Coke Making Technology
Coke Making Technology
Coke Making Technology
7.1 Introduction
7.1.1 Carbon as a Reducing Agent
Although the oxides of iron may be reduced to metallic iron by many agents, carbon (directly or
indirectly) is the reducing agent found to be best suited for the economical production of iron. Car-
bon of suitable reactivity and physical strength was at one time produced from wood by distilla-
tion, yielding wood charcoal; but for the operation of a modern large blast furnace the carbon
required for the smelting of iron is obtained from the destructive distillation of selected coking
coals at temperatures in the range from 900°C to 1095°C (1650°F to 2000°F).
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Coke, then, is the residue from the destructive distillation of coal. Structurally, it is a cellular,
porous substance which is heterogeneous in both physical and chemical properties. The physical
properties of metallurgical coke, as well as its composition, depend largely upon the coal used and
the temperature at which it is carbonized. Not all coals will form coke, and not all-coking coals
will give the same firm, cellular mass characteristic of coke suitable for metallurgical purposes.
Some coals will produce an acceptable coke without blending with other coals, while others are
usable only as constituents of blends. The type and method of operation of coking facilities also
exert a profound influence on the quality and yield of coke for the blast furnaces.
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Manufacture of Metallurgical Coke and Recovery of Coal Chemicals
lower than the beehive. Beehive coke is usually larger, though not as uniform in size. In general,
properly carbonized beehive coke and byproduct coke both are silvery gray in appearance. A mod-
ification of the beehive technology, known as non-recovery ovens, is gaining prominence and is
discussed in Section 7.8.
Other processes for producing metallurgical coke are known as continuous processes; many vari-
ations have been proposed but none has been adopted on a commercial scale. In one continuous
process, finely pulverized coking or non-coking coal is dried and partially oxidized with steam or
air in fluidized bed reactors to prevent agglomeration when coking coal is used. The reactor prod-
uct is carbonized in two stages a successively higher temperatures to obtain a char. Using a binder
produced from tar obtained in the carbonization stages, the char is briquetted in roll presses. The
“green” briquettes are cured at low temperatures, carbonized at high temperatures, and finally
cooled in an inert atmosphere to produce a metallurgical coke of low volatile content. This type of
coke often is referred to as formcoke. Briquetting will be discussed again later in this chapter.
Table 7.1 Coke and Coal Chemical Typical Yields Following Carbonization
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Other substances in the raw gases and vapors leaving the ovens, which are liquids at ordinary tem-
peratures and pressures, are discussed here.
7.1.6.2 Tar
Tar is the organic matter that separates by condensation from the gas in the collector mains. It is a
black, viscous liquid, a little heavier than water. The following general classes of compounds may
be recovered from tar: pyridine, tar acids, naphthalene, creosote oil and coal-tar pitch.
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Manufacture of Metallurgical Coke and Recovery of Coal Chemicals
Table 7.2 Procedure for Coking Coal Selection (modified from Ref. 1)
1) Obtain coal quality 1) Predict coking quality 1) Conduct test on 100% coal. 1) Monitor plant
data sheet. from 5 lb. sample. trial.
2) Predict coking 2) Conduct economic 2) Conduct test on blend. 2) Adopt coal for
quality. evaluation. plant use.
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Ironmaking Volume
130
Corporation (NSC) method, is widely
used to assess coke’s behavior inside
120
a blast furnace.6 CSR measures the
110
potential of the coke to break up 80 70
under a high temperature CO2 envi-
100
ronment, which occurs in the blast
60
Plastic Range ( C)
furnace.
90
The use of CSR as a coke quality tool
has been in use for about 20 years. 50
80
CSR prediction models have been
developed and successfully adopted.
70
The models are used to design blends 40
60
and to monitor changes in blend
design. 50
of coal, as determined by the Giesler 10 12.5 15 17.5 20 22.5 25 27.5 30 32.5 35 37.5 40
Plastometer, and the catalytic index
(CI) of CO2 gasification (Fig. 7.1). Fig. 7.1 Ispat Inland CSR prediction model.
The catalytic index is comprised of
the alkali index and sulfur. The alkali index is calculated as a product of coal ash content times the
weight percent ration of (CaO+MgO+Fe2O3+Na2O+K2O)/(SiO2+Al2O3). According to this model,
CSR increases with an increase in the plastic range and decreases with an increase in Catalytic
Index. This is explained by the fact that the increase in plastics range optimizes the extent and size
of anisotropic carbon form from mesophase which, in turn, reduces the CO2 gasification.7 The
increase in alkalies, Fe2O3, and sulfur may affect CSSR in two ways: (a) by creating functional
groups between the elements affecting fluidity and inhibiting of nematic liquid crystals and (b) by
simply acting as a catalyst of CO2 gasification.8
It has been shown that CSR is a lin-
130
30
7.2.1.2.2 Blend Design for Coke Strength
40
an ambient condition are generally 10 12.5 15 17.5 20 22.5 25 27.5 30 32.5 35 37.5 40
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Manufacture of Metallurgical Coke and Recovery of Coal Chemicals
indices measure the ability of coke to withstand breakup at room temperature and reflect coke han-
dling behavior outside the blast furnace and coke breakage in the upper part of the blast furnace.
ASTM Tumbler Test (stability and harness), Micum Test, IRSID Test, and Japanese Tumble Test are
variations of drum tests to characterize breakage and abrasion of coke. Blend design techniques
have been developed based on these tests. Various coal characteristics are used to predict the drum
indices. Of those, petrographic analysis has become the prime analytical tool for predicting the
drum strength index of coals. Various blend design techniques to achieve desirable coke strength
are presented below.
7.2.1.2.2.1 Coal Petrography Petrographic analysis of a coal is a major tool for predicting coke
strength.9, 10 Prediction through petrography is done in three steps. First step involves the identifi-
cation of macerals which are describes as microscopically distinct organic entities in coal. There-
after, the macerals are grouped into reactive, semi-inert, and inert categories. These categories are
partially based on maceral behavior during carbonization. Lastly, the rank of coal is determined by
measuring the reflectance and calculating the strength of the binding materials created through
carbonization of reactives. Using these characteristics, the strength (rank) and inert indices are cal-
culated and coke strength is predicted.
The petrographic coke strength (ASTM Stability factor) prediction method developed at U.S. Steel
(U.S.S.) is shown in Fig. 7.3. Coke of high stability can be produced from coal blends which have
an optimum ration of reactive components to inert components. The reactive components con-
tribute fluidity to the coal and act as binders, while the inert components (either organic or inor-
ganic) act as fillers in the formation of the coke structure. On the other hand, the Ispat Inland
stability prediction method, Fig. 7.4, considers inerts to be detrimental to stability. Some Japanese
steelmakers use modifications of the U.S.S. method; however, the iso-stability lines are replaced
by JIS D130/15 lines, Fig. 7.5. The optimum coal blend area is shown by the boxed area (Fig. 7.3)
or the hatched zone (Fig. 7.5).
7.0 Stability
Factor 65
Coke from low volatile coals
Coke Reactivity Relative to Strength Index
Forms coke
6.0 mass or
dead man
at the tuyeres
60
Coke Strength
50
40
4.0
Optimum Good tuyere
Optimum Metallurgical action
Coke Properties 30
Metallurgical
Properties 20
10
3.0 Coke from high volatile coals Coke used
0 before tuyeres
Least 2.0
9.0 7.0 5.0 4.0 3.0 2.0 1.0 0.8 0.6 0.5 0.4 0.3 0.2 0.1
10.0 8.0 6.0 0.9 0.7
COMPOSITION - BALANCE INDEX
Inert-r ich Inert-deficient
Fig. 7.3 U.S.S. stability prediction method. (Adopted from Ref. 26)
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Ironmaking Volume
8.0
40 50 55 59 60
65
7.0
6.0
5.0
Rank Index
65
4.0
30 60
59
20
3.0
55
10 50
40
30
2.0
20
10
1.0
9.0 5.0 3.0 2.0 1.5 1.0 0.7 0.5 0.4 0.3 0.2 0.1
Inert Index
Fig. 7.4 Ispat Inland stability prediction method. (From Ref. 11)
94 92 90 80
8
American LV
Beatrice
Keystone
Itmann
7 70
Yellow stone
Smokey river
Aus - LV
Saxson Cand. Soviet - MV
6
Field of Blended Coal Peak Downs Balmer
For B.R. Coke Making South Bulli
Fording
K - 10
Continental Balmer
Strength Index
5 Vicary creek
American - MV 50
Carribean
Aus - MV
Jap - HV Pittston
4
American - HV Lynco Moura
Blackwater
Yubari Kellerman Wollondilly
Ohyubari Elkhorn
Meiwo No. 2 Ashoken
3 Miike Bigben
Liddell Newdell
Akabira Aus - HV
2
30
JIS - Drum Index DI 15 (%)
(Coke from test oven)
1
0.2 0.3 0.5 0.7 0.9 1.2 2.0 3.0 5.0 10.0 15.0 20.0
0.4 0.6 0.8 1.0 1.5 2.5 4.0
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Manufacture of Metallurgical Coke and Recovery of Coal Chemicals
7.2.1.2.2.2 Gieseler Plastometry Some8, 13 have indicated that the fluidity of coal is an important para-
meter affecting coke stability by providing bonding to various coal components. In order to ensure
optimum coal particles interaction, it is important that the temperature intervals of the plastic state
for coals constituting a blend should overlap. The longer the overlapping of maximum activity
intervals of two particles, the more the number of chemical bonds formed in the contact area.
The Japanese have13 used reflectance and the maximum fluidity to define optimum blends that
would produce high strength coke, Fig. 7.6. The graph can be dissected into four quadrants. Coals
from quadrants I and II provide fluidity to the blend (bonding and high CSR), whereas coals from
quadrant IV provide rank (coke strength) to the coal blend. Those coals representing lower ranks
in quadrant III would provide filler and the most opportunities for cost reductions to a coke pro-
ducer. Reflectance and maximum fluidity values have also been used to predict stability with spe-
cial reference to Canadian coals, Fig. 7.7. The desired blending area suitable for Canadian coals is
shown by the cross-hatched zone.
7.2.1.2.2.3 Dilatometer Some measure coke strength through the use of dilatometry which is much
prevalent in some European countries. Dilatation is measured using either Arnu or Ruhr dilatome-
ters. Dilatation can be used to predict Micum Indices (M40 and M10). A cokability factor called
G-Factor has been developed. One application of the G-Factor15, shown in equation. 7.2.1, is to
predict M40, shown in equation 7.2.2.
V1k d
G - Factor = E + 2 + V1k + Ed (7.2.1)
Kyoei Oyubari VM 42 - 46
30 000 Miike Jap. HV (A)
Heiwa Yubari> 27 500 d.d.p.m.Inerts 48 - 96
20 000
VM 35 - 36
USA HV (A) Inerts 16 - 20
10 000 Blackhawk
Mass No. 3
5000 Lynco
4000
3000 II Gem No. 5 I
Elkhon
2000 St. Sewell 1
VM 22 - 31
1000 USA MV Inerts 12 - 26
Akabira
Ashibetu
Jap. HV (B)
Borehole
Aust. HV VM 38 - 45
Gem No. 3
50 Newdell Moura Relations between max.
1 fluidity and rank of coals in
1
case of low inerts content
20 Canada MV VM 17 - 21
VM 21 - 25
USA LV Inerts 8.5 - 24
Wolondilly 2
Inerts 26 - 34
Liddell
10 Indian Ridge
Hebburn Toro
Can
Vicary 2
Newdell 2 IV
ada
5 Moura 2
Keystone
LV
Vicary 1
3 III Australia MV Kopperstone
Sm
VM 29 - 32 Balmer
oke
Inerts 26 - 34 Bird B
Itmann
yR
G6 Beatrice
iver
1
0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2.0
Mean max. reflectance of vitrinite (%)
Fig. 7.6 D130/15 Prediction using reflectance and maximum fluidity. (From Ref. 13)
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Ironmaking Volume
30,000
20,000
10,000 14 kPa
8,000 30 35 45
40 50
6,000
4,000
55
Stability
2,000 factors
1,000
800
600 58 60
400
200
Fluidity (DDPM)
100
80 60
60
40 58
20
35 40 45 50 55 Increasing
10 kPa
8
6 Decreasing
4 30 kPa
2 25
0
0.8 1.0 1.2 1.4 1.6
Reflectance (R )
Fig. 7.7 Stability prediction with special reference to Canadian coals. (From Ref. 14)
where:
E = softening temperature (°C)
V1 = resolidification temperature (°C)
k = % contraction
d = % dilatation.
Thus,
1.196V5 2.57V2 88V
M = 103.9 + 24.8G + 106 + T – T (7.2.2)
where:
V = volatile matter of blend (dry ash free %)
T = time (h) of carbonization to a center temperature of 900°C in an oven of average
width of 46 cm.
The G-Factor for most medium and strongly caking coals is usually between 0.95–1.15. It has been
shown to be linearly additive for blends and can be used in equations to predict coke strength.16
Others have used a relationship between the total dilatation and reflectance to predict the ASTM
stability factor, Fig. 7.8. It should be noted that the stability factor lines in the graph are not based
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Manufacture of Metallurgical Coke and Recovery of Coal Chemicals
300.0
40 0
G - factor line 60 50 30
Japanese target
blending area
100.0
50
65 40
30
60
55 20 0
50 10
30 0
0.0
1.6 1.4 1.2 1.0 0.8
Reflectance
Fig. 7.8 Stability prediction using total dilatation and rank. (From Ref. 14)
on actual coke stability measurements but are calculated using reflectance and inert contents of
coals. The blend target areas as defined by the National Coal Board (NCB) and by Japanese steel-
makers are also shown in Fig. 7.8.
7.2.1.2.2.4 Free Swelling Index (Crucible Swelling Index), Gray-King Coke Test, and RogaTest These tests
give an indication whether a coal will carbonize to form a coherent coke or not. Table 7.3 shows
an approximate comparison between the three indices.15 These tests are used only to assess the
coking ability of a coal.
7.2.1.2.3 Blend Design for Coke Size The as-formed size of the coke is influenced by the amount of
inert components of the coal lend. As the inert content decreases, the size of coke decreases. Thus,
the coal type influences the coke size. The coke size is also highly dependent on operating vari-
ables. Various additives such as coke breeze, anthracite, petroleum coke when added to a coal
blend, can result in an increase in coke size. In normal practice, the coke size for blast furnace is
mostly controlled by screening.
7.2.1.2.4 Blend Design for Coke Yield The amount of coke produced in a coke oven will be inversely
proportional to the coal volatile matter. The relationship used at Ispat Inland is given in Fig. 7.9.17
Table 7.3 Comparison Between Free Swelling Index, Gray-King Coke Type, and Roga
Index
0–1⁄2 A–B
1–4 C–G2
41⁄2–6 F–G4
61⁄2–8 G3–G9
81⁄2–9 G7 and above
0–1⁄2 0–5
1–2 5–20
21⁄2–4 20–45
>4 >45
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Manufacture of Metallurgical Coke and Recovery of Coal Chemicals
100
50
20
Low inert coals
10
Peek coking pressure (psi)
5
Fig. 7.10 Effect of coal rank and coal
type on wall pressure. (From Ref. 19)
1
High inert coals
0.5
0.1
0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2
Reflectance of vitrinite
1.5
1.2
Center gas pressure (psi)
0.9
Fig. 7.11 Effect of rank on gas pres-
sure. (From Ref. 20)
0.6
0.3
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Ironmaking Volume
70
7.2.1.7 Assurance of Coal Quality Shipments
Blend design is half of the job. The other half is
to make sure that consistent quality coke is pro-
duced from the batteries. In order to produce a
consistent high quality coke, the producer must
monitor the coal quality and forecast the reserve
quality. Petrographic, rheologic, chemical and Fig. 7.13 Coal reserve evaluation for CSR. (From Ref. 1)
394 Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved.
Manufacture of Metallurgical Coke and Recovery of Coal Chemicals
ash chemistry characteristics are some of the inherent coal quality variables that should be moni-
tored on a routine basis for coal shipments.1, 25 In addition to monitoring shipments, it is essential
to forecast the coal quality data for the coal reserves and incorporate the quality data into the min-
ing plan.1, 25 This will assure consistent quality coal shipments in the future. An example of a
reserve evaluation map is shown in Fig. 7.13.
It should be noted that the coal blend design helps to achieve the potential mean value of a desired coke
property. Thereafter, the control of the battery operation is effectively used to reduce the variability.
Applying the coal selection procedure described in this section, cokemakers can achieve a balance
between the requirements of throughput, high coke quality, battery life, and cost efficiency with an
assurance of a consistent supply of high quality coals from the future mining areas.
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Ironmaking Volume
coal are not uncommon during the winter months, and contaminants such as wood, rock and metal
are usually present.
Primary crushers are used to break up the large coal with a minimum of fines generation. Not all
plants are equipped with primary crushers, but plants that are equipped usually employ roll type
crushers or Bradford breakers, Fig. 7.15. The Bradford breaker is a large rotating drum over 6 m
(20 ft) long and about 4.2 m (14 ft) in diameter, with holes about 63 mm (2.5 in.) in diameter
spaced uniformly over the entire shell. Baffle plates inside the drum lift and drop the coal as the
drum rotates. This repeated impact crushes the coal, which then passes through the holes in the
shell to a conveyor. The rock, slate and extraneous refuse are discharged from the end of the drum.
Plants not equipped with breakers of this type usually use magnetic separators and/or scalping
screens to separate foreign material.
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Manufacture of Metallurgical Coke and Recovery of Coal Chemicals
maximum performance from the combined mixing bin and weigh feeder systems. Coal propor-
tioning is too important to take lightly or to ignore simply because the facility is too old to main-
tain properly or because repair parts are difficult to obtain. The benefits in uniform coke quality
and in the resultant blast furnace performance justify a concerted operating effort and an adequate
maintenance program.
Each bin is provided with a discharge weigh belt for controlling the weight of the coal delivered.
Coal weight control is accomplished by scales and control circuitry which regulates either the
speed of the belt carrying a constant depth of coal or the depth of the coal on a constant-speed belt.
There is probably little difference in the performance of these two types of weigh feeders provided
the machines are of modern design and well maintained. Usually, if the weigh feeders and control
circuits are in good condition and an error exists, it is probably due to the bin above the feeder. If
the flow from the bin is not constant because of poor bin design or because of wet coal or extra-
neous material, the weigh feeder cannot deliver the required flow rate. The subject of bin design
and mass flow of materials from bins is too extensive to discuss in detail here. Suffice it to say that
the bin and feeder must be treated as an integral unit if accurate proportioning is to be accom-
plished. The best feeder is useless without a proper bin above it.
Dust gate
Breaker
block
Rotor
discs
Hammer
suspension impa
bars 1 or ct Breaker
ne z plate
zo
on
e
Hammers
Screen bars
nz
zo
io
ne
2 o r it
r a tt
Cage
Cage
adjustment
linkage
Trap
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Manufacture of Metallurgical Coke and Recovery of Coal Chemicals
A coke battery cannot be operated smoothly and efficiently without bulk density control. It would
be impossible to heat the battery properly, coal level in the ovens would be variable, stickers and
oven damage by high coking pressure and insufficient contraction could occur and coke strength
would be variable.
Bulk density of the coal blends is affected by moisture content, as shown in Fig. 7.19. For exam-
ple, coal with a bulk density of 700 kg/m3 (43.7 lb/ft3) containing 8% moisture actually contains
only 644 kg of dry coal per cubic metre (40.3 lb/ft3). Consequently, it is desirable to maintain a
constant moisture content in the coal blend by adding water if necessary.
Most bulk density control systems
are based on the use of No. 2 or
800 50
diesel grade oil, or other similar
oils, to increase bulk density of
Box bulk density (lb/ft3)
775
Box bulk density (kg/m3)
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these systems and the amount of oil needed to attain the control point is automatically adjusted.
The oil is sprayed onto the coal stream just ahead of the pulverizers or mixers where it is distrib-
uted and mixed with the coal blend.
The gamma ray unit, when applied to measuring bulk density of coal, is a very complex system in
which many factors influence the measurement. Some of the more important factors are: (1) the
depth of the coal on the belt as it passes under the radioactive source; (2) changes in the radiation
absorption coefficient of the coal; (3) dust or other material in the signal path; (4) temperature of
the detector; (5) thickness and tension of the conveyor belt; and (6) size consistency, moisture con-
tent and temperature of the coal. The advantages of the gamma ray system are that it is less expen-
sive than the weigh belt system and is less expensive to operate and maintain. Both systems,
properly maintained, can perform with an accuracy of at least ±16 kg/m3 (1 lb/ft3).
Fig. 7.20(a) shows the effect of oil addition on coal bulk density for a typical coal blend and Fig.
7.20(b) shows the changes in coke stability which result from changes in coal pulverization, bulk
density and coking rate for the same coal blend.
The use of oil is not the only means available to increase and/or control coal blend bulk density. In
Japan, many coke plants add water to the coal in the stockpiles as it is being conveyed into the plant
to control moisture content to about 9%. This is done primarily to control dust, but the operators
also aim for uniform moisture content. This uniform moisture content, in combination with a uni-
form coal blend pulverization level, results in a uniform bulk density for the coal blend. In most
cases, the bulk density is quite low, averaging only about 688 kg/m3 (43 lb/ft3). Some Japanese
plants briquette about one-third of their coal blend; this increases bulk densities and also improves
coke quality (see Section 7.5). In the Saar region of West Germany, a process called stamp charg-
ing is employed to increase the bulk density of the fine, high moisture coals used in that area. In
Pulverization (%_ 1/8")
60 67 74 81 88 95
x 59
54
x
22.9mm/h
850 x
A S T M c o n e b u l k d e n s i t y, l b / f t 3 ( w e t )
769kg/m3
(0.9in/h
x x 52 57 48lb/ft)
Coke stability
x Pulverization
Bulk density (kg/m3)*
800 50 55
_
70% 3.2mm
x x 22.9mm/h
(70%_1/8"
0.90in/h)
48 Bulk density
53
750
x 46 Coking rate 70%_3.2mm
51 769kg/m3
x (70%_1/8"
x _4 . 5 % m o i s t u r e 3
48lb/ft )
x _6 . 0 % m o i s t u r e 44
700 _7 0 % _1 / 8 " ( 3 . 2 - m m ) b l e n d
_8 0 % _1 / 8 " ( 3 . 2 - m m ) b l e n d 49
60 67 74 81 88 95
_9 0 % _1 / 8 " ( 3 . 2 - m m ) b l e n d
Puverization (%_3.2mm)
42
21 22 23 24 25 26
x Coking rate (mm/h)
650
40 750 775 800 825 850
0 0.5 1.0 1.5 2.0 2.5
sBulk density (kg/m3, dry)
Oil addition (litres per metric ton)
*Calculated from ASTM cone bulk density
(b)
(a)
Fig. 7.20 (a) Bulk density response to oil additions for a coal blend; (b) changes in coke stability resulting from changes
in coal pulverization, bulk density and coking rate.
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Manufacture of Metallurgical Coke and Recovery of Coal Chemicals
this latter process, a large compacting device located on the pusher side of the battery is used to
compress the coal blend into a rectangular mass slightly smaller in size than the coking chamber
of an oven. This stamped charge is then inserted into the oven from the pusher side. Bulk densities
as high as 1040 kg/m3 (65 lb/ft3) are not uncommon when using this practice. Coal preheating can
also be considered as a means of controlling bulk density because the moisture content (0%) and
the pulverization level are controlled.
Tr u n n e l h e a d Larry
car
Refractor y br ick
Ear th fill lining
Pusher
machine
Quencher
car
Fig. 7.21 Ideal section of a beehive coke oven in a single block battery, showing refractory lining, earth fill, larry car, pusher,
quencher car and other details, including the trunnel head at the top through which the coal was charged and the volatile
products escaped. Vertical lines in the coke bed indicate the fissures that developed during coking, giving beehive coke its
characteristic columnar structure.
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A beehive coke oven was a circular, domed firebrick structure with a flat floor that sloped toward
the door through which coke was removed when the coking process was completed. An opening
called the trunnel head in the center of the domed roof permitted coal to be charged into the oven
and allowed the gases generated during the coking process (called foul gas) to escape into the
atmosphere. A typical oven was about 3.7 m (12 ft) in diameter and processed about 4.5–6.3 tonnes
(5–7 tons) of coal per charge. From 48 to 72 hours were required to complete a coking cycle.
Beehive coke oven plants were constructed according to three general arrangements: (1) the bank
system, in which the ovens were built in a single row against a bank of earth, natural or artificial,
with a retaining wall in front of the ovens; (2) the single block system, which consisted of a single
row of ovens, all facing the same way, with retaining walls at both the front and back of the row,
Fig. 7.21; and (3) the double block system, in which the ovens, in a double row, were built back to
back or staggered with a retaining wall extending along the front of each row. In all cases, the space
above the ovens between the bank and the retaining wall or between the two retaining walls was
filled with earth. Tracks were laid on top of the rows to carry larry cars from which coal could be
charged directly into the ovens; other tracks at yard level in front of the ovens carried cars which
received the coke as it was removed from the ovens.
7.3.1.1 Charging
Beehive ovens were charged as soon as practicable after drawing the coke from the oven at the end
of the previous cycle, in order that stored heat from the previous charge would be sufficient to start
the coking process. New ovens had to be heated gradually to the coking temperature by wood and
coal fires, after which small charges of coal were coked until the ovens reached normal working con-
ditions. With the oven in readiness for charging, the door was partially bricked up and the coal charge
was dropped through the trunnel head from the larry car above, leaving the coal in a cone-shaped pile
in the oven. In order to secure uniform coking of the coal, this pile had to be leveled so that the coal
would lie in a bed of uniform depth of about 46–610 mm (18–24 in.) over the entire floor of the oven.
This leveling was done by machine or by hand. In works not equipped with a machine, the leveling
was accomplished with a long-handled scraper, operated through the door of the oven, which was pur-
posely bricked up to only two-thirds of its height at the time of charging. After leveling the coal, the
door opening was bricked up to within about 38 mm (1.5 in.) from the top.
402 Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved.
Manufacture of Metallurgical Coke and Recovery of Coal Chemicals
Fig. 7.22 Overall view of the pusher side of a typical byproduct coke oven battery.
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Manufacture of Metallurgical Coke and Recovery of Coal Chemicals
the top of the coking chamber into vertical flues in the oven walls. Gas from the ovens and air were
mixed and burned in a downward direction in these flues and passed to the stack through sole flues
under the oven. Known as the Francois oven when built in France and as the Rexroth oven when
used in Germany (hence the combination name, Francois-Rexroth), this so-called waste heat oven
was 8 m (26 ft) long, 1.5 m (5 ft) high, and 0.9 m (35 in.) wide.
In the earliest development of the industry, therefore, various facilities were developed for differ-
ent purposes. From the standpoint that the Francois-Rexroth oven was a rectangular, vertical cok-
ing chamber, which embodied vertical heating flues, it could lay claim to the distinction of being
the forerunner of the modern coking oven, notwithstanding the fact that it was not of the recovery
type and that it was designed primarily to overcome some of the objections to the then prevailing
coking method. The Knab oven similarly could be placed in the category of a pioneer among recov-
ery type ovens, despite its shortcomings in heating facilities. Both the Francois-Rexroth and the
Knab ovens were departures from the then contemporary practice in that air was excluded from the
coking chamber and external heat was supplied for carbonization.
7.3.2.3.2 Development of Vertical Flue Ovens The course that was pursued later in improving oven per-
formance led to two separate and distinct developments.
Carves of England, using the Knab principle, developed an oven in 1862 (Knab-Carves design) that
embodied horizontal heating flues in the oven walls. This oven was an improvement over the Knab
design, providing for greater yield of coke and requiring less time for carbonization. The principal
contribution by Carves, however, was the addition of an exhauster in the chemical recovery appa-
ratus. In the Carves oven system, gas was drawn from the oven by the exhauster, pumped through
the chemical recovery apparatus, and returned to the ovens for use as fuel, the present method of
recovering coal chemicals being based on this same principle. Because of the inclusion of hori-
zontal flues in the oven walls, the Carves system can claim the distinction of being the originator
of the horizontal flue system of oven heating.
Almost simultaneously with the Carves development, Coppee in Belgium, using the basic princi-
ples of the Francois-Rexroth oven, introduced the innovation of reducing the width of the oven and
providing additional vertical heating flues in the oven walls. The ovens built by Coppee at that time
were about 9 m (30 ft) long; 1 m (3 ft, 7 in.) high; and 0.5 m (18 in.) wide. In these ovens, stack
draft was used to draw the gases of combustion from the vertical downdraft flues through waste
heat boilers, recovering the sensible heat as steam. The ovens built by Coppee embodied 28 verti-
cal flues, and one of the chief contributions of this builder was the control of combustion by
dampering the air admitted to the flues. Since the ovens built by Coppee conformed more nearly
to present day conventional width ovens and also contained a substantial number of vertical flues
in the oven walls, this oven may, in some respects, be considered the true predecessor of the mod-
ern coke oven.
Up to that time, all these developments took place in Europe, although ovens of the Coppee or Bel-
gian design were built and operated in the United States. The installations were made at both the
Johnstown plant of the Cambria Iron Company and the Holidaysburg plant of the Blair Iron and
Coal Company, both in Pennsylvania.
Ovens of the Coppee design were built in the Ruhr district of Germany by Dr. C. Otto and Com-
pany, who added further refinements to the earlier Francois-Coppee design. Attempts at converting
these ovens from the so-called waste heat type to the recovery type byproduct ovens have been cred-
ited to this builder. In the ovens of Otto design, the volatile products from the coal were removed
from an opening in the top of the oven and the gas, after passing through the chemical recovery
apparatus, was returned to the flues in the walls of the ovens. The flow of combustion gases in this
oven was different from that of the early Coppee design, with products of combustion rising and
descending in alternate flues, thus forming the basis for the later ovens of hairpin flue design.
Heating of these ovens was rather crude and inefficient. Nevertheless, this early Otto-Coppee
development is significant because it was the first vertical flue oven of the recovery type built with
flues completely surrounding the oven chamber.
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Manufacture of Metallurgical Coke and Recovery of Coal Chemicals
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Ironmaking Volume
flue and nozzles. The nozzles were removable and made with orifices of various sizes. This per-
mitted control of the volume of gas to individual flues and provided for the replacement of nozzles
when required.
The next significant development in byproduct coke ovens was the erection of Koppers ovens for
the Coal Products Company at Joliet in 1912. These ovens were arranged with combination cross
regenerators to provide for simultaneous preheating of air and producer gas for coke oven under-
firing. By this procedure an additional amount of the richer coke oven gas was released for sale.
This type was the predecessor of the combination oven, so-called because the regenerators are
arranged to preheat both air and fuel gas in separate chambers.
Difficulties were experienced with the single horizontal flue (bus flue) above the vertical heating
flues through which the products of combustion passed from the heating flues to the downflow
flues of the early cross regenerative ovens because it had to be quite large to handle the volume of
combustion gases generated.
This condition was aggravated as ovens of greater capacity were built and increasing use was made
of lean fuels such as blast furnace gas and producer gas. This problem was solved in various ways
by different designers during the 1920s.
One solution to the horizontal bus flue problem was the Koppers-Becker design which incorpo-
rated an entirely new system of heating, as shown later in Fig. 7.58. In these ovens, first installed
as an experimental battery in Chicago in 1922, gas is burned in all of the flues on one wall of an
oven at the same time. The products of combustion from groups of two or more adjacent verti-
cal flues of the wall in which fuel gas is burning enter short horizontal bus flues and are then
conducted over the top of the oven coking chamber through crossover flues to a companion
series of bus flues, whereby the vertical flues of the entire opposite wall are simultaneously con-
ducting waste gases to the regenerator. On reversal of this process, the opposite conditions are
obtained.
Another solution to the horizontal flue problem is exemplified by the Wilputte double-divided
oven, see Fig. 7.58. The size of the flue is limited in these ovens by dividing it at the center of the
oven. Each half of the flue then serves an inner an outer zone of the heating system. Gas is burned
alternately in the two outer zones with the products of combustion being carried by the horizontal
flues to the two inner zones and then to the regenerators. On reversal, gas is burned in the two inner
zones and the products of combustion pass to the regenerators through the two outer zones; in
effect, these designs constitute two short cross regenerative ovens placed end to end.
Various improvements in the design of regenerative systems were made by different builders, and
the systems employed in some modern byproduct ovens are discussed extensively in Section 7.6 of
this chapter.
As vertical flue ovens of greater height came into use, the uniform heating of the flues in the
high walls from top to bottom became a problem, especially when heating with rich gas that has
a characteristically short flame. Some of the solutions for this problem included: (1) dilution of
fuel gas with waste gases to produce a longer flame (Koppers); (2) introducing combustion air
in successive vertical stages along the height of the heating flue (Carl Still); and (3) using high
and low burners in alternate heating flues (Wilputte). Application of these and other combustion
control principles to some modern byproduct coke ovens also is discussed Section 7.4 of this
chapter.
7.3.2.3.5 The Byproduct Oven in the United States Although reasonable success had been achieved
abroad with the byproduct oven, it was not used in the United States prior to 1890. It is pertinent
to recall that the first ovens of the byproduct type installed in the United States were not for pro-
duction of metallurgical coke. The distinction for launching the industry must be accredited to the
Solvay Process Company, which was interested in establishing the soda ash industry in this coun-
try. The plant that was built in Syracuse, New York and placed in operation in 1893 consisted of 12
Semet-Solvay ovens.
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Manufacture of Metallurgical Coke and Recovery of Coal Chemicals
It was not until two years later that recovery type (byproduct) ovens were installed in the United
States for producing blast furnace coke. In 1895, the Cambria Steel Company at Johnstown, Penn-
sylvania built a battery of 60 Otto-Hoffman ovens.
Until 1900, only nine plants with 1081 byproduct ovens had been constructed in the United States.
From 1900 through 1910, however, there was a period of rapid industrial expansion, particularly in
the iron and steel industries, and the number of byproduct coke plants more than tripled while the
number of byproduct ovens increased four-fold.
The need for coal tar dyes and explosives in World War I added impetus to this expansion, and by
1918 the byproduct coke industry had 59 plants with over 9000 ovens.
The construction of byproduct ovens for gas utilities in the 1920s further expanded the industry
and, by 1930, there were 89 plants with 12,771 ovens in existence.
Due to a worldwide economic depression, construction of byproduct ovens was halted during the
1930s and by 1940 there were fewer ovens in existence than during the 1930s. However, World War
II started a new construction era and between 1940 and 1950, 2359 ovens were added to the indus-
try total for ovens. The increase in total ovens, however, only partially indicates the vast construc-
tion program of this period because many of the ovens constructed were replacements or rebuilds
of ovens originally built during World War I. Actually, over 5000 ovens were constructed during
this period.
The construction of byproduct ovens continued after 1950, and in 1958 the number of ovens
reached an all-time peak of 16,244. Although ovens increased in number because of the expansion
of blast furnace plants, the number of byproduct coke plants in existence decreased to 77 during
this period, because seven gas utility plants were abandoned as markets for coke oven gas were lost
to natural gas which became available in many areas through the extension of gas pipelines after
World War II.
Since 1960, the total number of byproduct coke ovens in the United States started to decline, due
to a steady reduction in steelmaking output, environmental controls, more efficient coke-to-hot
metal rations achieved in blast furnaces, and ovens with larger capacity coking chambers. By early
1998 the total number of slot type ovens in the United States had declined to 3,409 from 6,350 in
1983. Correspondingly, coke capacity has dropped from 32 to 20 million tonnes annually over the
same period of time.
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Ironmaking Volume
The coal is charged through openings in the top of the oven and, after the coal has become coke,
the coke is pushed out from one end by a power driven ram, or pusher, Fig. 7.24. During the cok-
ing period, the ends of the coking chamber are closed by refractory lined doors, which are con-
structed to completely seal the ends of the ovens. The ovens first constructed in the industry
provided a space between the door and the jamb which was filled with a special luting mixture to
seal the oven prior to charging. Later, several types of self-sealing doors were developed, which
seal the opening when put in place and require no luting; several of these are described later in
this section.
To permit the escape of volatile matter driven from the coal during coking, an opening is provided
at the top of the oven at either one or both ends of the coking chamber. Each such opening is fit-
ted with an offtake pipe, which connects the oven with the gas collecting main for the battery.
The combustion chambers consist of a large number of flues which permit uniform heating of the
entire length of the coking chamber. Ovens have been built with either horizontal heating flues or
vertical heating flues, but vertical flues are used almost exclusively in present installations. Some
of the older ovens employed the recuperative principle for preheating combustion air. Modern prac-
tice utilizes the regenerative principle to achieve higher thermal efficiency whereby less gas is
required to heat the ovens. In all modern oven batteries, individual regenerators are provided for
each heating wall and are located under each oven. This permits separate control of the flow of pre-
heated air for combustion to individual vertical heating flue walls and allows close control of heat-
ing. An advantage of individual regenerators is that the control of heating for each oven is relatively
independent of the operation of the remainder of the battery.
410 Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved.
Separate
charging
larry
Pusher
E m p t y o ve n
r e a d y fo r
charging
( a ) T h e c h a r g i n g l a r r y, w i t h h o p p e r s c o n t a i n i n g m e a s u r e d a m o u n t s o f c o a l , i s i n p o s i t i o n
o ve r c h a r g i n g h o l e s f r o m w h i c h c o ve r s h a ve b e e n r e m o ve d . T h e p u s h e r h a s
b e e n m o ve d i n t o p o s i t i o n .
Coal
( b ) T h e c o a l f r o m t h e l a r r y h o p p e r s h a s d r o p p e d i n t o t h e o ve n c h a m b e r, fo r m i n g
peaked piles.
L eve l i n g b a r
Coal
( c ) T h e l eve l i n g d o o r a t t h e t o p o f t h e o ve n d o o r o n t h e p u s h e r s i d e h a s b e e n o p e n e d ,
a n d t h e l eve l i n g b a r o n t h e p u s h e r h a s b e e n m o ve d b a c k a n d fo r t h a c r o s s t h e
p e a k e d c o a l p i l e s t o l eve l t h e m . T h e b a r n ex t i s w i t h d r a w n f r o m t h e o ve n , t h e
l eve l i n g d o o r a n d c h a r g i n g h o l e s a r e c l o s e d , a n d t h e c o k i n g o p e r a t i o n b e g i n s .
Coke gide
Quenching
car Coke
( d ) C o k i n g o f t h e c o a l o r i g i n a l l y c h a r g e d i n t o t h e o ve n h a s b e e n c o m p l e t e d ( i n a b o u t
1 8 h o u r s ) a n d t h e o ve n i s r e a d y t o b e " p u s h e d . " T h e o ve n d o o r s a r e r e m o ve d f r o m
e a c h e n d , a n d t h e p u s h e r, c o k e g u i d e a n d q u e n c h i n g c a r a r e m o ve d i n t o p o s i t i o n .
Ram of pusher
Coke
( e ) T h e r a m o f t h e p u s h e r a d va n c e s t o p u s h t h e i n c a n d e s c e n t c o k e o u t o f t h e o ve n ,
T h r o u g h t h e c o k e g u i d e a n d i n t o t h e q u e n c h i n g c a r.
Fig. 7.24 Schematic presentation of the sequence of operations involved in charging, leveling and pushing in one coking
cycle of a byproduct coke oven.
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Manufacture of Metallurgical Coke and Recovery of Coal Chemicals
range to which silica coke oven refractories should be heated. With the flues operating within this
temperature range, time required to coke the coal depends primarily upon the width of the coking
chamber and the nature of the coals being coked, although a few other factors are involved. In gen-
eral, a coking time is selected that will produce a uniform skin temperature of the block of coke in
the coking chamber of 1040–1095°C (1900–2000°F) at the time the charge has been coked all the
way through to the center. The skin temperature referred to above applies to the coke adjacent to
the walls of the coking chamber. The time required for coking coal under the above operating con-
ditions generally varies from 16 to 20 hours. Normally, the average time is 17 to 18 hours.
Because the flue temperature should not exceed 1535°C (2800°F), the heating system must be
reversed on a regular basis. The frequency with which the firing of byproduct coke ovens is
reversed generally has been established on a 30 minute cycle. Batteries which require a higher aver-
age temperature level to sustain high production rates can be reversed on either a 15 minute or 20
minute cycle without exceeding maximum permissible temperatures.
Of particular importance in flue design is the position of the gas inlet in the vertical flue in rela-
tion to the air port, and the manner in which the gas and preheated air are mixed at the base of the
flue. Excessive turbulence at this point will result in quick combustion, and a short, intense flame
will cause local overheating at the base of the vertical flue.
Control of the rate of flame propagation and flame length in the vertical flues is desirable. This has
been accomplished in several ways. In some batteries, blast furnace gas is mixed with rich fuel gas
to lower the heating value of the latter and alter its combustion properties. One system recirculates
waste gas from the flues containing waste gas to the nozzle where fuel gas is being burned. This
feature is contained in the Koppers-Becker design, Fig. 7.62. By this recirculation, the flame length
can be controlled without cooling or purification of the waste gas and without having to heat the
diluent as would be required with external mixing. The ratio of recirculated waste gas to fuel gas
is controlled by the orifice size and the fuel gas pressure, and normally approximates one volume
of waste gas to one volume of fuel gas. Waste gas recirculation also prevents the accumulation of
carbon in the underjet gas ducts, as the contained carbon dioxide and water vapor both tend to
inhibit carbon deposition. In ovens not recirculating waste gas, air must be introduced into the gas
ducts during the gas off periods for decarbonization of the nozzles.
A feature of the Wilputte double divided oven shown later in Fig. 7.64 and Fig. 7.65, especially for
those over ten feet in height, is the high-low burner construction. Low burners in flues alternating
with high burners in adjacent flues prevent overheating at the bottom of the flues and improve the
vertical heat distribution.
The latest development is the air stage heating system. In this system gas is fed to the heating flues
through short burners at the bottom which all have the same height, approximately 300 mm (1
ft).The necessary combustion air enters the heating flues through air outlets located in most cases
at two different heights, but as many as six different heights. Instead of the very hot local flames
of a gas stage system, this results in an area of combustion with more even heat development over
the heating wall area. The result is a lower average heating flue temperature at the same coking
time. The emissions (NOx) are reduced as peak temperatures are lower. All presently active coke
oven builders have changed to the air stage system.
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Ironmaking Volume
Some modern coke oven designs can be heated with pure coke oven gas or blast furnace gas.
Because the calorific value of blast furnace gas varies based on the operating conditions of the fur-
nace it is stabilized in an automatic mixing station by the addition of a small amount of coke oven
gas in order to ease the coke oven heating operation.
The rich fuel gas is heated to above its dew point. The fuel gas mains located in the alleys on both
the pusher and coke side (or in the basement in the case of an underjet battery) are insulated to
limit condensation in the headers and to keep the gas at a uniform temperature throughout the
length of the header. Other designs keep the basement/alley temperature controlled in a range
which makes any insulation unnecessary.
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Manufacture of Metallurgical Coke and Recovery of Coal Chemicals
are allowed to enter the heating system at the horizontal or bus flue elevation through suitable
openings provided for this purpose, which later are plugged and sealed. The hot gases during the
initial or drying out period are vented down through the vertical flues and regenerators to the stack
flue and stack. When the flues become hot enough to ignite fuel gas, the gas is introduced through
the normal heating ducts. Where other gas is not available for
Corner stop heating up, liquid butane or propane may be vaporized and
b o l t ( t y p. )
used. In the earlier period, coal or coke has been used for
heating up by substituting a brick bulkhead for the oven door,
leaving openings for firing and ash removal. The same type
of false hearth is used to protect the oven liner brick. After
heating up, the false hearth and bulkhead are removed and
the oven door is installed.
L eve l e r d o o r
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Ironmaking Volume
Flue Flue
Buckstay
Fig. 7.27 Horizontal section of the self-sealing coke oven door shown in Fig. 7.26.
oven doorjamb. The Wilputte leveler door is constructed with a heavy ductile iron casting with
insulation and a stainless steel sealing edge that is adjusted by set screws. The leveler door latch
spring is made from a heat resistant stainless steel, Fig. 7.28 and Fig. 7.29.
7.4.1.6.3 Thyssen Still Otto Door The Thyssen Still Otto type self-sealing door with its spring-loaded
sealing strip is well illustrated in Fig. 7.30. The door body is a heavy casting. The Z-shaped sealing
fram from special stainless steel is adjusted to the contour of the chamber by separate adjusting bolts
and not by the sealing springs. The sealing spring pressure is 100% available as sealing force.
Replaceable Replaceable
Door lining
jamb jamb
Replaceable brick brick Replaceable
nose nose
brick brick
Buckstay
Jamb bolted
in place
Adjustable
spring
plunger
Door
Door frame
latch
416 Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved.
Manufacture of Metallurgical Coke and Recovery of Coal Chemicals
Fig. 7.30 Thyssen Still Otto self-sealing coke oven door with spring loaded sealing strips.
Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved 417
Ironmaking Volume
Fig. 7.32 Saturn door awaiting installation. Fig. 7.33 Saturn door cross-section through retrofit
seal.
around the entire door. Basic sealing pressure is applied to the Inconel seal through the plungers
while an even pressure is maintained around the entire length of the seal by leaf spring.
7.4.1.6.6 Thyssen Still Otto Door Thyssen Still Otto has developed the Autoseal door which incor-
porated the Z-type sealing strips. By adapting the sealing strip to the doorjamb contour, the door
can be adjusted without reducing the required forces exerted by the sealing strip. Sealing is
418 Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved.
Manufacture of Metallurgical Coke and Recovery of Coal Chemicals
Fig. 7.34 Cross-section through the Thyssen Still Otto AutosealTM door with automatic adjustment of the contact pressure
by means of compressing spring system.
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Ironmaking Volume
HP _ aspiration liquor
Flushing liquor
Mechanical and manual
operation of water-sealed lid
Pneumatically operated Pneumatically-operated
HP _ aspiration valve bleeder valve
Bitumen seal
Fig. 7.35 Thyssen Still Otto collecting main and ascension pipe with oval water-sealed cap for automatic gooseneck cleaning.
The flushing liquor spray nozzle is recessed in the standpipe elbow and protected by a shroud. The
nozzle provides 360° spray coverage of the elbow interior, to maintain maximum cooling and
cleaning. Easy access to the spray nozzles is provided.
The standpipe is lined with refractory brick or castable with a layer of insulation. The elbow is lined
with anchored castable refractory. The lined standpipe and elbow maintain the oven offtake gas at
a temperature high enough to minimize deposition on the walls until the spray in the elbow can
cool the gas and flush any deposits into the collecting main.
A gas-tight floating elbow connection to the collecting main is accomplished by the use of a flush-
ing liquor seal. Additional sprays located in the collecting main provide a flushing spray to the
damper valve housing to maintain trouble free valve operation. The height of the elbow cover per-
mits inspection of the inside of the elbow and the spray pattern when the oven is off the main.
All ovens of a battery thus are connected to a single or multiple pressure equalized collecting main
on either or both sides of the battery. The function of either the single or double collecting main is
not only to collect gas from the ovens but also to maintain at all times an accurately controlled pres-
sure in the oven during the coking process. Pressure in the oven during coking has a pronounced
effect on the coke and coal chemicals. The pressure in the collecting main usually is kept at a point
420 Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved.
Manufacture of Metallurgical Coke and Recovery of Coal Chemicals
Locking cover
assembly
Flushing liquor
nozzles
Refractory
lining
Insulation
Liquor seal
expansion joint
Liquor seal
valve
Fig. 7.36 Wilputte arrangement of standpipe, liquid-sealed damper valve, collecting main and automatic elbow cleaner.
that will give about 2 mm (0.078 in.) water gauge pressure at the bottom of the oven at the end of
the coking period. The pressure is regulated by a controller located in the connection between the
collecting main and the suction main which carries the gas to the coal chemical recovery units. The
collecting main also serves to transport to the tar decanters the products condensed from the gas
by the flushing liquor.
The gas passing from the ascension pipe to the collecting main is shock cooled with a flushing
liquor spray which causes precipitation of tar from the gas, and cooling of the gas to the desired
temperature.
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Ironmaking Volume
Fig. 7.37 View of a coal storage bin and larry car on top of a modern coke oven battery equipped with a double collecting main.
with volumetric sleeves, the gates usually are linked together and power operated as all gates may
be left open until the hoppers are full and the flow of coal is stopped by the sleeves.
The larry car in principle is designed in connection with the number of charging holes per oven so
that a predetermined quantity of coal is charged into the oven through each charging hole, the
mechanism for controlling discharge from each hopper being independently operated by powered
drives on new installations and by gravity on older batteries.
Improvements in larry cars, particularly the method of discharging coal, have been directed toward
making possible better charging practices. The aim has been to reduce the charging time; to reduce
the number of passes of the leveling bar necessary for leveling; to make a smokeless charge; to pre-
vent hanging up of the coal in the larry hoppers; and to make a uniform charge, regardless of coal
bulk density.
On more recent installations, Fig. 7.39, automatic lid lifters are provided to dispense with manual
removal of the charging hole covers.
The gravity discharge larry and the mechanically unloaded larry are the two main types in use at
the present time. The gravity discharge larry is equipped with conical shaped hoppers, shear gates,
and drop sleeve mechanisms. With this type, the coal charge flows by gravity from the hoppers into
the ovens. There are two designs of mechanically unloaded larry cars in use at present; namely, the
turntable and screw discharge types. The turntable larry is equipped with a revolving table serving
as the bottom of each hopper. The revolving table forces the coal through an opening in the side of
422 Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved.
Bunker gate operator
Power collector
Coal hopper
Pusher side
Antenna for
inductive radio Thyssen Still Otto
Discharge
equipment
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Drop sleeves and
sliding gate
423
Fig. 7.38 Front elevation of a coal charging larry for a modern byproduct coke oven.
Ironmaking Volume
Fig. 7.39 View of an automatic charging hole lid lifter assembly as mounted on a coal charging car.
Fig. 7.40 Pusher side equipment of a battery of byproduct coke ovens, showing the machine which is equipped to level
the coal charge in the oven and also push the finished coke out of the oven, as well as remove and replace oven doors
before and after the pushing operation.
424 Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved.
Manufacture of Metallurgical Coke and Recovery of Coal Chemicals
the hopper leading to the shear gate and drop sleeve and thence to the oven. The screw discharge
larry is equipped with rectangular shaped hoppers with the lower section tapering to a small open-
ing directly over the screw trough. The trough contains the screw conveyor that forces the coal hor-
izontally to the vertical drop sleeve and shear gate section.
To reduce emissions to the atmosphere a stage charging practice has been adapted, see Fig. 7.71.
With this concept, the two outer hoppers of the charging car, each of which contains approximately
40% of the coal charge, discharges coal into the oven while the charging hole lids of the inner
charging holes are still in place. When coal discharge from the outer hoppers is completed, the
outer lids are replaced and the lids from the inner charging holes are sequentially removed and the
remainder of the coal is charged into the oven. At a predetermined time during the discharge into
the inner charging holes, the leveler bar levels the coal in the oven. With stage charging, the oven
charging takes between three and eight minutes as compared to approximately two minutes
required when coal was discharged from all hoppers simultaneously.
Nearly all modern plants worldwide today use screw feeder coal charging cars as they are a well-
proven design, provide better control over the charging operation, and can be easily integrated into
modern process control systems.
Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved 425
Operator and electric cab
Door emission collecting device
426
Leveller bar
Pusher equipment
Ironmaking Volume
Structural framing
Maintenance platform
Drive truck
Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved.
Counter pressure device
Fig. 7.41 Byproduct coke oven pusher machines, equipped to level the coal charge in the oven, push the finished coke out of the oven and to remove and replace oven door before
and after the pushing operation.
Manufacture of Metallurgical Coke and Recovery of Coal Chemicals
Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved 427
Ironmaking Volume
Fume hood _ Emergency duct Fume hood _ Door emission collecting device
Fume hood
Fume hood _ Connection pipe
Drive truck
Quench car
Drive truck
The latest design machines for the coke side, Fig. 7.44, are called coke transfer cars and combine
in one machine the functions of coke guide, door extractor, door and jamb cleaner as well as the
hood for collection of the pushing emissions. They travel with only one row of wheels on the out-
side of the bench, thus keeping a greater distance between the machine and the battery clear for
more safety The other row of wheels travels either on the ground or on the collecting duct sup-
porting structure.
Generally, most coke oven machinery in the United States operates on direct current (DC) power;
however, on many new installations oven machinery is powered by alternating current (AC) motors
instead of DC motors and AC power generated at the plant can be used without rectification.
Use of AC motors is made possible by silicon controlled rectifiers. There are several advantages in
this method of control. With silicon-controlled rectifiers (SCR), stepless control is obtained and
the movement of machines is fast and smooth with reduced stress on equipment.
428 Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved.
Manufacture of Metallurgical Coke and Recovery of Coal Chemicals
is then taken to a coke wharf where the coke is discharged. The handling of the coke from the wharf
will be discussed later.
The quenching car is designed so that by moving the car during the pushing operation the coke is
caught in a relatively uniform bed about two feet thick on the sloping bottom of the car, Fig. 7.43.
The quenching car has gates at the low side of the sloping bottom, operated by electric or air power,
so designed and arranged that the quenching water not evaporated may drain readily from the car.
When the charge of hot coke has arrived at the quenching station, it is spotted under a system of
stationary sprays located in the quenching tower that is operated by remote control. The purpose of
quenching, obviously, is to cool the coke rapidly to stop any further combustion. However, it must
be recognized that coke with a low moisture content is desired. This is accomplished by so arrang-
ing the sprays and the time of quenching that sufficient heat will remain in the center of the indi-
vidual coke lumps to evaporate excess water. The usual practice is to aim at an average moisture
content of 2.5% in the metallurgical coke after screening.
Modern quenching stations are of the recirculating type in which the water drainage from the
quench car discharges into a settling basin where the coke fines collected with the excess quench
water settle out. The clear water is then reused for quenching. Because of environmental regula-
tions, the makeup water to the quench stations must be fresh water; the discharge of contaminated
water into the quench basin is no longer permitted.
Baffles have been installed near the top of some quenching station stacks to minimize carryover of
entrained dust and water droplets out of the top of the stacks by the steam generated in quenching.
These eliminators consist of wooden grid-type baffles, provided with auxiliary water sprays for
periodic flushing to remove accumulations of dust.
Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved 429
Ironmaking Volume
the quenching chamber at 175°C (347°F) and exits at about 800°C (1472°F). This inert gas flows
from the top of the chamber through a dropout chamber to remove coke particles and then enters
the waste heat boiler that serves as a steam generator. Cooled gas at 175°C (347°F) flows through
cyclones for dust removal prior to entering the recirculating fan. Depending upon the intended
application, as much as 0.46 tonnes (0.5 tons) of steam at 3920 kPa (60 kg/cm 2 or 70 psi) and
440°C (824°F) can be generated per ton of coke.
430 Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved.
Manufacture of Metallurgical Coke and Recovery of Coal Chemicals
sequence, beginning with A-2. With this system, when an oven is to be pushed, the coking cycle
of the oven next to it on its left is about 52% complete and that of the adjacent oven to its right is
about 48% complete. This system requires that the two odd-numbered ovens be next to each other
where the sections adjoin.
Two other pushing systems used in the United States coke plants are the even-odd series, or 2-1
series, and the 5-2 series. These pushing series are more popular in coke plants in Europe and
Japan. In both of these systems ovens are numbered consecutively.
The even-odd sequence, or 2-1 sequence, is the most basic as all of the even numbered ovens are
pushed in sequence followed by all of the odd numbered ovens in the next round of pushing, i.e.,
1, 3, 5, 7, etc., 2, 4, 6, 8, etc. This pushing sequence allows the ovens adjacent to the oven being
pushed to be about 51% and 49% through the coking cycle.
In the 5-2 series, ovens adjacent to the oven being pushed are 61% and 39% through the coking
cycle. Ovens are numbered consecutively. The first number, 5, indicates the sequence in consecu-
tive ovens pushed in a round from end to end on the battery. The second number, 2, indicates the
difference in the ovens pushed first in each round of pushing. The first oven pushed using this
schedule would be oven No. 1 followed by oven No. 6 (1+5), oven No. 11 (6+5), oven No. 16
(11+5), etc., until the end of the battery is reached. The next round begins with oven No. 3 (1+2),
followed by oven No. 8 (3+5), then oven No. 13 (8+5), etc., until this sequence is completed to the
end of the battery. The cycle is then repeated at oven No. 5 (3+2) and ovens No. 10, No. 15, No.
20, etc. are pushed. The full sequence would be: 1, 6, 11, 16, …; 3, 8, 13, 18, …; 5, 10, 15, 20, …;
2, 7, 12, 17, …; 4, 9, 14, 19, …; and then begin again at 1, 6, 11, 16, …
The Marquard pushing system, the 2-1, and the 5-2 sequence make it possible to design one spot
pusher machines for pushing and charging operations. This is desirable when pushing fast operat-
ing rates since the machinery operating sequence and travel time are more efficient. The system
presently preferred internationally in modern plants is the 5-2 system as it: features pusher
machines that operate pushing and leveling from one spot, reduces machinery sizes, reduces the
traveling distances and provides favorable coking conditions for the ovens next to the one to be
pushed.
Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved 431
Ironmaking Volume
used in the setting of individual oven controls. Another instrument used is a portable pyrometer
with which periodic temperature readings are taken of the flues and emerging coke. Probably the
most widely accepted pyrometer for the latter purposes is of the incandescent filament type. Newer
pyrometers which can collect temperature data for downloading into computers for records and
analysis are in common use. Recording pressure and temperature gauges also are installed in the
gas collecting mains.
The pressure in the collecting main is controlled by a back pressure regulator located at the junc-
tion of the collecting main with the suction main; its function is to maintain a closely controlled
pressure in the ovens during coking.
Many plants record the regularity of oven operation by some related activity, such as the time of
pushing by the peak-load recording of the pusher power circuit, or by recording the time of quench-
ing of each charge. All utilities have the usual types of instrumentation.
432 Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved.
Manufacture of Metallurgical Coke and Recovery of Coal Chemicals
coal sampler
Automatic
Coal Bulk Coal
moisture density coking
analyzer analyzer calorimeter
Stack
Target excess flue gas
Fuel gas air
wobbe Gas flow rate Operating analyzer
analyzer calculation schedule
Coke
temps
active coke oven building companies. The use of the computer to manage the very complex over-
all battery heating strategy and to make continuous overall underfiring adjustments allows opera-
tors the time to maintain underfiring components, such as gas nozzles, and to fine-tune individual
oven temperature profiles which can be done only by manual adjustments.
Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved 433
Ironmaking Volume
Fume
main
Collection
main
Coke side
Quench door
loco machine
Wharf
Fig. 7.47 Coke side shed for collecting emissions from a byproduct coke oven during the pushing operation.
434 Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved.
Manufacture of Metallurgical Coke and Recovery of Coal Chemicals
In this system, an enclosure hood is suspended from the door machine and is fabricated over the
coke guide and extends to cover the hot car. The emissions from the push are pulled by fan into a
large duct extending the full length of the battery. This duct is stationary but allows for the inter-
connection between the hood transition piece and the duct at each oven by designing an appropri-
ate opening at each oven. As the gases are collected in the hood during the push, the hot car moves
under the hood and collects the coke. The effectiveness of the traveling hood design depends
mainly on the designer being able to keep all interface openings between moving parts to an
absolute minimum; that is, the interface points between the coke guide, oven jamb, enclosure hood
and the hot car.
Another similar hooded system is the Minister-Stein system. The basic differences of the Minister-
Stein system are: (1) the fume collecting duct is located outside the hot car track on heavy struc-
tural supports; (2) the duct is covered with a rubber belt and a mobile tripper carried with the hood
is used for introducing the pushing emissions under the belt at the location of the push; (3) a large
heat exchanger is carried with the hood to control the emissions and to protect the rubber belt while
atmospheric air cools the heat exchanger between pushes; and (4) a third rail mounted on the duct
bearing structure supports the hood and heat exchanger.
Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved 435
Ironmaking Volume
Modern design traveling hood systems, Fig. 7.48, are provided by all coke oven building compa-
nies. In the latest designs the hood is an integral part of the coke transfer car operating during all
coke side functions.
Fig. 7.49 General view of a manually-operated coke wharf showing freshly quenched coke being discharged from the
gates of the quenching car onto the brick paved sloping wharf. When the wharf gates are opened, coke slides down the
wharf as at the lower left onto a conveyor belt that carries it to the screening station
436 Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved.
Manufacture of Metallurgical Coke and Recovery of Coal Chemicals
operations will not interrupt the desired regularity in oven pushing sequence. Most modern
wharves are paved with hard-burned clay brick.
The coke wharf receives the quenched coke from the quenching car. The coke is spread out on the
wharf in a thin bed for quick drying and visual inspection for the detection of unquenched coke.
Manually directed streams of water are used to quench any still-hot coke detected on the wharf
before the coke is conveyed on rubber belt conveyors to the screens.
The coke is retained on the wharf by a series of gates which, when opened, permit the coke to slide
down the wharf and onto the belt conveyor to be delivered to the screening station. Fig. 7.49 shows
a manually-operated coke wharf. The present trend is to use automatic mechanically-operated
wharf gates, Fig. 7.50, with automatic sequence and memory circuits to maintain proper utilization
of the wharf for surge capacity for the screens and the quenching car. In either case, whether oper-
ated automatically or manually, the wharf design and construction is the same.
The more modern coke wharves are provided with rotating coke plows. The coke wharf is designed
with a flat shelf at the bottom of the sloping wharf. The coke plow consists of a multi-bladed vari-
able speed rotating unit mounted on a frame which automatically travels back and forth over the
length of the wharf. During travel in both directions, the rotating unit discharges coke from the
wharf shelf onto the wharf belt. As the coke belt leaves the wharf, a temperature sensing device
monitors the temperature of the coke and activates water sprays to cool any hot portions of coke.
Fig. 7.50. General view of part of a modern coke wharf with automatic mechanically-operated gates.
Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved 437
Ironmaking Volume
438 Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved.
Manufacture of Metallurgical Coke and Recovery of Coal Chemicals
failure will be 28–50°C (50–90°F) lower than in another brick in which this sum is only 0.5%. At
temperatures about 593°C (1100°F), silica brick is nearly volume stable and virtually free from
thermal spalling, while at temperatures below 593°C (1100°F) silica brick is highly susceptible to
thermal spalling.
Since the later 1950s there had been a general trend in the industry to use high bulk density silica
brick (greater than 1858 kg/m3 or 116 lb/ft3) in coke oven battery construction, because increasing
bulk density is accompanied by corresponding increases in cold strength and thermal conductivity.
Therefore, it was presumed that higher heat transfer rates from flue to oven would be realized
because of the higher thermal conductivity.
Measurement of flue to oven temperature differentials on operating batteries conducted by U.S.
Steel showed that higher bulk density silica brick did not result in improved heat transfer over reg-
ular bulk density, 1740–1804 kPa (108–112 lb/ft3) silica brick. In addition, a series of tests on sil-
ica brick of varying bulk density showed that the hot strength in the range of 649–1316°C
(1200–2400°F) did not appreciably change as a function of bulk density, and that the lower bulk
density brick were less brittle and less susceptible to failure from thermal cycling.
7.4.8.3 Mortars
There are two primary types of mortars used in coke oven battery construction, silica coke oven
mortar and fireclay coke oven mortar. The silica mortar is further divided into a heat-set and an
air-set type; normally the silica brick in a battery is laid up with the heat-set type.
Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved 439
Ironmaking Volume
Silica mortars are made from a sized silica sand for aggregate along with some small amount of
bond clay. The air-set silica mortar is the same composition, but is has a small amount of dry
sodium silicate added. The fireclay mortar is made from a sized calcined kaolin with a small
amount of bond clay. No mortar used in battery construction contains any type of cementitious
bond. Silica mortars are refractory up to about 1682°C (3060°F) and clay mortars up to about
1604°C (2920°F). Shrinkage on drying from a workable or trowelable consistency is an important
parameter, and is specified as less than 2.5% and 4.0% for silica and clay mortars, respectively.
Mortars used in coke oven battery construction do not develop a coherent bond with the refrac-
tory to which they are applied at normal battery operating temperatures. Mortars therefore do not
contribute to the structural integrity of a battery. The mortar used in a battery serves two primary
functions. It is used to compensate for inconsistencies in brick size, and it acts as a sealant
between brick to prevent gas leakage among the combustion air, fuel gas, and foul gas systems
within the battery.
7.4.8.4 Castables
Refractory concretes made with calcium aluminate (CA) cements and various refractory aggre-
gates, are used in various locations in a coke oven battery. The service capability of a castable is
dependent on the purity level of the CA cement as well as of the aggregate. There are three purity
levels of CA cement, low purity, medium purity and high purity. The aggregates can range from
calcined clays to high purity tabular alumina. Size grading of castable aggregates can also vary
considerably.
From a practical standpoint, many castables are used in coke oven battery construction. These
include low and medium purity castables. In addition to regular cement castables, low cement and
ultra-low cement castables are used.
Low purity castables are used to line the waste heat tunnels and flues; it can be formed up and cast
in place or it can be gunited. The gunite application is faster and lower cost. Low purity castables
are also applicable to areas in the battery top, for example as a filler material in the parapet area.
Low purity castables used in battery construction or repairs are generally specified to satisfy
strength requirements and carbon monoxide resistance.
Medium purity castables are used for the higher temperature areas in a battery to which castables
are applicable, for example door plug refractories and standpipe lining.
440 Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved.
Manufacture of Metallurgical Coke and Recovery of Coal Chemicals
Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved 441
Ironmaking Volume
If only a few oven walls are to be replaced, the repair is done with the battery in the hot condition
with one or two buffer ovens (empty ovens) on each side of the wall being repaired. The other ovens
of the battery may be producing coke. Before demolition of the damaged wall, roof support beams
must be added in the adjacent ovens, insulating panels must be installed on the adjacent hot walls,
charging car rail bridges must be installed on the oven top, and support provided for the oven roof
under which the wall will be replaced. Care must be taken to maintain the heat in the regenerators
and on the adjacent walls. On an individual oven wall replacement, the heatup period for the
repaired oven is approximately 15 days.
If an entire battery of through walls is to be replaced from the oven floor to the underside of the
oven roof, the repair may be performed with the battery in the idle hot condition or with the bat-
tery refractory cooled to atmospheric temperature.
The idle hot condition means that the ovens are maintained hot while the repairs are done. Pairs of
walls are replaced together with the adjacent ovens maintained in the hot condition. Each pair of
walls being replaced is called an increment and work may proceed on several increments at one
time. The heating of each increment of the repaired walls takes approximately 15 days. Ovens may
be placed back in service before all the walls have been replaced.
The replacement of the through walls of an entire battery may also be accomplished by permitting
the battery to be cooled down to the cold condition under controlled conditions before the repairs
are made. The cool down may take up to 21 days during which time pressure is maintained on the
oven walls by adjusting the upper and lower tie rods. The oven roofs must be supported as
described for the hot repair procedure. After the walls are rebuilt and before heatup, all the check-
ers must be removed from the regenerator and any cracks in the pillar walls must be cleaned and
packed with ceramic floss before the checkers are replaced so as not to hinder brickwork expan-
sion during heatup. The repaired battery is heated up in the same manner as a new battery.
A repaired battery with all new through walls, with proper maintenance can be expected to have a
life of approximately 15 to 20 years at a fraction of the cost of a new coke oven battery.
With through wall replacement of an entire battery, with the repairs done in either the hot or cold
condition, additional items usually replaced include the side buckstays above the bench, collecting
mains, doors and jambs, oven top paving, and tie rods and springs.
Two other repair techniques have come into prominence. Ceramic welding is used to repair cracks,
open joints and spalls in the refractory by fusing a ceramic material to the existing brick. Zero
expansion brick repairs are used for panel patches or end flue repairs. Zero expansion brick repairs
are used for panel patches or end flue repairs. The zero expansion brick repairs can be made under
hot conditions without an allowance for expansion.
Today repairs in hot idle condition are preferred. In the case of a cold repair, the refractory block
of a battery may be heavily damaged during cooling down by the contracting material. Bracing sys-
tems, even with increased forces, can not prevent these damages. If all damage can not be repaired
on cold batteries, operation with blast furnace gas may not be possible due to unavoidable leakages
in the regenerator area. Hot idle battery repairs are somewhat more expensive but provide the oper-
ators with the maximum life expectancy for the ovens.
442 Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved.
Manufacture of Metallurgical Coke and Recovery of Coal Chemicals
Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved 443
Ironmaking Volume
Basically two different coal preheating sys- Fig. 7.52 Schematic arrangement of a Rosin-Buttner type of
tems are used in drying and preheating of coal preheating unit.
the coal: (1) the flash drying and preheat-
ing system such as Rosin-Buttner shown in
Fig. 7.52 and (2) a fluidized bed and entrainment system such as Cerchar shown in Fig. 7.53. Other
processes use combinations of different preheaters, conveying and charging systems.
The Rosin-Buttner type preheating unit is a two stage entrainment dryer/preheater. Wet coal is fed
by a centrifugal feeder into the first stage where it is flashdried and preheated to approximately 80°C
(175°F) and 2–3% moisture by concurrent flow of hot gases from the second stage unit. The
entrained coal is separated from the gas in a cyclone and is conveyed to the second stage unit in
which the coal is preheated to 200–230°C (390–445°F). The hot gases flowing concurrently are sup-
plied in part by burning natural gas or coke oven gas in a combustion chamber supplemented by a
recycle stream of inert gas from the first stage. The preheated coal is separated from the gas stream
by a series of cyclones and is conveyed to a set of storage bins to be charged to the battery ether by
drag conveyors or a hot coal larry car. Part of the process gas from the first stage is scrubbed or
cleaned in the electrostatic precipitator and the rest is recycled back to the combustion chamber.
The Cerchar preheater is a single stage fluidized bed and entrainment unit. The wet coal is fed by a
double screw conveyor into a flash drying section. The velocity of gases is high enough to transport
Secondary cyclones
Hammer
mill
Primary
Wet coal cyclone
supply 260 C Screw conveyer
100%
_20mm Coal distribution
Wet coal hopper
feed hopper
To atmosphere Charge bins
40 C Booster fan 250 Cs
Venturi
800 C 250 C
Combustion From fuel fines Steam
chamber recovery area Gas scrubber
Shut-off
Recycle To coal fines valves
blower recovery area
Rotary
Fuel gas Accelerators feeders
To charging
Combustion manifold
air fan
444 Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved.
Manufacture of Metallurgical Coke and Recovery of Coal Chemicals
all the coal upward. The coal is dried and preheated in a fluidized bed in which a crusher disperser
decreases the size of coal until it is removed from the preheater by entrainment. Coal is separated
from the gas stream in a series of cyclones and is conveyed to a storage bin. The offgas is split, part
of it returning back to the combustion chamber and part of it being cleaned in a wet scrubber.
The most common coal preheating processes operating in the world today are described below.
The Coaltek system is a combination of a Cerchar single stage fluidized bed entrainment preheater
coupled with a pipeline charging system developed by Allied Chemical. The preheated coal is dis-
charged from the storage bin to weigh bins. The bins are pressurized with steam after the proper
amount of coal is loaded, and coal is then conveyed via a pipeline aided by additional steam jets to
the battery oven. The coal and steam entering the oven are then separated by a specially designed
baffle, and the gases emitted during charging are channeled to a specially designed collecting main.
The Precarbon process, developed by Bergbau-Forshung and Didier of Germany, utilizes a Rosin-
Buttner type of double stage entrainment dryer/preheater coupled with sealed drag conveyor charg-
ing of the preheated coal by way of a charging chute system to the battery oven. The charging is
accomplished by specially designed pneumatic level probes which automatically stop charging pre-
heated coal when predetermined coal lines are obtained. Two of the three 6 metre batteries being
operated by U.S. Steel at its Gary Works are equipped with Precarbon processes.
The Otto-Simon Carves system is a combination of a Rosin-Buttner type double stage entrainment
preheating system and a hot larry charging system. This system was one of the first ones com-
mercially installed in South Africa and in England.
A preheater developed by Buttner-Schilde-Haas of Germany was installed by U.S. Steel in 1978.
The BSH process utilizes a single stage entrainment type preheater which is equipped with a solids
recycle system. The classifier at the exit of the column allows recirculating of a variable amount
of coarser material back to the preheat column. The preheat system is coupled with a hot larry car
charging system.
The worldwide steel industry is challenged with providing facilities to produce high strength coke
from increasingly poorer coking coals. Coal preheating combined with charging of preheated coal
is an economically viable process that offers the steel industry a method for attaining this goal, as
demonstrated by general acceptance of the practice of coal preheating.
Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved 445
Ironmaking Volume
Coal hopper
and compaction chamber
Oven
chamber
Pusher
machine
Coal compaction
chamber
Pusher ram
Coal compaction
and charging unit
Fig. 7.54 Top, side and end elevations of a coke oven pushing machine incorporating a stamp charging unit.
Oven
chamber
Coal h
Fig. 7.55 Schematic section showing side view of a stamp charging unit.
446 Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved.
Manufacture of Metallurgical Coke and Recovery of Coal Chemicals
into more intimate contact with each other, which enhances the coking properties. This process was
developed as a way to make high strength coke from the relatively poor quality coking coals found
in these areas. The coals are either too low in rank and/or too high in organic inert contents to pro-
duce strong coke by conventional means without bringing in expensive, better quality coking coals.
Stamp charging produces a more abrasion resistant coke, and the yield of blast furnace size coke
is higher than with conventional charging. In addition, even though some coke oven volume is lost
due to the thickness of the charging chamber floor and the oven taper, and longer coking times are
required, the amount of coke throughput is increased about 5% over conventional charging.
The initial capital costs are high due to the expense of the combination stamping/pushing machine
and the complex charging procedure. There is no need for a larry car, however. Gas emission prob-
lems used to occur during charging, but new procedures such as charging with suction have helped
in this area. The need for better coke quality and higher coal throughputs dictates that stamp charg-
ing techniques must be improved and further developed, especially in view of the fact that cham-
ber heights are continually being increased.
Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved 447
Ironmaking Volume
Non-coking coal
Crusher
Kneader 30 40 C
Briquetting
machine
Binder
Briquettes
30% 40%
In addition, Sumitomo lists advantages of the briquette blending over coal preheating to be that
more of the cheaper non or poorly coking coal can be incorporated into the coal blend, operating
costs are cheaper, simpler and more stable equipment is used, and installation into existing plants
is easy.
448 Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved.
Manufacture of Metallurgical Coke and Recovery of Coal Chemicals
Binder Kneader
(tar &
pitch) Raw Briquette
material bin
bin
Steam
Mixer
Briquetting
machine
(30 t/hr. x
2 units)
Net conveyor
(cooler)
Fig. 7.57 Schematic flow of diagram of Nippon Steel’s briquette blending system.
Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved 449
Ironmaking Volume
Charging holes
Charging holes
Combustion
s
occurs in er flue
verical Crossov
flues
(not shown)
Dividing walls
Com
in bus
to Hot fluedividution oc
s (n al v cur
Coking chamber
he wa
Coking chamber
at ste ot s er tic s in He
regated
Coking chamber
Coking chamber
reg g how al
Coking chamber
n)
Coking chamber
en ase en air
era fro
era s
tor tor m
s
Fu
He el
ga
a s in
Early Koppers oven
reg ted
en air Koppers_Becker oven let ase
s
te g ator
era fro was ner
tor m Hot at rege
h e
Fuel gas to
inlets
Charging holes
Combustion
occurs in
verical
flues
(not shown)
Fuel
gas
inlets
He
Coking chamber
regated
Coking chamber
en air
era fro
Coking chamber
tor m
s
to Hot w
he a
at ste
reg ga
en se
era s
tor
Wilputte oven He
regated
en air
era fro Combustion
tor m occurs here
s
Fig. 7.58 Schematic representation of the differences in firing methods employed in the three most common types of
byproduct coke ovens used in the United States. Individual flues are not shown. The firing procedures shown are for a sin-
gle phase of heating which is reversed at the end of a specified period, at which time the flow directions indicated by the
arrows become reversed.
Horizontal
flue
Combustion Door
flues with
gas nozzles Oven
PUSHER
at bottom SIDE
COKE
SIDE
Fuel Fuel
gas gas
main Regenerator main
Regenerator (checker chamber)
(checker chamber)
Cast Cast
iron iron
air box air box
Flue to Flue to
stack stack
Fig. 7.59 Transverse sections of Koppers regenerative single-divided by product coke oven battery. Section at left is
through combustion chambers (flues), that at right is through oven chamber.
450 Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved.
Manufacture of Metallurgical Coke and Recovery of Coal Chemicals
The chief differences in the Koppers, Koppers-Becker and Wilputte design types are in the heating
system. Fig. 7.58 illustrates, by simplified sketches, how each of these types is heated. A fourth
general type, the hairpin- or twin-flue oven, is discussed later in Section 7.6.4.
The Koppers oven, more technically referred to as a regenerative, single-divided oven, was the
most prominent from about 1916 to 1928, and many are still in operation. In a typical oven of this
design, Fig. 7.58 and Fig. 7.59, all parts except the regenerator checkers and battery tip are con-
structed almost entirely of high-quality silica brick.
The majority of ovens of this type initially constructed in the United States had a coking volume
of approximately 14 m3 (500 ft3). The general dimensions of these ovens were: length, 11.28 m (37
ft) from face to face of the doors; height, 3 m (9.8 ft) from floor to roof; and width, tapering from
430 mm (17 in.) at the pusher end to about 495 mm (19.5 in.) at the discharge end. Usually, four
charging holes were provided in the top of each oven for admitting the coal charge, while a sepa-
rate opening in the top at one end provided an outlet for volatile matter. The oven is of the verti-
cal-flue type with individual regenerative chambers, Fig. 7.59. The heating chamber has a total of
about thirty vertical flues per flue wall.
The flues are provided with openings to the regenerator chambers, the fuel-gas mains, and to a
large horizontal flue on a level a little below the tope of the coking chamber. A dividing wall near
the middle of the regenerators separates the heating system, except the horizontal flue, into two
parts with (in the case of the thirty-flue wall) sixteen vertical flues on the narrower end of the oven
and fourteen on the wider end. Each end, approximating half of the oven, thus may be heated alter-
nately, and in practice the reversals are made at regular intervals for each battery of ovens by a
reversing mechanism controlled by a timing device. Two large underground flues, one on each side,
extending along both sides in front of and parallel to the battery, and connected to the checker
chambers (regenerators) by cast iron air boxes, provide for escape of the products of combustion.
These flues lead to a stack about 61 m (about 200 ft) high at one end of each battery to furnish the
draft necessary to draw the gases through the heating system.
4
1
4
3 12
12 3
3 3 3
1
9 9
5 5
9
5
5
10
7 10
6
6
6 7
6
11
11
8
8
Fig. 7.60 General perspective cut-away section of Koppers-Becker combination ovens with gun-flue heating facilities (see
Fig. 7.63 for underjet-fired type). Legend: 1. oven chamber; 2. vertical combustion flues; 3. horizontal flues; 4. cross-over
flues; 5. regenerators; 6. oven sole flues; 7. gas and air connections to waste-gas flue; 9. gas ducts for coke oven; 10. oven
gas main; 11. blast furnace gas main; 12. charging holes.
Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved 451
Ironmaking Volume
Ascension pipe
Bus flues
Collecting
main
Oven Door
COKE
SIDE PUSHER
SIDE
Section
thru gas
nozzle
Waste Waste
heat fuel heat fuel
(a)
Flue
Flue
Flue
Flue
Flue
Flue
Longitudinal section
(b)
452 Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved.
Manufacture of Metallurgical Coke and Recovery of Coal Chemicals
Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved 453
Ironmaking Volume
Ascension
pipe
Gas
Coal
collecting
charging car
main
Leveler
Door
Oven
Pusher
COKE PUSHER
SIDE SIDE
Section
thru ports
Regenerator
Blast
furnace
gas main
Air
duct
Coke
oven gas Waste
Fill main heat
flue
Oven
Oven
Flue
Flue
Flue
Flue
Flue
Flue
Fig. 7.63 Tranverse and longitudinal sections through Koppers-Becker combination gun-flue type of byproduct coke oven,
showing detail of part of Fig. 7.61(b).
454 Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved.
Longitudinal
Standpipe tie rod Oven top fill
Larry car rails
Charging hole Charging hole Inspection hole
Oven cross tie rod
and spring
Oven top
Leveler door Roof blocks
Buckstay
Buckstay Heat up plug
Horizontal flue E
PUSHER SIDE COKE SID
an d ja mb brick
Oven door Nose
bench
Coke side
Pusher side ber bench rails
Vertical Oven cham Coke side
bench heating flue Quench
Pusher machine locomotive
power rails Low burner power rails
Oven floor
er blocks
H igh burn
Door still
mb
Door ja
Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved
perspective cut- e sla
Blas ce
a Bas
away drawing of a furn main
gas
Wilputte four- as
te g
divided combina- Wasflue
tion underjet-fired
byproduct coke
Manufacture of Metallurgical Coke and Recovery of Coal Chemicals
oven.
455
heating system. The rich gas and lean gas referred to on the drawing are coke oven gas and blast furnace gas, respectively.
Fig. 7.65 Sections through a battery of Wilputte underjet, combination, byproduct ovens, designated as double-divided ovens, having two outer zones and one double inner zone in the
Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved.
Ascension pipe
Collecting
main Outlet for
volatile materials
Openings through top
Charging holes (inspection holes)
Horizontal flue
COKE PUSHER
SIDE SIDE
Oven
Oven
Flue
Flue
Flue
Flue
Oven Vertical flues
High burner
Door
Low burner
Outer zone Inner zone
regenerator regenerator
Division Bus flue
Rich to outer
Air wall gas Decarboniz-
intake ing air Combustion zone
manifold air inlet
Ironmaking Volume
456
through oven and regenerators through flues, burners and underjet gas-ducts and air ports charging holes
Manufacture of Metallurgical Coke and Recovery of Coal Chemicals
Fig. 7.66 Section showing arrangement of flue ends, door and jambs of a Koppers-Becker low-differential combination
underjet coke oven battery.
Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved 457
Ironmaking Volume
required if clay or other dissimilar refractory materials were used in these important areas. The
heating flue walls are constructed of vertically and horizontally tongued-and-grooved hammerhead
and liner brick, spaced with sturdy flue partition shapes, Fig. 7.66. The oven ends are firmly sup-
ported by strong buckstays, face plates and rigid metal jamb castings bolted to the face plates. The
jamb brick are provided with a vertical cleavage joint to permit expansion independently of the hot-
ter interior heating flue brickwork. These features are all provided in all three types of ovens of the
Koppers design.
Uniform distribution of up-flow air (and lean gas when used), as well as down-flow waste gas,
between the sole flue and the regenerator chamber is accomplished by specially designed sole-flue
ports. The size and taper of these ports are varied as required across the length of the regenerators
and sole flues to force the desired distribution of gases. A patented system is also provided to sup-
ply more heat to the checkers at the ends of the regenerators to compensate for heat losses through
the regenerator faces. A high-efficiency extended-surface checker brick is used in the regenerators
to secure efficient heat recovery. These features also are provided in all three types of ovens of the
Koppers design.
458 Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved.
Manufacture of Metallurgical Coke and Recovery of Coal Chemicals
5
1 6
2
3 3
16
12 15
10
11
14
15 8
13
17
Fig. 7.67 Sectional view of a Koppers-Becker low-differential combination underjet coke oven battery operating on rich
gas. Legend: 1. oven; 2. burning flue; 3. waste-gas flue; 4. cross-over flue; 5. high air port; 6. low air port; 7. horizontal
collecting flue; 8. recirculating duct; 9. checker brick; 10. sole-flue parts; 11. sole flue; 12. gas port; 13. rich-gas manifold;
14. rich-gas main; 15. blast furnace gas main; 16. gas or air and waste heat boxes; 17. waste heat flue.
The corbel area between the regenerators and the ovens is strong and simple. Symmetrical, short
and direct ducts connect with the regenerators immediately beneath the combustion flues, result-
ing in great strength and tightness.
The regenerators contain no transverse partition walls, but are open for their entire length. Blast
furnace gas and air are metered to each vertical flue by ports at the base of the flues. The open
regenerators supply gas and air at equalized pressure and temperature at the point of metering to
each vertical flue. The open space above the checkers at the top of the regenerators acts as an equal-
izing chamber permitting continued good distribution of blast furnace gas and air to the vertical
flues as the battery ages, even if portions of the regenerators become locally restricted as a result
of blast furnace gas dust deposits.
The wide regenerators are divided longitudinally by specially designed checker brick, and above
these by a baffle wall extending the length of the regenerator, providing for effective control of the
distribution of blast furnace gas or combustion air to each individual flue wall. Pressure (draft) con-
ditions at the top of the regenerators are easily controlled at the reversing boxes.
The vertical heating flues of the oven walls are arranged in small groups. Each group has its own
cross-over flue. Regardless of the length or height of the oven each branch horizontal collecting
flue remains small in cross-section and short in length, giving the walls extra strength where it is
most needed. Low pressure drop through the horizontal flues and crossover flues results in a low
overall pressure drop through the entire combustion system. A standard height stack can be used.
Air and blast furnace gas flows are metered to each flue by the air and blast furnace gas ports,
where pressures and temperatures are equalized across the battery, and distribution does not change
Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved 459
Ironmaking Volume
with coking rate changes. For tall ovens, in order to assure uniform heating for the full height of
the oven, air and blast furnace gas are supplied through ports located part way up the flue, as well
as at the bottom of the flue.
When underfiring with rich gas (coke oven gas), all of the fuel is supplied at the base of the flues.
For tall ovens the combustion is staged by supplying a portion of the air required at the base of the
flue and the remainder at a high elevation. This elongates the flame, creating uniform vertical heat-
ing and eliminating low temperatures near the oven top.
The up-flow rich gas risers are always at substantially the same pressure as the two adjacent regen-
erator chambers which contain up-flow air. There is no possibility of leakage of rich fuel gas into
the down-flow regenerator chambers or sole flues.
To further lengthen the flame, assuring uniform vertical heating when underfiring with rich gas, an
automatic waste gas recirculation system is used. Recirculating ducts connect the bases of the
down-flow and up-flow rich gas risers which are provided with venturi throats, Fig. 7.68. The rich
fuel gas flows through jet-type nozzles into the venturi sections, serving as eductors to aspirate a
portion of the products of combustion from the down-flow flues, through the down-flow risers and
horizontal recirculating ducts, mixing this recirculated portion of waste gas with the rich fuel gas
in the up-flow risers to the burning flues. This results in dilution of the rich fuel gas with inert prod-
ucts of combustion. This mixture burns more slowly, producing a longer flame of lower luminos-
ity, similar to a blast furnace gas flame.
The Koppers waste-gas recirculation system suppresses the tendency to form carbon near the top of
the up-flow fuel gas risers. Any carbon that may be deposited on the up-flow cycle is automatically
consumed during the down-flow cycle by reaction with the excess oxygen, water vapor and carbon
dioxide in the recirculated waste gas. This eliminates the need for a separate decarbonizing air system.
460 Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved.
Manufacture of Metallurgical Coke and Recovery of Coal Chemicals
4
5
6
3
1 2
8
12
9 13
10
15 11
16
14
Fig. 7.69 Sectional view of a Koppers twin-flue underjet byproduct coke oven battery. Legend: 1. oven; 2. burning flue; 3.
waste-gas flue; 4. turnaround; 5. high gas port; 6. low gas port; 7. differential heating flue; 8. recirculating duct; 9. checker
brick; 10. sole-flue ports; 11. sole flue; 12. air port; 13. rich-gas manifolds; 14. rich-gas main; 15. air and waste-heat boxes;
16. waste-heat flue.
This twin-flue design incorporates most of the structural and design features that have been proven
successful over the years in the Koppers single-divided and Koppers-Becker ovens, which have
been described in the preceding sections. Automatic waste-gas recirculation is achieved by the use
of recirculating ducts connecting the base of the rich-gas risers of each pair of twin flues. The recir-
culating ducts and venturi throats at the base of each riser are built into the silica brickwork of each
heating flue wall. Alternating high and low coke oven gas burners are provided in alternate flues
across each heating flue wall to assure uniform vertical heating of the modern tall twin-flue ovens.
Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved 461
Ironmaking Volume
The patented jamb cleaner is mounted on a separate ram which positions the cleaner against the
door jamb. Variable settings automatically provide a programmed number of strokes for the scrap-
ing tools which effectively remove deposits from the jamb surfaces. An additional tool enters the
oven at the floor, and as the cleaning head is retracted from the oven the bottom tool removes any
floor deposits which would prevent the door from being properly replaced.
Foul gas is removed from each oven through single or double ascension pipes at the oven ends. The
collecting main is shaped to allow the ascension pipes to be as short as possible, Fig. 7.70. Each
ductile iron return-bend section contains two flushing liquor sprays and is connected to the col-
lecting main by a sealed expansion joint. A liquor-sealed valve at the base of the return bend allows
the oven to be isolated from the main. Charging steam is directed through the return-bend section
to pull the gas and smoke generated during charging into the collecting main. A return-bend cover
is provided for venting the oven to the atmosphere for decarbonizing purposes.
Mechanical-cleaning devices are provided on the coal charging car for removal of carbonaceous
deposits from the return bend and ascension pipe. Other mechanical devices are available to manip-
ulate the covers and dampers from the coal charging car.
Flushing
liquor
header
Water-sealed
Steam lid
header Water
header
Charging
steam
Collecting
main
Liquor seal
valve
Water
drain
header
Fig. 7.70 Cross-section through a collecting main and ascension pipe on a byproduct coke oven charged with wet coal.
462 Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved.
Manufacture of Metallurgical Coke and Recovery of Coal Chemicals
Coal
charging
Crossover main car
Manually-set
Regulator-controlled butterfly valve Collecting
butterfly valve main
Pitch trap
Coke
guide
Quench
car
Pusher
machine
Fig. 7.71 Schematic arrangement of a coke oven equipped for staged charging or sequenced charging
emission control effort, the Koppers designs have available the following facilities and equipment
for these major sources of coke oven emissions.
7.6.2.5.1 Charging Emissions An overall charging concept, commonly called staged charging or
sequenced charging, is available. This system, Fig. 7.71, involves the ability to discharge the coal
from the charging car hoppers in the proper sequence and at the proper times so that the blockages
of the gas passageways from the oven are prevented. Double collector mains or jumper-pipe sys-
tems are available to provide a gas outlet at each end of the oven chamber. Suction is provided by
aspirating steam at both gas outlets during a charge. Successful smokeless charging by this method
is greatly aided by certain auxiliary control devices which include mechanical feeders to control
the flow of coal from the hoppers to the ovens; automatic lid lifters with slide gates; automatic lev-
eler-door operators with leveler-bar smoke seals; mechanical standpipe and gooseneck cleaners;
and self-cleaning steam aspirating nozzles.
7.6.2.5.2 Pushing Emissions The Koppers designs have available a number of systems to reduce the
emissions generated during the pushing operation. A coke-side enclosure or shed has been pro-
vided to contain and collect these emissions. Wet scrubbers and baghouses are being used to clean
the captured emissions from the push and also the gases evolved from the coke-side oven doors.
Another system for control of pushing emissions is the Koppers-Ford system which consists of an
enclosed coke guide with an attached hood that covers a quench car. The hood is connected to a
fume main and a land-based gas scrubbing system to remove and clean the emissions.
7.6.2.5.3 Quenching Emissions Particulate matter entrained with steam from the quenching operation
can be controlled with the use of mist suppressors installed in the quench station stacks. Usually
these are wooden baffles arranged to cover the area of the stack and are installed with cleaning
sprays to wash down the collected particulates.
Dry coke cooling is another method of controlling quenching emissions. In this process, hot coke
is dumped into a chamber and inert gas is circulated through it to cool the coke. This gas is then
passed through a waste-heat boiler where the heat from the coke is recovered and used to generate
steam. Although this system does not emit a plume of steam with particulates, control devices are
still used at coke transfer points and in the gas stream to collect and clean emissions.
Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved 463
Ironmaking Volume
464 Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved.
Manufacture of Metallurgical Coke and Recovery of Coal Chemicals
lower average flue temperature than required for 114.3 mm (4.5 in.) thick liners of standard den-
sity, or an increased coking rate with the same temperature.
The heating walls are of interlocked header and stretcher brick construction with headers inter-
locked to each other and to the liners as well. Courses are not less than 152.4 mm (6 in.) in height,
thereby reducing the number of joints substantially.
The ends of the heating walls can be constructed with removable nose and jamb brick made of sil-
ica clay or fused silica. The construction is such that all nose and jamb brick can be replaced with-
out disturbing the end flues.
7.6.3.5 Heating
Wilputte coke oven batteries can burn either coke oven or blast furnace gas, or a combination of
these. The changeover may be made from a central control room.
Alternating high and low burners are installed in the heating flues. This arrangement lengthens the
initial vertical combustion zone when heating with rich gas and, by enabling the use of wall liners
of uniform thickness from floor to roof, materially improves the vertical distribution of tempera-
tures when underfiring with lean gas.
The regenerator distribution system using venturi ports which are graduated in size along the bus
flue achieves uniform distribution of flow through the regenerator, thereby improving its effi-
ciency. Also, this graduated venturi-port design, in that it compensates for adverse manifold effects
in the bus flue, permits the use of a single side waste-gas flue.
Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved 465
Ironmaking Volume
With the double collecting main system, the space about the coal tends to be cooler in the latter
portions of the coking cycle, thus reducing the tendency to form roof carbon. However, care must
be exercised to close off the oven from one of the collecting mains in the latter part of the coking
cycle to prevent the possibility of cool, wet raw gas being drawn into the oven chamber and possi-
bly causing damage to the silica brickwork
Fig. 7.36, shown earlier, depicts the arrangement of the standpipe, damper valve and collecting
main at one end of an oven.
466 Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved.
Manufacture of Metallurgical Coke and Recovery of Coal Chemicals
The Wilputte door jambs can be either the ell-shaped contour or the block contour, securely bolted
to a steel nose plate behind the buckstay so that the jamb and steel nose plate can be held tightly
against the brickwork despite any tendency of the buckstay to distort. This design also permits
replacement of door jambs without removing buckstays while providing maintenance access to the
nose brick.
Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved 467
Ironmaking Volume
468 Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved.
Manufacture of Metallurgical Coke and Recovery of Coal Chemicals
Fig. 7.72 TSOA twin-flue heating unit system operating Fig. 7.73 TSOA twin-flue heating unit system operating on
on coke oven gas. mix gas.
Each heating unit can be individually controlled and adjusted for optimum battery heating.
A number of these independent heating units arranged side-by-side form the heating wall of the
TSOA oven.
7.6.4.1.3 Underjet System, Coke Oven Gas In the underjet system, coke oven gas is distributed in the
battery basement under the nozzle deck by means of steel nozzle headers off the distribution main
and through steel connections on the riser pipes and openings to the burners in the heating flues.
In the underjet system to coke oven gas is distributed in steel pipes which operate under pressure.
Consequently, a good distribution can be obtained to ensure consistent flow of gas to the individ-
ual flues. By taking maximum advantage of the available fuel gas pressure, graded stainless steel
metering nozzles are installed to ensure an accurate and consistent delivery of fuel gas to each indi-
vidual burner.
Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved 469
Ironmaking Volume
These are external from the battery refractory block and are easily accessible within the basement.
In the underjet system the nozzle headers are supplied from a single distribution main and a pro-
gressive adjustment can be obtained across the length of the heating wall.
The coke oven gas is fed to individual burners in the heating flues through vertical openings within
the refractory block. They are of small diameter, having no detrimental effect o the stability of the
refractory block.
Tightness, especially in the regenerator walls, is achieved by tongue-and-groove brick design with
staggered joints.
All TSOA heating systems may and have been provided as gun-flue systems, based on the special
requirements of the owner.
7.6.4.1.4 Regenerator Arrangement The regenerators are located under the oven chambers and the
heating walls and are continuous from pusher side to coke side. When heating with coke oven gas
two adjacent regenerators are supplied with combustion air and one with mix gas. The regenera-
tors exchange duties with each reversal.
The regenerators with their checker bricks are divided up lengthwise by partition walls into as
many compartments as there are twin flues. Each twin flue is connected with its regenerator com-
partments by short ducts.
The sole flues form a composite part of the regenerator and do not require any lining. The checker
bricks form the regenerator packing above the sole flues.
The packing is subdivided into separate compartments by tiles between the regenerator walls.
These are inserted, dry tightened with ropes, and can be removed should it ever be necessary to
repack the regenerator.
The majority of the checker bricks are manufactured from low alumina fireclay, but in higher
temperature zones of the regenerator the top four layers are manufactured from 40% alumina
fireclay.
Metal exchangeable nozzle plates with calibrated adjustable openings are located above the sole
flues and below the regenerator compartments. The volume of air/mix gas, which is distributed to
the regenerators and effectively into independent compartments, is determined by the adjustable
openings of the nozzle plates. Thus, a uniform and controlled air/mix gas flow is obtained together
with optimum heat recovery in the regenerator.
7.6.4.1.5 Heat Distribution across the Heating Wall Due to the taper of the oven chambers it is neces-
sary to increase the heat input from pusher side to coke side. This is achieved by increasing the
heating flue temperature from pusher side to coke side. Increasing amounts of gas and air have to
be fed to the heating flues in order to adapt the heat distribution across the heating wall exactly to
the heat requirements of the charge.
The major calibrations for this distribution are already built into the system based on design cal-
culations.
For distribution of coke oven gas across the heating wall, steel nozzle headers are installed in the
basement and are connected to each heating flue by riser openings. The calibrated stainless steel
nozzles are exchangeable.
Air/mix gas is distributed to the checkerwork of the regenerators by adjustable metal nozzle plates
arranged between sole flues and regenerator compartments. Waste gas is recollected to the sole
flues by the same nozzle plates.
The fine tuning of the heat distribution across the heating walls is done during commissioning by
adjusting the coke oven gas nozzles in the nozzle headers and the nozzle plates between the sole
flue and the regenerator.
470 Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved.
Manufacture of Metallurgical Coke and Recovery of Coal Chemicals
The heat distribution form pusher side to coke side, once adjusted properly, does not need to be
readjusted with changing operating conditions. This is achieved by pause heating as described in
Section 7.6.4.1.8.
The total amount of air fed to any heating wall and the total amount of waste gas collected from
any heating wall are adjusted by finger plates at the air inlets and dampers at the waste gas valves,
which are simple and specially designed for this function, thus ensuring an even and efficient
regenerator loading.
The total amounts of coke oven gas and mix gas fed to any heating wall are adjusted by orifices
installed downstream of the reversing cocks.
7.6.4.1.6 Vertical Heat Distribution A uniform vertical temperature distribution in the coke mass is of
fundamental importance to avoid heat being wasted and to control coke quality.
For vertical heat distribution, the major calibrations are also built into the system based on design
calculations. These are cross-section of the heating flues, cross-section of the air/mix gas entering
the ports at the flue bottom, and cross-section and location of the second air stage.
The fine tuning of the vertical heat distribution is done during commissioning by adjusting the air
inlet and draft at the air inlet boxes and the waste gas valves. For coke oven gas heating, additional
adjustments are possible at the two air regenerators feeding different the different air stages.
Coke oven gas enters above the heating flue sole and partially burns with the air of the lower stage.
Combustion is completed with the additional air at the higher air stage. During mix gas firing, mix
gas and part of the air enter at the bottom of the heating flue. The balance of the air is added in a
second higher stage. In both cases, this combustion results in a soft flame characteristic over the
entire height of the heating flue.
Once the optimum flame length has been obtained, changes in coking rate can be achieved by using
the pause heating facility described in Section 7.6.4.1.8. By using the pause heating facility, opti-
mum vertical heat distribution will maintained at all times.
7.6.4.1.7 Heat Distribution in the Longitudinal Direction of the Battery In the longitudinal direction
of the battery, equal amounts of air and gas must be distributed to each heating wall and, corre-
spondingly, equal amounts of waste gas must be collected from each heating wall into the waste
gas flue.
To avoid the wasting of heat, by increasing the amounts of gas/waste gas from the first to last heat-
ing wall, the amounts of gas/waste gas to and from the heating walls are controlled by throttling
devices in the connections. On the inlet side these throttling devices are orifices in the branches
from the coke oven gas or mix gas distribution main, arranged behind the reversing cocks of each
heating wall.
On the outlet side, throttling dampers are installed in the connecting piece between the sole flues
and the waste gas valves. In case the underfiring is changed from mix gas to coke oven gas, or vice
versa, these dampers must be manually adjusted to the different amounts of waste gas. The air inlet
fingers must also be adjusted.
In the case of changing operating conditions, with changing heat requirements for the battery
unchanged, even heat distribution and optimum pressure and flow conditions are maintained by
pause heating.
7.6.4.1.8 Pause Heating High efficiency of the heating system depends mainly on maintaining the
optimum adjustment and control of the distribution and pressure conditions under all operating
conditions.
This is achieved by pause heating, which keeps all operating parameters constant once they are
adjusted.
Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved 471
Ironmaking Volume
During commissioning, the battery is adjusted to the shortest possible coking time, i.e. maximum
possible heat requirement and maximum possible amounts of gas, air and waste gas. Under these
conditions the battery will be operating at the minimum pause during the reversal of the regenera-
tor half-periods.
If the heat requirements are reduced, i.e. in the case of longer coking times, the amounts of air and
gas entering the system and amount of waste gas leaving the system per unit of time are kept con-
stant and the reduced heat requirements are achieved by a pause between regenerator half-periods.
This simplifies the operation of a coke oven battery. All readjustments normally necessary with
changing coking times are eliminated.
With pause heating, a single timer is set to a certain pause depending on the selected coking
time. No further manual adjustments to the battery are necessary, except at very extreme coking
times.
The amounts of gas, air and waste gas flowing constantly per unit of time result in an even distri-
bution of heat in the longitudinal direction of the battery as well as across the heating wall. At the
same time, a constant flame characteristic in the heating flues at normal coking times results in an
even vertical heat distribution in the coke mass.
Operating times between the nominal coking time and 30% longer coking times are achievable
with consistent, high thermal efficiencies. The consistent heating parameters for all coking times
in this range result in evenly coked charges and consistent coke quality. Furthermore, pause heat-
ing reduces the manning/labor requirements for battery heating control, and therefore reduces
operating costs.
7.6.4.1.10 NOx Formation in the Heating System As can be seen from the heating cross-section in Fig.
7.74, the TSOA oven is an “air stage oven” which ensures low NOx formation in case of heating
with coke oven and mix gas.
In developing this heating system, TSOA embarked at first on a test program with extensive labo-
ratory tests, which included tests on small heating flues as well as the construction of cold models
to visualize the flow and mixing conditions in the heating flue.
Because of the results of these tests, test heating flues for 7.5 m high oven chambers were con-
structed in order to study all possible air and gas supply configurations and the resultant impact on
the NOx formation and the vertical temperature distribution.
The outcome of this work was the air stage oven, a design which produces long flames with a low
flame temperature and low NOx values for both mix gas and coke oven gas heating.
472 Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved.
Manufacture of Metallurgical Coke and Recovery of Coal Chemicals
After this extensive testing, the heating system was successfully built for owners worldwide.
Numerous batteries, with over 1000 ovens of this design, are in operation today.
7.6.4.1.11 Coke Oven Gas Heating To best illustrate the operation of a twin-flue air stage compound
oven system with coke oven gas, Fig. 7.74 will be extensively referenced in this section. The num-
bers referenced in parentheses, ( ), apply to heating after reversal.
Coke oven gas is supplied to each heating wall from the coke oven gas distribution main, 13, which
runs the length of the battery in the oven basement.
The gas flows through the reversing cocks into the nozzle headers, 15 (15a). Connections off the
nozzle headers incorporate adjustable stainless steel nozzles, 16 (16a), through which the gas
passes vertically upwards via the riser openings, 17 (17a), and enters the heating flues, 11 (11a), at
the burners, 18 (18a).
The combustion air is drawn through the open flaps, 20 (20a), of the air inlets and the sole flues,
3 and 4 (3a and 4a), and distributed to the regenerator compartments, 6 and 7 (6a and 7a), via the
metal nozzle plates, 5.
The heat stored in the regenerator, 6 and 7 (6a and 7a), during the previous reversal period as a
result of the waste gas being drawn off is then transferred to the combustion air that enters the heat-
ing flue, 11 (11a), via short connecting ducts, 8 and 9 (8a and 9a), partially at the heating flue sole
and partially at the higher air stage, 10 (10a).
Each twin flue forms a heating unit with the appropriate regenerator compartments to which it is
connected by short ducts.
Coke oven gas and air flow up the heating flues, 11, during the two stage combustion and wasste
gas flows down the adjacent heating flues, 11a. From there, the waste gas flows to the regenerator
compartments, 6a and 7a (6 and 7), via the ducts.
The waste gas passes through the nozzle plates, 5, and is collected in the sole flues, 3a and 4a (3
and 4), from where it is drawn through the waste gas valves, 19 (19a), and the waste gas flue, 21,
to the chimney. The two sole flues, 3a and 4a (3 and 4), lead to one waste gas valve, 19 (19a).
The coke oven gas burners not on fire are supplied with decarbonizing air. The air flows from the
air main, 22, through the nozzle headers, 15 (15a), and the riser openings, 17 (17a), to the burners,
18 (18a), in order to burn away any carbon deposits.
7.6.4.1.12 Mix Gas Heating To best illustrate the operation of a twin-flue air stage compound oven sys-
tem with mix gas (blast furnace gas stabilized with coke oven gas), Fig. 7.75 will be extensively ref-
erenced in this section. The numbers referenced in parentheses, ( ), apply to heating after reversal.
Mix gas is supplied to each heating wall from the mix gas distribution main, 1, which runs the
length of the battery in the oven basement.
The gas flows through the reversing cocks, 2 (2a), and the sole flues, 4 (4a), and is distributed to
the regenerator compartments, 7 (7a), through the metal nozzle plates, 5. The heat stored in the
regenerators, 7 (7a), during the previous reversal period as a result of the waste gas being drawn
off is then transferred to the mix gas which enters the heating flues, 11 (11a), via short connecting
ducts, 9 (9a), at the heating flue sole.
The combustion air is drawn through the open flaps, 20 (20a), of the air inlets and the sole flue, 3
(3a), and distributed to the regenerator, 6 (6a), via the nozzle plates, 5.
The preheated air enters the heating flues, 11 (11a), via short connecting ducts, 8 (8a), partially at
the heating flue sole and partially at the higher air stage, 10 (10a).
Mix gas and air flow up the heating flues, 11, during the two stage combustion and waste gas flows
down the adjacent heating flues, 11a. From there, the waste gas flows to the regenerator compart-
ments, 6a and 7a (6 and 7), via the ducts.
Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved 473
474
Section A-A Section B-B Section C-C Section D-D Section E-E
E D B A C
Ironmaking Volume
12 12 12
11 11 11
11a 11a 11a 11a 11a
10 10a 10a 10a 10a
10a 10 10
18
18a 18
18a 18a 8a 8
17 9a 9
17 17a 17a
17a 7 7 6a
6a
7a 7 6a 7
6a 7
20,20a 5 5 7a 6
7a 6
19,19a 5 5
4a 4 4 3a
4 3a
3a 4 3a 4
4a 3 4a 3
14,14a 16a 16a 2 2
13 16 15 2a
2,2a 16 16a 15,15a
22 15a 14 1
1
14a 13
21
D B
E A C
Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved.
Air Coke oven gas Waste gas
Fig. 7.74 Cross-section of the heating system for a twin-flue underjet-fired compound oven operating on coke oven gas.
Section A-A Section B-B Section C-C Section D-D Section E-E
E D B A C
12 12 12
11 11 11
11a 11a 11a 11a 11a
10 10a 10a 10a 10a
10a 10 10
18
18a 18
18a 18a 8a 8
17 9a 9
17
17 17a 17a
17a 7 7 6a
17a 6a
7a
7a 77 7
6a 7 6a
55 55 7a 7a 6
20,20a 6
19,19a 5 5
4a
4a 4 4 3a
4 3a
3a 4 3a 4
4a 3 4a 3
14,14a 16a 16a 2 2
13 16 15 2a
2,2a 16 16a 15,15a
22 15a 14 1
1 14a 13
21
D B
E A C
Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved
Fig. 7.75 Cross-section of the heating system for a twin-flue underjet-fired compound oven operating on mix gas (blast furnace gas stabilized with coke oven gas).
Manufacture of Metallurgical Coke and Recovery of Coal Chemicals
475
Ironmaking Volume
The waste gas passes through the nozzle plates, 5, and is collected in the sole flues, 3a and 4a (3
and 4), from where it is drawn through the waste gas valves, 19 (19a), and the waste gas flue, 21,
to the chimney. The two sole flues, 3a and 4a (3 and 4), lead to one waste gas valve, 19 (19a).
7.6.4.1.13 Waste Gas Flues and Chimneys Batteries are drafted by one single waste gas flue on one side,
which is connected to the chimney located in front of the battery. The waste gas flue is connected
to the chimney by a chimney flue.
The waste gas flue contains a hand-operated damper for control during startup or in case of a fail-
ure of the main butterfly valve.
The chimney flue contains a butterfly valve as a main control damper. This damper is automati-
cally controlled by a regulator.
7.6.4.1.14 Operation of the Battery Heating System The TSOA battery is noted for its ease of operation
and maintenance. This is enhanced, of course, by the presence of single rows of equipment: a sin-
gle row of waste gas valves with air inlets; a single coke oven gas main and reversing/isolating
cocks; single mix gas main and reversing/isolating cocks; and a simple hydraulic reversing gear.
The battery is adjusted by the TSOA commissioning team and is fine-tuned for optimum perfor-
mance before hand-over to the client. Thereafter, no adjustments to the heating system settings will
be necessary between the nominal coking time and 30% longer coking times. However, should the
operators wish to modify the battery settings for any reason, the facility is there and it is easily
accesible.
Provided that the basic maintenance requirements as laid down in the operating and maintenance
manuals provided are satisfied, the design performance of the battery heating system will be main-
tained for the major portion of the battery life. Data for a typical TSOA twin flue compound bat-
tery are presented in Table 7.4.
7.6.4.2 TSOA Double Pair Flue, Rich Gas Oven System
7.6.4.2.1 Double Pair Flue Heating Wall The TSOA heating wall consists of vertical heating flues
arranged in double pairs. The design has important technical features which should be noted. High
stability of the wall is achieved as only every second binder is a hollow binder, resulting in only
half the number of ducts between the regenerators and the heating wall. Uniform vertical heat dis-
tribution on the wall is achieved by multi-stage combustion with low NOx formation. Pressure
losses and pressure differentials are kept to a minimum by a nearly consistent cross-sectional area
Table 7.4 Data for a Typical TSOA Twin Flue Compound Battery
476 Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved.
Manufacture of Metallurgical Coke and Recovery of Coal Chemicals
path for the combustion gases to travel up the flues on fire, over the turnover point and down the
waste gas flues. Therefore, the likelihood of cross-leakage to occur within the refractory block as
the battery ages is reduced.
Two adjacent heating flues burn in each double pair flue unit, while the other two discharge waste
gas. The four flues are connected at the top by a small horizontal channel.
On the other side of the charge, the pair opposite the pair carrying waste gas is fired. With the
reversing after each regenerator half-period, the pattern of firing is changed.
Rich gas controlled by the calibration of the nozzles is introduced only on the base of each heat-
ing flue via a short burner. Combustion air preheated in the regenerator is introduced in the indi-
vidual heating flues through vertical hollow binders with calibrated slot openings at several
elevations over the height of the heating flue. The calibrated slot openings feed the combustion air
at a specific angle into the heating flue.
Each pair of heating flues has a central hollow binder channel directly connected to the regenera-
tor. Through this channel each pair of flues is either supplied with combustion air or after the rever-
sal, discharged of waste gas.
Solid header walls divide the individual flue groups within a heating wall and connect into the oven
roof.
After an incomplete combustion at the lowest stage, the air/gas mixture is diluted by the already
developed waste gas at each stage and finally burned with excess air at the highest stage in the
upper part of the flue. This staged combustion reduces the production of NOx.
To burn away any carbon deposits at the burners, decarbonizing air is fed through the 3-way revers-
ing cocks into the offgas nozzle headers by a forced air system.
The waste gas passes through the connecting canal into the adjacent flues and is carried down to
preheat the regenerator checkerwork before it leaves the system via the single waste gas flue and
the chimney.
Sliding bricks are arranged on top of the heating flues for fine tuning the heat distribution across
the heating wall according to the heat demand of the charge and the chamber taper.
Each double pair flue is always serviced by the same regenerator compartments, thus forming a
heating unit. One heating unit, Fig. 7.76, consists of the air regenerator cell, one group of heating
flues, the waste gas regenerator cell and the straight coke oven gas riser openings. Each heating
unit can be individually controlled and adjusted. Several heating units side-by-side build up the
heating wall.
7.6.4.2.2 Underjet System for Coke Oven Gas In the underjet system, coke oven gas is distributed in the
battery basement under the nozzle deck by means of steel nozzle headers off the distribution main
and through steel connections to the riser pipes and openings to the burners in the heating flues.
The coke oven gas is distributed in steel pipes which operate under pressure. Consequently, a good
distribution can be obtained to ensure consistent flow of gas to the individual flues. By taking max-
imum advantage of the available fuel gas pressure, stainless steel metering nozzles are installed to
ensure an accurate and consistent delivery of fuel gas to each individual burner. These are external
from the battery refractory block and are easily accessible within the basement.
The nozzles headers are supplied in the underjet system from a single distribution main and a pro-
gressive adjustment can be obtained across the length of the heating wall.
The coke oven gas is fed to individual burners in the heating flues through vertical openings within
the refractory block. They are of small diameter, having no detrimental effect on the stability of the
refractory block.
Tightness, especially in the regenerator walls, is achieved by a tongue-and-groove brick design
with staggered joints.
Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved 477
Ironmaking Volume
Fig. 7.76 Heating unit for a double pair flue underjet oven operating on coke oven gas.
All TSOA heating systems have also been provided as gun flue systems, based on the special
requirements of the owner.
7.6.4.2.3 Regenerator Arrangement The regenerators are located under the oven chambers and heat-
ing walls and are continuous from the pusher side to the coke side. They are divided into simple,
wide chambers. Each regenerator chamber operates on combustion air or waste gas. Two adjacent
regenerators always operate on different media.
478 Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved.
Manufacture of Metallurgical Coke and Recovery of Coal Chemicals
The regenerator chambers, with their checker bricks, are divided by partition walls into cells. The
regenerator cells are calibrated to the different heat requirements of the heating flues due to the
chamber taper by built-in flow resistance.
The corbel section contains only half of the number of connection ducts between regenerator cells
and heating flues found in other designs as only every second binder wall has a canal.
The two tapered sole flues form a composite part of the regenerator and do not require any lining.
The checker bricks, which form the regenerator packing, are supported by supporting bricks above
the sole flues.
The packing is sub-divided into the separate compartments by tiles. These are inserted dry and can
be removed should it every be necessary to repack the regenerator.
The majority of the checker bricks are manufactured from fireclay, but in the higher temperature
zone of the regenerators the top four layers are manufactured from 40% alumina fireclay.
Distribution bricks with calibrated openings are located above the sole flues and below the regen-
erator cells. The volume of air which is distributed to the regenerators is effectively sub-divided
into independent cells by the calibrated openings of the distribution blocks. Thus, a uniform and
controlled air flow is obtained together with optimum heat recovery in the regenerator.
7.6.4.2.4 Heat Distribution across the Heating Wall Due to the taper of the oven chambers it is neces-
sary to increase the heat input from the pusher side to the coke side. This is achieved by increas-
ing the heating flue temperature from the pusher side to the coke side. Increasing amounts of gas
and air must be fed to the heating flues to adapt the heat distribution across the heating wall exactly
to the heat requirements of the charge.
The major calibrations for this distribution are built into the system based on design calculations.
For distribution of coke oven gas across the heating wall, steel nozzle headers are installed in the
basement connected to each heating flue by riser openings. The calibrated stainless steel nozzles
are exchangeable.
Air is distributed to the checkerwork of the regenerators by calibrated distribution bricks arranged
between the sole flues and the regenerator compartments. Waste gas is recollected to the sole flues
by the same calibrated distribution blocks. The different flow resistances necessary for the distrib-
ution of air and the recollection of waste gas is ensured by the configuration of the calibrated open-
ings, which result in different flow resistances for different flow directions.
The amount of air fed to the heating flues is pre-calibrated by the built-in flow resistance of the cells.
The fine tuning of the heat distribution across the heating walls is done during commissioning by
adjusting the coke oven gas nozzles in the nozzle headers and the sliding bricks arranged at the top
of the heating flues.
The heat distribution from the pusher side to the coke side, once adjusted properly, does not need
to be readjusted with changing operating conditions. This is achieved by pause heating as described
in Section 7.6.4.2.7.
The total amount of air fed to and the total amount of waste gas collected from any heating wall
are adjusted by finger plates at the air inlets and by dampers at the waste gas valves. These ele-
ments are simple and specially designed for this function to ensure a uniform and efficient regen-
erator loading.
The total amounts of coke oven gas fed to any heating wall are adjusted by orifices installed down-
stream of the reversing cocks.
7.6.4.2.5 Vertical Heat Distribution A uniform vertical temperature distribution in the coke mass is of
fundamental importance to avoid heat being wasted and to control coke quality.
Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved 479
Ironmaking Volume
For vertical heat distribution, the major calibrations are also built into the system based on design
calculations. These are cross-section of the heating flues, cross-section of the air canals in the
binder walls, and cross-section and location of the air stages.
The fine tuning of the vertical heat distribution is done during commissioning by adjusting the air
inlet and draft at the air inlet boxes and the waste gas valves.
Coke oven gas enters above the heating flue sole and partially burns with the air of the lower stage.
Combustion is completed with the additional air at the higher air stage. This results in a soft flame
characteristic over the entire height of the heating flue when burning high calorific gas.
Once the optimum flame length has been obtained, changes in coking rate can be achieved by using
the pause heating facility described in Section 7.6.4.2.7. By using the pause heating facility, opti-
mum vertical heat distribution will maintained at all times.
7.6.4.2.6 Heat Distribution in the Longitudinal Direction of the Battery In the longitudinal direction of the
battery, equal amounts of air and gas must be distributed to each heating wall and, correspondingly,
equal amounts of waste gas must be collected from each heating wall into the waste gas flue.
To avoid the wasting of heat, by increasing the amounts of gas/waste gas from the first to last
heating wall, the amounts of gas/waste gas to and from the heating walls are controlled by throt-
tling devices in the connections. On the inlet side these throttling devices are orifices in the
branches from the coke oven gas distribution main, arranged behind the reversing cocks of each
heating wall.
On the outlet side, throttling dampers are installed in the connecting piece between the sole flues
and the waste gas valves.
In the case of changing operating conditions, with changing heat requirements for the battery
unchanged, even heat distribution and optimum pressure and flow conditions are maintained by
pause heating.
7.6.4.2.7 Pause Heating High efficiency of the heating system depends mainly on maintaining the
optimum adjustment and control of the distribution and pressure conditions under all operating
conditions.
This is achieved by pause heating, which keeps all operating parameters constant once they are
adjusted.
During commissioning, the battery is adjusted to the shortest possible coking time, i.e. maximum
possible heat requirement and maximum possible amounts of gas, air and waste gas. Under these
conditions the battery will be operating at the minimum pause during the reversal of the regenera-
tor half-periods.
If the heat requirements are reduced, i.e. in the case of longer coking times, the amounts of air and
gas entering the system and amount of waste gas leaving the system per unit of time are kept con-
stant and the reduced heat requirements are achieved by a pause between regenerator half-periods.
This simplifies the operation of a coke oven battery. All readjustments normally necessary with
changing coking times are eliminated.
With pause heating, a single timer is set to a certain pause depending on the selected coking time.
No further manual adjustments to the battery are necessary, except at very extreme coking times.
The amounts of gas, air and waste gas flowing constantly per unit of time result in an even distri-
bution of heat in the longitudinal direction of the battery as well as across the heating wall. At the
same time, a constant flame characteristic in the heating flues at normal coking times results in an
even vertical heat distribution in the coke mass.
Operating times between the nominal coking time and 30% longer coking times are achievable with
consistent, high thermal efficiencies. The consistent heating parameters for all coking times in this
range result in evenly coked charges and consistent coke quality. Furthermore, pause heating
480 Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved.
Manufacture of Metallurgical Coke and Recovery of Coal Chemicals
reduces the manning/labor requirements for battery heating control, and therefore reduces operat-
ing costs.
7.6.4.2.8 Thermal Efficiency The design features and operating modes outlined in this description
ensure even heat distribution in the horizontal direction of the battery and the horizontal and ver-
tical directions of the heating wall. These features combine to contribute to the high thermal effi-
ciency associated with the TSOA oven.
Other factors which influence the thermal efficiency include optimum utilization of the regenera-
tor filling, effective oven bracing system, insulation of the oven block, and the exclusion of cross-
leakage in the regenerator area.
The TSOA checker bricks in the regenerator compartments offer a large exchange surface to the
through-flowing media. The checker bricks are shaped so that the gas flow is split up into multiple
streams. This ensures good heat transfer by their large surface area.
Pressure differentials are low because disturbances in the flow from the inlet checkerwork to the
outlet checkerwork are minimal.
Horizontal surfaces which could collect dust in the regenerator are avoided.
7.6.4.2.9 NOx Formation in the Heating System As can be seen from the heating cross-section in Fig.
7.77, the TSOA oven is an “air stage oven” which ensures low NOx formation in the case of heat-
ing with coke oven gas.
In developing this heating system, TSOA embarked at first on a test program with extensive labo-
ratory tests, which included tests on small heating flues as well as the construction of cold models
to visualize the flow and mixing conditions in the heating flue.
Because of the results of these tests, test heating flues for 7.5 m high oven chambers were con-
structed in order to study all possible air and gas supply configurations and the resultant impact on
the NOx formation and the vertical temperature distribution.
The outcome of this work was the air stage oven, a design which produces long flames with a low
flame temperature and low NOx values.
After this extensive testing, the heating system was successfully built for owners worldwide.
Numerous batteries, with over 1000 ovens of this design, are in operation today.
7.6.4.2.10 Coke Oven Gas Heating To best illustrate the operation of a double pair flue with underjet
firing operating with coke oven gas, Fig. 7.77 will be extensively referenced in this section.
The rich gas distribution main, 13, is arranged in the oven basement opposite the waste gas flue
and extends the length of the battery. The gas supply to the individual heating walls is controlled
by adjusting shut-off and reversing cocks with the gas being fed through the gas headers, 15, in the
oven basement extending the longitudinal direction of the heating wall. From these gas headers, the
gas flows via short connecting lines, 16, into the vertical rich gas risers, 17, and to the burners, 18,
at the flue bottom. Control of the gas volume is effected by means of replaceable nozzles in the
connecting lines, 16.
The decarbonizing air main, 22, is arranged beside the rich gas main and serves the purpose of
feeding a minor amount of air to the rich gas burners, not on gas in the heating flues, via the rele-
vant distribution pipes and rich gas risers. This enables the prevention and burning away of any car-
bon deposits on the burners.
Combustion air is taken in through the alley and open air intake flaps, 20 and 20a, and drawn into
the sole flues, 3 and 4, from where it is distributed over the regenerator compartment, 7, via cali-
brated distribution bricks, 5. By means of throttling equipment mounted in the air intake boxes the
air volume allowed to enter a heating wall can be controlled and adjusted. The stored heat, which
the hot waste gas has conveyed to the checker bricks before heating system reversal, is absorbed
by air flowing through the regenerators. Through connecting ducts, 8, in the regenerator covering
and duct, 10, running up the binder, the hot air flows to the opening locations in the heating flue.
Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved 481
482
Section D-D Section E-E
Section A-A Section B-B Section C-C
E D
B A C
Ironmaking Volume
12 12
11a 11 11 11
11 10 11a 10 12
10a 11
10 10a 11a
18a 10 10a
18 10
18a 9
18 9a 8
18 9 8a
17 17 8 7a
7a 7
7a 17a 8a 7
20,20a 7
17a 17 9a 9 7a
5 7 5
5 5 7a
7 7a 3a
4
3a
4a 4 3a 4 4
4a 3 4 3
19,19a 16 16 3a
15 16a 4a
14,14a
14 15a
16 16a 15 14a
14a
13 14
21 22 13
E D B C
A
Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved.
Air Coke oven gas Waste gas
Fig. 7.77 Cross-section of the heating system of a double pair flue underjet heating oven operating on coke oven gas.
Manufacture of Metallurgical Coke and Recovery of Coal Chemicals
In the case of the double pair flue group carrying gas, the gas is burned in several stages accord-
ing to the staged supply of air. The ascending combustion gases pass the reversal point of the dou-
ble pair flue, flow downwards in the neighboring flue pair, and are then discharged through
connecting ducts in the regenerator compartment, 7a, where the transfer of heat to the checker
bricks takes place. Via the distribution bricks, 15, the cooled waste gas flows into the regenerator
sole flues, 3a and 4a, and on to the chimney through waste gas valves, 19 and 19a, and the waste
gas collecting flue.
When the regenerator heating system reversal has been effected, the flow of the media is reversed.
The gas supply is changed over to the second gas header, 15a, of the heating wall and the other flue
pair of the double pair flue is now on gas. The functions of the regenerator are also then reversed.
7.6.4.2.11 Waste Gas Flues and Chimneys Batteries are drafted by one single waste gas flue on one side,
which is connected to the chimney located in front of the battery. The waste gas flue is connected
to the chimney by a chimney flue.
The waste gas flue contains a hand-operated damper for control during startup or in case of a fail-
ure of the main butterfly valve.
The chimney flue contains a butterfly valve as a main control damper. This damper is automati-
cally controlled by a regulator.
7.6.4.2.12 Operation of the Battery Heating System The TSOA battery is noted for its ease of opera-
tion and maintenance. This is enhanced, of course, by the presence of single rows of equipment: a
single row of waste gas valves with air inlets; a single coke oven gas main and reversing/isolating
cocks; and a simple hydraulic reversing gear.
The battery is adjusted by the TSOA commissioning team and is fine-tuned for optimum perfor-
mance before hand-over to the client. Thereafter, no adjustments to the heating system settings will
be necessary between the nominal coking time and 30% longer coking times. However, should the
operators wish to modify the battery settings for any reason, the facility is there and it is easily
accessible.
Provided that the basic maintenance requirements as laid down in the operating and maintenance
manuals provided are satisfied, the design performance of the battery heating system will be main-
tained for the major portion of the battery life. Data for a typical TSOA double pair flue rich gas
battery are presented in Table 7.5.
Table 7.5 Data for a Typical TSOA Double Pair Flue Rich Gas Battery
Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved 483
Ironmaking Volume
Expansion (%)
The following describes the 1.0
systems for the example of
the twin flue underjet com-
0.8
pound coke oven.
7.6.4.3.2 Refractory Material Characteristics The graph in Fig. 7.78 illustrates the thermal expansion
characteristics of fireclay and silica over the operating temperatures encountered in the coke oven
battery. The following trends are noted. Silica undergoes practically no dimensional change
between 800°C and 1400°C (1450°F and 2550°F). Fireclay undergoes a significant dimensional
change over the range of 800°C and 1300°C (1450°F and 2350°F). At this upper temperature it has
already reached its safe working limit beyond which its mechanical properties diminish.
Over the range 375–800°C (705–1450°F), silica undergoes some dimensional change, but far less
than that of fireclay. Below 400°C (750°F) silica undergoes a dramatic, non-linear dimensional
change. In contrast, fireclay undergoes a linear dimensional change below 400°C (750°F), a
change which is far less severe than that of silica.
In addition to thermal expansion, other characteristics must be taken into account. Silica maintains
its mechanical properties up to a temperature of 1600°C (2900°F), while low alumina fireclay is
serviceable only up to temperatures of 1000°C (1830°F). Silica resists chloride attack, while fire-
clay is susceptible to attack from chlorides within the coal. The closed pore surface structure of
fireclay provides a better resistance to sulfur attack than the open pore structure of silica.
7.6.4.3.3 Sole Flues and Lower Regenerator Section By design, the regenerators undergo a time-related
temperature fluctuation, normally on a 30 min. cycle. The sole flue and the lower section of the
regenerator (approximately 65% of the total regenerator height) operate within a range of
95–350°C (200–950°F). Within this range, silica undergoes a 1% linear expansion, an expansion
which is critical in the range of 200–300°C (400–600°F).
In contrast, fireclay undergoes an expansion of less than half that of silica and the expansion curve
is linear, thus there is no critical zone on the temperature curve.
484 Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved.
Manufacture of Metallurgical Coke and Recovery of Coal Chemicals
Sillimanite
clay
Fire
Qoin brick
Silica
Fireclay
Fig. 7.79 Refractory cross-section of a twin flue underjet Fig. 7.80 Wall bond for a twin flue underjet oven
compound oven. system.
The TSOA oven design, Fig. 7.79, therefore employs fireclay for the construction of the regenera-
tor sole flues and the major part of the regenerator walls.
Experience shows that a battery with regenerator walls constructed solely from silica will usually
display signs of cross-leakage between regenerators after heatup, particularly in the critical zone
where the normal reversal temperature fluctuations are in the region of 320°C (600°F). In contrast,
a fireclay wall with proper bracing will remain tight for the duration of the battery life.
7.6.4.3.4 Upper Regenerator Section and Heating Walls Above the critical temperature of 800°C
(1450°F) silica displays characteristics far superior to those of fireclay both in thermal expansion
and in mechanical properties. Therefore, in the TSOA design the upper portion of the regenerator
walls, the strong corbel section in the battery center, and the oven heating walls are constructed of
silica and not fireclay, Fig. 7.80.
Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved 485
Ironmaking Volume
In the case of the heating walls, the wall surface temperature may fluctuate between 1000°C and
1250°C (1850°F and 2250°F) as hot coke is pushed and cold, wet coal is charged. However, the sil-
ica volume is stable over this temperature range and therefore negligible thermal stresses are devel-
oped within the walls.
7.6.4.3.5 Oven Roof By the same logic fireclay is more suitable than silica for the construction of the
battery roof above the cover blocks of the oven chamber.
Temperature fluctuations occur within the oven roof and where this is constructed of silica a weak-
ening will develop in the critical zone below 800°C (1450°F). By employing fireclay, the TSOA
design in Fig. 7.81 enables the roof to be maintained tight and strong for the duration of the bat-
tery life.
7.6.4.3.6 Silica and Fireclay Interface There are few coke oven designers who would argue against the
selection of fireclay as the most suitable material of construction for the regenerator walls. How-
ever, most important for the design is the achievement of an adequate joint between the silica and
fireclay layers at their interface.
In the case of the TSOA oven, the design is based on many years of experience. A special sliding
joint is constructed between the fireclay substructure and the upper silica section, a joint system
which has been proven over many decades on tens of thousands of TSOA coke ovens of every size.
The performance of the sliding joint is most important during the heat up of the coke oven battery,
Fireclay
Silica
486 Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved.
Manufacture of Metallurgical Coke and Recovery of Coal Chemicals
when silica and fireclay undergo their different expansions. This differential expansion is not only
accommodated by the sliding joint, but also controlled precisely by the TSOA bracing system
described in Section 7.6.4.3.9. The end result is a gas-tight joint necessary for the integrity of the
overall battery structure.
A sliding joint is also employed between the silica and fireclay layers of the oven roof. Again, by
special design of the joint and the controlled bracing, a gas-tight structure is assured.
It will be noted here that in the case of the coke oven gas riser pipes, trumpet bricks are provided
at the interface between the concrete and fireclay and at the interface between fireclay and silica.
This is a well-proven and practical method of accommodating the difference in expansion which
may occur in deviation to the theoretical calculation. It ensures that there is no restriction within
the riser pipe and that a clear through-way is available for rodding of the riser pipes following rou-
tine maintenance grouting. This design is a standard TSOA feature and is incorporated in all of the
battery designs.
7.6.4.3.7 Quoin Design for the Heating Wall End The quoin brickwork is particularly vulnerable to tem-
perature changes and is subject to thermal shock each time an oven door is removed. Silica can be
used in the construction of the quoins, but in operational practice it tends to crack and spall, result-
ing in a high level of corrective maintenance.
In the TSOA design, Fig. 7.82, the silica bricks are replaced by special spall-resistant sillimanite
bricks.
This material has proved eminently suitable for quoin duty on TSOA batteries around the world
over many years.
The special bricks are bonded into the silica end brickwork. This ensures uniform expansion of the
quoins as well as gas tightness in this critical zone of the heating wall. Should the need arise, the
quoin brickwork can be replaced without opening or disturbing the brickwork of the last heating flue.
7.6.4.3.8 Insulation of the Oven Block In the design of the TSOA battery, particular attention is paid to
thermal insulation. This promotes good thermal efficiency, comfortable working conditions, and
minimizes heat degeneration of the battery steelwork and ironwork.
Sillimanite
Qoin brick
Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved 487
Ironmaking Volume
Particular areas of insulation and the protection afforded are: concrete nozzle deck of the battery
beneath the sole flues to prevent radiation into the basement; regenerator faces to reduce radiation
into the alleys; brickwork at the battery ends to protect the buttress walls; and the large, flat oven
roof to prevent radiation to the atmosphere.
The insulation is provided by courses of insulating brick.
Also, the charging hole lids are insulated against heat radiation by special design and being filled
with an insulating compound.
7.6.4.3.9 Battery Bracing System In battery design, proper and effective bracing of the refractory block
is considered to be of paramount importance, and the current TSOA design reflects many years of
development, testing and site experience. The importance of the battery bracing is very often
underestimated both by battery designers and operators, and it plays a different but equally impor-
tant role during the heating up and subsequent operation of the battery. Many instances of prema-
ture battery failures around the world can be traced back to inadequate bracing control, either
during the battery heatup or during its early years of operation.
The bracing system of a coke oven battery has to perform two functions: (1) restrain the fireclay
refractory brickwork during the heatup expansion to allow the silica refractory brickwork to slide
over or under it due to its higher expansion, and (2) to restrain the battery block during operation.
The vertical and longitudinal expansion of the refractory oven block is allowed for by expansion
joints built into the brickwork.
The forces arising in the vertical direction are taken up by the weight of the oven block.
The bracing forces in the horizontal direction are adjusted such that the expansion joints are nearly
closed and that the fireclay material is not taken apart at the sliding joints by the more expanding
silica material in the lower temperature range.
Due to the higher expansion of silica compared with fireclay material, the silica part of the oven
block is built up with recesses in the horizontal direction.
After complete expansion, a gap of 10–20 mm between the buckstay and the oven quoin avoids a
direct heat transfer into the buckstay.
7.6.4.3.10 Buckstays and Tie Rods The buckstays represent the heart of the battery bracing system and
it is from these that loads and forces are distributed to the critical areas of the refractory block to
ensure that it is correctly restrained. On the one hand, the bracing system from the buckstays must
be sufficiently flexible to allow the battery to breath and move normally throughout its life, while
on the other hand it must be sufficiently strong to ensure that such movements are not unrestrained
to the detriment of the battery life.
Opposite buckstays are drawn towards the oven heating walls by two upper cross-tie rods per heat-
ing wall inside protection channels made of stainless steel. Two bottom cross-tie rods per wall will
be installed in the nozzle pad openings. The cross-tie rods are spring loaded from the buckstays
and thus controllable and measurable forces are exerted at these points, ensuring that the correct
pressure is maintained during heat up and operation. The springs are protected from heat and dirt
accumulation and are equipped with spring position indicators.
Buckstays and upper and lower tie rods form a frame around the refractory block in the cross-direc-
tion of the battery.
The cumulative forces from the cross-tie rods are then distributed from the buckstay onto the
refractory block through the bracing system. Furthermore, the buckstays are capable of supporting
additional peripheral equipment, including gas collecting mains, coal charging car collectors wire
supports and the like.
Against vertical loads during heat up, the buckstay bases are connected to the concrete waste gas
flue/basement bottom slab by vertical anchors. The horizontal mobility of the buckstay bases is
ensured by slotted holes and friction bearings.
488 Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved.
Manufacture of Metallurgical Coke and Recovery of Coal Chemicals
Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved 489
Ironmaking Volume
stamping compound. Cast-in grooves with gaskets are arranged at the back sides of the door
frames. T-bars laid in between the roof brick layers and supported from the buckstays by pressure
bolts hold the fireclay roof brickwork above the door frames on both the pusher side and the coke
side of the oven. Steel plates located under and sloped downward from the oven doors to the bench
are provided. They are designed to prevent coke spillage from passing between the battery and
benches to the alleys below.
7.6.4.3.12 Regenerator Bracing In the TSOA design the lower portions of the regenerator walls are
constructed from fireclay, which displays expansion characteristics different from those of silica.
To prevent the fireclay from being torn apart by the silica material as it expands during heat up, a
regenerator bracing is installed.
Controlled forces are applied by springs from the buckstays to hold the silica and fireclay parts of
the regenerator top and regenerator wall sections together while the silica slides over the fireclay.
The regenerator wall under the chamber is held by a spring-loaded I-beam and the regenerator wall
under the heating wall is held by a U-profile that is spring loaded from the buckstay.
490 Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved.
Manufacture of Metallurgical Coke and Recovery of Coal Chemicals
to the upper area rods. The hydraulic cylinders and the hydraulic power unit are located in a sepa-
rate room near the coal charging station.
In the event of a gas failure during a heating up period, the valves of the walls on fire are closed
automatically. The position of the air inlet flaps and the waste gas valves remains unchanged and
the battery is purged with air.
In the case of a gas failure during a reversing operation, the actual reversal of the flaps/valves is
completed to achieve defined purging conditions as well.
To monitor the correct operation of the individual reversing elements, an infrared safety system is
provided.
7.6.4.3.15 Raw Gas System Each battery normally incorporates a single gas collecting main on the
pusher side or the coke side, Fig. 7.85. The gas collecting main handles the raw gas evolved from
the battery when operating at its design maximum coking rate. The gas collecting main is divided
down into sections based on the number of ovens, with each section incorporating a raw gas offtake.
A flushing liquor feed connection is installed at the end of each main to enable the mains to be
flushed through at selected intervals.
HP _ aspiration liquor
Flushing liquor
Mechanical and manual
operation of water-sealed lid
Pneumatically operated Pneumatically-operated
HP _ aspiration valve bleeder valve
Bitumen seal
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Ironmaking Volume
Each gas collecting main section is provided with two bleeder stacks, one at each end. Each bleeder
stack is closed by a liquor-sealed valve which is actuated remotely and automatically in the event
of high gas collecting main pressure. An electric system ensures ignition and a cowl induces air to
the bleeder stack. The flame will be stabilized by the addition of steam to the center of the com-
bustion burner.
The ascension pipes are mounted in cast iron base sockets which are set into the battery top. The
ascension pipes have a refractory material lining.
The ascension pipe top section is of mild steel and is refractory lined as in the case of the ascen-
sion pipes. They are equipped with water-sealed ascension pipe caps, operated from the battery top,
which consist of a cast iron water trough bolted to the ascension pipe top and a double skin lid. The
lower plate of the lid is fabricated in steel and is designed to withstand the radiant heat from the
oven. This plate forms a seal against the inner face of the cast iron trough. The upper plate is a stan-
dard vessel bottom from steel fitting into the water trough which is the primary seal. The air gap
between the two plate ensures that the lower plate remains hot, thus preventing condensation of tar.
The goosenecks are cast iron and are equipped with wide-angled liquor sprays which ensure that
the entire surface is wetted and remains clear of deposits. These normally remain clean down to
bare metal.
This nozzle also cools the gas prior to entering the collecting main.
High pressure nozzles are installed in the goosenecks directed towards the collecting main valve.
The positioning and design of these nozzles ensure maximum aspirating efficiency with minimum
liquor consumption. The liquor valves associated with the nozzles are operated from the battery top.
Oven chamber isolation from the gas collecting main is possible by a cast iron collecting main
valve which is irrigated by the flushing liquor to form a liquor seal. Each collecting main valve is
housed in a separate casting external from the gas collecting main so that it can be easily main-
tained, and should the need ever arise, it can be replaced without undue difficulties. These valves
are operated from the battery top.
A flushing liquor distribution main is installed along the coke side gas collecting main, complete
with branches including isolation cocks to each flushing liquor spray in the goosenecks, collecting
main and bleeder stack.
Additionally, branches are provided with valves to the ends of each gas collecting main.
Gas collecting main supports are secured to the top of the buckstays at every second oven.
Industrial water mains, complete with branches, are installed on the coke side of the battery along
the length of the gas collecting mains to supply water to the troughs of each ascension pipe lid.
Each branch is fitted with an isolation cock.
Water from the ascension pipe lid seals overflows through a coarse steel mesh filter into an open
trough. Each trough is connected to a drain main on the coke side which runs the entire length of
the battery. The water is collected in a closed recirculation and treatment system. The surplus water
is discharged into the collecting main for final treatment in the byproduct plant.
An emergency water main is provided. This main is connected into the flushing liquor main adja-
cent to the battery. This main includes isolation valves.
492 Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved.
Manufacture of Metallurgical Coke and Recovery of Coal Chemicals
Moreover, deformations of door bodies and chamber frames vary both in the long and short term
due to operationally conditioned temperature variations.
However, it is not the absolute temperature but rather the temperature gradient in the door body
and the chamber frame that is the determinant of thermal deformation. The thermal deformation
of the door body and/or the chamber frame can be determined by the following relationship:
T . DT . L2
YT = 8H (7.6.1)
where
YT = thermal deformation
T = thermal expansion coefficient
DT = temperature difference in the element
L = element length
H = door body web height.
The deformations due to thermal stress for a chamber frame and door body are plotted over the
chamber height in Fig. 7.86. The resultant deformation difference, more or less wide gaps, must be
closed by the sealing element.
7.6.4.4.1.2 Gas Pressure in Sealing Element Area The tightness of a coke oven door furthermore is influ-
enced by the level of gas pressure in the sealing element area and by the configuration of the gas
discharge duct which is formed by the heating wall door plug and sealing element.
The development of the gas pressure mainly depends on the type of charged coal (i.e. volatile mat-
ter, grain size and bulk density) and the coking time.
An example of the chronological development of gas pressure in the area of the door seal is pre-
sented in Fig. 7.87. The maximum is reached shortly after charging.
Measurements revealed that the gas pressure mostly is approximately 100 mm WG shortly after
coal charging, although pressure peaks of 500 mm WG and more were also noted.
The gas pressure, however, can be influenced by the appropriate choice of the gas discharge duct.
Fig. 7.88 shows the dependence of gas pressure on the cross-section of the gas discharge duct.
7.6.4.4.2 Demands on Modern Coke Oven Doors Modern coke ovens, with chambers up to 8 m (26.3 ft)
tall and up to 600 mm (24 in.) wide, demand increased performance of the coke oven doors. Door
Locking
Fig. 7.86 Deformation differences between the chamber frame and the door body.
Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved 493
Ironmaking Volume
Time (hrs)
Fig. 7.87 Pressure development in the gas discharge duct after the start of the coking time.
494 Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved.
Manufacture of Metallurgical Coke and Recovery of Coal Chemicals
The coke oven door is vertically supported by means of a round carrier bar installed horizontally
through the door body, resting on cams that are cast to the chamber frame.
Between the sloped inner surfaces of the chamber frame and the door plug side surface, gas escape
channels are created on both sides that may be cleaned mechanically.
Gas developing behind the door seal can freely escape into the free gas space on top of the charge,
and thus the buildup of an excessive gas pressure at the seal is safely prevented.
The distance between the door plug and the wall is approximately 20 mm (0.8 in.). This narrow gap
prevents the ingress of coal into the gas escape channels and the resultant pressure accumulation
at the seal.
7.6.4.4.3.2 Sealing System The efficiency of the TSOA door sealing system is based on the follow-
ing features and properties.
The sealing strip is adaptable to variations in the frame and door contours and local unevenness,
up to approximately 50 mm (2 in.), just by moving the sealing system (spring casing, sealing spring
and sealing strip) with the set screws above the spring casings.
There is no bending to the cross-section of the Z-sealing strip profile. The 90° angle in the profile
cross-section is maintained. The entire spring deflection of the sealing system is thereby retained
for the automatic adaptation.
The theoretical spring forces and therefore the compressive force of the sealing strip onto chamber
frame contact surface adjust themselves automatically.
At the same time, the adaptation of the sealing system to the chamber frame contour, as well as the
spring forces onto the sealing strip, are adjusted by the set screws above the spring casings.
Automatic adaptation to variations in the bending line of the chamber frame and the door body due
to temperature variations during the coking time are effected by the spring-loaded sealing strip.
Distances between adjustment points are approximately 200 mm (8 in.), making the adaptation for
local unevenness of the chamber frame possible.
The door and especially the sealing element is strong enough to withstand mechanical cleaning.
Only by combining all of the above features can TSOA door, Fig. 7.89, fulfill and meet today’s
demands and requirements at normal temperatures.
7.6.4.4.3.3 Door Plugs The door plug must protect the door against overheating, reduce heat losses
from the oven chamber, and bridge the gap between the door and the first heating flue to ensure
coked out ends of the coke cake.
The door plugs can be of fireclay refractory brickwork and held in place by cast iron brick retain-
ers or precast fused silica blocks.
7.6.4.4.3.4 Leveler Door The leveler door body is made of cast iron. A spring-loaded Z-shaped seal-
ing strip is clamped to the leveler door body and automatically adapts itself to the machined sur-
face of the leveler door frame contact surface.
The leveler door has a center spring-loaded latch which is hinge-mounted, opening upwards (to one
side in most older plants).
7.6.4.4.3.5 Door Positioning in the Chamber Frame Adjustable stopper bolts, limiting the horizontal
movement of the door toward the chamber frame, are installed to protect the sealing strip when the
door is placed into the chamber frame.
Furthermore, the door is equipped with four guide pieces in the area of the latch hooks.
To avoid damage to the door as it is moved in and out, the distance of the guide pieces toward the
latch hooks is adjusted by shims to 3mm (0.12 in.). Thereby, the gap between the chamber wall and
the door plug on both sides is kept the same as much as possible.
Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved 495
Ironmaking Volume
For vertical positioning, the door is equipped with a carrier bar resting on two cams cast to the
frame.
The machining of these cams ensures an exact positioning of the door in the vertical direction.
7.6.4.4.3.6 Chamber Frame The pusher side and the coke side chamber frames are made of heat resis-
tant cast iron.
They are easily replaceable in the oven without the necessity to loosen buckstays. Their nearly
square cross-section keeps temperature differentials, and thereby deflection, low.
Pairs of latch hooks are bolted to each frame to accommodate the coke oven door.
Supporting cams are cast on to the chamber frame for vertical door supporting.
The chamber frame is held in position by pressure bolts from the wall armoring plates.
Devices placed on each side of the chamber frame and acting from the wall armoring plates pre-
vent hour glassing.
The sealing surfaces on the chamber frame front are machined for contact with the door sealing strip.
496 Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved.
Manufacture of Metallurgical Coke and Recovery of Coal Chemicals
serves an entire battery of ovens, running parallel with the battery and extending above it on one
side or on both sides, depending on whether it is a single or double collecting main operation.
The gas and vapors ordinarily leave the oven at temperatures in the range 600–700°C
(1100–1300°F), and are shock-cooled by spraying with flushing liquor in the goosenecks and fur-
ther cooled by spraying again with flushing liquor at different points along the collecting main. The
cooling is effected by the evaporation of a portion of the water from the flushing liquor which
removes some of the sensible heat from the gas and condenses some of the vapors, with the resul-
tant condensation of heavy tar from the gas.
The gas and remaining vapors pass from the collecting main through one or more cross-over mains
into the suction main. A pressure-regulating valve, automatically controlled, is located in each
cross-over main. After the gas and vapors have passed this control valve their temperature drops to
a range of 80–100°C (175–212°F), as a result of atmospheric cooling and further evaporation of
the flushing liquor.
The flushing liquor, used for cooling in the spray system, is liquor which has been condensed in
the mains, collected and recirculated, amounting to 3–4.5 m3 (800–1200 gal) per ton of coal car-
bonized in coke oven batteries with a single collecting main and up to approximately 7.5 m3 (2000
gal) on those with two mains. The flushing liquor, which cools and condenses various vapors in the
gas, provides a carrying medium for the condensable tars and other compounds formed in the oper-
ations. These liquid materials flow from the collecting main through a seal into a downcomer and
are delivered through the return flushing lines to a collecting unit customarily called a flushing
liquor decanter, Fig. 7.90 and Fig. 7.91.
The uniform flow of gas and vapors into the system is accomplished by the charging of coal into
the ovens at regularly prescribed intervals and the withdrawal of the evolved gases at a constant
rate. This constant rate of removal of the gas is controlled by varying the speeds of the turbines and
exhausters which pull the gas away from the ovens and by automatic pressure regulators in the
cross-over main. This pressure regulator provides a slight pressure of about 1 mm (0.04 in.) of
water at the base of the oven prior to pushing. This control of pressure is for the purpose of elimi-
nating the infiltration of atmospheric air or gases from the heating system into the oven, which
would have a deleterious effect on the quality and quantity of the coke and coal chemicals.
As a consequence of this practice, the pressure on the collecting main is about 8–12 mm (0.3–0.5
in.) of water with a variable suction of about 200–300 mm (8–10 in.) of water in the cross-over
main after the regulating valve.
These pressure differentials are maintained by the use of either low speed positive turbo or cen-
trifugal-type exhausters designed to remove the gases and vapors at a controlled rate.
Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved 497
River
498
Fig. 7.90 Flowsheet showing the major steps
Coal hoist involved in the carbonization of coal by the
byproduct process and the subsequent recovery
Conveyer belts of coal chemicals from the gases generated.
Coal
R.R. car storage
Ironmaking Volume
dumper Bin
mixing
X
Primary
cooler
Coal bridge
Precipitator Flushing liquor
Flushing
liquor Crusher
decanter Coke
crusher
Metallurgical coke
Tar Tar Coke
Coke ovens
storage Coke screenings
Dehydrator
Raw Quenching Coke Screening
gas station wharf station
Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved.
Ammonium Debenzolized wash oil
sulfate From stripper
Ammonia
still Benzolized wash oil
To stripper
Sodium phenolate
for further
processing Naphthalene
Manufacture of Metallurgical Coke and Recovery of Coal Chemicals
Incoming tar
and liquor
Flushing liquor
to oven collecting
main
Flushing liquor
decanter tank
Drag scraper Perforated Tar level
baffle plate control From primary cooler
Pitch
sludge Flushing To tar collecting tank
liquor
Tar Flushing liquor
Pump
collecting tank
Tar drain
Tar from final
To ammonia storage tank cooler
Fig. 7.91 Schematic representation of a flushing liquor decanter tank or hot tar drain tank
to regulate the retention time of the tar in the decanter. Carbonaceous deposits in the bottom of the
decanter are continuously removed by scrapers dragged slowly along the bottom by two endless
chains.
Normally, the tar recovered from the flushing liquor contains 2–5% water. When the water content
of the tar is in excess of 5%, further decantation or blending may be required to reduce the water
content. This is usually accomplished by placing tar receiving tanks and separating tanks in the
process lineup prior to the tar storage tanks. Tar receiving tanks are simply intermediate storage
tanks which receive the tar from the decanters prior to being pumped into the tar storage tanks.
Depending on the water content of the tar in a receiver, the tar may be pumped directly to storage,
heated to lower the water content, or be pumped back into the decanter system.
Heavy tar
box
Tar / water
Heavy to primary cooler
tar
Excess
flushing
liquor
Flushing
liquor
Tar
Fig. 7.92 Flushing liquor handling system with a circular decanting tank
Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved 499
Ironmaking Volume
With this arrangement, the heavy tar or sludge is separated before the actual tar decantation takes
place. This separation occurs by passing the flushing liquor through the openings of a slowly rotat-
ing sleeve drum. Large size particles or agglomerations will not pass through the drum. Instead,
they settle in the bottom of the tar box. A continuously moving drag conveyor carries the heavy tar
out of the box into a container. To prevent plugging of the sieve drum, brushes remove deposits off
of the rotating drum.
The pre-cleaned flushing liquor flows from the inside of the sleeve drum to the actual tar/water
decanter (circular decanting tank). The decanting tank consists of three compartments: the tar
water separating zone, the conical bottom where the tar will settle, and the outer chamber where
the cleaned flushing liquor will flow into after overflowing a weir in the upper part of the decanter.
This outer chamber serves as a pumping tank for the flushing liquor and, more importantly, pro-
vides the heat to the conical section that is necessary for a good tar/water separation. From this
outer chamber, the excess ammonia liquor (or virgin liquor) will be withdrawn and pumped back
to the gas collecting main of the coke oven battery.
This liquor/tar handling system contains all moving parts in a relatively small vessel and therefore
a spare can be provided at low cost. The decanter itself is a sophisticated tank and therefore needs
no spare. Because of the relatively high undisturbed settling time, a low-moisture tar is produced.
There is another beneficial side effect with this type of decanter. On the outer perimeter, at a cer-
tain elevation, a special tar with low viscosity and a high solubility for naphthalene can be with-
drawn. This quality of tar is the ideal additive to the primary cooler circulation liquor in the case
of direct primary coolers or the correct flushing medium for indirect primary coolers for the pre-
vention of naphthalene deposits.
Certain modifications have been made, mainly to eliminate the so-called heavy tar box, from the
system, Fig. 7.93. No matter what type of tar/liquor separation system is installed, a certain quan-
tity of heavy tar (sludge) is produced. This fraction must be removed from the tar or it will plug
lines and settle in the tar storage tanks.
In most plants this heavy tar is fed into a container and then carried to the coal yard and mixed onto
the coal. Because the heavy tar is a hazardous and strong-smelling material, it is becoming more
and more difficult to handle. As such, some plants have begun to process the heavy tar in a machine
where the particles are ground down.
Because the particles produced with this machine will stay in suspension with the tar, it is no
problem to feed the ground heavy tar solution to the liquor flow entering the decanter. As the
Downcomer
Coke oven gas
Coke oven gas to primary cooler
and
flushing
liquor Decanter
Tar / water
to primary cooler
X Excess
flushing
liquor
Flushing
liquor
Tar
Fig. 7.93 Flushing liquor handling system without a heavy tar box.
500 Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved.
Manufacture of Metallurgical Coke and Recovery of Coal Chemicals
Downcomer
Coke oven gas
Coke oven gas to primary cooler Tar centrifuge
and
flushing
liquor Decanter
Fines to
coal
Tar / water
to primary cooler
X Excess
flushing
liquor
Flushing
liquor
Fig. 7.94 Flushing liquor handling system with a centrifuge to reduce fines content.
quantity of heavy tar, <0.5% of all tar produced, is negligible, the increase of fines in the tar prod-
uct is minimal.
With more stringent pollution control on coke oven batteries, the concentration of coal and coke
fines in tar is steadily increasing. To counteract complaints from tar processors, some plants have
installed centrifuges, Fig. 7.94, to free the tar from most of the fines before it is sent to the stor-
age tanks.
In these centrifuges, nearly all particles greater than 75 m are removed. The particles are recovered
in the form of a very dry powder-like fraction, which can be easily mixed with coal.
Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved 501
Ironmaking Volume
Downcomer
Suction main
Coke oven gas
from battery
Vents
Motor-operated
valve
Parition
plates
Tar spray
Steam
Inspect
hole
Manhole
Drain
Water
Fig. 7.96 Three indirect primary coolers of the vertical tube type.
502 Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved.
Manufacture of Metallurgical Coke and Recovery of Coal Chemicals
} Heat
recovery
stage
Cooling water
direct contact between gas and cooling liquor should not
cool the gas below 30–35°C (86–95°F), otherwise the
resultant plugging problem for the vessel(s) and heat
exchangers becomes too severe. With the indirect pri-
mary cooler in Fig. 7.98, gas outlet temperatures of
18–24°C (64–75°F), depending on available cooling
water temperature, are typical. The benefit of a gas tem-
perature that low for the subsequent byproduct train is
obvious. With a continuous spray of tar/water mixture
form the tar and flushing liquor decanter onto the tubes
of the primary cooler, a naphthalene absorption takes
place which will lower the naphthalene dewpoint of the
by 1–2°C (2–4°F) below the gas outlet temperature. This
Cooling water is even more important if one considers the fact that the
Chilled water
gas leaving a direct primary cooler is supersaturated
with naphthalene in the form of aerosols. Deposits in the
Coke oven gas Chilled water top of these primary coolers and in the gas outlet lines
to
Electrostatic Condensate are caused by this carryover of naphthalene.
precipitator
In warmer climates, this indirect primary cooler may be
Fig. 7.98 Indirect primary cooler operated with chilled water in the lower part of the cool-
ing bundles to achieve the required low gas temperature.
For heat recovery purposes, some coolers have been designed to produce hot water in the upper
section. This hot water may be used for heated buildings or sanitary purposes.
Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved 503
Ironmaking Volume
Vent Purging
steam Suspension compartment
Manhole
Clean gas
Coke oven
gas from Oil compartment
exhausters Entrance bushings
Manhole/handhole
Insulator heater
Insulator
Tube assembly
Bus duct
Bus
High voltage bushings
Ground switch housing
Ground switch
Transformer
Tar drain Discharge electrode
seal pot
Vent Weights
To condensate sump
The ammonia present in the weak liquor is in two forms classified as free and fixed. The free
ammonia is that which is readily dissociated by heat, such as the ammonium carbonate, sulfide,
cyanide, and so on, while the fixed
ammonia is that which requires the
presence of a strong alkali to effect To ammonia cooler
displacement of the ammonia from and absorber
Cooling water
Dephlegmator
the compound in which it is present, Cooling water
such as ammonium chloride, thio-
cyanate, ferrocyanide, sulfate, and
so on. The operation to recover this
ammonia is carried out in an ammo-
nia still. Lime Free leg
leg
Ammonia
Lime water
dephlegmator to cool the vapor and Fig. 7.100 Diagrammatic representation of the essential parts and oper-
remove excess water which is ation of an ammonia still.
504 Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved.
Manufacture of Metallurgical Coke and Recovery of Coal Chemicals
returned to the still. The vapor leaving the dephlegmator consists of ammonia which may vary
between 10–25%, depending upon the vapor temperature, with the balance consisting of water and
some acidic gases and neutral oils.
The liquor leaving the base of the free leg passes into the lime leg where it is treated with milk of
lime. The calcium hydroxide reacts with the fixed ammonium salts of which ammonium chloride
is the main constituent.
The liquor then flows into the fixed leg which consists of a series of trays to provide effective strip-
ping of the ammonia by a counter-current flow of steam. The steam pressure required at the base
of the still is of the order of 21–28 kPa (3–4 psi). Some ammonia stills are operated with caustic
soda (NaOH) instead of lime to avoid the column fouling caused by lime salts. However, the cost
of caustic soda is several times that of lime.
The vapors leaving the ammonia still are added to the gas stream so that all of the ammonia can be
recovered in the ammonia absorbers.
Ammonia and
acid gases
Free-still
Cooling
condenser
water
Acid gas
seperator Fixed
Free still
still
Free-still
jet compressor
Wastewater
feed Steam
Steam
Phosam Fixed-still
fractionator bottoms jet
Tray washwater
compressor
Flash
Slaking
Lime column
water Free-still
reboiler
Cooling water
Prelimer
Reflux
Lime handling Pump tank
accumulator
and Clarifier Treated
slaking system wastewater
Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved 505
Ironmaking Volume
A second feature of the process is its relative freedom from fouling by lime salts, achieved by a
combination of process design and an anti-fouling additive. The system can operate a year or more
without cleaning, which negates the need for a spare still. The CYAM system can also use caustic
soda (NaOH) and achieve high cyanide removal, if higher alkali cost is accepted.
The flowsheet in Fig. 7.101 shows a typical arrangement of the CYAM system in which steam
jet compressors are used to recover heat (low pressure steam) from the effluent stream. Overhead
vapor from the fixed still, typically 70–84 kPa (10–12 psig), flows into the free still reboiler
where it is partially condensed to generate ammonia-free stripping vapors for the free still. Over-
head vapor from the free still, normally at 28–42 kPa (4–6 psig), is passed through a partial con-
denser to achieve the desired concentration, which is typically in the range of 12–16 wt%
ammonia. Remaining vapors from the free and fixed stills are then sent to the coke oven gas
upstream of the ammonia recovery equipment. Stripping-stream requirements are about
0.12–0.14 kg of steam per litre of feed (1.0–1.2 lbs of steam per gallon of feed). Lime require-
ment are roughly 2.2 kg of 90% CaO per kg of fixed ammonia (2.2 lbs of CaO per lb of fixed
ammonia).
Ammonia nitrification and removal of carbonaceous material can be achieved in a single totally-
mixed aeration basin when CYAM effluent is treated in a biological treatment plant. Ammonia
concentration can be reduced from the 25–100 ml/m3 (25–100 ppm) range normally produced
by the CYAM system to about 10 ml/m3 (10 ppm). Free cyanide concentration (CNA) in treated
water from the CYAM system is about 1–2 ml/m3 (1–2 ppm) and is further reduced to about 0.25
ml/m3 (0.25 ppm) in the biological treatment plant. Sulfide removal is essentially complete in
the CYAM system, and effluent from the biological treatment plant is normally below 0.3 ml/m3
(0.3 ppm).
7.7.4.1 Saturator
At coke plants built prior to about 1930, ammonia-absorbing facilities consisted mainly of devices
called saturators. These were large dome-shaped, cast iron, lead-lined vessels. Gas was admitted to
the saturator through a distributor called a cracker pipe. This arrangement provided for direct con-
tact between the ammonia and dilute acid, which reacted according to reaction 7.7.1 to form
ammonium sulfate.
2NH3 + H2SO4 = (NH4)2SO4 (7.7.1)
More modern processes have superceded the saturator.
506 Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved.
Manufacture of Metallurgical Coke and Recovery of Coal Chemicals
Tar sludge
tank
Gas
outlet To mother
liquor trough
Overflow to Gas Tar sludge
liquor receiver inlet to ladles
Liquor
To to liquor
centrifugal receiver
dryers Ammonia
absorber
Down- Liquor
Crystallizer comer from tar
sludge tank
Benzol acid
Dryer drains
Slurry tank
Tar
overflow
Fresh sludge
acid tank
Overflow
tank
Liquor Mother
receiver liquor
Slurry
Crystallizer trough
pump Overflow
pump
tank pump
Tar sludge
pump
Fig. 7.102 Schematic flowsheet of the operation of an Otto spray-type absorber for the recovery of ammonia as ammo-
nium sulfate.
Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved 507
Fig. 7.103 Flow diagram of the Wilputte low-differential controlled-crystallization process for producing ammonium sulfate.
Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved.
To atmosphere
H R STM
Cooling
Ammonia absorbers water
Scrubber
fan Scrubber
Gas out Gas out
PIC PIC To To circulation
circ tank Vent tank
Cake wash
Crystallizer 0.8 gpm Centrifuge
LRC Crystallizer Slurry Bay water
LRC feed tank 5 gpm
Gas in
Gas in
Fluid bed Circulation
To hotwell dryer pump
Water DRC DRC
H SO
2 4 Overflow from High pressure
slurry feed Screw conveyer steam
tank
To bucket
elevator Air
in
Air fan Condensate
Recirc pump Recirc pump to flash
Air heater tank
FM Filtrate Filtrate
pump tank
Slurry
pump
Absorber Circulation
feed tank
Transfer pump Slurry
pump pump
FM Transfer pump FM
Steam
To
Crystallizer Crystallizer Heater intercepting
Ironmaking Volume
508
Manufacture of Metallurgical Coke and Recovery of Coal Chemicals
Clean
coke oven gas
(ammonia-free)
water
Water
Coke oven Water
gas
Anhydrous
Vapor from ammonia
ammonia steam steam (NH3)
liquor still
Rich Lean
phosphate phosphate water
solution solution
Aqua ammonia Ammonia
fractionator
Absorber Stripper
Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved 509
Ironmaking Volume
The overhead vapor from the stripper is condensed to form an aqueous ammonia feed to the frac-
tionator where anhydrous ammonia is produced by pressure fractionation, again by using direct
steam. The overhead product is liquid anhydrous ammonia, of high purity, ready for shipment.
Both of the distillation operations are conducted under pressure for reasons of economy. The opti-
mum pressures depend somewhat on the cooling water temperature, but are generally in the range
124–1515 kPa (180–220 psig). This means, in turn, that steam at a gage pressure of 1380–1725
kPa (200–250 psi) is required.
Stripper and fractionator towers in the PHOSAM process are quite small in diameter, and, together
with the associated heat exchangers and vessels can be accommodated in an area of about 9.1 3
21.3 m (30 3 70 ft).
When indirect processes for ammonia removal from coke oven gas are used (water wash or liquors
associated with desulfurization processes), ammonia-rich vapors generated in these systems can be
passed through a hot PHOSAM absorber to recover the ammonia. The hot absorber would operate
in the range of 80–100°C (176–212°F). The absorbing solution (ammonia-lean phosphate solution)
from the hot absorber would be processed in a conventional PHOSAM stripper and fractionator to
produce liquid anhydrous ammonia.
510 Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved.
Manufacture of Metallurgical Coke and Recovery of Coal Chemicals
light oil
Dephenolized
Light
light oil
oil
To dephenolized Caustic
ammonia liquor charge
storage tank Washer
No.1
Water
charge
Washer
No.2
Vent to
atmosphere
Light oil To
L1 circulation sump
tank tank
Carbolate Carbolate Caustic soda
Phenolized concentrator storage storage
ammonia
liquor LLCV
Fig. 7.105 Diagrammatic representation of the equipment for recovery of phenol by the solvent extraction process.
The sodium phenolate in No. 1 washer is drained into the carbolate concentrator. When this is com-
plete, the partially phenolized caustic in No. 2 washer is drained to No. 1 washer, leaving No. 2
washer empty to receive a fresh supply of caustic soda solution. The plant is then ready to resume
operation.
The sodium carbolate in the concentrator is boiled to remove entrained solvent and moisture. It is
then neutralized with carbon dioxide to liberate crude phenols and phenol homologues.
Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved 511
512
Table 7.6 Fractions of Coke Oven Gas Light Oil and Boiling Points of Some of Their Constituents
Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved.
Nitrogen and
Oxygen
Compounds Pyridine C5H5N 115.3°C
(continued)
Table 7.6 (continued)
Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved
Tetramethylthiophene 182 to 184.0°C
Nitrogen and Cresols C7H8O 190 to 203.0°C
Oxygen
Compounds
Picolines C5H7N 131 to 143.0°C Dimethyl Pyridines C7H9N 143 to 164.0°C
Phenol C6H6O 182.0°C
Manufacture of Metallurgical Coke and Recovery of Coal Chemicals
513
Ironmaking Volume
7.7.7.2.1 Process using Petroleum Wash Oil The practice of using petroleum wash oil, Fig. 7.106, is
the one almost universally followed in the United States due to the availability and low cost of
petroleum wash oil. The efficiency of recovery varies widely with the seasons in that one of the
major considerations is the temperature of the coal gas and wash oil entering the absorbing process.
Another consideration is the ratio of wash oil to gas. The absorption equipment should be of rea-
sonable design as to size and contact time. The oil-to-gas ratio varies depending on the equipment
design and the light oil content of the gas prior to light oil removal.
Typical operating conditions are as follows: the temperature of the coke oven gas entering the
absorption process is 15–30°C (59–86°F); the temperature of the wash oil entering the process is
17–32°C (60–90°F); and the wash oil circulated per tonne of coal carbonized is 525–825 dm3
(150–200 gal/net ton).
The boiling point of the wash oil should be well above 200°C (390°F) so as to permit an effective
separation of light oil from wash oil in debenzolization. The oil should not thicken and should have
Spray header
and piping
Gas Gas
in out
(From final
cooler)
To Wash oil
refining coolers
plant Waste Pump
Light Light oil Crude Wash Pump Muck to
crude oil rectifying residue oil oil separating Wash oil Wash oil
Wash oil
basin recovery from
column To purifier stripping Wash oil
refining still decanter Wash oil tank tank cars
plant circulation
tank
514 Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved.
Manufacture of Metallurgical Coke and Recovery of Coal Chemicals
a low viscosity to permit its distribution in the scrubbing towers. It should not deteriorate readily
but maintain its initial properties as long as possible to keep makeup oil at a minimum. It must be
especially stable with respect to the repeated heating which takes place in the recycling of the oil
in the process. Its absorptive capacity should be very high and it should not react with or contam-
inate the coke oven gas. The specific gravity should be low enough to permit effective separation
of wash oil and water in the processing and keep emulsification of the two to a minimum. The spe-
cific heat should be low because the oil is subjected to repeated heating and cooling as it is recy-
cled in the process.
The petroleum wash oil normally used for this absorption process has a boiling range of
270–350°C (518–622°F). Other specifications which are general for petroleum was oil include a
specific gravity of about 0.830, a viscosity of 45 Saybolt seconds at 38°C (100°F), a pour point of
2°C (35°F), an emulsification of 95% separation in 50 seconds, a flash point of 150°C (300°F), a
fire point of 168°C (335°F), and a low residue under 0.10% when heated for a period of five days
at approximately 150°C (300°F).
7.7.7.2.2 Process using Coal Tar Coal tar wash oil, having a boiling range of 230–300°C (446–572°F),
is used for light oil removal in a packed-type absorptive tower. The benzolized oil, which has a per-
fect heat stability, is preheated by the regenerated oil and finally heated to 185°C (365°F) in a tubu-
lar furnace before being flashed into the wash oil still for regeneration. Through oil-to-oil heat
exchange and because of the use of a tubular furnace, steam consumption is minimized. There are
two processing sections in the still: (1) the top one for light oil rectification, including top reflux
and side-stream draw-off for the naphthalene oil fraction; and (2) the bottom one for wash oil
debenzolization. A split stream of wash oil is passed through a purifier where by direct steam injec-
tion volatile components are returned into the bottom section of the still and heavier components,
such as pitch at 70°C (158°F) solidification point, are withdrawn from the purifier bottom. The
activated wash oil is reused for light oil absorption after heat exchange and cooling. A typical flow-
sheet of a light oil recovery system is shown in Fig. 7.107.
7.7.7.2.3 Final Cooler The first step in the recovery of light oil by absorption in a liquid medium is
that of cooling the gas leaving the ammonia absorbers at a temperature of 50–60°C (112–140°F)
by direct contact with water in a tower scrubber called a final cooler. The facilities are so named
Gas in Purifier
Stripping
section
Injector
Air Fuel Steam
blower gas
Pump
Wash oil Pump Pitch
heat exchanger
Fig. 7.107 Typical flowsheet of a light oil recovery system with coal tar wash oil.
Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved 515
Ironmaking Volume
as the gas is here given its final cooling during coal chemical processing. This is necessary to
remove naphthalene from the gas and also to cool the gas prior to its admission to the wash oil
scrubbers.
The tower consists of a tall cylindrical shell of steel approximately 3–4.5m (10–15 ft) in diameter
and 15–23 m (50–75 ft) in height, filled with a suitable packing material that is either wooden or
metallic. The gas enters near the bottom of the tower and passes up through the tower and out near
the top. The cooling water enters the top of the tower through a spray system and the water passes
down through a tower, coming in direct contact with the gas in a counter-current manner. The water
leaves the tower at the bottom through a sealed outlet pipe to prevent escape of any gas. The heat
from the gas is transferred to the water, which in turn is cooled in an induced-draft water cooling
tower with air or in an atmospheric water spray cooling operation. Cooling of the water depends
upon air circulation and the vaporization of a part of the water in circulation, the latent heat of
vaporization of the water being responsible for additional cooling. Operating practice is to cool the
water, and in turn cool the gas, to as low a temperature as practicable, depending upon atmospheric
temperature, as most effective absorption of light oil is obtained at low temperatures. Cooling is
not carried out below 15°C (60°F), because below that temperature petroleum absorbing oil
becomes too viscous to flow freely.
This direct cooling operation causes the condensation of a major portion of the naphthalene and
any entrained tar and vapor-phase gums. The naphthalene is recovered in a sump operation and is
either added to the tar or refined directly to provide a salable product.
In some of the more modern facilities, the lower part of the final cooler tower is redesigned to per-
mit the outlet water to come in direct contact with tar in order to dissolve the naphthalene as it is
being removed from the gas.
This cooling operation may also be carried out using petroleum wash oil instead of water. A small
bleed stream of debenzolized wash oil from the light oil stripper may be used for this purpose. In
this case, the wash oil will absorb most of the naphthalene so that the gas leaves with less than
about 460–685 g/m3 (2–3 gr./scf) of naphthalene in the gas. However, the quantity of wash oil used
is small enough so that the light oils are not absorbed to any great extent in the final cooler.
A typical final cooler is divided into two spray compartments, Fig. 7.108. Each compartment is
provided with its own set of recirculation pumps in order to recirculate wash oil from the top-sec-
tion drains to the bottom section. The wash oil which is recirculated in the bottom section is cooled
in a series of wash oil coolers. An oil-water separator is provided at the bottom of the column to
decant condensed water from the wash oil.
The naphthalene which is absorbed in the wash oil may be stripped out by feeding the wash oil into
the top of the wash oil scrubber at a point which is about 16 trays above where the benzolized wash
oil is introduced. Otherwise, the naphthalene may be stripped out in a separate still.
Depending on the byproduct plant system, semi-direct or indirect, there are different technologies
to cool the pre-cleaned coke oven gas down to the temperature necessary for further processing.
In the so-called semi-direct byproduct plants, it is necessary to install a final gas cooler down-
stream of ammonium saturators to cool the water-vapor saturated coke oven gas to an optimum
temperature for the naphthalene and light oil removal.
As the ammonia absorption with sulfuric acid is a strongly exothermic reaction, an intensive final
gas cooling is needed before the gas enters the benzol/naphthalene scrubbing.
One intensive final cooling method is the so-called three stage tower, developed and built by Dr. C.
Otto and Company. This tower consists of a primary cooling stage in the lower part, a naphthalene
washing stage in the middle part, and a low temperature cooling stage in the upper part, Fig. 7.109.
The significance of this arrangement is that mixing of gas condensate and wash oil is avoided. In
the primary cooling stage, the gas is cooled down to a temperature just above the naphthalene dew-
point of the gas. Therefore, there is no fouling of the cooler due to naphthalene deposition.
516 Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved.
Manufacture of Metallurgical Coke and Recovery of Coal Chemicals
Gas
Primary
sprays
Resprays
Naphthalene-rich
Gas wash oil Make-up
wash oil
Cooling
water
Respray Final Wash oil
pump cooler Oil-water Pumps coolers
separators
To increase the washing efficiency of the naphthalene washing stage, it is filled with ceramic rings.
Wash oil corresponding to the necessary wetting rate, is recirculated through this stage. Part of the
wash oil is continuously blown down to the oil regeneration plant. A corresponding amount of lean
(fresh) oil is pumped as makeup to the wash oil recirculation. Enriched naphthalene oil leaves the
sump of the washing stage via seal pot and passes to the regeneration plant.
The gas leaving the naphthalene removal stage will receive its final cooling per section, using recir-
culated liquor, which in turn is cooled in indirect heat exchangers using cooling water.
The first cooling stage, as well as the low temperature cooling stage, are designed without internals.
Several spraying systems provide adequate spraying of the cooling liquor in both cooling stages.
In the gas mains connecting the three stages, and the main leaving the final cooler, demisters are
installed to prevent carryover of oil and water droplets to the next stages.
7.7.7.2.4 Wash Oil Scrubber The second step in the recovery of light oil is its absorption in the liquid
petroleum wash oil. The gas comes in direct contact with the wash oil in one or more tall scrub-
bing towers. The gas passes from the first tower to the last in series and the wash oil travels from
the last tower to the first in reverse series. The flow of gas and wash oil is counter-current in each
tower. The steel towers are approximately 4.5–6.7 m (15–22 ft) in diameter and 30.5 m (100 ft) in
height.
The wash oil is introduced through a number of sprays in the top of the tower and comes into direct
contact with the gas, which flows from the bottom to the top. An oil storage tank is provided in the
base of the tower to receive the oil and maintain a surge capacity for pumping the oil away. The oil
passes from the gas compartment to oil storage through a sealed pipe. It is pumped from the base
of one tower to the spray system in the top of the next tower in series. From the last tower the oil
is pumped at a controlled rate to the stripping stills for separation of light oil from wash oil. Wash
oil prior to light oil absorption is called debenzolized and after absorption it is called benzolized.
Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved 517
518
Ironmaking Volume
Steam
Condensate
Wash oil
outlet
Wash oil
Wastewater inlet
Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved.
Coke oven gas Coke oven gas
inlet outlet
Fig. 7.109 Direct final gas cooling in a three stage tower with a naphthalene washing stage.
Manufacture of Metallurgical Coke and Recovery of Coal Chemicals
The benzolized wash oil contains 2–3% light oil. The debenzolized wash oil is cooled in indirect
coolers to a temperature several degrees higher than that of the gas entering the scrubbers, which
is 15–25°C (60–75°F). This is to prevent condensation of water from the gas, which would form
an emulsion with the oil, causing clogging of the free space in the packing of the tower. The rate
requirement for the circulation of oil through the scrubbers is a function of the vapor pressure dis-
tribution between the light oil dissolved in the absorbent oil and that remaining in the gas at tem-
perature of operation. From 90–95% of the light oil content is recovered in this operation. The wash
oil, after being cooled, passes through a large decanting tank which acts as a settling compartment
for the emulsified and resinous materials present in the wash oil. This material accumulates in the
bottom of the tank, and the wash oil decants off at a higher level to a small receiving tank, from
which it is pumped to the top of the first scrubbing tower in the series. Generally, two decanting
and two receiving tanks are provided to permit cleaning the residue from the tanks periodically.
Recent designs of wash oil scrubbers are not fitted with hurdles and packing used in the previous
types. Contact between the gas and absorption oil is accomplished by the use of single conical
sprays placed at three or four different elevations within the tower, as shown in Fig. 7.110.
Each of the sets of sprays is provided with its own set of recirculation pumps. The wash oil is recir-
culated in each set to obtain adequate contact between the gas and liquid in the scrubber. The wash
oil is collected and recirculated by chimney trays at the bottom of each spray chamber, except at
the bottom where the oil is pumped from the scrubber sump.
7.7.7.2.5 Debenzolization of Wash Oil In the debenzolization step, light oil (2–3%) in the benzolized
wash oil is separated by steam distillation. The carryover of absorbing oil into the light oil is kept
to about 5% and the debenzolized absorbing oil contains 0.2% light oil.
In the straight steam distillation process at atmospheric pressure, the benzolized was oil is pre-
heated to approximately 100°C (212°F) with a vapor-to-oil and an oil-to-oil heat exchanger. Heat-
ing is continued to 145°C (295°F) with an indirect preheater of the shell-and-tube type, with the
oil flowing through the tubes, using steam as the heating medium on the shell side. The preheated
Mist suppressor
Gas
Koppers
spray type
light oil
scrubbers
Overflow
pipe
From Weir
light oil
plant
A A
To B B
light oil
plant Wash oil
suction
Downcomer
Section A - A
Gas Annular
chamber
Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved 519
Ironmaking Volume
oil is introduced near the top into a multi-plate bubble-cap fractionating column leaving several
plates above the feed to keep entrainment of wash oil to a minimum. The benzolized wash oil flows
down the column counter-current to upward flow of live steam, which is introduced in the base of
the still column. The debenzolized wash oil leaving the base of the column through a sealed outlet
at a temperature of 145–150°C (290–300°F) passes through the oil-to-oil exchanger in which it is
cooled to 100°C (212°F), giving up its heat to the incoming benzolized wash oil. Water separates
out at this point and is drained off. The wash oil passes through a pumping tank and is pumped at
100°C (212°F) to cooling coils for cooling prior to being used again as an absorbent for the light
oil in the scrubber towers.
The mixture of steam and light oil vapors leaving the top of the column flows through the tubu-
lar vapor-to-oil heat exchanger which recovers heat and also acts as a partial condenser. Sufficient
heat is imparted to the incoming benzolized oil to raise its temperature 25°C (45°F) and, at the
same time, the vapors are cooled to cause a portion of the steam and high-boiling constituents of
light oil to condense (the condensate of which carries along some of the wash oil which was car-
ried over the top of the column as entrainment). The mixture of oil and water is separated in a
gravity in a gravity separator tank, the water flowing to the sump system and the oil being
returned to the debenzolized oil streams. The mixture of steam and light oil vapors leaving the
vapor-to-oil heat exchanger passes to a water-cooled condenser, which is of a multi-pass design,
with the vapor and water flowing counter-current to each other. The condensate flows to a grav-
ity separator effecting a separation of the light oil and water, the light oil flowing to storage and
the water to the sump system.
In some designs, an additional fractionating column is added to the debenzolization process for
rectifying the light oil vapors from the vapor-to-oil heat exchanger. In this case, the condensate of
the vapor-to-oil heat exchanger, after separation of the water, is also introduced into the rectifying
column. The mixture of steam and light oil vapors enters the multi-plate bubble-cap rectifying col-
umn near the middle section. The light oil is separated into two fractions: (1) the distillate con-
taining forerunnings, benzene, toluene, xylene and low-boiling solvent, and (2) a residual fraction
containing an admixture of high-boiling solvents, naphthalene and wash oil. A portion of the dis-
tillate is returned to the top of the column as reflux, the control point being the vapor temperature
at the top of the column.
In the more modern debenzolization processes, the benzolized wash oil is processed at a
temperature of 90–120°C (195–250°F) and this eliminates the need for an oil-to-oil heat exchanger
in the process lineup.
520 Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved.
Gas
outlet Mist
suppressor Seconda
ry
actified
solution
Primary
foul
solution
Secondary stage
Primary stage
Secon Vapor
dary
foul
solutio
n
Primary
ejector Second
Water ary
Primary stage
Flash ejector
Secondary stage
Solutio Solutio
n n
cooler cooler
Cond
NA C Steam .
Ma 2 O3
ke Water Flushin Vapor
wat -up
er g liqu conde
Flash to batte or n Vent Acid g
To solutio ry Flash s sers Inte as
efflu n Actifie olution
trea nt e d
soluti
conde r
nser
tme on
nt Fresh Flash
soluti Vapor
Abso
rbe sol. Conde
n
pump on knock
tower r sate
out dru
Soluti m
circu on Flush Vent
latin in
tank g liquo g
Fresh r
solu
Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved
mixin tion Actifi
g tan er Conde
n sate
k towe
r
Flush Conde To sulf
in Con nsate u r plan
to flas g liquor
h solu
dens
ate and p tank
or t
heat umps s
excha tion acid p
nger lant
Fig. 7.111 Flow diagram of a two-stage vacuum carbonate process for removal of hydrogen sulfide from coke oven gas.
Manufacture of Metallurgical Coke and Recovery of Coal Chemicals
521
Ironmaking Volume
Table 7.7 Major Wet Oxidation Desulfurization Processes and Their Catalysts
Process Catalyst
Coke
Sweet oven
gas Air
coke oven gas
H2S,Na2CO3
Absorber Regenerator
Make-up
solution Submerged
Sour combustion
coke oven gas plant
Purge solution
Sulfur
seperation
Sulfur Sulfur
purifier
Fig. 7.112 Flow diagram of the Takahax process for desulfurization of coke oven gas.
522 Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved.
Manufacture of Metallurgical Coke and Recovery of Coal Chemicals
Type A Takahax oxidizes the waste solution with compressed air to form ammonium sulfate.
Ammonium sulfate crystals are recovered in a conventional crystallizer. Type B Takahax inciner-
ates the entire waste solution, along with the sulfur cake produced in the absorber, to produce sul-
fur dioxide gas that is converted to sulfuric acid. Type C Takahax produces sulfur cake from the
absorber and a portion of the sulfur is bled off and sent to a combustion furnace along with the
waste solution. In the submerged combustion furnace, fuel is burned in a reducing atmosphere to
convert the sulfur compounds to hydrogen sulfide. The hydrogen sulfide gas and the remaining sul-
fur are sent to the sulfuric acid plant. Type D Takahax produces sulfur cake, and a portion of the
sulfur cake and waste solution is sent to the submerged combustion furnace as in Type C. Hydro-
gen sulfide produced in the combustion furnace is re-absorbed in the Takahax absorber, so that the
entire discharge of sulfur from the process is elemental sulfur. Sulfur cake is melted in an autoclave
to purify the product, producing a sulfur with a purity of 98–99%.
All of the wet oxidation processes produce a low-grade sulfur and a highly contaminated waste
stream requiring elaborate waste treatment facilities. Operation of these processes requires a more
sophisticated chemical control than the absorption stripping processes.
The Holmes-Stretford process is used to economically remove hydrogen sulfide from coke oven
gas. In addition to the basic hydrogen sulfide absorption plant, an effluent treatment plant is
included to convert the plant waste streams for recycling through the plant. This process will
remove all but a trace of hydrogen cyanide, reduce the hydrogen sulfide content to substantially
less than 0.23 g/m3 (10 gr./100 ft3) of gas, and produce a very saleable grade of liquid sulfur. An
elementary flow diagram of the process is presented in Fig. 7.113.
The Holmes-Stretford process provides for scrubbing of coke oven gas with an alkaline solution of
sodium ammonium vanadate which oxidizes the hydrogen sulfide in the gas to form free sulfur.
Sulfur is collected as a froth which is washed, concentrated and purified to a final molten product.
The reduced vanadate solution is re-oxidized with anthraquinone disulfonic acid and air to its orig-
inal state and is recycled to the hydrogen sulfide scrubber.
The basic plant utilizes the Holmes-Stretford process parts which are available under license from
the British Gas Corporation. The complete plant consists of: (1) basic hydrogen sulfide removal
system, (2) sulfur recovery and purification system, and (3) spent liquor reprocessing system. The
combines systems result in a plant with economical operating costs, a saleable grade of sulfur prod-
uct, and no effluent waste streams.
Clean
gas out Vent
Flash
Centrifuge tank
Liquor
heater/cooler Sulfur
seperator
Air
Steam
Sour
gas in Sulfur Spent
meter liquor
Product reprocessing
system
sulfur
H2S Oxidizer Reslurry Spent Spent Recovered
Pump Slurry Slurry Reslurry pump liquor liquor
absorber (2) tank tank pump tank solution
tank pump tank pump
Circulation
liquor pump
Fig. 7.113 Flow diagram of the Holmes-Stretford process for desulfurization of coke oven gas..
Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved 523
Ironmaking Volume
7.7.8.2 Absorption Stripping Processes The absorption stripping processes are characterized by
generally lower hydrogen sulfide removal, but, since air is not included in the regenerating system,
contaminated waste products are minimized or eliminated. The processes can be operated to
produce sulfuric acid or a very high purity elemental sulfur.
7.7.8.2.1 Vacuum Carbonate Process In this process, the gas is contacted with a solution of sodium car-
bonate in an absorber tower to remove the hydrogen sulfide and other impurities such as hydrogen
cyanide. The foul solution from the base of the absorber is circulated over the actifier where the
hydrogen sulfide is removed by counter-current stripping with water vapor under vacuum. The act-
ified solution is pumped from the base of the actifier through a cooler back to the absorber.
The actifier is maintained under a relatively high vacuum to reduce the quantity of heat required
to generate the water vapor for actifying the solution. The mixture of hydrogen sulfide and water
vapor leaving the top of the actifier is passed through a condenser where most of the water vapor
is condensed. The vacuum in the actifier and condenser is maintained by a two-stage steam ejec-
tor. After the ejector system the concentrated acid gas stream is further cooled and processed in a
Claus plant to produce elemental sulfur, or in a sulfuric acid converter.
The heat requirements to generate the water vapor to strip the hydrogen sulfide from the foul solu-
tion in the actifier can be obtained almost completely from indirect heat exchange of the solution
in the base of the actifier with the vapors at the discharge of the steam-jet vacuum pumps, and sup-
plemental indirect heat exchange with the flushing liquor from the coke oven batteries or from
other waste heat sources.
The single-stage vacuum carbonate process is economical for removal of approximately 90% of the
hydrogen sulfide from typical coke oven gas. In order to meet more stringent requirements in some
locations, the Koppers two-stage vacuum carbonate process was developed to remove approximately
98% of the hydrogen sulfide, producing a clean gas with no more than 0.23 g/m3 (10 gr./100 ft3).
In the two-stage process, the coke oven gas flows upward through two sections of a packed
absorber. In the lower section the gas is contacted with sodium carbonate solution from the upper
stage of a two-stage vacuum actifier tower, and about 90% of the hydrogen sulfide is removed.
The gas then flows to the upper stage of the absorber where it is contacted with a smaller stream
of sodium carbonate solution from the lower stage of the actifier. This solution has been very
highly actified, and removes 80–90% of the remaining hydrogen sulfide, for an overall removal
of 98%.
The same stripping steam is used in both sections of the two-stage actifier, resulting in high
removal efficiency and low operating cost. The condensing system, vacuum system, and heat
exchange system are substantially the same as those used for the single-stage process.
The choice between the Koppers single-stage and two-stage vacuum carbonate processes depends
upon the stringency of the regulatory requirements which must be met.
7.7.8.2.2 Hydrogen Sulfide and Ammonia Removal The ammonia/hydrogen sulfide circulation scrubbing
process (AS circulation scrubbing), developed and patented by Carl Still in 1971, lends itself ide-
ally to the removal of ammonia, hydrogen sulfide and hydrogen cyanide (partially) from the coke
oven gas.
This process works according to the neutralization principle and utilizes as its basic component the
ammonia present in the gas. With the help of an inherently generated ammonia liquor mixture and
without making use of external chemicals the acidic components hydrogen sulfide and hydrogen
cyanide are eliminated by scrubbing.
As shown in Fig. 7.114, the system mainly consists of four columns: a hydrogen sulfide scrubber,
an ammonia scrubber, a hydrogen sulfide desorber (deacifier), and an ammonia desorber (still).
The two absorbers (scrubbers) are normally turbulent-flow expanded metal stage scrubbers, while
the desorbers are normally tray-type columns. The coke oven gas passes first through the hydrogen
524 Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved.
Manufacture of Metallurgical Coke and Recovery of Coal Chemicals
Coke
Excess Steam
oven
flushing
gas Waste water
liquor
sulfide absorber and through the ammonia absorber. The scrubbing solution used in the in hydro-
gen sulfide scrubber is the liquor drained from the ammonia scrubber as well as an ammonia-rich
liquor from the desorption process. The heat released during the absorption process is eliminated
by pumping the scrubbing solution through intermediate cooling stages. In this manner, the favor-
able absorption isotherm is maintained and the spraying density increased.
Stripped liquor coming from the desorption stage is fed to the top of the ammonia scrubber. On its
way to the sump of the tower, this solution is enriched with ammonia and from the sump it is with-
drawn and passed as scrubbing solution to the hydrogen sulfide absorber.
The enriched scrubbing liquor is passed from the sump of the hydrogen sulfide scrubber to the
regeneration unit (desorption). In the regeneration system, which consists mainly of a still and a
deacifier, components such as ammonia, hydrogen sulfide, carbon dioxide and hydrogen cyanide
absorbed from the gas are stripped off by means of steam. As a result of the special mode of regen-
eration column operation, a deacified liquor rich in ammonia but having a low acid gas content is
produced along with a stripped steam of wastewater quality.
This process arrangement enables the thermal energy contained in the ammonia still overheads to be
utilized in the deacifier. Further savings in steam can be realized by making use of steam ejectors.
Part of the liquor flows from the sump of the deacifier to the hydrogen sulfide scrubber as scrub-
bing solution and another stream is passed to the top of the ammonia still. The virgin liquor (excess
ammonia liquor) can also be fed in at this location. Part of the stripped liquor is used as ammonia
washing solution while the excess quantity will be sent to the wastewater treatment plant for fur-
ther processing.
If necessary, the so-called fixed-ammonia compounds can also be split up by mean of alkaline,
such as sodium hydroxide, and the fixed ammonia can be driven off.
The amount of wastewater branched off corresponds with the virgin liquor quantity fed into the
system plus stripping steam condensate.
The deacifier overheads contain all of the substances absorbed from the gas and stripped from the
virgin liquor, e.g. ammonia and hydrogen sulfide. These components are converted in downstream
process steps to obtain products such as liquid sulfur or sulfuric acid form the hydrogen sulfide and
ammonium sulfate, or the ammonia may be cracked.
Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved 525
Ironmaking Volume
With the system described above, a hydrogen sulfide removal efficiency of 0.4 g/Nm 3 can be
achieved. Innovations introduced to the process by Thyssen Still Otto enable even lower hydrogen
sulfide levels to be reached. As may be needed for the individual application, a final purity of 0.2
g/Nm3 of hydrogen sulfide per Nm3 of coke oven gas can be realized by modification of the AS
circulation scrubbing system. This modification may be beneficially applied in cases where ammo-
nium compounds that cannot be cracked thermally, e.g. chlorides and SO4, must be eliminated
from the excess ammonia liquor. Up to 90% of the sodium hydroxide needed for this purpose can
be used first for the cleaning of the coke oven gas.
7.7.8.2.3 Ammonia Cracking and Liquid Sulfur Production In conformity with the trend in recent years, a
modified Claus plant has been provided for the processing of the hydrogen sulfide where, simul-
taneously, the total amount of ammonia is cracked.
Apart from the nitrogen-laden compounds such as ammonia and hydrogen cyanide, vapors con-
taining hydrogen sulfide produced in a coke plant also carry organic products such as naphthalene
and phenols. A processing of these vapors in a conventional Claus plant has not been feasible as
evidenced by all of the experience to date. Complete conversion of ammonia and hydrogen cyanide
to nitrogen gas, carbon dioxide gas and water vapor and conversion of hydrocarbon compounds by
means of water steam to carbon monoxide and hydrogen gas are both sensibly not feasible with the
given process parameters of a Claus process.
It is well known that incompletely converted ammonia in a Claus system entails a formation of salt
in the waste heat boiler downstream of the Claus furnace that will plug it. Moreover, it is a well-
known fact that the soot formation in a Claus furnace blocks the catalyst beds, causing substantial
interferences in operation and thus inevitably some unacceptable environmental performance.
These facts and the many years of operational experience gained by Thyssen Still Otto in the field
of catalytic cracking of ammonia from still vapors gave birth to a process combination illustrated
in Fig. 7.115. In this process the conventional Claus furnace was replaced by a cracking reactor,
which is equipped with a special catalyst.
The most significant benefits of this modified Claus principle are listed here:
1. Processing of hydrogen sulfide vapors from deacifiers/desorbers with ammonia and
hydrogen cyanide constituents as well as organic products such as naphthalene, phe-
nols, etc. is possible to obtain Claus sulfur.
2. It is feasible to process the hydrogen sulfide vapors with the entire ammonia vol-
ume from the coke plant.
Air Boiler
Boiler feed
feed Steam water Steam
water Tail gas to
coke oven gas
main
Molten sulfur
to storage
Fig. 7.115 Schematic of an ammonia cracking process with a cracking reactor in the place of the conventional Claus furnace.
526 Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved.
Manufacture of Metallurgical Coke and Recovery of Coal Chemicals
3. Return of the Claus residual gas (tail gas) into the coke oven gas at a reduced sul-
fur dioxide content is possible.
4. Recycling of Claus residual gas into the pre-cracking stage by addition of oxygen
is possible.
The process can be planned to run on one or more catalytical Claus reactor. If a return of Claus resid-
ual gas upstream to the hydrogen sulfide scrubbing of coke oven gas is applied, then the hydrogen
sulfide conversion in the Claus stage bears no significance, such that one catalytic Claus stage or pos-
sibly two should be adequate for an economic operation. A reduction in the residual sulfur dioxide
content towards zero should be targeted in order to avoid any additional load on effluents with salts.
7.7.8.2.4 Sulfiban Process The Sulfiban process was developed jointly by Bethlehem Steel Corp. and
Applied Technology Corp. The process utilizes monoethanalamine (MEA) as the absorbing solu-
tion. In the Sulfiban process, coke oven gas is contacted counter-currently with an aqueous solution
containing 13–18% MEA. The process is reported to remove organic sulfur as well as hydrogen sul-
fide, and sulfur content in the treated gas is guaranteed less than 0.23 g/Nm3 (10 gr./100 scf).
Rich solution from the absorbers is pumped to the still, where hydrogen sulfide and hydrogen
cyanide are steam-stripped and the regenerating solution from the bottom of the still is cooled and
recycled to the absorber. The steam for the stripping operation is produced in a steam-heated
reboiler connected to the still. A small amount of insoluble compounds, mainly ferrocyanide, are
formed and must be removed from the system. About 3% of the circulating stream is sent to a
reclaimer which is heated with high pressure steam to totally evaporate the water and MEA. Vapors
from the reclaimer are sent to the still and solids are periodically removed for disposal.
Acid gases from the top of the still, containing both hydrogen sulfide and hydrogen cyanide, are
sent to a cyanide reactor where the cyanide is catalytically converted to ammonia so that it will not
interfere with the operation of the sulfur plant. This ammonia could be recovered with a USS
PHOSAM absorber. Where a USS PHOSAM plant already exists, the integration of this small
absorber into the system would be inexpensive and advantageous.
Gas from the cyanide reactor passes to a plant for conversion to high purity sulfur.
7.7.8.2.5 Carl Still or Diamox Processes Both the Carl Still and Diamox processes utilize aqueous
ammonia as the absorbing solution to desulfurize coke oven gas. The difference in the two
processes is primarily in materials of construction and in some operating refinements. Either
process can be synergistically combined with a USS PHOSAM process to recover both ammonia
and high-grade elemental sulfur.
Coke oven gas following the naphthalene scrubber passes through the hydrogen sulfide scrubber,
where it is counter-currently contacted with ammonia solution. The ammonia-absorbing solution
is made up of ammonia liquor from the free leg of the coke plant ammonia still, recycled solution
from the deacidifier, and ammonia from the top of the PHOSAM stripper. If the hydrogen sulfide
absorber is operated with no recycled ammonia from the USS PHOSAM stripper, it will remove
hydrogen sulfide to a level of 0.92–1.14 g/Nm3 (40–50 gr./100 scf). If about 15% of the ammonia
from the PHOSAM stripper is recycled to the hydrogen sulfide absorber, the hydrogen sulfide con-
centration will be reduced to about 0.23 g/Nm3 (10 gr./100 scf). The only penalty for the improved
hydrogen sulfide removal is 15% additional capacity in the PHOSAM stripper. Absorbing solution
from the bottom of the hydrogen sulfide absorber is pumped to the deacidifier, where it is con-
tacted with steam from the coke plant ammonia still, augmented by additional low pressure steam.
Stripping solution from the bottom of the deacidifier is cooled and recycled to the hydrogen sulfide
absorber. Acid gases from the top of the deacidifier, containing hydrogen sulfide, ammonia, hydro-
gen cyanide and carbon dioxide, are sent to a small PHOSAM absorber, where the ammonia is selec-
tively removed. Acid gases from the PHOSAM absorber pass to a hydrogen cyanide reactor, where
the hydrogen cyanide is catalytically decomposed. Gases from the hydrogen cyanide reactor then
pass to a plant for production of high purity sulfur.
Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved 527
Ironmaking Volume
The integration of the Carl Still process with the USS PHOSAM process permits reduction of
hydrogen sulfide in the coke oven gas from about 1.03 to 0.26 g/Nm3 (about 45 to 10 gr./100 scf).
In addition, removal of ammonia from the acid gases is advantageous to the operation of the sul-
fur plant. The successful combination of these two processes offers a new technology in coke oven
gas desulfurization.
The Diamox process is similar to the Carl Still process, except that it operates with lower ammo-
nia concentrations so that ammonia recycle from the PHOSAM stripper and the acid gas PHOSAM
absorber can be eliminated.
7.7.8.2.6 DESULF Process The dominating coke oven gas liquid desulfurization process in Europe,
which started in the 1940s, uses ammonia water. This process, in fact, combines hydrogen sulfide
removal with ammonia removal. The basic process has been updated recently to achieve lower
hydrogen sulfide figures in the purified gas and to adjust to the climatic conditions (higher ambi-
ent temperatures) of other countries.
In the DESULF process, Fig. 7.116, the gas is contacted counter-currently by the liquor in three
absorptive towers operated in series where the liquor’s ammonia content decreases in the direction
of the gas flow. The first washer provides for hydrogen sulfide bulk removal; in the second washer,
ammonia and hydrogen sulfide are absorbed; while the third washer effects final removal of ammo-
nia (0.02 g/Nm3 or 0.82 gr./100 scf) and hydrogen sulfide (0.2 g/Nm3 or 8.2 gr./100 scf). The
absorption liquor streams are as follows: fresh water is used in the third tower and pumped from
the tower bottom up to the top of the second washer, where activated ammonia liquor is also added;
the liquor is pumped to the middle section of the first washer, while weak ammonia liquor and liq-
uid ammonia enter its top section.
The loaded ammonia liquor is preheated and activated in the deacidifier which is equipped with
bubble-cap trays. Activated ammonia liquor is pumped out of the bottom section and, after heat
exchange and cooling, reused in the second washer. Surplus liquor is pumped from the deacidifier
into the ammonia still, where the ammonia is removed by direct low pressure steam injection. After
Flash
Receiver
pot
Waste water
Liquid ammonia
528 Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved.
Manufacture of Metallurgical Coke and Recovery of Coal Chemicals
heat exchange, the liquor is discharged into the wastewater system. The vapors from the ammonia
still are directed into the bottom section of the deacidifier. Top vapors from the deacidifier partially
condense, so that hydrogen sulfide and the like remain as sour gas, while steam and ammonia
mostly condense. A controlled proportion of the condensate is refluxed; most of the flow is pumped
into the ammonia fractionator after heating and flashing off any still-entrained sour gases. The
fractionator is operated at increased pressure. The concentrated ammonia liquor is fractionated by
direct steam injection into lean liquor, which is returned to the deacidifier bottom, and into
ammonia vapor, which is liquefied in the condenser and then directed into the first washer.
This process can be easily adjusted to changed operating conditions by modifying the ratio of acti-
vated ammonia liquor to liquid ammonia.
Ammonia
Oil acid gases
Solids Tar
disposal
Dilution
water
Biological Clarification
treatment Equalization
Biosolids Solids
recycle disposal
Public waterway
Clarification Filtration discharge
Solids
disposal
Biosolids
disposal
Fig. 7.117 Simplified diagram of a system for biological treatment of coke plant wastewaters.
Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved 529
Ironmaking Volume
tling tanks. Oil is skimmed from the top and tar is recovered from the bottom of these tanks. From
the settling tanks, the wastewater is normally steam-stripped to reduce ammonia and acid gases,
primarily hydrogen cyanide and hydrogen sulfide, prior to biological treatment. The CYAM
process, discussed in Section 7.7.3.2, is a particularly efficient steam-stripping system. It is com-
posed of a free-ammonia still. The free ammonia and the acid gases are removed in the fixed still
after addition of lime. The wastewater stream from the stills is clarified and then flow and con-
centration equalized before undergoing biological treatment.
In most instances, biological treatment or activated sludge treatment of coke plant wastewater is an
aerobic process, or one that requires oxygen. Oxygen is normally obtained from the air by mechan-
ical mixing of the water and air or sparging with air from air blowers. Some processes that use pure
oxygen gas have also been developed. The biological process is one where active bacteria, in the
form of solids, are suspended in a containment vessel commonly referred to as an aeration basin.
The raw wastewater, sometimes diluted with relatively clean process water to reduce the waste-
water toxicity, enters the aeration basin where it contacts the suspended bacteria, which absorb the
contaminants from the water and biologically oxidize them to ultimately carbon dioxide and water
in the case of carbonaceous compounds and to nitrate in the case of ammonia and other nitroge-
nous compounds. Generation of biological solids, which must be periodically removed from the
system to maintain control, is a direct result of this process. Typically, wastewater is held in the aer-
ation basin about two days to complete the biological process, while the biological solids are kept
in the system about fifty days. The former is referred to as the hydraulic retention time of the bio-
logical system, and the latter is referred to as the solids retention time or sludge age of the system.
These two parameters are very important control points which need to be maintained if a quality
discharge is to be realized.
Following biological treatment, the wastewater is clarified and usually filtered through dual media
filters or other filtering devices, or routed through large settling or polishing ponds to reduce the
suspended solids content before finally discharging into a public waterway. Refer to Table 6.30 for
expected effluent quality.
530 Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved.
Manufacture of Metallurgical Coke and Recovery of Coal Chemicals
7.7.10.5 Phenol
Phenol (C6H5OH), sometimes called carbolic acid, is recovered from both coal tar and ammonia
liquor. Its most important use is in the manufacture of resinous condensation products by reaction
with formaldehyde, for example Bakelite. As a chemical intermediate it is used in the preparation
of synthetic tannins, dye intermediates, perfumes, plasticizers, picric acid, salicylic acid, and in the
refining of lubricating oils.
7.7.10.8 Naphthalene
A large percentage of the naphthalene produced from coal is converted to phthalic anhydride. The
principal use of the anhydride is in plasticizers, such as dioctyl phthalate and disoctyl phthalate,
for use in synthetic resins. Nearly as much phthalic anhydride is used, however, in the alkyd resins,
the important outlet for which is in coatings. In addition, polyester resins, dyes, agricultural chem-
icals, pharmaceuticals, insect repellents, beta-naphthol, surface active agents, tanning agents, and
insecticides consume large volumes of phthalic anhydride.
7.7.10.9 Creosote
Creosote (from coal tar) constitutes a large part of the distillate from tar, and is a blend of different
fractions to meet specifications established by the American Wood Preservers Association. Practically
all of it goes into the pressure impregnation of wood such as piling, utility poles and railroad ties.
7.7.10.10 Pitch
Pitch is employed as a binder in making carbon electrodes, as roofing pitch, fiber pitch, road tars,
and in pipeline enamels.
7.7.10.11 Benzene
Recovered from refining light oil, benzene is industrially the most important member of the aro-
matic family. The principal use is for the manufacture of styrene, which goes into polystyrene
resins and important grades of snythetic rubber. Other important uses of benzene are for manufac-
ture of phenol, nylon, synthetic detergents, aniline, and a host of other important organic chemi-
cals, including DDT, maleic anhydride, benzene hexachloride, mono- and dichlorobenzene and
nitrobenzene. The uses for some these benzene derivatives are evident, but others are intermedi-
ates, in turn, for additional chemicals, plastics, dyes, fungicides, and the like.
7.7.10.12 Toluene
The principal uses for toluene are in the manufacture of synthetic organic chemicals, detergents,
resins, plasticizers, explosives, solvents, dye intermediates, and pharmaceuticals, and for conver-
sion to benzene.
Toluene is converted through synthesis to phenol, benzoic acid, benzoyl chloride, benzoates, para-
cresol, dye intermediates, toluene sulfonates, di-isocynates and trinitrotoluene. Considerable quan-
tities of toluene are also used as a diluent in various types of coatings.
Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved 531
Ironmaking Volume
7.7.10.13 Sulfur
Approximately 90% of the sulfur produced in the Western World is utilized for the production of
sulfuric acid. Sulfur is also burnt to produce sulfur dioxide needed as bleaching agents for wool,
silk, gelatin, straw, and other materials.
Roughly 10% of the sulfur is consumed as elementary sulfur to produce vulcanizing agents, is used
as an additive for forming sand in the aluminum industry, or is used to produce sulfuric putty, black
powder and fireworks, sulfur dyes and carbon disulfide. In agriculture sulfur is utilized to jacket
fertilizers, as an important fungicide, and moreover as an additive to animal feed.
In pharmaceuticals sulfur is exploited for production of ointments or colloidal sulfur preparations
against scabies, acne, seborrhea, and other skin diseases, and moreover to produce sulfurated baths
against rheumatism.
More recently, sulfur has also found new fields of application in the production of sulfuric con-
crete. Substantial portions of asphalt contained in road pavement are already substituted by sulfur
without any adverse effects.
532 Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved.
Manufacture of Metallurgical Coke and Recovery of Coal Chemicals
Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved 533
Ironmaking Volume
D.C. - Downcomer
U.T. - Uptake
Adjacent oven
Thermo-
couple
Adjacent oven
Charging is done through an open door using a conveyor-charging machine. Coal is discharged
onto the oven floor by a drag conveyor which can be adjusted to accommodate various coal depths.
Charging starts at the pusher side door and progresses into the oven to the coke side door.
Oven pushing and quenching is basically the same as the byproduct coke ovens except that the
pushing machine is an integral part of the charging machine. When operating on a 48-hour cycle,
odd numbered ovens are pushed and charged on one day and the even numbered ovens the next.
Thus, there are fewer pushing and charging operations or cycles on the machine for the same pro-
duction of coke.
In general, blast furnace operators require minimum 60 A.S.T.M. stability coke, particularly for the
large blast furnaces. Coke produced has averaged 62 stability with a standard deviation of 0.4. The
amount of a +75 mm (+3 in.) coke averages over 40% of the run-of-oven coke primarily due to the
deep coal bed charge.
One of the greatest environmental concerns that affects the cokemaking industry today is the emis-
sion of hazardous chemicals. A test of emissions using a blend of high, medium and low volatile
coals showed stack emissions to be below the maximum levels allowable in the U.S.
In that all of the volatile products are combusted within the system, there is a large quantity of ther-
mal energy available which can be recovered in the form of steam used to drive electric generators.
The products of combustion would be cooled sufficiently to permit sulfur dioxide and particulate
scrubbers to lower the emissions to acceptable levels. Provisions have been made for the inclusion
of heat recovery for steam production and power generation.
In 1998, utilizing the Jewell Technology, the Indiana Harbor Coke Company30 commissioned the
first non-recovery coke plant in North America coupled to a co-generation facility for conversion
of the waster heat into electrical power. The plant consists of four 67-oven batteries designed to
produce 1.21 million tonnes (1.33 million tons) of coke per year. At peak production, the co-gen-
eration facility can produce 87 MW of electricity.
534 Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved.
Manufacture of Metallurgical Coke and Recovery of Coal Chemicals
The SCS was developed recognizing coke required for the blast furnace process would have to be
produced at low cost, with high quality, using a wide range of coals, with high thermal efficiency
and in an environmentally benign manner.
An essential characteristic of the new coking system is the process-controlled single chamber reac-
tor in combination with coal preheating. This means that the conventional multi-chamber system
with heating walls and coking chambers arranged alternately has been converted to a single cham-
ber system, abbreviated SCS, while maintaining the chamber principle. In terms of modular tech-
nology, the single chamber is a structurally and operationally independent component in a coke plant.
This arrangement offers a range of advantages: greatly increased static load-bearing capacity by
means of side-anchoring of the heating walls; an increase of approximately 100% throughput or
more, due in particular to coal preheating and productivity and as a result of this; a ≥ 50% reduc-
tion in the number of coking units; an increase in production flexibility due to individual computer
control of the coking process; more flexibility in the coal basis and/or improved coke quality; a
reduction in the specific energy consumption; increased freedom when determining the dimen-
sions of the coking chamber and the heating walls; and a decrease in harmful emissions from the
underfiring.
The emphasis in development work was focused on: proving the operability of the single reactor
design (SCS); determining the SCS potential for improving coke quality and for a greater usage of
poorly coking coal components in coal charging blends; proving high thermal efficiency in coke
production; and proving the operability of all of the integrated process techniques to improve envi-
ronmental performance.
Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved 535
Ironmaking Volume
5650
7400
1000
1200
850
60 850
60
10000
10000
Regenerator
Chamber floor
Chamber floor
Regenerator
Fig. 7.120 Construction alternative I, SCS-B. Fig. 7.121 Construction alternative II, SCS-S.
imbalanced coking pressure impacts on structural mechanics. Heat engineering investigations and
measurements on environmental protection were made.
7.8.3.3 Results
The test using various charging coal blends demonstrated that significant improvements were
achieved in the CSR values, providing more flexibility in the coal basis and improved blast furnace
coke quality. The main causes for this are coal preheating and higher bulk density. Consequently,
it is possible to achieve the required coke quality necessary for high rates of oil or coal injection
into the furnace and/or to use a greater proportion of cheaper, poor coking coals in the charging
coal blend.
The process of combining coal preheating with program-controlled heating reduced heat con-
sumption for the underfiring by a total of approximately 8%, improving thermal efficiency. By
incorporating coke dry quenching in addition to coal preheating, thermal efficiency can be
increased from its present level of 38% to over 60%.
The coking technique of the future must offer an economical solution regarding environment pro-
tection and safety at the workplace. The single chamber system fulfills an important technological
need for the environmentally friendly process of the future. First of all, there is a reduction of emis-
sion sources by the use of low-emission or emission-free components in the process. There is a
reduction in coking units utilized. The charging system is a completely sealed transportation
method; there is no need for leveling because of preheating of the coal charge. Coke pushing is car-
ried out into a cassette which is coupled to the reactor chamber by a perfect sealing system. The
result in total is a reduction in emissions by approximately one-half.
536 Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved.
Manufacture of Metallurgical Coke and Recovery of Coal Chemicals
An economic evaluation of capital and operating costs for a large-scale plant indicates that cost
savings may be realized compared to conventional cokemaking.
Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved 537
Ironmaking Volume
120
100
80
60
40
20
0
0 200 400 600 800 1000 1200
Te m p erature ( C )
Fig. 7.122 Throughput for coal devolatization process.
Antaeus Energy has developed the Antaeus Continuous CokeSM process, which uses a two-stage
pyrolysis-based process to produce high quality coke for both foundries and blast furnaces. The
process takes advantage of the split in the devolatilization process by minimizing the reaction res-
idence time and managing the coke quality by adding suitable binders before the secondary pyrol-
ysis zone. The process can produce coke in five hours. For these reasons, it is estimated that the
Antaeus Continuous CokeK process operating and capital costs can be significantly reduced. In
addition, a wide variety of coal feeds can be used to produce acceptable quality coke for foundry
and furnace use. Moreover, the process can produce other premium carbon products made from
waste materials such as spent automobile tires and coal tar. Another positive feature of the two-
stage pyrolysis coke production process is that it can produce marketable byproducts. The char pro-
duced is a marketable intermediary product used in ferroalloys production.
An important feature of this two-stage cokemaking process is that it is environmentally advanta-
geous. Not only can the process significantly reduce the air emissions problems associated with
traditional cokemaking; it will actually benefit the environment by the reclamation of coal waste
sites into safe and attractive properties for future use.
538 Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved.
Manufacture of Metallurgical Coke and Recovery of Coal Chemicals
C om bus ter
Vol ati l e
Vent
gas es
C l ean
c oal
Coal fi nes
fi n e s Pr i m ar y
De- ashing Dewater ing C har
D r y i ng py r ol y s i s
F l ue
gas es
Pon d
Gas
c ondi ti oni ng Vent
Vol ati l e
gas es
Binder s C ogenerati on
Supplem en tal
ener gy
S t ack gas es
C o a l fe e d Liquids
To t. vo l
Air
Te m p p o r t s
C har
Coal
H eat i ng gas es
Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved 539
Ironmaking Volume
During carbonization, the coal fines undergo thermal breakdown of their hydrocarbon bonds that
attempt to escape the coal matrix. This process leads to a buildup of gas pressure, forming a
pseudo-plastic regime. The result is coal swelling and liberation of hydrocarbons. The pyrolyzing
reactor vessel, which is heated at atmospheric pressure, removes part of the hydrocarbons, result-
ing in a carbon known as char. The char undergoes particle agglomeration and subsequently exits
the reactor after being cooled.
During stage two of the pyrolyzing process, the char is ground into fine particulate and blended
with suitable binders under a unique formulation to produce stable green briquettes with a uniform
distribution of porosity and strength. These green briquettes are pyrolized at high temperatures for
calcination in a rotary kiln/tunnel furnace to produce uniformly shaped and sized, high-quality
coke briquettes. The process has been optimized to reduce the residence in the high-temperature
kiln to two to five hours followed by the gradual coking process. The size of the coke briquettes
can be customized to meet the requirements of the coke consumer.
The volatile matter from the devolatilization process are combusted in a reducing atmosphere to
provide supplemental energy sources for the coking process. The flue gases are conditioned and
cleaned before being vented to the atmosphere.
The sensible heat from flue gases can be utilized to generate power through a co-generation sys-
tem. It is estimated that for 500,000 tons per year of coke production, a total of 30 MW of electric
power can be produced through the Antaeus process.
540 Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved.
B raci ng system
Wa s te gas
Charging hole
collecti ng mai n
Door
C a st a bl e
R e f ra ct o r y
Air inlet
C oke D ow ncome r R C sl a b
Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved
Gas c ol l ecti ng S ol e fl ue C astabl e
cha mber
Manufacture of Metallurgical Coke and Recovery of Coal Chemicals
541
Ironmaking Volume
The oven doors are made of steel equipped with a refractory door liner. Door jambs are made of
cast iron. Because the pressure in the oven chamber is negative, there is no need for technically
sophisticated sealing systems.
The charge car rails are located above the oven roof, arranged such that no load is introduced into
the brick crown. Charging holes with frames and lids are arranged in the roof and are located on
the centerline of the chamber.
The oven substructure below the sole flues is made of refractory castable and the entire bank rests
on steel beams. The free space between the I-beams running in the longitudinal direction of the
chamber allows air cooling to protect the base plates and the foundation against overheating.
The non-recovery ovens are arranged in such a way that two ovens with one intermediate gas col-
lecting chamber form a unit, Fig. 7.125. Six such units form one bank which is approximately 61
m long and 20 m wide (200 ft 3 3 85 ft).
The oven machinery needed to operate a non-recovery cokemaking plant consists of one set of each
of the following: the charging car, the pusher machine, the quench car and locomotive, and the sta-
tionary coke pushing device. Charging a single oven takes approximately 90 seconds for a 44 tonne
(48 ton) coal charge with a leveled coal bed height of 1000 mm (40 in.). Charging emissions will
not occur because the ovens are operated under negative pressure and both the pusher side and coke
side doors are closed.
In order to achieve a uniform coke quality in the wide chamber non-recovery oven, it is important
to provide for a constant coal bed height. It is therefore required that the coal mass in the chamber
is properly leveled after charging. Leveling through a partially opened pusher side door has been
successfully demonstrated in Australia.
As soon as the coal is charged and comes into contact with the hot oven chamber and radiation heat
from the oven cavity, coke oven gas begins to evolve. The raw gas produced is subsequently burned
in two stages and provides the heat required for carbonization.
In the first stage, i.e. in the oven cavity above the coal mass, the raw gas burns in the presence of
a sub-stoichiometric air volume at temperatures around 1200–1300°C (2200–2370°F). The heat
transfer into the coal bed takes place mainly by radiation. In this way, the coal is progressively car-
bonized from the surface of the coal mass down towards the oven sole. The required primary air
flow enters through the oven doors and is controlled with the help of manually-operated air
dampers. The control variable in this case is the cavity temperature.
Combustion of the residual raw gas volume is completed in the sole flues which are arranged hor-
izontally underneath the oven sole and connected with the oven cavity via downcomers. Combus-
tion in the presence of excess air in the range of 6–8% of oxygen in the waste gas leads to a
complete incineration of the raw gas at temperatures of 1300–1400°C (2370–2550°F).
From the front face of the ovens, the supply of air to the sole flues can be adjusted by means of
slide bricks located below the sole flues. Air flow is induced and maintained by the negative pres-
sure inside flue chambers, similar to the primary air supply. In the event that the coke plant is oper-
ated without energy recovery facilities, a suitable waste gas stack will produce the required
negative pressure by natural draft.
In plants with energy recovery systems, the required additional negative pressure is created through
fans located downstream of the waste heat boiler. In addition, an emergency stack will be provided
to ensure the required suction in case of a power failure.
As a result of the transfer of heat from the sole flues through the oven sole, carbonization pro-
gresses from the oven sole towards the surface of the coal mass. Identical carbonization rates from
the top and bottom surfaces can be achieved by appropriately adjusting the primary and secondary
air flows. Uniform coking velocities from top and bottom will result in a coke seam located in the
middle of the coke mass.
542 Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved.
Manufacture of Metallurgical Coke and Recovery of Coal Chemicals
To accomplish as uniform heating as possible of the coal mass via the oven floor, the sole heating
flues are designed in a double serpentine configuration. The raw gas-waste gas mixture from the
oven cavity passes to the outer sole flues via downcomers. The required combustion air is induced
to the sole flues in stages via ducts arranged below the sole flues.
With this unique heating system with nine downcomers per oven and staged combustion air sup-
ply, a uniform temperature profile is achieved, comparable to that in the proven heating system of
the horizontal chamber oven.
In addition, the multi-staged heating system with air introduced at different levels leads to the for-
mation of lower NOx levels in the waste gas. From the sole flues, the waste gas enters into the gas
collecting chamber.
From the gas collecting chamber, the hot waste gas enters a collecting main supported upon the
coke side buckstays. Twelve individual ovens each are connected via six collecting chambers to a
single collecting main. For control reasons and due to thermal expansion of the hot collecting
mains, the number of ovens connected to a single main has to be limited. Due to high waste gas
temperatures, the entire collecting main up to the waste heat boiler has to be refractory lined.
The collecting mains of two banks of twelve ovens each connect into one suction main through
which the hot waste gas enters the waste heat boiler. As a rule and depending on the sulfur content
of the coal feedstock, a flue gas desulfurization unit is provided to meet the environmental regula-
tions.
The coke pushing operation starts with unlatching and extracting the oven doors on the pusher and
coke side. Following this, the pusher machine and the quench care are exactly spotted in front of
the oven to be pushed.
The electro-mechanically driven pusher ram pushes the undisturbed coke cake into the quench box.
A most significant characteristic of the pushing operation is that the coke is not dumped, but is
pushed horizontally into the quench box. The shape that the coke cake had inside the chamber is
maintained. Emissions normally encountered when coke is dumped are therefore avoided.
This concept of pushing the coke cake onto a flat-bed quench car has been in practice for over 80
years in Australia. In a modern plant, the quench box is provided with a moveable cover to elimi-
nate windblown ash. This cover slides sideways when the quench car enters the quench tower.
The coke is quenched in a tower similar to the system being used in a conventional coke oven plant.
Quenching commences after the cover over the coke bed is removed. After the quenching process
has been completed, the quench train moves onto a stationary coke pushing station. This station
mainly comprises of two pusher rams, one for each bay of the wharf, including a common drive,
that engages either ram alternately.
The quench train operator aligns the loaded quench box with the pusher ram of the stationary unit
and the coke wharf. At this point, the coke is pushed out of the quench box onto the coke wharf.
Some typical characteristics of the TSOA/PACTI coke produced from blends of Queensland, Aus-
tralia coals are presented in Table 7.9.
Ash 12.6%
Volatile Matter 1.4–1.5%
ASTM Stability 60–61
Hardness 60–64
CSR 60–62.6
CRI 24.6–24.7
Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved 543
Ironmaking Volume
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544 Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved.
Manufacture of Metallurgical Coke and Recovery of Coal Chemicals
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Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved 545
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546 Copyright © 1999, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved.