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49th

OPERATING COMMITTEE MEATING JSPL Raigarh

Confidential and Privilege

JSPL Raigarh.

November ’2018November 2018Members:

M. Raman , Mgr Umesh Nayak, Jr. MgrRahul Rana, Executive

Plant Configuration

Name of the Plant Recovery type stampcharged coke oven plant

Technology Adopted China Shougang International trade

Plant Capacity 0.85 MTPA

Short Description 2×64 , 4.3m Stamp ChargeShort Description 2 64 , 4.3m Stamp Charge

Total length of Carbonising Chamber 14.08 m

Height of Carbonizing Chamber 4.30 m

Effective Height 4.00 m

Average width of Carbonising Chamber 500 mm

Carbonising Chamber centre distance 1200 mm

Conical degree of Carbonising Chamber 20 mm

Number of vertical flues 28

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Number of vertical flues 28

Standard flue temperature P/S 1290

Standard flue temperature C/S 1310

Raw material used Imported Coal

Final Product Coke

By – Products Tar, BTX, Ammonium Sulphate

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Deriving Benefits Of Automation to Promote Battery Health

PRI & PC Value

Pushing Current

Technological Cleaning

Machine Positioning and Oven Identification

Pushing and Charging with Uniform Coking Period

Anti – Collision Machine

Ch i L l C t l

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Charging Level Control

Door Optimization

Gas Emission Controlling

PRI & PC Value

lPRI- Percentage of ovens pushed with in ±20 min of the average coking period.

lPC- Percentage of ovens pushed with in ±15 min of the schedule pushing time

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Pushing Current

lAutomation help us to Collect, store and compile pushing current data from pusher car.

lIdentify abnormalities in pusher ram drive mechanism.

lAnalyze coke quality.

lJudge Coal blends Performance.

lEvaluate coking cycle time.

lExplore Oven Sole Abnormalities.

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Technological Cleaning

lCollecting data of technological cleaning like door cleaner and

lframe cleaner from machines.

lMonitor and Improve surrounding environment.

lMaintain PLD as per Safety Environment norms.

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Machine Positioning and Oven Identification

lControl Room To Machine Connectivity.

l Equipment Protection (Anti Collision & wrong pushing).

l Machine To Machine Connectivity.

l Alignment Of Machines.

Avoid Wrong Pushing

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l Avoid Wrong Pushing.

l Wireless system needs less maintenance.

Pushing and charging with Uniform Coking Period

lAutomation System facilitate us to maintain uniform

lcoking period of ovens.

lIt is Paperless and less time consuming and zero

lhuman error process.

lPushing schedule display in HMI in all machines which

i h l f l f t t f ll hi h d l

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l is helpful for operators to follow pushing schedule

l without any error.

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Anti-collision Mechanism

lKeep desired gap between two machines avoid collision of machines and derailing of machines on

l both ends of tracks.

lWarning signal and collision system in HMI of both Machine and LT speed reduction to 1st notch.

lWhen machines come closer, LT supply goes off and machines come to halt avoiding collision.

lWhen individual machines move to either ends, warning and collision signal is shown in HMI and the LT speed is reduced to 1st notch

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lspeed is reduced to 1st notch.

lWhen the machines reach closer to end stoppers then LT supply goes off and machine comes to halt.

Charging Level Control

lIndividual Hammers level control.

lControl Different Stamping Units.

lFix Coal Cake Height.

lSafe Stamping Operation.

lAvoid Breakdowns.

lIndividual coal feeders control.

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f

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Gas emission control

Introduced 4.3m Coke Oven Battery wet de dusting system for controlling of gas emission in battery, during

pushing and charging

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Working Principle

Sucking the smoke from the hole of the coke and mix some air to facilitate the emission toSucking the smoke from the hole of the coke, and mix some air to facilitate the emission to burn and then passing through Venturi separator, and under Suction force of the fan to emitthe clean air into atmosphere.

Meanwhile the door head emission will be collected by door top fume hood and flow into the main pipe under the suction force of the auxiliary fan, by same procedure of top emission, the fume from door head will be burnt and washed, then emitted into atmosphere.

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p

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Coke Oven By Product PlantIn order to make raw coke oven gas suitable for use as a fuel gas at the coke oven battery and else where in the steel making facility the by-product plant must:

1.Cool the Coke Oven gas to condense out water vapor and contaminants.2. Remove tar aerosols to prevent gas line/equipment fouling .3. Remove ammonia to prevent gas line corrosion.4. Remove naphthalene to prevent gas line fouling by condensation. 5. Remove light oil for recovery and sale of Crude Benzol.

Other duties include:

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1. Remove Hydrogen Sulfide (H2S) to meet local emission regulations governing the combustion of coke oven gas.

Block Diagram Of By-Product

Coke Oven Fl hi

Excess for distillation

Batteries

Gas liquorSeparator

Primary gas Cooler (PGC)

Electrostatic tarprecipitator (ETP)

Decanter Sludge

Flushingliquor tank

Liquor To Coal yard

Tar Storagetank

To marketTar Separator

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precipitator (ETP)

DesulphurizationUnitExhauster

SuctionAmmonium

SulphateUnit

Crude Benzol unitGas

holder

ConsumerConsumers

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Coke Oven‐1 By‐Product

Cold Blast Section(AREA -1)

•GLS (Gas Liquor Separator)

•PGS (Primary Gas Cooler)

•ETP (Electrostatic Tar Precipitator)

Ammonium Sulphate & Crude Benzol Unit

(AREA – 2)

•Ammonia Stripper•Ammonium sulphate•Saturator•Crystallizer•Centrifuge 

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•Exhauster

•Refrigeration Unit (Chiller & Cooling Tower)

•Decanter & Tar Separator

g•Vibrating bed Dryer•Crude Benzol •Benzol Washer•Distillation Column•Tube Type Furnace 

Flow Sheet of Crude Benzol Recovery Plant

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Simple Block Diagram of Benzol Recovery Plant

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Problem Statement

Quality of Crude Benzol i:e; %age of Benzene in the BTX is lowered to 63%.

We contacted our customers for the problem they are facing in final product extraction from theCrude Benzol i;e Benzene.

We have received following response from them

1. They have to do Double Distillation for 99.15% Benzene over Single Distillation2. They are incurring a excess cost of Rs.3 over other Crude Benzol distillation (Increase of 60% in

cost)

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cost).

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Therefore we spend some time and many sessions on figuring out the related factors affecting the percentage of Benzene in the Crude Benzol.

500

Pareto Analysis of Out of Norm. parameters

CountOthe

r

pressur

e

perature

pressure

moutl

et

peratur

e

peratur

e

peratur

e

500

400

300

200

100

0

100

80

60

40

20

0

Para

met

ers

Perc

ent

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Parameters 108 106 85 75 29 21 17 20Percent 23.4 23.0 18.4 16.3 6.3 4.6 3.7 4.3Cum % 23.4 46.4 64.9 81.1 87.4 92.0 95.7 100.0

column t

op pre

column t

op tempe

column b

ottom pre

steam

rich oil in

let te

mpe

column botto

m tempe

rich o

il outl

et tempe

First we start to tackle the superheated steam temperature which fluctuated a lot at that period of time.

Superheated Steam Temperature fluctuated between 340°C to 350°C

We tried to increase the temperature to 370°C without affecting the Tube Type furnace Parameters by much.

did h b dj i h b i i h b d bl

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We did that by adjusting the combustion in the Tube Type Furnace and now we are able to attain a temperature of 365°C and above.

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Process Characterization

Upper spec *Target *Lower spec 360

Customer Requirements

Low High

0 6

Z actual = 4 41

Z potential = 5.36

Capability Analysis for Steam Out TemperatureSummary Report

How capable is the process?

Mean 373.74Standard deviation (overall) 3.1141

Actual (overall) capability Pp * Ppk 1.47 Z.Bench 4.41 % Out of spec 0.00 PPM (DPMO) 5

Process CharacterizationZ actual = 4.41

LSL

parts from the process that are outside the spec limits.• The defect rate is 0.00%, which estimates the percentage of

Actual (Overall) CapabilityAre the data above the limit?

Comments

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380376372368364360

shifts and drifts were eliminated.Potential (within) capability is what could be achieved if process Actual (overall) capability is what the customer experiences.

Then we diverted our attention to increase the Washing Oil temperature and in the process increasing the bottom temperature of the Distillation Column.

Increased the temperature of the oil to 190°C (at the inlet to the Distillation Column) and hence thetemperature of Distillation Column bottom increased to 179°C to 182°C and the top temperature ismaintained at 94°C.

Maintaining these parameters showed us a very positive result in the Benzene content of the Crude Benzol.

Initial improvements are:

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Initial improvements are:1. Total BTX content in the product increased from 87% to 90%.2. Quantity of Crude Benzol also increased by 0.5 ton per shift.

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At present we are attaining a Benzene percentage of around 72% - 74% and that to very consistently in the last month without any loss in the productivity .

Customer RequirementsReduction in % Out of Spec

Before/After Capability Comparison for Benzene perc vs Benzene %ageSummary Report

Customer Requirements

68 * *Lower Spec Target Upper Spec

Process Characterization

Mean 67.362 70.311 2.9492StDev(overall) 6.5816 1.0675 -5.5141

Actual (overall) capability Pp * * * Ppk -0.03 0.72 0.75 Z.Bench -0.10 2.17 2.26 % Out of spec 53.86 1.52 -52.34 PPM (DPMO) 538613 15188 -523425

Statistics Before After Change

97%

Yes No

0 0.05 0.1 > 0.5

P = 0.032

Yes No

0 0.05 0.1 > 0.5

P < 0.001

Reduction in % Out of Spec

to 1.52%.% Out of spec was reduced by 97% from 53.86%

Was the process standard deviation reduced?

Did the process mean change?

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BeforeLSL

After and drifts were eliminated.Potential (within) capability is what could be achieved if process shifts Actual (overall) capability is what the customer experiences. • The process mean changed significantly (p < 0.05).0.05).• The process standard deviation was reduced significantly (p < Before: Benzene perc After: Benzene %age

Actual (Overall) CapabilityAre the data above the limit?

Comments

THANK YOU

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