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W E L C O M ER A S H T R IY A IS P A T N IG A M L IM IT E D
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Vizag Steel Plant
COAL BLENDING MODEL
ON COST OPTIMIZATION
AT VIZAG STEEL
S.K.SEET
D.S.SASTRY
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TOPIC
% Introduction
%Coke Requirement vis--vis BlastFurnace operation
%Challenges for Steel Industry for coke
%Opportunity & Alternatives
%Efforts at Vizag steel
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introduction
% Steel industry is highly energy intensive having 5 to 8Gcal/tls in Indian scenario. Where as in other part of theworld it is around 4.5 to 5.5 Gcal/tls. Out of this 60 to 70 %is contributed from energy being consumed in iron makingthrough coke oven blast furnace route. To day 50 to 60 % ofsteel is made through this route, which is still a dominanttechnology. In this energy consumption coke is the maincontributor & many a time redefining coke qualityrequirement remains the crux of the subject The redefinitionof coke quality takes in to cognizance several factors thatput the biggest challenges as well as opportunity to the cokemaking technology. They include designing of suitable cokingblend against constraints such as; economic, logistic and
pollution. A targeted coke quality production against theseconstraints has been the major driving force to developvarious alternate technology of coke making, blendformulation with cost optimization, coke making withenergy efficient and environment friendly route.
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BLAST FURNACE SHOP
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PROCESS OF COKE QUALITY
DETERMINATION
Blast
Furnace
Volume, operating regime
Extent of auxiliary fuel
Productivity requirement
Coking coal availability/Cost/Logistics
Up stream Fuel gas requirement
CokeQuality
specification
Coke Chemical requirementCoke Physical requirement
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CONSTRAINTS BEFORE
STEELMAKERS TODAY
% CRUDE STEEL PRODUCTION BY 2019-20 WILL BEARROUND 110 MT AS PER NSP
% SHARE OF HOT METAL THROUGH BF ROUTEWILL BE 65 MT
% COKING COAL CONSUMPTION WILL THEN
INCREASE FROM PRESENT LEVEL OF 25 MT TO70 MT
% INDIAN COKING COAL ARE INFERIOR INQUALITY
% INSPITE OF VARIOUS AUXILLARY FUEL
INJECTION IN BF THE DEMAND FOR MET COKEWILL INCREASE
% INDIA TODAY HAS NO OPTION BUT TOHEAVILY DEPENDANT ON HARD COKINGCOAL IMPORT
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1 8
C o k in g C o a l R e q u ire m e n t
P re s e n t & o n P la n t e x p a n s io n( In M i l l io n T o n n e s )
0 . 4 9 20 . 4 2 0- -P C I
7 . 5 2 54 . 9 2 53 . 5 9 8T o t a l
0 . 6 9 10 . 6 7 50 . 5 3 8M e d i u m
- -- -0 . 5 4 0S o f t
6 . 3 4 23 . 8 3 02 . 5 2 0H a r d
1 0 .0 M T b y
2 0 1 2 - 1 32 n d P h a s e
6 .3 M T b y
2 0 0 8 - 0 91 s t P h a s e
P r e s e n t
2 0 0 6 - 0 7C o k in g C o a l
COKING COAL REQUIREMENT AT VIZAG STEEL
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2 6
L o c a lA v e r a g e1 0S m a l l
V o l u m e s o f
e v e r y t h i n g
M a in l y
u n d e r g r o u n d
I n d i a
E u r o p e /
U S A /
A r g e n t i n a
A v e r a g e1 5H a r d a n d
s e m i- s o f t
M a in l y
u n d e r g r o u n d
, s m a l l
m i n e s .
In d u s t ry i s
s t i ll e v o l v i n g
C o lo m b i
a
L o c a l , s o m e
to J a p a n ,
K o r e a , B r a z i l
A v e r a g e4 0 0 / 2 0 0
( 5 0 % l o s s o n
w a s h i n g )
- d o -M a in l y
u n d e r g r o u n d
, s m a l l a n d
la r g e
s a f e t y fa c t o r
a q u e s t io n
m a r k
C h i n a
J a p a n ,
E u r o p e ,
B r a z i l
- d o -5 0- d o -- d o -C a n a d a
J a p a n ,
K o r e a , I n d i a ,
B r a z i l
E x c e l l e n t1 0 0H a r d , S e m i -
s o f t & S o f t
O p e n c a s t &
U n d e r g r o u n d
la r g e m in e s
A u s t r a l i a
P r i n c i p a l
M a r k e t s
L o g is t ic s &
P o r t s
A p p r o x .
a n n u a l Q ty .
(M T )
T y p e o f C o a lT y p e &
N a t u r e o f
M in in g
C o u n t r y
World Coking Coal at a Glance
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3S e m i-
f t
e r re n e z e l
E u r eE x c e l l e n t3S e m i-
f t
O p e n c a s tS o u t
f r i c a
L o c a l , s o m e t o
a p a n o re a
T e r r i le5 0- o -- o -R u s s i a
E u ro p eA v e ra g e3 0H a r ,
S e m i s o f t
/s o f t
n d e rg ro u n d -
la rg e m in e s
P o l a n d
5 5 6T
ot a l
a p a n , E u ro p eE x c e l l e n t5 0- d o -n d e rg ro u n d
O p e n c a s t
S A
L o c a l E u ro p eA v e ra g e3 0H a rd ,s e m is o f t
/ S o f t
n d e rg ro u n d la rg e m in e s
a n d re s e rv e s
d e p l e t i n g
U k ra in e
L o c a l , s o m e t o
c h i n a
T e r r i le5H a rdU n d e rg ro u n dN o r t h
o re a
L o c a l o n lT e r r i le1 0H a rd /
S e m i-
s o f t
U n d e rg ro u n d -
la rg e m in e s
K a z a k h s t a
n
P r in c i p a l M a rk e tsL o g is t i c s
P o r ts
A p p ro x .
a n n u a l
t . ( M T )
T y p e o f
C o a l
T y p e N a t u re
o f M in in g
C o u n try
World Coking Coal at a Glance
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CONSTRAINT IN CONVENTIONAL
COKE MAKING
%AGEING OF BATTERY
%USE OF HIGH COST COKINGCOAL
%HIGH ENERGY CONSUMPTION
%HIGH LEVEL OF POLLUTION
%MODERATE PRODUCTIVITY
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1. Explore new & emerging technology to meet
environmental and energy constraints
2. To utilize indigenous coal quality
3. To enhance battery life4. Measure on low cost blend and energy
conservation to make the coke making
technology more cost effective
5. Bring about an clarity of understanding onexact nature of coal to coke transformation vis-
-vis coal quality and operating parameters.
ISSUES TO BE RESOLVE
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Popular Routes of Iron making
Primary Secondary
Blast FurnaceDirect Reduction
a. DRI
b. MIDREX
Smelting Reduction
a. COREX
b. FINEX
c. ROMELT
d. HISMELT
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D E V E L O P E D B Y M / s V A I , I T IS
T H E F IR S T C O M M E R C I A L
S M E L T IN G R E D U C T IO NP R O C E S S .I T C A N U S E L U M P I R O N O R EA N D N O N C O K I N G C O A L S
R E Q U I R E M E N T : L O W A S H (8 - 1 2% )
H I G H V .M . ( 20 - 2 5% )N O N C O K I N G C O A LO X Y G E N 5 0 0 - 60 0 m 3 /T h m
J V S L S C O R E X F U R N A C E I S
O P E R A T I N G W IT H 1 0 0 %IM P O R T E D C O A L .
C O R E X P R O C E S S
S m e ltin g R e d u c t io n
OPPORTUNITY TO REDUCE MET COKE DEMAND
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D E V E L O P E D
P O S C O A N D
M/ V A I,
I O N S I S T S O FT W O S T A G E S
I T P E R M I T S P R O D U C T I O N O F
H O T M E T A L W I T H C H E A P
& A B U N D A N T O R E F I N E S
A N D N O N - C O K I N G C O A L S .
T H E F I R S T A N D O N L Y P L A N TU S I N G T H I S P R O C E S S I S A T
P O S C O . I T S T A R T E D I N M A Y
2 0 0 3 , W I T H A N A N N U A L
C A P A C I T Y O F 0 0 , 0 0 0 T O N S .
F I N E X E S S
OPPORTUNITY TO REDUCE MET COKE DEMAND
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D E V E L O P E D B Y JIS F.
I T IS A 2/ 3 S T A G E
S M E L T I N G R E D U C T I O N
P R O C E S S I R O N O R E F I N E S A N D H IG H
A S H , H IG H V M C O A L S C A N
B E U S E D IN T H IS P R O C E S S .
A P IL O T P L A N T O F
C A P A C IT Y 0 0 T/ D A Y W A S
C O M M I S S IO N E D I N 9 9 3 I N
J A P A N
Y E T T O S T A R T L A R G E S C A L EC O M M E R C I A L P R O D U C T IO N
D I O S O C E S S
OPPORTUNITY TO REDUCE MET COKE DEMAND
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ALTERNATE TO COKE MEKING
TECHNOLOGY
%JUMBO COKE OVEN
%
MIXED PROCESS WITHALTERNATE USE OF COG
%HEAT RECOVARY OVENS
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JUMBO COKE OVEN
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ALTERNATIVE PROCESS SCHEME IN AN INTEGRATED
STEEL PLANTWITH VARIOUS USE OF COG
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COAL BLOCK CHARGING IN HEAT
RECOVARY OVEN
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21
SLOT OVEN VS HEAT RECOVARY
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ENABLERS OF COKING
TECHNOLOGY AT VIZAG STEEL
%PHYLOSOPHY OF BLEND DESIGN
%BLENDING MODEL ON COSTOPTIMIZATION
%ECO FRIENDLY COKE MAKING%OPERATING DISCIPLINE TO
ENHANCE BATTERY LIFE
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COKE GAS
LIGHT OIL
WASH OIL
HP NAPHTHALENE
ANTHRACENE OIL
PHENOL
PITCH
CT FUEL
BENZENE
TOLUENE
H.B.F
SOL110
SOLVENT NAPTHA
STILLBOTTOMS
COKING COALFROM RMHP
COKE OVEN
BATTERIES
RUN OF OVEN
COKE (HOT)
COKE DRY
COOLING PLANT
STEAM
BPTS
COOLED COKE
COKE SORTING PLANT
BREEZE COKE
0-10 MM
NUT COKE
10-25 MM
BF COKE
25-80MM
COKE DUST
0-3 MM
BURDEN HANDLINGSECTION(B.F)
TOS.P
SINTER
PLANT
COKE SLUDGE
0-3 MM
TO SALE
COAL PREPARATION PLANT
TO
YARD
TO
YARD
SEPARATOR
FLUSHING
LIQUOR
RAW COKE
OVEN GAS
PRIMARY GAS
COOLERTO GCM
TO DECANTER EXHAUSTER
AMMONIUM
SULPHATE
FINAL GAS
COOLER
CLEAN COKE
OVEN GAS
CONSUMER
BATTERYUNDER FIRING
CRUDE
BENZOL
BENZOL
RECTIFICATION PLANT
TAR DISTILLATION PLANT
PROCESS SCHEME OF COKE
MAKING
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Tippler
house
Jn-1
Track
hopper
Ground
Hoper
Jn-3 Jn-4 Jn-5
B O I LE R C O A L
B O I LE R C O A L
B O I LE R C O A L
B O I LE R C O A L
C -5
S O F T C O A L
IC C 2 C OA L
IC C 1 C O A L
M C C C O A L
IC C 3 C OA L
IC C 2 C OA L
S O F T C O A LB E L T C O N V E Y O R
B E L T C O N V E Y O R
B E L T C O N V E Y O R
B E L T C O N V E Y O R
B E L T C O N V E Y O R
B E L T C O N V E Y O R
T OT hermal
Power
Plant
Jn-1 8
Jn-1 9 CokingCoa l
T o Coa l
Preparation
P lan t
Tail
end
Drive
end
SCHEME OF COAL HANDLING & STORAGE
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SHEMATIC VIEW OF COKE OVEN
OVENCH
I
M
N
E
Y
GCM GCM
S
PS
P
PUSHER SIDECOKE SIDE
STEAM
CROSS OVER MAIN
SUCTION MAIN
BF GAS LINE
CO GAS LINE
BUS FLUE
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CARBONIZATION PROPER( PROCESS PARAMETER OF CARBONIZATION)
%
DRY COAL CHARGED 8300 TONS/DAY% MICROFINES CONTENT IN CHARGE 30% MAX
% MOISTURE CONTENT IN CHARGE 7-9%
% VOLATILE MATTER IN CHARGE 25-27%
% MMR OF CHARGE UP TO 1.15
% VERTICAL SHRIKAGE OF CHARGE > 5%
% AVERAGE COKING PERIOD 16-18 HRS
% CONTROL VERTCAL TEMPERATURE 1250-1330 OC
% FREE SPACE TEMPERATURE < 800 OC
%PRI & CRI > 0.96
% COEFFICIENT OF HEATING UNIFORMITY(Kb) > 0.9
% ALL EMMISIONS LEVEL BELOW STIPULATED NORM
% RARE INSTANCE OF HIGH PUSHING AMPERAGE
CONTD.
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% Strict control on coal blend quality such as; MMR, VM, Moisture,granulometry etc, to avoid chance of higher coking pressure.
% Blend composition, CO gas quality is monitored every shift.
% Micro fines were allowed as low as possible in the blend alongwith strict vigilance on Q.I content of coal tar
% Batteries were operated at a fixed coking time as far as possible
% GCM pressure is maintained at 16 mmwc with an aim to achievepositive sole pressure at the end of coking time
% Ascension pipes, door, doorframe are cleaned every day
% Inspection of oven, stand pipes, charging hole & door leakage byoperator after every pushing
%
Lutting of lids and immediate adjustment of knife sealing of doors% Coking hours variation is kept within 30 minutes (max )
% Gas temperature, GCM Pressure, pushing amperage, steam flow,heating gas flow, Flue temperature were monitored and loggedthrough computer
CARBONIZATION PROPER( PROCESS PARAMETER OF CARBONIZATION)
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Fugitive Emission Stack Emission
Parameter PLD PLO PLL SPM SO2 NOX
Norm
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B O I
C H A M B E R D C B
C Y C L O N E
C O N V E Y E R
1 ,
2
IL L
N
S A F E T Y V A L V E
H O T C O K E
N 2
2 T O N
3 T O N
T O
3 T O N B K R .
T O
B P T S
E
C
O
N
O
M
I
S
E
R
E
V
E
P
O
R
A
T
O
R
S H
1 2 6 V A L V E
G 1 , 3G 2 , 4
C D C PS C H E M A T I C
D I A G R A M
A i rA i r
CDCP- ENVIRONMENTAL AND ENRGY EFICIENT
COKE MAKING PRACTICE
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%LESS POLLUTION
%POWER GENERATION 12 MW
%LESS WATER IN COKE
%HIGHER STABILITY OF COKE
%HIGHER CSR OF COKE
CDCP- ENVIRONMENTAL AND ENRGY EFICIENT
COKE MAKING PRACTICE
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% CHEMICAL REQUIREMENT OF COKE
% PHYSICAL REQUIREMENT OF COKE
% REQUIREMENT OF CARBONIZATION YIELD
% REQUIREMENT OF BATTERY LIFE% CONSIDERATION FOR COAL WEATHERING
% INCORPORATION OF LOW COST SEMICOKING COAL COMPONENT
% COST OPTIMIZATION OF BLENDING OPTIONS% LOGISTICS
CONTD.
BLENDING PHYLOSOPHY
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J n - 1 9C o a lF r o m
R M H P
F o r e i g nO b j e c t
S e p a r a t i o n
( F O S )
J n -2
1
3
5
7
9
1 1
1 3
1 5
2
4
6
8
1 0
1 2
1 4
1 6
C o a l
C r u s h i n g
- 3 m m
J n -3C o a l
to e r
C h a r g e d
T o b a t t e ry
1 6 n o s
S i l o
T o
S t o r e
D i ff e r e n tC a t e g o r y
o f c o a l s
F o r
b l e n d i n g
W e ig h f e e d e r
D e s i g n a t e d
b l e n d
D e s i g n a t e d
b l e n d
THE COAL BLENDING PROCESS
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ROUTINE TEST
% PROXIMATE
% ULTIMATE
% CSN/FSI
% LTGK
% ALKALI
% ASH BASICITY INDEX
% DEGREE OF OXIDATION
% PHYSICAL TESTS ON
COKE STRENGTH MICUM TEST
CRI/CSR (AS PER ASTM
D 5341)
SPECICIAL TESTS ADDED
% MMR & PETROGRAPHY
% PILOT OVEN TESTFACILITY
%
PLASTOMETRY
CONTD.
CHARACTERIZATION OF COAL
AND MET COKE
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MMR & PETROGRAPHY
TESTINGFACILITY AT VIZAG STEEL
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BLEND COAL SAMPLE SHOWING
VARIOUS MACERALS
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3
capacity--- 250kg
length of oven --- 920mm
idth of the oven --- 405mm
height of the oven --- 1035mm
useful volume --- 0.32 m3
movable heating all TYPE
SALIENT FEATURE OF PILOT OVEN
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PILOT TEST RESULT OF PLASTIC &
ANTHRACITE
Parameter
B end coal+
Plast c
5%
Ant racite
% V.M 0.62 0.62
% A H 6.3 16.3
% F.C 3.08 83.08
M- 40 78.0 79.0
M- 10 11.0 10.0
C 27.0 23.0
C 56.2 63.0
1. 5% use of anthracite in the blend is tested
and found to be suitable
2. Use of plastic in the coal blend gave resultwhich is encouraging
3. Use of low ash Non-Coking coal in the blend
is under progress
4. A systematic difference to the tune of 5 to 7
points in CSR value is observed between
pilot and actual battery.
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F
x
g!
f" ! #
e q$
a% &
y by BF
B % e '
g a% &
e(
a& )
e 0
B % e ' g a % & e ( a & ) e 0 0 a & 0 fy g
Te " 1 " a % " ( & e ( a
Be0 &
B% e '
g Op& ! 0
B 2 e 3 4 C 5 a 2 q 6 a 2 7 8 y
5 9
De@
7 g 3 C 9 7 8 e 9 7 a
CSR/CSR0 &
a b % & y/ 1 a( '
e0 0
A0 1 A 0 $ % p 1 $ ( A a 0 1 ba 0 " & y &a % # a %
Ex 0 &
g p( ! "
e0 0
fa" % &
y
L &
e(
a& $ (
e0 $ ( )
e y
P % ! & " ! B B e ( " a % ! ) e & ( a % f! ( B a & !
Ba& &
e ( y p ( e 0 0 $ ( e &" ! #
g p ( e 0 0 $ ( e
Fa) ! (
a b % e% !
g 0 & "
C! 0 &
! p& B
za& !
& e " 1 q $ e /LP & e " 1 q $ e
Pilot Testing of the model
output blend
Decision to go for commercial
trialBlend for regular use
PROCESS OF BLENDING DECISION
AT VIZAG STEEL
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CONCLUSION
%
Dependence on imported coal is likely to increase in which case the coal selection andblend formulation will require focused attention. Vizag steel has started few efforts inthis direction and one among them is development of a cost optimized blend designmodule.
% Handling of coal storage and proportioning in port and plant need augmentation.
% An improvement in the conventional system of coke making includes high capacityovens. They will provide cost savings, better stability & lifetime, operational performanceand less environmental problems
%
In total CO2 emission in China is no-2 and India is in no-5 position. Hence ecology isgoing to be the biggest concern for Indian steel industry in future. A suitable selection ofcoke making alternative fulfilling the future environ mental requirement will beprudent to keep coke production on sustainable basis.
% As Met coke will remain the most critical input to the Steel Industry sustainable long-term strategy is necessary. In this regard modern HR coke oven offers economical,environmental friendly and technologically viable solution to feed future coke demand.It should be the Technology For The Future. However for integrated steel plant it needa judicious mix of both by-product recovery and HR type
% World coals generally fall into broad categories resembling high fluidity USA coal or lowfluidity high ash and sulfur of Australian type. High fluidity coal generally predominatesin Columbia, Russia, China, and New Zealand regions. Low fluidity coals are common inAustralia, Canada, and India & CIS regions. A judicious mix of both categories with useof cheaper addition of reverts, low rank coal with the adoption of coal blending modeldeveloped at Vizag Steel can help in addressing this issue.
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Questions
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