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ON

COAL CHEMICAL PLANT


(OBJECTIVES)
To clean Coke Oven Gas for using it as fuel
for heating Coke Oven Batteries and for
other consumers.
COAL CHEMICAL PLANT
(CLEANING PROCESS)
Co-gas coming out of Batteries has Tar,
Ammonia,Crude Benzol and gas rich in
Hydrogen and methane. The Tar ,Ammonia
and Crude Benzol is removed from Co-gas
before it is used as fuel in batteries.
COAL CHEMICAL PLANT
(CLEANING PROCESS- WHERE & HOW)
The Tar, ammonia and crude benzol is removed in Gas
Cleaning Plant (RECOVERY PLANT).

Tar is removed and sent to tar plant for the distillation to
get tar products.

Ammonia liquor is separated from tar and pumped back to
gas collecting mains.

Excess ammonical liquor is pumped to ammonia columns
for further treatment. After treatment it is sent to MBC.

COAL CHEMICAL PLANT
(CLEANING PROCESS- WHERE & HOW)
Ammonia is removed in gas cleaning unit
(Ammonium Sulphate plant). The gas
passed through the 4-5% Sulphuric Acid
Bath. Ammonia in Co-gas Reacts with acid
and forms ammonium Sulphate.

Crude Benzol is removed in Benzol
Recovery unit of gas Cleaning Plant.

COAL CHEMICAL PLANT
(SUB-SECTIONS)
RECOVERY

BENZOL PLANT

TAR DISTILLATION PLANT
RECOVERY
GAS CONDENSATION PLANT(GCP)

AMMONIUM SULPHATE PLANT

BENZOL RECOVERY PLANT

MBC PLANT
RECOVERY
Bat-1
Bat-2
Bat-3
PGC
ESP
EXH
FGC Sc-2 Sc-1
Centrifuge Drier
Amm-liquir
SLUDGE
Saturator
Amo- Slurry
To consumers
Co gas
BO OIL
DBO OIL FROM BDP
Bagging
Tar Fog
Tar
TAR
OIL
CO-GAS
seperator
GAS CONDENSATION PLANT
(OBJECTIVES)
Exhaust Co-gas from Batteries.
Maintaining Constant Suction.
Condensation of TAR& Amm. liquor.
Continuous pumping of F.L to Batteries.
Separation of Tar, F.L & Sludge.

GAS CONDENATION PLANT
(EQUIPMENT)
PGCs -10 no -20,000 cum/hr.
ESPs -06 nos -40,000 cum/hr.
Exhausters-5 nos -76,000 cum/hr.
F.L Pumps -6 nos - 1,200 cum/hr.
Decanters 8nos - 380 cum.

AMMONIUM SULPHATE PLANT
(OBJECTIVES)
To purify Co-gas
To recover Ammonia.

CAPACITY OF ASP unit
:-41,700 Ton / year

AMMONIUM SULPHATE PLANT
(EQUIPMENT)
Saturators -5nos.
Centrifuges -5nos -3.2 Ton/hr.
Drier -2nos -8.0 Ton/hr.
Bagging Machine-2nos-10bags/min


BENZOL RECOVERY PLANT
(OBJECTIVES)
Recovery of slip Naphthalene from
Co-gas.
Enriching Tar with Naphthalene.
Recovery of Crude Benzol from
Co-gas.
BENZOL RECOVERY PLANT
Two Streams of Co-gas flow.
Each stream consists of
One Final Gas Cooler.
Two Benzol Scrubbers.
MBC PLANT
(OBJECTIVES)
Effluent Water treatment.
BENZOL PLANT
(OBJECTIVES)
To recover Crude Benzol from Benzolised
Oil.
To remove Impurities from Crude Benzol.
To produce Pure Products from C.B.
BENZOL PLANT
(SUB-SECTIONS)
Benzol Distillation Section.
Hydro Refining Unit.
Extractive Distillation Unit.
Crude & Finished Products Storage.
BENZOL DISTILLATION
SECTION
(OBJECTIVES)
To separate Crude Benzol from Benzolised
Oil.
To separate HCB from Crude Benzol.

BENZOL DISTILLATION
SECTION
(EQUIPMENT)
Two streams.
Each Stream consisting of
- Stripping column -1No.
- Steam pre-heater -2Nos.
-DBO Coolers -6Nos.
- Oil-Oil Heat Exchangers-3Nos.
- Oil Dephlegmators -2Nos.
- Water Dephlegmators -1No.
- Decanter -1No.
Common for both streams-
-CB-1 Condensers -2Nos.
-CB-1 Column -1No.
-CB-2 Column -1No.

BENZOL DISTILLATION UNIT
CRUDE BENZOL
DBO TO SCRUBBERS
LIVE STEAM
S
T
R
I
P
P
I
N
G

C
O
L
U
M
N
C
B
ONE
C
O
L
U
M
N

CB-I
COOLERS
TO CFPS
C
B
TWO
C
O
L
U
M
N

CB-I
STEAM
STEAM
CB-II
B.O
HYDROREFINING UNIT
(OBJECTIVES)
To remove Sulphour Compounds from
Crude Benzol.
To produce BTXS Raffinate for processing
in Extrative Distillation Unit.
HYDROREFINING UNIT
(FLOE SCHEME)
De-Fronting agent
(For removal of CS2)
CB-1
STAGE EVAPORATOR
Heating by tharmal oil.
Recycle gas mixing
Evaporation in stage.
PER-REACTOR
Ni-Mo Catalyst
Styrene Ethyl Benzene

H2
MAIN-REACTOR
Co-mo Catalyst
Thiophene Butane+H2S
Condensation &seperation of RC gas

H2
STRIPPER COLUMN
THERMAL TREATMENT
REMOVAL OF H2S
BTXS REFINATE
EXTRACTIVE DISTILLATION UNIT
(OBJECTIVES)
To separate non aromatics from benzene &
tolune.
To produce pure benzene, pure tolune,
Light solvent oil &still bottom oil from
BTXS Raffinate.
EXTRACTIVE DISTILLATION
UNIT
(FLOW SCHEME)
BTXS
P.D COLUMN
XS Fr.
Batch Distillation for
LSN / SBO products.
B/T Fr.
E.D COLUMN
N- Formyl Morphiline solvent used for removal
of CH, MCH, from Aromatic Benzene, toluene.
NFM dissolves H.C.
N . A leaves as Vapours from top of column.
NFM with dissolved H.C.
STRIPPING COLUMN
(VACUUM)
HC(B/T)
NFM Recycled to ED column.
HC(B/T)
BT SEPARATION
COLUMN
BENZENE
TOLUENE
CRUDE &FINISHED PRODUCT
STORAGE UNIT
(OBJECTIVES)
To store crude benzol HCB and pure
products.

To despatch HCB and pure products to
customers by road tankers.
CRUDE &FINISHED PRODUCT
STORAGE UNIT
(EQUIPMENT)
Total Storage capacity
CB Tanks -4Nos -2800kl.
PB Tanks -4Nos -2000kl.
PT Tanks -2Nos - 400kl.
LSO Tanks -5 Nos - 250kl.
NA Tanks -2Nos - 100kl.
HCB Tanks -2Nos - 200kl.
TAR DISTILLATION PLANT
(SUB-SECTIONS)
Tar Distillation Section.
Pitch Cooling & Loading Area.
Naphthalene & Anthracene Fraction
Crystallization section (NAFC).
Tar & Oil Storage.
Tar & oil storage Decanter 1 no
Reciprocating
pump 2 no
Furnace Fist stage
1
st
Evaporator
Water
Reciprocating
pump 2 no

Furnace 2nd stage

2 nd Evaporator
Soft pitch
Reactor
MH Pitch
Collecting Tank
Pitch Bays
For cooling
Cutting & Bagging
Light Oil
Phenol
Naphthalene
Wash Oil
Anthracene I OIl
Anthracene II OIl

Distillation column
To NAFC
TAR DISTILLATION PLANT
TAR DISTILLATION SECTION

Tar received from FGC unit to TOS unit.
From TOS tar is pumped to Decanter in TDS unit.
After removal of water from decanter moisture
content in tar reduces to 5-6%.
Tar is heated in the first stage of furnace to a
temp.of120-150 deg C and sent to first stage
evaporator.
In first stage evaporator complete de-
moisturisation is done.

TAR DISTILLATION
SECTION

Tar after first stage evaporator is again heated in II
stage of furnace to a temp. of 330-350deg C.
In the second stage evaporator oil fraction is
separated from top of second stage evaporator(35-
40%) and soft pitch from bottom.
The oil fraction is sent to the distillation column,
where individual oil products are tapped , cooled
collected in storage tanks.

TAR DISTILLATION SECTION
THE PRODUCTS FROM DISTILLATION
COLUMN ARE AS FOLLOWS:-
Light oil
Phenol Fraction.
Naphthalene fraction.
Wash oil.
Anthracene oil-I & II.


PITCH COOLING AND
LOADING AREA
The soft pitch from second stage evaporator is sent
to reactors, where it is subjected to areation to
increase the softening point to get the Alluminium
grade pitch.
Al. grade Pitch is cooled in dumping yards. It cut,
bagged and dispatched to customers.
Part of the soft pitch is used to make PCM by
mixing it with Anthracene & Wash Oil mixture
NAFC

Naphthalene fraction is further processed in
NAFC unit to make Hot Pressed
Napthalene(35-40Kg Cakes). The cakes are
crushed, bagged and dispatched to customers.
Drained Naphthalene oil is also produced in
NAFC unit. It will have around 35-40%
Naphthalene.


TAR & OIL STORAGE
(OBJECTIVES)
To store crude Coal tar and Oil
products.

To despatch Tar, PCM and Oil
products to customers by road / rail
tankers
PERFORMANCE -CCP
S.No PARAMETERS UNIT APRIL'05 MAY'05 JUNE'05 JULY'05 AUG'05 SEPT'05 2004-05
1 Ammonium Sulphate Yield Kg/Tdc 13.70 13.00 12.70 12.80 12.60 13.00 13.20
2 Crude Benzol Yield Kg/Tdc 6.50 6.50 6.40 3.50 3.00 5.50 6.00
3 Crude Tar Yield Kg/Tdc 31.50 31.60 31.70 32.00 31.80 32.10 31.80
4 NH3 Content in Raw Gas g/Nm3 9.128 9.258 9.150 8.860 9.475 9.090 -----
5 NH3 Content in Clean Gas gm/Nm3 0.039 0.034 0.031 0.022 0.035 0.034 -----
6 Benzol Content in Raw Gas gm/Nm3 27.190 28.830 28.960 28.350 23.180 29.810 -----
7 Benzol Content in Clean Gas gm/Nm3 9.190 11.360 9.770 11.360 18.940 11.040 -----
8 Naph.Content in Clean Gas gm/Nm3 0.318 0.372 0.380 0.150 0.029 0.220 -----
9 Q I of Tar 2.394 2.304 2.473 2.200 2.320 2.620 -----
S.No PRODUCTIONS UNIT
JAN'0
5
FEB'05 MAR'05 APR'05 MAY'05 JUNE'05 JULY'05 AUG'05 SEPT'05 2004-05
1 Ammonium Sulphate Ton 3299 3000 3414 3434 3345 3178 3287 3257 3150 37578
2 Crude Tar Ton 8033 7257 8061 7890 8162 7951 8186 8197 7763 90379
3 Crude Benzol Ton 1553 1358 1518 1422 1481 1400 785 705 1125 14750
4 C G Benzene Ton 680 800 590 700 660 510 410 500 600 7433
5 N G Tolune Ton 210 260 216 245 280 200 200 200 240 2220
6 Light Solvent Oil Ton 65 133 105 130 145 120 90 110 125 1066
7 SOL-110(N.A) Ton 130 175 165 145 210 185 150 164 158 1465
7 Heavy Crude Benzol Ton 142 163 182 206 195 200 100 70 200 2319
8 Still Bottom Oil Ton 20 15 12 15 10 15 10 15 18 247
9 H P Napthalene Ton 270 190 260 186 170 205 157 167 108 2543
10 Coal Tar Fuel(PCM) Ton 3180 3610 2450 3300 3570 2800 2930 2740 2540 39390
11 M H Pitch Ton 2280 690 2820 1700 1220 2185 1345 1625 640 20430

1 TAR DISTELLED Ton 6630 4700 7050 5800 5200 6300 4910 5200 3350 70590
2
CRUDE BENZOL
PROCESSED
Ton 1263 1580 1275 1400 1485 1170 980 1120 1215 13698
S.
N
o
PRODUCTS UNIT
JAN'0
5
FEB'0
5
MAR'0
5
APRIL
'
0
5
MAY'0
5
JUNE'
0
5
JULY'
0
5
AUG'0
5
SEPT'
0
5
2004-05
1 Ammonium Sulphate Ton 3104 2865 2170 4226 3606 3112 3323 3532 3187 36309
2 Crude Tar Ton 1957 1518 2797 956 1641 2476 2420 3438 4097 19774
3 H P Napthalene Ton 252 174 245 200 51 303 145 201 127 2502
4 M H Pitch Ton 1030 1161 2700 451 572 286 576 615 500 17561
5 Coal Tar Fuel(PCM) Ton 0 0 0 0 12 77 71 84 20 0
6 WASH OIL Ton 14 90 119 52 52 53 68 74 9 283
7 D.N.O Ton 99 154 139 99 113 85 98 167 109 1241
8 Phenol Fraction Ton 124 89 148 109 105 116 107 120 57 1312
10 Heavy Crude Benzol Ton 140 153 127 186 132 171 142 81 152 1887
11 C G Benzene Ton 587 869 590 341 618 928 321 164 701 8228
12 N G Tolune Ton 161 240 239 228 308 218 205 182 246 2449
13 Light Solvent Oil Ton 64 115 101 22 91 216 118 135 107 1159
14 SOL-110(N.A) Ton 128 154 181 148 183 212 137 84 119 1491
15 Still Bottom Oil Ton 10 19 20 9 10 20 6 0 9 126
## SALES REVENUE Crore 8.97 10.56 12.64 7.67 9.32 10.99 7.99 8.35 10.43 117.58
8
.
9
7
1
0
.
5
6
1
2
.
6
4
7
.
6
7
9
.
3
2
1
0
.
9
9
7
.
9
9
8
.
3
5
1
0
.
4
3
0
2
4
6
8
10
12
14
1 2 3 4 5 6 7 8 9
OUR SALEABLE CHEMICALS
Ammonium Sulphate
(PUSHKALA)
Crude Coal Tar
Hard Pitch
HP Naphthalene
Drained Naphthalene
Oil (DNO)
Phenol Fraction

CG Benzene
NG Toluene
Light Solvent
Naphtha
SOL 110
Coal Tar Wash Oil
Anthracene Oil
Coal Tar Fuel / PCM




AMMONIUM SULPHATE
(PUSHKALA)
Nitrogen by Wt. 20.60 % (min.)
Moisture by Wt. 1.00 % (max.)
Free Acidity by Wt. 0.04 % (max.)
Packing 50 Kg Bag
CRUDE COAL TAR



Grade - 1 Grade - 2
Specific Gravity at 20
0
C 1.16 1.20 1.16 1.20
Moisture % (max) 4.00 4.00
Viscosity ( E deg.) at 93
0
C 1.70 2.50 1.70 2.50
Residue on Distillation (above
360
0
C) % min.
53 53
Benzene Insoluble % max. 14 15
Quinoline Insoluble % max. 8 8
HP NAPHTHALENE

Colour White or Light Brown
Crystallization Point 78.50
0
C
Ash by Wt. 0.20 % (max)
Moisture by Wt. 0.50 % (max.)
Sulphur by Wt. 0.40 % (max.)
Benzene Insoluble 0.20 % (max.)

DRAINED NAPHTHALENE
OIL (DNO)
Specific Gravity 1.02 (max.)
Moisture 4.00 % (max.)
Naphthalene 30 - 50 %
PHENOL FRACTION

Specific Gravity 0.99 1.00
( at 20 deg C)
Distillation(0-210
0
C) 95.0 %
Phenol (%) 18 30
Naphthalene 30 % (max.)
Moisture 4% (max)

SOL 110
(NON AROMATICS)
Specific Gravity 0.84 (min)
(at 15 deg C)
Distillation Range 55 - 110
0
C
( 1 95 %)
COAL TAR WASH OIL
Specific Gravity at 38
0
C 1.04-1.08
Moisture % (max) 4.00
Distillation-------
Up to 230
0
C % (max) 10.00
230
0
C- 300
0
C % (max) 85.00
Above 300
0
C % (max) 5.00
Naphthalene % (max) 15.00

TOLUENE (Nitration Grade)

Distillation Range 0.6 (Including 110.6
0
C)
(1 - 96%)
Specific Gravity at 15/15
0
C 0.870 - 0.874
Residue on Evaporation 5 mg/100 ml (max)
H
2
S & Mercaptanes Negative
Purity (by GLC method) 99.2 % (min)
TOLUENE (Industrial Grade)

Distillation Range
Up to 105
0
C 5 ml
Up to 120
0
C 90 ml
Specific Gravity at 15/15
0
C 0.860 - 0.875
Residue on Evaporation 10 mg/100 ml (max)
H
2
S & Mercaptanes Negative
Purity (by GLC method) 92.0 % (min)
CG BENZENE
Distillation Range 0.6 (Including 80.1
0
C)
(1 - 96%)
Specific Gravity at 0.879 - 0.886
15.6/15.6
0
C
Residue on Evaporation 5 mg/100 ml (max)
H
2
S & Mercaptanes Negative
Total Sulphur (ppm max.) 2.0
Non Aromatics (ppm max) 500
Crystallization point (min) 5.3
0
C
Purity by GLC method 99.92% min
HARD PITCH
BALCO GRADE
Softening Point (R&B) 90 95
0
C
Coking Value (conradson) 53 (min)
Benzene Insoluble 30% (min)
Quinolene Insoluble 10% (max)
Ash 0.3% (max)
HARD PITCH
INDAL GRADE
Softening Point (R&B) 86 - 105
0
C
Coking Value (conradson) 52 (min)
Benzene Insoluble 27% (min)
Quinolene Insoluble 10% (max)
Ash 0.2% (max)

HARD PITCH
NALCO GRADE
Softening Point (R&B) 105-112
0
C
Coking Value (conradson) 52 (min)
Quinolene Insoluble 5-12% (max)
Ash 0.5% (max)

HARD PITCH
HINDALCO GRADE
Softening Point (R&B) 107-114
0
C
Coking Value (conradson) 54 - 56
Benzene Insoluble 30 37 %
Quinolene Insoluble 7 - 12%
Ash 0.5% (max)

HARD PITCH
GRADE # 1
Softening Point (R&B) 90 105
0
C
Coking Value (conradson) 48 (min)
Benzene Insoluble 25% (min)
Quinolene Insoluble 12% (max)
Ash 0.5% (max)

HARD PITCH
GRADE # 2
Softening Point (R&B) 101-115
0
C
Coking Value (conradson) 51 (min)
Benzene Insoluble 28% (min)
Quinolene Insoluble 12% (max)
Ash 0.5% (max)

ANTHARACENE OIL
Specific Gravity 1.12
at 20
0
C (max)
Moisture % (max) 3.00
Distillation % (max) 20.00
up to 300
0
C
COAL TAR FUEL
(Pitch Creosote Mixture)
Moisture % (max) 4.00
Viscosity ( E
0
) 2 8
at 93
0
C

IN ADDITION TO ABOVE,
MEDIUM HARD PITCH
CAN ALSO BE MADE AS
PER THE CUSTOMERS
SPECIFICATION.
TOLUENE
Solvents
Artificial
Sweetening
Paint Industries
Rubber Industries
Rubber
Chemicals
Printing Ink.
Benzoic Acid
Sodium
Benzoates
Synthetic Fibers
Adhesives
Benzyl Chloride
Thinners &
Varnishes
HP NAPHTHALENE
Dye intermediates
Insecticides
Dispersing Agents
Tanning Agents
Beta Naphthol
Refined Naphthalene

BENZENE
Raw material for
various Drugs, Dye-
stuff, Synthetic
Rubber, Styrene.
Pesticides
Monochlorobenzene
Caprolactum
Phenol
DDT
LAB

Nitro Benzene
Aniline
Maletic Anhydride
Cumene
Cyclo-Hexavon
Nylon-6
Resin Intermediates
Nylon Intermediates
Styrene
HARD PITCH
Hard Pitch is used in Industries
requiring Pitch Carbon for
Electrodes and it is used by
Aluminium Industries.
It is also used for manufacturing
graphite and in blast furnaces
ladle repair.
AMMONIUM SULPHATE
Mainly used as Fertilizer due
to its nitrogen content.
Presently also used as a
Nitrogen bearing material in
mixed Fertilizer in Fertilizer
manufacturing plant.
LIGHT SOLVENT NAPHTHA
Solvents
Starting material for Dyes.
Printing Ink
Thinner

COAL TAR WASH OIL
Preservation of Wooden
Sleepers
Carbon Black Feed Stocks.
Disinfectant
ANTHRACENE OIL
Anthracene Oil is an
excellent material as a feed
stock for Carbon Black and
gives better yields and
quality of the finished
product.
DRAINED NAPHTHALENE OIL
Naphthalene bearing feed
stocks.
Naphthalene and Coal Tar
Oils are separated and used
for their specific end uses.
BENZOL PRODUCTS- RINL PRICE MOVEMENT
MONTH BENZENE TOLUENE LSO
SOL-
110
HP
NAPHTHALENE
NOV'10
PRICE `) 35690 37875 37200 34700 53180
QTY SOLD (T)
1013 260 112 101 43
DEC'10
PRICE `) 38600 40175 39450 36000 51400
QTY SOLD(T)
907 80 64 107 241
JAN'11
PRICE `) 40000 40175 39450 37500 53000
QTY SOLD (T)
564 388 128 84 108
FEB'11
PRICE `) 46200 40250 41050 40400 50750
QTY SOLD(T)
704 273 96 80 133
MAR'11
PRICE `) 46600 47200 42750 46050 51750
QTY SOLD (T)
1183 220 97 59 67
Upto
28
th

APR'11
PRICE `) 46600 48250 42750 45100 54650
QTY SOLD (T)
185 116 110 90 67
72
MOVEMENT OF C C TAR PRICES
Month RINL
September10 20500
October10 21300
November10 21000/21200
December10 21200
January11 20500
February11 20500
March11 21200
April 11 24000
73
OILS - PRICE MOVE MENT
NOV 10 DEC 10 JAN 11 FEB 11 MAR 11 APR 11
PHENOL
FRACTIONS
21500 21500 22100 22100 23100 24100
DNO 21500 21500 22100 22100 23100 24100
HCB 20000 20000 20600 20600 21600 23600
STILL BOTTOM
OIL
17400 17400 18000 18000 19000 21000
74
SPECIFICATIONS
VSP
HCO
Sp.Gr 1.18 max
H
2
O: 3%
Upto 200
0
- 20% max
LCO
Sp.Gr 1.04 to 1.08
H
2
O: 4%
Upto 230
0
- 10% max
230 to 300
0
85%
>300 - 5%
DNO
Sp.Gr 1.02
H
2
O: 4%
Naph 35- 40%
SBO
Sp.Gr 0.95
H
2
O
0 250
0
; 90% min
AMMONIUM SULPHATE PRICE MOVEMENT
Month RINL MONTHLY
PRICE
JAN 11 5400
FEB 11 5800
MAR 11 5800
APR 11 5700
76