LCB is purified from sulphur, non-aromatics and other compounds.
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. LCB from the storage tank is pumped to a surge
tank, which is meant for intermediate storage. The LCB from surge tank is pumped to
the distillation column through feed pre-heater. The feed enters the column at a rate of
3 T/hr and at 70°c. Pressure in the column will be 0.5 kg/cm 2. Sulphur content in the
feed is 2000-1800 ppm. This is decreased to about 1200 ppm in the column.

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. The remaining bottom called de-fronted crude benzol is fed to the reaction
section through feed pre-heater. The sulphur is removed in the form of CS 2. Simple
distillation is carried out and due to heating CS 2 vapors rise in the top and these are
condensed in a water condenser. Condensed CS2 is collected in CS2 vaporizer. Part of it
is fed to the column as reflux and the other part is stored. The DCB obtained is at 70°c
and this is fed to the intermediate storage.

Feed rate to the column 3T/hr

Pressure in the column 0.5 kg/cm2
Sulphur content in the feed 2000-1800 ppm
Sulphur content in DCB 1200 ppm
No. of bubble cap trays 30
Boiling point of CS2 45
Temperature at the top of the column 55-65°c
Column bottom temperature 105°c.

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.

PROCESS:

The de-fronted crude benzol is pumped to the de-fronted storage tank (V-401) through
a filter. The filter is provided to remove the solid particles and polymers, which may be
present in the crude benzol. The benzol filter is an edge type filter and consists of a slotted
tube inside a shell with a specified filter fineness, which is determined by the slots and
scrappers. This is agitated by a hard crank.

The particles are retained at the edges of the slots and must be scrapped off. If the pressure
difference between the inlet and the outlet streams is too high the concerned filter must be
opened and cleaned. The filtered DCB is stored in the surge drum (V-401). The drum is set
to approximately two bars split range controlled by feeding N2and venting gases. From
surge drum, the DCB is fed to pre-vaporizer at a pressure of 30 bars using 32 stage
centrifugal pumps.

PRE-VAPORIZER:

It is nothing but a vertically mounted shell and tube heat exchanger. The feed is
mixed with a part of cycle gas (containing H2 approximately 15% of the total gas) before it
is fed to the vaporizer. This feed is pre-vaporized to about 160-165°C by means of the
main reactor effluent passing through shell side. The feed at a temperature of 160-165°C
is fed to the third mixing nozzle of stage evaporator.

This vertical heat exchanger is provided with turbulence promoters in the tube
side to achieve high turbulence so that more heat exchange will occur and no scale
formation is attained. This arrangement is provided as the feedstock is in partial vapor
stage (gas-liquid stage) and so fouling of the tubes will occur rapidly. This arrangement
also provides easy cleaning of tubes by simply pulling the turbulence promoters.

STAGE EVAPORATOR:

The stage evaporator is a long cylindrical vessel provided with three stages,
which are separated by two plates. Demister pads are provided at the top of the evaporator.
Each stage is provided with a mixing nozzle. Two reboiler E-402 and E-403 are provided
for second and first stage respectively. A gas pre-heater E-404 is also provided in which the
rectangle gas (85% of the total gas) is pre-heated to 210°C by the main reactor effluent. E-
402 and E-403 are heated by hot oil through tubes at a temperature of 250°C. Rectangle
gas mixed with feed is passed through the shell side.
Down comers are placed so that the liquid in the third stage will enter the
second and from second to first. Pressure inside is about 20kg/cmm.
 The DCB mixed with 15% of rectangle gas is fed at the third mixing nozzle of
the evaporator. The vapors coming from the second stage and the feed are mixed
thoroughly and fed to the third stage. Lighter vapors are passed through the demister pads
and to the pre-reactor. The liquid containing lighter and heavier substance is passed

through down comers to the second stage. Here the fed is mixed with the vapors from first
stage in the mixing nozzle II and heated in reboiler E-402. This is fed to the top of the
second stage.
Similarly liquid from second stage flows to first stage. This liquid is pre-heated
in E-403 and mixed with 85% of the rectangle gas in first mixing nozzle and again fed to
the first stage. The temperature at the bottom of the evaporator is 210°C. Due to heating of
the feed the vapors are sent to the top and any residue or polymers in the feed are collected
at the bottom. Part of the liquid from the first stage is fed to the residue flash drum (V-406)
from where they are recycled to benzol distillation plant. The lighter vapors from the flash
drum are fed to the surge drum (V-401) nearly this residue would be 3-4% if total feed.
The vaporization of feed (DCB) in the evaporator is done by reduction of
partial pressure of DCB, which is manipulated by addition of the rectangle gas. This results
in lower operating temperature even at higher pressures. Vaporization of feed in heat
exchanger should be avoided to reduce fouling of surfaces.

PRE-REACTOR:

The vapors from the top of the evaporator at 180°C are heated in a heat exchanger
E-406 to 190-225°C by passing main reactor effluent through shell side. The reactor is
provided with a bed of catalyst i.e. NICKEL MOLYBDEBUM. In this pre-reactor such as
diolefins, styrene and CS2 are removed by hydrogenation. Feed enters from the bottom of
the reactors through catalyst bed. Hydrogenation of diolefins, styrene takes place in the
presence of catalyst.
The temperature at the inlet of the reactor is 190-225°C and this depends on the
life cycle of the catalyst. Due to the exothermic reaction the outlet temperatures increases
to 200-235°C. Due to continuous operation of the catalyst bed coke like polymerization
products deposit on the catalyst bed resulting in the lower efficiency. This can be overcome
by increasing the inlet temperature of the reactor. Catalyst activity can be determined by
the temperature difference between inlet and outlet, which should be more than 10°C.
Catalyst can be regenerated by heating the bed with steam and air. The reactions in the pre-
reactor are

Diolefins + H2 mono olefins

CnH2n-2 CnH2n

Cyclopentadiene + H2 cyclopentane
C5H6 C5H8

Styrene + H2 ethyl benzene

C8H8 C9H10
 Carbon disulphide + H2 methane + H2S
CS2 CH4

MAIN REACTOR:

In main reactor treated pre-reactor effluent is hydrogenated on special sulphide

molybdenum catalyst. The main reactor consists of two beds of catalyst makeup gas i.e.
pure H2 gas from the compressor at pressure of 18 bars provided more hydrogenation and
hence complete saturation of olefin hydrocarbons. The inlet temperature is about 270°C
and the outlet temperature is 330°C due to exothermic reaction. Mainly desulphurization,
densification and olefin saturation feed stock occurs in main reactor. The hydrogen is fed
through a distributor below first bed of catalyst oxygen content in H 2 gas should be very
low so that no polymerization occurs in the reactor. Hydrogenation of aromatics should be
prevented. Catalyst deactivation can be determined by the amount of thyophene content at
the outlet of the reactor. If this increases hydrogenation of aromatics, coke formation
increases. So the temperature of the reactor should be increased or other regenerations
should be done.

Main reactions are:

Mono olefins + H2 Paraffin

Ethyl mercaptans + H2 Ethane + H2S
Thyopene + H2 Butane + H2S
Coumarone + H2 Ethyl benzene + H2
Pyridine + H2 Pentene + H2
Pyridine + H2 Butane + H2
Benzene + H2 Cyclohexane
Toluene + H2 Methyl cyclo hexane

Hence required to maintain a heater to which part of the effluent is passed,

Heated and fed to the main reactor supplies the temperature. Coke oven gas is used as fuel
in the heater.
The effluent from the main reactor collected at the bottom, which is at 330 оc.
This effluent is passed through E-407, E-406, E-404, E-401 and finally cooled in water
cooler E-408. This condenser effluent is fed to the separator. Before water cooler hot water
is dosed into the effluent. This dissolves the deposits of salts such as NH 4HS2 and NH4Cl.
The cooled effluent at 50 оc is fed to the separator. A water leg provided separates the dosed
water. The water free effluent is fed to the stripping column. The gases i.e. un reacted
hydrogen gas and other gasses are sucked by recycle gas compressor and are recycled part
of the gas is purged out through vent provided.

HOT OIL SYSTEM:

 The heat demand of the process is supplied by a separate hot oil system. The
hot oil is used as a heating medium for several heat exchangers in hydro refining unit and
extractive distillation unit. A horizontal furnace is used to heat the oil; the furnace is fired
using coke oven gas. Hot oil is pumped in to the coils into the furnace. The temperature of
the oil increases to about 340-350 оc. The hot oil is pumped by P-404 pump. The oil at
temperature of 340 оc is fed to the HR unit by using another pump. This is again recycled to
the suction side of P-404.

PRESSURE SWING ADSORPTION UNIT:

The required hydrogen gas to HR units is supplied from this section. The clean
coke oven gas after benzol recovery is fed to a filter at a pressure of 800mm WC. Moisture
and carbon particles present in the gas are filtered and the filtered coke oven gas is fed to a
reciprocating compressor, which compresses the gas to about 2.5 kg/cm2. The compressed
gas is again fed to the other compressor where the pressure of the gas increases to 6.5
kg/cm2. The gas is then fed to another filter, which removes the moisture in the gas. From
the filter the gas is fed to the pressure swing adsorption unit. It consists of 4 cylindrical
vessels in a bed of molecular sieves is placed. The coke oven gas is passed form the bottom
of the bed and the molecular sieves absorb the hydrogen present in the gas. The hydrogen
thus collected is fed to the make up gas compressor. The gas is passed through one catalyst
bed only. At this time, the remaining beds are in regeneration. This is because catalyst for
180 seconds only. Then it has to be regenerated. This is done by using pure H 2 gas. The
regeneration of then bed is done automatically.

The H2 gas is collected form the top of the bed and is fed to the make up gas
compressor. This is a vertical reciprocating compressor of double stage. The H2 gas is
compressed to about 30 bar. The recycle gas from the gas separator is fed to the recycle gas
compressor, which is a horizontal single stage compressor.

PURIFICATION:

This section consists of a stripping column in which the sulphur content as H 2S

and any dissolved gases in the DCB are removed.

PROCESS:

The liquid part from the separator is fed to the stripping column through a pre-
heater, which is heated by BTX solvent from the stripping column. The fed at a
temperature of 135 оc is fed to the column. The column consists of sieve trays. Top
temperature is 125-135 оc and bottom temperature is 150 оc. Pressure is about 4.3 kg/cm 2.
Re boiler is provided which supplies the required heat to the column. MP steam is fed to
the shell side of the re boiler. The gas from the column contains H 2S. These are condensed
in the condenser where water issued. This condensate (70 оc) is fed to the reflux drum. Part
of the condensate is refluxed to the column. Moisture present in the gas is removed from
the water leg and the off gasses are fed to the off gas mains.
 The bottom product called BTX solvent raffinate is passed through the pre
heater where it is cooled and finally raffinate is cooled in the raffinate cooler which is
cooled by water. This is stored in intermediate storage.

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

PRESSURE DISTILLATION SECTION:

This section consists of a distillation column in which the BT & X solvent are
separated by simple distillation from reffinate.

PROCESS:

The BTX solvents raffinate from the IPS is pumped to the feed surge drum (V-513).
The drum is a horizontal tank provided with a vane and line from reflux drum (V-501) that
carries vapors to this drum. The BTX solvents raffinate from the surge drum is pumped to
pressure distillation column through four heat exchangers I series E-502, E-503, E-504 &
E-505respectively. E-502 and E-505 are heated by bottom product i.e. Xs fraction. E-503
and E-504 are heated by BT fraction. The column consists of 50 bubble cap trays of which
25th trays is the feed tray. Column pressure is about 15 kg/cm2.

A re boiler is provided to the column through which hot oil passes through shell
side. These supplies the heat required for the column. The BT vapors from the top of the
column a collected in reflux drum before which they are condensed in E-504 and E-509.
This condensed BT fraction is collected in reflux drum. Some of it is reflux to the column
and the remaining is passed to E-503 and cooled in BT condensed in E-501 by using water.

EXTRACTIVE DISTILLATION COLUMN (C502):

The BT surplus is conveyed by steam pressure from V-501 via heat exchangerE-
503 and cooler E-501 as feed to extractive distillation column C-502. The feed is
introduced on the 31st tray at the middle of the column. The N-formylropholine (NFM)
solvent is introduced on the top tray of the ED Column at the physically required
conditions at the flow ratio of 56 kg NFM per kg of feed at 92оc. The NFM temperature is
regulated for the achievement of the low level of aromatics in the non-aromatics.
ED column serves for the separation of non-aromatics 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.
ED column is supplied by the reboiler E-507 (LP Steam), E-508 (Hot NFM) and
partially via vapor heated reboiler E-509. The NFM at the top of the column promotes the
scrubbing of aromatics out of ascending vapors; where as non –aromatic vapors are
dissolved only to a slight extent.

ED column trays 60-bubble cap

Feed plate 31 tray
Top temperature 110оc
Bottom temperature 150 оc
Top pressure 0.8kg/cm2
Bottom pressure 0.4kg/cm2

SOLVENT RECOVERY COLUMN:

The column is used for separation of non- aromatics yielded at the top of ED
column from the residual carried over solvent contents. For this purpose the top vapor of
the ED column are fed at the point below at the pall rings packing in the column. Bottom
heating to the column is affected using reboilerE-510, also by means of hot NFM from the
solvent circulation. The top phase in the column, consisting principally of non-aromatics is
condensed in condenser E-511 and the liquid phase yielded is routed to the reflux vessel V-
502. A portion of the non-aromatics is routed as reflux to the column. While bottom
product is discharged through a level controller to CFPS.
NFM recovered at the bottom of the column is returned to the ED column. The
solvent recovery column minimizes the NFM losses by means of extensive recalculation of
NFM flow inevitably leaving the top of the extraction column. The basic difference as
compared to the normal hydrocarbon distillation and ED column is that its bottom section
must be operated in the phase occurs in V-509. The bottom contains large quantities of
non-aromatics due to the reflux required for scrubbing. In contrast to an ED column, the
recovery column is operated under normal circumstances with a two-phase bottom product.

Packing Pall rings

 Bottom pressure 0.25 kg/cm2
Top pressure 0.2 kg/cm2
Top temperature 100оc
Bottom temperature 125 оc

STRIPPING COLUMN:

The product yielded at the bottom of the ED column consists of NFM in which the
extracted aromatic substances are dissolved. The non-aromatic content will be in low PPM
due to the existing pressure drop. This flow is conveyed into the aromatics column, which
is operated under vacuum. In this column the pure aromatics are separated from the NFM,
which is yielded as the bottom product and cooled in the heat exchanger system of the
equipment prior to be being returned to the ED column.

Before feeding NFM to the ED column, it is passed through the following equipment:

1. Center re boiler E-508 on ED column C-502.

2. Re boiler E-512 on solvent recovery column.
3. NFM re boiler E-514 on the stripper column
and then fed to the ED column.
Solvent cooler E-522 serves as a trim cooler for NFM. The bottom of the stripper
column is heated by means of the two continuous re boilers E-512 and E-513, which are
heated by BT vapors and E-514 heated by means of NFM.
The reflux to the stripping column serves to remove the solvent in the lower section
of the column. The vapor liquid mixture discharges from the re boiler E-514 is fed below
the chimney tray in the stripping column. Traces of the solvent flash are washed back by
the aromatics reflux and directed into the lower part of the column.

Total trays 30
Feed tray 5 th
Top temperature 56 оc
Bottom temperature 119 оc
Pressure 0.36-kg/cm3 vacuums

BENZENE TOLUENE SEPERATION COLUMN:

BT separator is a normal two-phase distillation for pure aromatics. The BT fraction
is routed using a reflux pump from reflux drum via exchanger E-517 to separation column
C-505. The heat required for distillation is supplied to the system via re boilers E-518 by
means of LP steam. Overheads are pure benzene, bottom are pure toluene as specified.

Total trays 65 Bubble cap

Feed tray 30 th
Pressure 1.2 bars
Benzene purity 99.97%
Toluene purity 99.95%