3.1 Coal Preparation 3.1.1 Design Job and Adopted Standards and Specifications

1,500,000t/a Coking Plant for JSW Steel Works, India·Preliminary Design processing
3.1 Coal preparation

3.1.1 Design job and adopted standards and specifications
The design job for coal preparation system is to provide acceptable raw material (coal)
to coke ovens.
3.1.2 Design scope and division of work
The design scope for the workshop ranges from the transport station before the
blending bin to the coal feeding layer of the coal tower for coke oven, including
blending, crushing, and convey of raw coal.
3.1.3 General
The raw coal is blended with the automatic electronic proportion scale for the
blending bin, through a process of blending followed by crushing. The coal
preparation system is divided into feed preparation system and blending/crushing
system; wherein, the system from the transport station before the blending bin to
the top of the blending bin is the feed preparation system; the system from the
electronic proportion scale below the blending bin to the top of the coal tower is the
blending/crushing system. The capacity of the coal preparation system is designed
to support the producing capacity of 1,500,000t/a tamping coke ovens. The capacity
of the feed preparation system is 600t/h; the capacity of the blending/crush system
is 400t/h.
The fine coal for coking and the blending ratio is: charred coal: rich coal: lean coal:
1/3 charred coal = 30%: 10%: 20%: 40%.
3.1.3.1 Transport capacity of raw coal:
The amount of fine coal required is calculated as follows, in accordance with the coke
yield of 1,500,000t/a coke ovens:
Annual Daily Hourly
Blended coal
Raw coal type consumption consumption consumption
ratio 100%
(t/a) (t/d) (t/h)
Blended coal (dry) 100% 2009945 5507 229.45
Blended coal
(with 11% 100% 2258365 6187 257.80
moisture)
Charred coal (wet) 30% 677510 1856 77.34
Rich coal (wet) 10% 225837 619 25.78
Lean coal (wet) 20% 451673 1237 51.56
1/3 charred coal
40% 903346 2475 103.12
(wet)
General Coking Project Department, China Second Design Institute of Chemical Industry 3-1
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3.1.3.2 Convey, storage and storage capacity of raw coal

The raw coal is conveyed with TD75 and DTII belt conveyors.
The raw coal is stored in the following forms: the coal fed to the blending bin is
buffered; the coal for the coal tower is buffered; the blending bin comprises 8
hyperbolic port bins in 8m diameter, each of which has about 500t storage capacity,
the total storage capacity is about 4000t, equivalent to 16h coal consumption of the
coke ovens; the coal tower capacity is about 1400t, equivalent to 6h coal
consumption of the coke ovens.
3.1.3.3 Raw coal storage, transportation, and processing
3.1.3.3.1 Coal blending
Blending is to blend the coal for coking of different designations at the blending
ratio determined by blending experiment, so that the blended coal can be used to
product coke meeting the quality requirements and attain the purpose of reasonable
utilization of coal resource and reduction of production cost.
The blending bin employs a hyperbolic bin port with constant section contraction
ratio, lined with rolled hydrophobic microcrystal plate to prevent coal scab
building-up in the blending bin and ensure good fluidity and stable operation, and
thereby improve blending accuracy.
The unloading equipment above the blending bin employ electric unloading cars to
unload different types of coal conveyed on the belt conveyor #1 into the bin for storage.
The blending equipment below the blending bin employs 8 automatic electronic
proportion belt scales featured with stable blending, accurate blending ratio, and
high degree of automation. During the production, the belt scales can be chosen to
start/stop as required by coal type and blending ratio.
3.1.3.3.2 Crushing
Crushing is to crush the blended coal to crushing fineness <3mm and fine coal ≥8%,
so as to ensure coal granularity into the tamping coke oven, and meet the demand
for tamping and coking.
The crushing equipment employs two PFCK1825 reversible impact jump hammer
crushers, wherein, one working, the other standby. The unit processing capacity is 450t/h.
3.1.3.3.3 Control of moisture in blended coal
The tamping coke oven has requirement for coal granularity and moisture in the
coal. That is to say, the coal with granularity <3mm shall account for 85% or above;
wherein, the coal with granularity <1mm shall account for 50% or above, the
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moisture shall account for about 11%.

In order to control the moisture in coal at 11%, humidification equipment is provided at
two positions in the system. The first position is for coarse humidification, arranged on
belt conveyor 3# (A80503); the second position is for fine adjustment, arranged on belt
conveyor 4# (A80504) and belt conveyor 6# (A80506).
3.1.3.3.4 Coal distribution layer on tower top
The coal from the crushing workshop is humidified and then sent to the top layer of
the coal tower, and unloaded into the coal tower with the electric plough-type
unloading cars.
3.1.3.5 Mechanization and automation level
The system employs a PLC central control and local control scheme.
The blending equipment employs automatic electronic proportion scale (W80501),
which is highly automatic.
Each post is provided with audible/visual alarm; the belt conveyors are provided
with off tracking switch and emergency pull-wire switch, to ensure safe operation
of the system.
3.1.4 Overview of process flow
The fine coal for coking is conveyed on the belt conveyor to the transport station
before the blending bin, and fall on the belt conveyor 1# (A80501); the electric
unloading cars on the belt conveyor 1# (A80501) unload the coal by coal type into
the bins for storage.
The automatic electronic proportion scale (W80501A-H) under the blending bin
blends the coal by coal type at appropriate mix ratios to the belt conveyor 2#
(A80502) under the blending bin, where the coal is treated by the iron remover
(M80502) to remove iron, and then sent to the impact jump hammer crusher
(B80501A, B) and crushed, till the coal with granularity<3mm accounts for 85% or
above; next, the coal is conveyed by the belt conveyor 3# (A80503) and dispensed
by the electro-hydraulic tee joint dispenser (M80505); wherein, one coal stream is
dispensed onto belt conveyor 4# (A80504) and sent by the electric plough-type
unloading cars on belt conveyor 5# (A80505) into coal tower 2# for use by coke
ovens 1# and 2#; the other coal stream is dispensed onto belt conveyor 6# (A80506)
and sent by the electric plough-type unloading cars into coal tower 1# for use by
coke ovens 3# and 4#.
See process flow diagram of coal preparation.
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3.1.5 Selection of major production equipment

3.1.5.1 Principle for selection
In view of the system capacity, high quality and easy-to-operate homemade
equipment with reliable performance is selected; see Equipment Schedule for the
detailed data.
3.1.5.2 Description of new equipment
3.1.5.2.1 The crashers employed in the design are composite reversible impact
jump hammer crushers produced with combination of techniques from Japan and
Germany. They overcome the drawback of jamming in PCK reversible hammer
crushers for high moisture content materials. The crasher features with high crushing
rate, high capacity, low rotation speed, low dust, and high adaptability to moisture
content in coal, etc.; it employ a hydraulic coupler, which can effectively protect
against overload and supports soft startup; the open/close of enclosure and adjustment
of counteracting board are hydraulic operated, and it is easy to repair and replace the
hammer head; a combined type hammer head is used, featuring with long service life,
low maintenance and service cost, and low production cost.
3.1.5.2.2 In order to prevent the coal cakes from collapsing during feeding because
the material is too dry, the system is provided with automatic humidification device
after crushing of blended coal. The automatic humidification device measures the
moisture content in the coal on the belt conveyor; if the moisture content is lower
than the preset value, the nozzles will spray water automatically, till the moisture
content exceeds the preset value. The device will not spray water if there is no coal
on the belt conveyor. In addition, the device has moisture content over-limit and
emergency alarm function against the moisture content limit preset in accordance
with the actual production conditions.
3.1.6 Description of installation of large equipment
The reversible impact jump hammer crusher requires the foundation kept level
during installation; hoisting equipment must be used in accordance with the
function and the specified hoisting capacity.
3.1.7 Working regime
The system will operate 365 days per year. A two-shift system with 7h per shift
will be used before the blending bin; a three-shift system with 6h per shift will be
used after the blending bin.
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3.1.8 Power consumption

The installed capacity at AC433V voltage is about 600KW; the installed capacity at
AC6.6KV voltage is about 1800KW (wherein, the backup capacity is 900KW).
Consumption of humidification water for blended coal: depends on the moisture
content in coal.
Consumption of rinsing water (0.4MPa): 20t/h max., 1.5h per day.
3.1.9 Environmental protection and treatment of the three wastes
The reversible compact jump hammer crushers that produce high noise will be
installed in isolation to the building; the installation foundation will be separate
ones, isolated to the frame of crushing workshop, so as to reduce the vibration
effect to the crushing workshop.
Dust removal units are provided for the crushers that produce heavy dust, to ensure
the dust concentration in the exhaust gas meets the national standard.
3.1.10 Safety and health measures
Mechanical dust removal units will be provided for reversible compact jump
hammer crushers and at material unloading points of belt conveyors during material
blending, storage and transportation, to ensure the dust concentration in the exhaust
gas meet the national standard. In addition, terrace water flushing facility will be
provided on the trestle and in the crushing workshop, and natural vent holes will be
provided on the blending bin and coal tower, in order to improve operating conditions
for the workers.
3.1.11 Table of staffing
Staff per shift Persons

Name of Managerial Operation
No. resting Total Remark
procedure Production Assistant staff shift
by turn
worker worker
Belt
1 1 2 1 3
conveyor 1#
Electric
2 unloading 1 2 1 3
car
Automatic
electronic
3 1 3 1 5
proportion
scale
Belt
4 1 3 1 5
conveyor 2#
Reversible
5 compact 1 3 1 5
jump
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by turn
worker worker
hammer
crusher
Belt
6 1 3 1 5
conveyor 3#
Belt
7 1 3 1 5
conveyor 4#
Belt
8 1 3 1 5
conveyor 5#
Electric
plough-type
9 1 3 1 5
unloading
car
Belt
10 1 3 1 5
conveyor 6#
Electric
plough-type
11 1 3 1 5
unloading
car
Maintenance
12 2 2 0 4
man
Managerial
13 2 2
staff
14 Total 13 2 2、3 11 57
3.2 Coking and coke quenching

3.2.1 Coking
3.2.1.1 General
1. The nominal design capacity of coking section is 1,500,000t/a dry coke; the design
scale of coke ovens is 4×56 ports. The coke ovens will be TJL4350F twin-flue
downward-spraying reheated tamping coke ovens, with wide charring chamber, wide
regenerative chamber, and exhaust gas circulation. Coal cake tamping, side loading,
hot dry distillation, and wet coke-quenching process will be used.
2. The coking section will comprise coke ovens, coal tower, intermediate platform,
terminal platform, oven port service station, coke pushing pole and coal sole plate
replacement station, wet coke-quenching equipment (including coke quenching tower,
coke-cooling wharf, powder-coke sedimentation tank, and coke-quenching pump
room, etc.), chimney, and associated coke oven machinery. The task of coking section
is to feed the wash fine coal blended in the coal preparation section into the coke
ovens for dry distillation at a high temperature, to produce coke and coal gas. The
coke is cooled by water spraying and then sent to the coke storage section from the
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coke-cooling wharf; the raw coal oven gas is cooled by spraying circulating ammonia
at the bridge pipe and gas collector, and then pumped to the condensing/blowing
section; the smoke from coal feeding to the coke oven is removed by the smoke and
dust removal cars and then discharged to the standard; the smoke from the coke
discharging section is treated in the ground dust removal system and then discharged
to the standard.
3.2.1.2 Process scheme
The coking section will employ TJL4350F coke ovens designed and developed by use;
the following matured and applicable techniques are employed in the design to reduce
environmental pollution and improve the working environment.
(1) The coal tower port employs hyperbolic structure, with pneumatic coal vibration
and feeding with vibrating feeder; therefore, it can prevent scab building-up and
reduce the workers' labor intensity;
(2) The smoke escaped from coal feeding is combusted in the smoke and dust
removal cars on the top of oven and washed, to reduce the pollutant emission during
coal feeding by 90%;
A ground dust removal system with smoke collection rate > 90% will be used for dust
removal for coke discharging, the system will improve the pollution protection against
intermittent smoke from coke discharging in the coking plant.
(3) The water sealed ascending pipe cover and bridge pipe valve can reduce escape of
raw coal oven gas;
(4) The spring-loaded oven port has good sealing effect and is simple in structure and
easy to service, helpful to reduce gas escape from oven port;
(5) The gas collector is provided with a raw coal oven gas ignition device, in case of
any accident, the raw coal oven gas will be combusted before it is discharged, and
thereby the environmental pollution in the coking plant is reduced;
(6) The enclosing walls of regenerative chamber of coke oven, the lining tiles for
oven port, and the patch-up bricks for the ascending pipe are made of special thermal
insulating material, so as to reduce heat loss and improve thermal efficiency and the
operating environment;
(7) The high-performance tampers can shorten operation time and increase the
number of oven ports, and thereby improve economic efficiency;
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(8) The upper part of coke quenching tower is provided with dust collection device
made of wood baffling plate and spraying device, and thereby the dust emission
during coke quenching can be reduced;
(9) The coke wharf employs scraper coke pushing car to carry out coke pushing
automatically, which reduces the labor intensity and improves the operating
environment;
(10) A central/distributed computer control system is employed to improve automatic
control level and thermal efficiency of coke oven operation, and reduce energy
consumption.
3.2.1.3 Coke oven and process indexes
1. TJL4350F coke oven is a downward spraying reheated side loading tamping coke
oven with wide regenerative chamber, twin flues and exhaust gas circulation,
designed by us on the basis of existing coke ovens, with reference to experience in
design and operation of TJL-80 and other twin downward spraying coke ovens, in
accordance with the structural characteristics in coking plants in metallurgical
industry. Compared to conventional top loaded coke ovens in China, it has the
following advantages:
(a) Wide raw material range: Coal with high volatilization and weak or moderate
cohesiveness can be mixed in the raw material to produce high quality shaft oven
coke; in addition, coke breeze and petroleum coke breeze can be added in the raw
material to produce high quality shaft oven coke and casting coke; furthermore, 100%
highly volatile coal can be used to produce gasified coke.
(b) The quality of coke can be improved at the same blending ratio: For M40, the
quality can be improved by 1~6%; for M10, the quality can be improved by 2~4%;
the CSR can be improved by 1-6%.
(c) In production of coke at the same quality, additional 20~25% coal with high
volatilization and weak cohesiveness can be added; in other words, the coal with high
volatilization and weak cohesiveness in the oven coal can be up to 70~80%.
(d) With the same number of oven ports and the same dimensions of charring
chamber, the yield of coke can be improved.
2. Structural dimensions of coke oven:
The major structural dimensions of TJL4350F coke oven are as follows:
Total length of charring chamber: 14080mm
Effective length of charring chamber: 13280mm
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Total height of charring chamber: 4300mm

Average width of charring chamber: 500mm
Taper of charring chamber: 20mm
Center distance of charring chamber: 1220mm
Center distance of vertical flue: 480mm
Number of vertical flues: 28
Dimensions of coal cake: 13250/13050x450x4100mm
3 . Major technical indexes of coking process:
Number of coke oven ports: 4×56 ports
Dry coal capacity of charring chamber: 24.26t
Cycle time of coke oven: 22.5hr
Yield ratio of dry coal gas: ~359Nm3/t
Annual consumption of dry coal: 2009945t
Annual yield of dry coke: 1491379t
Temperature of raw coal oven gas from gas collector: ～84℃
Pressure of raw coal oven gas from gas collector: 80～120Pa
4 . Brick amount of oven shell:
See the following table for brick amount of 4×56-port TJL4350F coke oven:
No. Name Unit Quantity
1 Silicon brick T 5821x4
2 Clay brick T 3129x4
3 Clinker brick T 144x4
4 High aluminum brick T 71x4
5 Heat insulating brick T 159x4
6 Red brick T 576x4
7 Aluminum silicate fiber brick Block 9048x4
3.2.1.4 Specifications and quantities of raw materials and products

1. Specifications and quantities of raw materials
The specifications of blended fine coal are shown in the following table:
Full sulfur Thickness of
Raw coal Industrial analysis % Cohesiveness
% gelatinous layer mm
type GR.I
Ad Vdaf St.d X Y
Blended coal 8.74 29.89 0.63 80 25.5 18.5
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Consumption of washed fine coal (dry): 2009945t/a

2. Specifications and quantities of products
(1) Coke
Specification Ad:11.51 % Vdaf:1.06 % St,d:0.54 % Mad:1.07
Analytical method GB/T2001 GB/T2001 GB/T2286
Yield of dry coke (dry): 1491379t/a
80~25mm: 1386983t/a (Wet, moisture content =4%)
25~6.3 mm: 58253 t/a (Wet, moisture content =10%)
<6.3mm: 35703 t/a(Excluding dry coke breeze in powder-coke sedimentation tank:

10440t/a) (Wet, moisture content =14%)
(2) The components in raw coal oven gas are as follows:
Dry coal gas: 82206 Nm3/h
Tar: 8061 kg/h
Coarse benzene: 2846 kg/h
Hydrogen sulphide: 412 kg/h
Hydrogen cyanide: 114.5 kg/h
Ammonia: 641kg/h
Naphthalene: 824kg/h
3.2.1.5 Overview of production process:
Washed fine coal from the coal preparation workshop is conveyed to the coal tower
through the coal trestle; the coal loader travels to below the coal tower; the sway
feeder feeds coal evenly layer of layer; then, the coal is tamped with the tamper layer
of layer; next, the coal loader travels to the charring chamber and load the tamped
coal cakes into the charring chamber from one side. The coal cakes are treated
through dry distillation at 950~1050℃ high temperature for about 22.5h; then, the
coke is pushed to the coke quenching car by the coke pusher via the coke guide grate;
the coke quenching car conveys the coke to the coke quenching tower for coke
quenching by water spraying; after coke quenching, the coke is conveyed by the coke
quenching car to the coke-cooling wharf; after secondary coke quenching and cooling
on the coke-cooling wharf, the coke is pushed by the scraper coke pushing car onto
the belt conveyor and then conveyed to the coke yard. The coke quenching tower is
equipped with an automatic photoelectric controller; with the time relay in the
controller, the spraying time is adjusted to ensure quenching of red coke.
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The raw coal oven gas produced during dry distillation runs through the top of
charring chamber, the ascending pipe, and the bridge pipe, to the gas collector. The
gas is cooled by spraying circulating ammonia at ~78℃ under ~0.3MPa pressure at
the bridge pipe and gas collector, so that it is cooled from ~700℃ to ~84℃; then, it is
sucked through the suction elbow and suction pipe to the condensing/blowing section.
The tar and ammonia condensed in the gas collector flow through the tar box and
suction main to the condensing/blowing section.
The recovered coal gas for coke oven heating is sent through the external pipe to the
coke oven and into the combustion chambers through the gas main, gas pre-heater,
main pipe, and branch pipes; in the combustion chambers, the recovered coal gas is
mixed with preheated air in the regenerative chamber and burn; with addition of
partial recovered gas, the mixture of coal gas and air boosts the flame and make
vertical heating more even; therefore, the temperature of burning fume can be up to
~1300℃; the exhaust gas runs through the span holes, vertical flue, and chute,
exchanges heat with the lattice bricks in the regenerative chamber, runs through sub-
flues and main flue, and finally is discharged from the chimney.
The raw coal oven gas escaped during the coal feeding process is sucked by the
smoke prevention and dust control car on oven top to the combustion chamber for
burning; the smoke prevention and dust control car travels to the correct position at
the charring chamber to be loaded; then, the dusting door cover opens, the dust
removal sealing bushing drops, and the exhaust blower begins to operate at a high
speed. The car sucks the raw coal oven gas escaped during the coal feeding process to
the combustion chamber for burning; after burning, the exhaust gas is treated in the
Venturi scrubber on the car to remove the dust in the exhaust gas; then, the gas is
exhaust to atmosphere. The scrubbing water is sent to the water tank below the dust
removal car, and then drained to the powder-coke sedimentation tank for precipitation.
The dust removal for coke discharging from coke oven is treated in the ground dust
removal station for coke discharging.
3.2.1.6 Machinery for coke oven:
See the following table for machinery required for 4X56-port TJL4350F coke oven:
No. Name Quantity Remark
1 Coal loader 4 sets Two for left-handed and two for right-handed
2 Coke pusher 4 sets Two for left-handed and two for right-handed
Smoke prevention and
3 4 sets
dust control car
4 Code guide for dust removal 4 sets
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No. Name Quantity Remark

5 Coke quenching car 4 sets Two working, two standby
6 Electric locomotive 4 sets Two working, two standby
7 Hydraulic exchanger 4 sets
8 2X6 hammer tamper 4 sets 4 X 3-hammer tampers
9 Sway feeder 36 sets
The coke oven machinery chosen in this project is designed and manufactured on the
basis of experience in mechanical operation of coke ovens in China, with reference to
the merits of matured, reliable, leading, and practical coke oven machinery, focusing
on improving efficiency, reduce labor intensity, and improve operating environment,
on the principle of safety, reliability, and practicality.
Each coke oven is equipped with a coal loader, a coke pusher, a set of 2X6-hammer
mobile tampers (with a 3-hammer tamper for backup), a smoke prevention and dust
control car, a coke guide for dust removal, a set of hydraulic exchanger, 9 sway
feeders; the 4 coke ovens are equipped with 4 coke quenching cars (two working and
two standby) and 4 electric locomotives (two working and two standby).
3.2.1.7 See the following table for power consumption (including power consumption
of coke quenching equipment):
Service Consumption
No. Name Specification Unit Remark
condition Normal Max.
Fresh water Continuous m3/hr 27 28

1 Water
Reused water Continuous m3/hr 126 138
Installed
2 Electricity 380V Intermittent kW 4676
capacity
Intermittent t/hr 0.3 0.32
3 Steam 0.5MPa (gauge)
Continuous t/hr 0.64 0.68
Compressed
4 0.6MPa (gauge) Continuous m3/hr 1200
air
Mixed gas,
wherein
5 Coke oven gas Qnst=17900KJ/Nm3 Continuous Nm3/hr 4918 Dust
content
Shaft oven gas Qnst=4055KJ/Nm3 Continuous Nm3/hr 159041 <15mg/m3
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3.2.1.8 Table of staffing:

Staff per shift
Managerial Operation Staff per
No. Name of procedure production Total
staff shift shift
staff
I Production staff
1 Coke oven operator
Coke discharging and
oven port cleaning 4x2 3 5 40
worker at pusher side
Coke discharging and
oven port cleaning 4 x2 3 5 40
worker at coke side
Ascending pipe worker 2 x2 3 5 20
Oven cover worker 2 x2 3 5 20
Coke oven
2
conditioning worker
Fire adjusting worker,
temperature measuring 4 x2 3 5 40
worker
Exchanger operator 2 x2 3 5 20
Ironworks worker 2 x2 1 1 4
Coke oven machine
3
operator
Coal loader driver 4 x2 3 5 40
Coke pusher driver 4 x2 3 5 40
Smoke prevention and
4 x2 3 5 40
dust control car driver
Coke guide driver 4 x2 3 5 40
Electric locomotive driver 2 x2 3 5 20
Tamper operator 4 x2 3 5 40
4 Coke wharf operator 2 x2 3 5 20
5 Repairman
Oven port repairman 4 x2 1 1 8
Oven tiler 4 x2 1 1 8
Technician 2 x2 3 5 20
Electrician 2 x2 3 5 20
Pipe man 2 x2 1 1 4
Oil man 2x2 1 1 4
Tower worker 2 x2 1 1 4
II Managerial staff
1 Workshop director 2x2 1 1 4
2 Technician 4x2 1 1 8
3 Section chief 2x2 3 3 12
Total 62 x2 8 516
3.2.1.9 Flue gas emission:

The 4 coke ovens are equipped with two chimneys; two coke ovens share a 125m high
chimney with Φ3.8m top emission aperture. The flue gas emission amount and flue
gas composition are shown in the following table:
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Emission Emission Emission Composition of exhaust gas

Name
section altitude amount (%)
CO2 H2O O2 N2
Chimney Φ上 3.8mx2 ～125m 355759m3/h
19.51 4.49 3.84 72.16
The coal gas from chemical recovery is used as the coal gas for oven heating; the
content of hydrogen sulphide in the coal gas is 300mg/Nm3, conforming to the
environmental requirement; therefore, the SO2 content in the exhaust gas meets the
emission standard.
3.2.1.10 Ironworks for coking and associated equipment
The coke oven ironworks for coking and associated equipment mainly include oven
columns, longitudinal and cross tiebacks, oven ports, oven frames, armor plates, and
exhaust valves, etc.
The oven columns are made of H steel, with upper and lower parts tied with
longitudinal cross tiebacks and springs mounted on terminal. There are a variety of
brackets mounted on upper part of the oven columns, designed to support the
operating platform, gas collector, suction elbows, and exhaust stack, etc.
The armor plates for oven frame of oven port are in the same structure at machine side and
coke side. They are mainly made of heat resisting vermicular cast iron. The leak tightness
between oven port and oven frame is ensured with the spring-loaded blade structure.
The bridge pipe valve body is made of gray cast iron. The bridge pipe is connected
with the valve body in socket structure; the water seal disk of valve body and the
water seal cover of bridge pipe are configured with counter weight reasonably, so that
both of them can be opened/closed smoothly.
The exchange actuator employs lever and sector-shaped wheel drive mechanism; the
actuator is composed of cylinder, twin-fork pipe, dead-weight disk, adjusting flap, damper,
lever, and sector-shaped wheel, etc. The main components are made of gray cast iron.
Besides above main components, the ironworks and accessory equipment of coke
oven include oven port service station, hoist, adjusting plug, switch plug, adjusting
butterfly valve, orifice plate box, tar box, diffuse water seal valve, diffuse water seal
tank, coal gas pre-heater, main flue and branch flues, and flap, etc.
3.2.2 Coke quenching
A wet coke-quenching process with two sets of coke quenching devices is used in the design.
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Each set of wet coke-quenching devices comprises coke-quenching pump room, coke
quenching tower, coke quenching water spraying pipes, dust collectors, powder-coke
sedimentation tank, clean water tank, powder-coke dehydrating platform, and electric
single-track grab bucket hoist crane, coke wharf, scraper coke pusher, etc. To ensure dust
collecting efficiency for the coke quenching tower, water flushing pumps are provided in
the pump room to flush the dust collectors. In addition, in order to ensure water for smoke
prevention and dust control, a feed pump for dust removal is provided.
Two automatic coke quenching pumps in "one working and one standby"
configuration are provided in the coke-quenching pump room. The startup of water
pump is controlled by the infrared remote control probe automatically; the cycle time
of coke quenching is controlled at 90~120s with time relay, to ensure red coke
quenching result.
The coke quenching tower is 36m high; water spraying pipes for coke quenching are
provided below the coke quenching tower; wood baffling dust collectors are provided
on the top of the coke quenching tower to collect coke breeze and water drops
produced during coke quenching; the dust removal efficiency can be 70% or above,
improving the ambient environment effectively.
The length, width and depth of powder-coke sedimentation tank are designed
appropriately to ensure enough sedimentation time and speed of the circulating water
containing coke breeze and ensure water circulation for coke quenching.
In order to remove coke breeze in the powder-coke sedimentation tank periodically,
electric grab buckets with 0.75m3 capacity are used to grab the coke breeze on the
bottom of the sedimentation chamber onto the powder-coke dehydrating platform,
where the coke breeze is dehydrated and then transported out.
3.3 Ground dust removal station
3.3.1. General
The coke ovens will produce a great deal of smoke with major pollutants including
TSP, BSO, and BaP during the coal feeding and coke pushing process. In view of the
harm of pollutants in coking, the coking equipment and operation management were
improved from 1980s, mainly including: utilize coke ovens with high charring
chamber (above 4m); improve coke oven mechanization and automation level;
employ dust collecting plates for coke quenching tower; employ water seal for
ascending pipe cover; utilize ground dust removal station, etc. In coking plants that
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are well managed, those measures have certain effects to reduction of emission of
pollutants (emission amount is about 8.75Kg/t coke).
The dust removal for coke oven includes dust removal during coal feeding and dust
removal during coke discharging; in this project, the smoke prevention and dust
control car on oven top is utilized for dust removal during coal feeding; it is belongs
to the design scope of coking discipline, and thereby will not be described in this
chapter. Ground dust removal station is used for dust removal during coke discharging;
it can reduce greatly the pollutants: TSP is reduced to 1.2g/t coke; BSO is reduced to
0.5Kg/t coke; BaP is reduced to 1200mg/t coke.
The section is an auxiliary section for the 1,500,000t/a coking plant. It comprises two
identical ground dust removal stations, each of which provides dust removal service
during coke discharging for two coke ovens; the ground dust removal stations are
identical to each other in process flow, equipment composition, and control part. See
the general layout for the locations of the two ground dust removal stations. The space
for dust removing equipment during coal feeding is reserved in this project.
3.3.2 Composition of ground dust removal station and overview of process
3.3.2.1The section comprises the following two parts:
1) Dust collecting mains part (two sets): the dust collecting mains at coke side
comprise multiple sets of interface flap valves, pipe expansion joints, balance valves,
and terminal sound dampers. The main purpose is to connect the dust collecting hood
of coke guide and the ground dust removal station, and send the collected smoke
during coke discharging to the ground dust removal station for dust removal;
2) Ground dust removal station part (two sets): the equipment is in the workshops in
the ground dust removal station and comprises regenerative coolers, cloth bag pulse
dust collectors, blower sets, dust convey and humidification device, and central
lubrication device. The main purpose is to suck the smoke produced during coke
discharging with the blower sets to the cooler and dust collector to remove dust; then
the dry and clean gas is exhausted to atmosphere through the chimney; the collected
coke dust is sent to the dust bin, humidified, and then transported out.
3.3.2.2Overview of process
When the red coke is pushed out from the charring chamber, it burns in the air and produces
flue gas and coke dust, which will cause pollution if it is emitted to the air directly.
The dust produced during coke discharging is cleaned in the dry-type ground station
for dust removal, i.e., the intermittent smoke produced during coke discharging is
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sucked into the large collecting hood on the coke guide under the thermal floating
effect of the coke and suction effect of the blower; then, the smoke is sent into the
dust collecting mains via the interface flap valve and then to the ground dust removal
station; in the ground dust removal station, the smoke flows through the regenerative
cooler, separated by sparkling, cooled, and then filtered in the cloth bag pulse dust
collector, and finally exhausted to atmosphere through the chimney.
The dust removing system for coke discharging comprises three parts: large suction
hood on the coke guide (in the design scope of coke guide); fixed dust collecting
interface valve above the coke wharf; ground pipeline, regenerative cooler, bag-type
pulse dust collector, sound damper, blower sets, and chimney, etc.
The dust collected by the dust collector is conveyed on the chain conveyer to the dust
bin; to prevent the dust from flying about again and polluting the environment, the
dust convey system is enclosed; the dust in the dust bin is humidified and then
transport out by truck.
When the coke guide at coke side reaches to the predefined position, the dust
removing guide sleeve is connected to the fixed interface valve. At that time, the dust
removing blowers receives the signal from the coking system and begins to speed up;
the smoke is sucked through the dust collecting mains at coke side to the ground
station for dust removal, and then exhausted to atmosphere through the chimney.
When the blowers operate at a high speed, the cold gas valve before the bag dust
collector closes; after dust removal, the blowers slow down, and the cold gas valve
opens, to maintain system pressure and cool the regenerative cooler, and thereby is
ready for the next cycle. When the blowers operate at a low speed, the PLC controls
the pulse controller for the bag-type dust collector for back flushing, to blow off the
dust from the cloth bag; at the same time, the dust discharge valve acts to discharge
the dust to the scraper dust conveyor; then, the dust is conveyed to the dust bin,
humidified, and transported out. During the entire process, blower speed switching,
open/close of cold gas valve, on/off of pulse controller, and action of scraper dust
conveyor and dust discharge valve are controlled by PLC.
The flue gas processing capacity and relevant parameters of the dust removal system
for coke discharging are as follows:
Processing capacity: 220000m3/h
Gas pressure: 6500Pa
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Flue-gas temperature: ≤200℃

Dust content in flue gas: 5～12g/m3
Operation of coke discharging: 1min
Fore of dust collector: Explosion-proof bag-type pulse dust collector
Filtering material: high temperature resistant antistatic needle wool
Filtration area of dust filter: 3280m2
Installed capacity of blower: 710kW 6.6kV
Since the coke discharging from coke oven is carried out intermittently and cyclically,
a variable speed hydraulic coupler is utilized between the main blower and the electric
motor in the ground dust removal station to regulate blower speed and reduce
operation cost. That is to say, the blower operates at a high speed during coke
discharging but operates at a low speed at other times.
The block flow diagram is as follows:
Suction hood for
coke discharging
Flue gas valve at

coke side
Regenerative cooler
Bag-type pulse dust

collector
Dust convey Storage

Main blower
system bin
Sound damper Humidification
Transport out
Chimney Atmosphere by trunk
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Hourly consumption Remark
No. Name Specification Unit
Normal Max.
1 Circulating water 35℃ m3 35 40 Continuous
3
2 Compressed air 0.6MPa m 720 720 Continuous
6.6KV kW 710 Installed capacity
3 Electricity
240/415V kW 98.5 Installed capacity

Staff per shift
No. Name Productio Assistant Operation shift Total Remark
n worker worker
Operation room 2 3 10 Five-shift system
Total 10
3.4. Coke screening/storaging

3.4.1 Design job
The purpose of coke screening system is to transport the crushed coke from coke
ovens to the coke-screening building for screening and storage and transport the
sorted coke to the steel works or coke storage yard.
3.4.2 Design scope
The design scope ranges from coke belt conveyor 1# below the coke-cooling wharf to
the coke storage yard, including coke crushing, screening, convey, and storage; the
main constructions include: crushing building, coke-screening building, coke storage
yard, belt conveyor trestle, and transfer station, etc.
3.4.3 General
The coke screening system is designed into two series, each of which is provided with
a coke-cooling wharf and has 180t/h system capacity. The coke is classified into three
grades: 25-80mm, 6.3-25mm, and <6.3mm. The coke can be transported out by trunk
or transported by belt conveyor to the coke yard or steel works (reserved).
3.4.3.1 The yield of 1,500,000t/a tamping coke ovens is as follows:
Granularity of coke Annual yield (t/a) Daily yield (t/d) Hourly yield (t/h) Transport means
Blended coke (dry) 1491379 4086 170.25
80-25mm (dry) 1386983 3800 158.33 Belt conveyor or trunk
25-6.3mm (dry) 58253 160 6.65 Belt conveyor or trunk
35703 98 4.08 Belt conveyor or trunk

<6.3mm(dry)
10440 28 1.19 Trunk (sedimentation tank)
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3.4.3.2 The physical and chemical properties of coke are shown in the following table:
Physical and chemical properties of coke
Granularity Stacking Rest angle Moisture
No. Cohesiveness Remark
(mm) density (t/m3) (°) content (%)
1 0~250 0.5 42 4.6 N/A
2 >25 0.5 42 4 N/A
3 25~6.3 0.55 45 10 N/A
4 <6.3 0.55 45 14 N/A
3.4.3.3 Coke convey, storage, and storage capacity

The coke is conveyed with TD75 and DTII belt conveyors. Since the coke is still hot
when it is scraped onto the belt conveyor by the scraping machine, the belts of belt
conveyor for conveying coke to the coke bunkers in coke-screening building are heat
resisting rubber belts. Due to high abrasion by coke, the belts of all belt conveyors in
the system have 6mm rubber layer.
The coke bunker in coke-screening building can store 2000t coke with granularity
>25mm, equivalent to about 16h coke yield; 200t coke with 25~6.3mm granularity,
equivalent to about 1.2d coke yield; 150t coke with granularity <6.3mm, equivalent to
about 1.4d coke yield.
3.4.3.4 Determination of coke handling, storage and transport, and treatment scheme
Coke is shipped out by belt conveyor or by trunk. A coke-screening building is
provided in the system to store coke. Due to the severe abrasion by coke, cast stone
slabs are lined on inner surface of the cone part of coke bunker in the coke-screening
building, and cast stone slabs are lined locally in the coke sliding chute, so as to
reduce abrasion by coke to the coke bunker and sliding chute.
The coke screening system is designed into two series, each of which is provided with
a coke-cooling wharf. To facilitate management, the crushing equipment for the two
systems is provided in the same crushing building, and the screening equipment for
the two systems is provided in the same coke-screening building.
3.4.3.4.1 Coke-screening building
After the coke is sorted with the vibrating screen, coke with granularity >25m is
loaded into the coke bunker by belt conveyor; coke with granularity <25mm is loaded
into appropriate coke bunkers through the coke sliding chutes.
In view of the coke yield and the granularities after sorting, coke with granularity
>25m is stored in 7 coke bunkers; coke with 25~6.3mm granularity and granularity
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<6.3mm are stored in a coke bunker, respectively. That way can ensure continuous
production of the coke ovens and ensure the coke can be allocated flexibly in the
system after it is sorted and conveyed to the open-air storage yard.
Two rows of discharge ports are provided below the coke bunkers; wherein, one row
is provided with vibrating feeders below it; the other row is provided with coke
pushing gates below it. The coke from the vibrating feeders is conveyed on the belt
conveyors to the steel works; the coke pushing gates can discharge the coke onto
trunks for external transportation.
The coke-screening building is provided with three 2148 vibrating coke screens
(B83502A-C) and three 1224 vibrating coke screens (B83503A-C), in "two-working
and one-standby" configuration. The equipment has travel mechanism, enclosed dust
collecting hood, and hopper under screen, and is easy to use and service.
3.4.3.4.2 Coke cutting workshop
The coke cutting workshop is provided with three dual toothed roller crushers
(B83501A-C), in "two-working and one-standby" configuration; each system use a
dual toothed roller crusher, and the two systems share a standby crusher. The
equipment has a travel mechanism and is easy to use and service.
3.4.3.5 Mechanization and automation level
The system employs central PLC control and local control, and is provided with
machine start/stop alert signal; each belt conveyor is equipped with off tracking
switch and emergency pull-wire switch.
Electric belt scales (W80501 and W83502) are provided on coke belt conveyor 7# (A83507AB)
as metering instrument, so as to implement control of system production capacity.
3.4.4 Description of system process flow
3.4.4.1 Coke screening/storaging system for coke ovens 1# and 2#
The coke from coke oven 1# and 2# is treated through coke quenching and then laid
on coke-cooling wharf 2#; then, the coke is scraped by the scraper coke pushing
machine onto coke belt conveyor 1# (A83501), and conveyed to the crushing building
via coke belt conveyor 2# (A83502) and coke belt conveyor 3# (A83503); the coke in
the crushing building is screened by the bar screen; then, coke with granularity
>80mm is sent to the dual toothed-roller crusher for crushing to granularity <80mm;
next, the coke is conveyed with the screenings to the coke-screening building via the
coke belt conveyor 7# (A83507A); the coke in the coke-screening building is
screened with a single-layer vibrating coke screen (B83502A); the oversize coke
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(granularity>25mm) is unloaded by coke belt conveyor 8# (A83508A) into 7 coke

bunkers for coke with granularity>25mm; the screenings (coke with
granularity<25mm) is sent to the single-layer coke screen (B83503A) and sorted into
two grades (25-6.3mm and <6.3mm), which is sent to appropriate coke bunkers
respectively. Each of the coke bunkers has to discharge ports; wherein, at one
discharge port, the coke is loaded on trunks with the reversed fan gate (M83501A-I);
at the other discharge port, the coke is loaded onto the belt conveyor to the steel works
with the vibrating feeder (M83502A-I).
3.4.4.2 Coke screening/storaging system for coke ovens 3# and 4#
The coke from coke oven 3# and 4# is treated through coke quenching and then laid
on coke-cooling wharf 1#; then, the coke is scraped by the scraper coke pushing
machine onto coke belt conveyor 4# (A83504), and conveyed to the crushing building
via coke belt conveyor 5# (A83505) and coke belt conveyor 6# (A83506); the coke in
the crushing building is screened by the bar screen; then, coke with granularity
>80mm is sent to the dual toothed-roller crusher for crushing to granularity <80mm;
next, the coke is conveyed with the screenings to the coke-screening building via the
coke belt conveyor 7# (A83507B); the coke in the coke-screening building is screened
with a single-layer vibrating coke screen (B83502A); the oversize coke
(granularity>25mm) is unloaded by coke belt conveyor 8# (A83508B) into 7 coke
bunkers for coke with granularity>25mm; the screenings (coke with
granularity<25mm) is sent to the single-layer coke screen (B83503B) and sorted into
two grades (25-6.3mm and <6.3mm), which is sent to appropriate coke bunkers
respectively. Each of the coke bunkers has to discharge ports; wherein, at one
discharge port, the coke is loaded on trunks with the reversed fan gate (M83501A-I);
at the other discharge port, the coke is loaded onto the belt conveyor to the steel works
with the vibrating feeder (M83502A-I).
3.4.5 Selection of major equipment
In view of the capacity of coke screening/storaging system, high quality and easy-to-
operate homemade equipment with reliable performance is selected; see Equipment
Schedule for the detailed data.
3.4.6 Description of installation of large equipment
The coke screening/storaging system has large-size screening equipment. In order to
ensure the screen travels on the tracks smoothly and can be used stably, the track
gauge shall be adjusted during installation and the track clamps shall be mounted well,
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so as to fix the screen and prevent dislocation in vibration. The installation shall be
carried out with the installation holes reserved in the building. The hoisting equipment
must be used in accordance with the function and the specified hoisting capacity.
3.4.7 Working regime
The system will operate 365 days per year, in a three-shift regime.
The total installed power capacity of the coke screening system is about: AC433V,
760KW.
Consumption of rinsing water (0.4MPa): 20t/h max., 1.5h per day.
3.4.9 Environmental protection and treatment of the three wastes
Spring damping facilities are provided under coke vibrating screens that produce high noise
and vibration, so as to reduce the live load on floor resulted from noise and vibration.
3.4.10 Safety and health measures
Dust suppression and removal measures during processing, storage, and transportation: dust
removing devices are provided for single-layer coke vibrating screens that produce heavy
coke dust; mechanical dust removing devices are provided at the material dropping points of
dual toothed-roller crushers and belt conveyors, to ensure the dust content in the exhaust gas
meets the national discharge standard. In addition, terrace water flushing facilities are
provided on trestle, in crushing workshop and coke-screening building, so as to wash off coke
dust produced during production. Natural vent holes are provided on the top of the coke
bunkers, to eliminate gasses and dust in the bunkers and improve the operating conditions.

by turn
worker worker
Coke belt
1 1 3 1 5
conveyor 1#
Coke belt
2 1 3 1 5
conveyor 2#
Coke belt
3 1 3 1 5
conveyor 3#
Coke belt
4 1 3 1 5
conveyor 4#
Coke belt
5 1 3 1 5
conveyor 5#
Coke belt
6 1 3 1 5
conveyor 6#
Dual
7 1 3 1 5
toothed-
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by turn
worker worker
roller
crusher
Coke belt
8 1 3 1 5
conveyor 7#
Coke belt
9 1 3 1 5
conveyor 8#
Single-layer
10 vibrating 1 3 1 5
coke screen
Single-layer
11 vibrating 1 3 1 5
coke screen
Reversed
fan gate
12 1 3 1 5
Vibrating
feeder
13 Loader 2 3 2 10
Maintenance
14 2 2 0 4
man
Section
15 2 1 2
chief
Total 14 2 2 14 76
3.5 Condensing/blowing and electric tar precipitation

3.5.1 General
3.5.1.1 Equipment, scale, and composition
(1) Overview of the section
The section is a coal gas cleaning installation for 4x56-port TJL4350F coke ovens,
including coal gas condensing, cooling, and pressurized convey, separation, storage
and convey of tar, ammonia, and tar slag, precipitation of tar fog drops and
naphthalene in coal gas, and cleaning of tail gas.
(2) Production method and process characteristics
The coal gas is cooled with transverse pipe cooler. The transverse tube cooler is
composed of upper and lower sections; wherein, the upper section employs circulating
water to cool coal gas to about 45℃; the lower section employs refrigerating water to
cool the coal gas to below 22℃, in order to precipitate thoroughly tar and naphthalene
in the coal gas.
The coal gas is pressurized with centrifugal blower, which overcomes the defects of
Roots blower, such as high noise, low efficiency, short service life, and gas leakage;
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the associated hydraulic coupler is used to regulate the speed, and is easy to operate
and can save energy.
Tar and ammonia are separated in four mechanical ammonia sedimentation tanks with
300m3 effective volume each, which are high in mechanization level and easy to
service.
The tar and naphthalene in coal gas are precipitated with high-performance honey-
comb electro tar precipitator, which is located before the blower and can remove tar
fog drops and naphthalene in coal gas as far as possible and thereby improve success
ratio of subsequent procedures.
3.5.1.2 Discharge/emission and treatment of the three wastes
(1) The tar slag separated from the mechanical ammonia sedimentation tank is
discharged to the tar slag car and transported to the coal yard periodically, and then
added to the coal for coking.
(2) The liquids from the equipment are discharged to the liquid waste catch tank; the
liquid leaked from the pumps is sent for biochemical treatment.
(3) The tail gas from the storage tanks is collected and sent to the gas cleaning tower,
where the gas is washed with circulating water and then exhausted; the circulating
water is replenished continuously from the circulating water system, and a part of the
circulating water is pumped continuously for biochemical treatment.
3.5.1.3 Production regime
365 days per year, five shifts prepared, with three shifts working for continuous
production.
3.5.2 Specifications and quantities of raw materials and products
3.5.2.1 Raw materials
Quantity of dry coal gas: 82206Nm3/h
Temperature of coal gas: ~81℃
Pressure of coal gas: ~0.001MPa
Composition of dry coal gas (volumetric %)
Component H2 CH4 CO CmHn CO2 N2 O2 Heat value (low) KJ/Nm3
% 56~60 23~27 5~8 2~4 1.5~3 3~7 0.3~0.8 17000~18000
Content of impurities in dry coal gas
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Coarse Hydrogen Hydrogen

Name Tar Ammonia Naphthalene
benzene sulphide cyanide
Dry coal gas
39.22 34.62 7.80 5.01 1.40 10.02
g/Nm3
3.5.2.2 Products
(1) Coal tar
Yield: 76510t/a
Specification:（YB/T5075-93）
(2) Coal gas
Quantity of dry coal gas: 82206Nm3/h
Temperature of coal gas: ~ 43℃
Pressure of coal gas: ~ 0.017MPa
Content of impurities in dry coal gas:
Coarse Hydrogen Hydrogen
Name Tar Ammonia Naphthalene
benzene sulphide cyanide
Dry coal gas
~0.01 34.62 7.03 4.94 1.38 0.4
g/Nm3
(3) Residual ammonia (intermediate product)
Yield: 31660kg/h
Composition:
Name of impurity NH3 (fixed) NH3 (volatile) H2S HCN CO2
g/l ~1.5 ~2.0 ~0.2 ~0.05 ~1.5
3.5.3 Major characteristics of hazardous substances

Time Allowable
Maximum
weighted concentration
Ignition allowable
Molecular Explosion limit average for short-
Name point concentration
weight in air (V%) allowable time indirect
(℃)
concentration contact
(mg/m3)
(mg/m3) (mg/m3)
Upper Lower
Coal ___ CO:20 CO:30
~10.1 640~650 limit limit
gas
30 5.5 H2S:10 --- ---

The mixture of tar, ammonia, and coal gas from coking section enters into the gas-
liquid separators (V81501A, B) at about 81℃, where the tar and ammonia are
separated from the coal gas. The coarse coal gas enters into the transverse pipe initial
condensers (E81501A-E) in this section; the initial condenser comprises upper part
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and lower part; the upper part employs circulating water to exchange heat with coal
gas to cool the coal gas to 45℃ and the circulating water rises from 35℃ to 43℃.
Then, the coal gas enters into the lower part of the initial condenser, where the coal
gas exchanges heat with the refrigerating water and thereby is cooled to 22℃, while
the refrigerating water rises from 16℃ to 23℃. The cooled coal gas enters into the
electro tar precipitators (X81501A-C), to precipitate tar fog drops and naphthalene
from the coal gas; after electric tar precipitation, the coal gas enters into the
centrifugal blowers (C81501A-C) and is pressurized, and then sent to the
desulphurization section.
The coal gas condensate in the initial condenser flows from the upper section and the
lower section, through the water seal tanks (V81507A and B) of the initial condenser,
and then enters into the intermediate condensate tank (V81512) and condensate
circulation tank (V81513); the excessive condensate in the intermediate condensate
tank (V81512) overflows to the condensate circulation tank (V81513), pressurized by
the condensate circulation pumps (P81504A, B) in the upper section and the
condensate circulation pumps (P81505A, B) in the lower section, and then sent to the
upper and lower sections of the initial condensers for sprinkling; the excessive part is
pumped out by the condensate circulation pumps (P81505A, B) in the lower section to
the raw coal oven gas pipe before the initial condenser.
The tar and ammonia separated in the gas-liquid separators (V81501A, B) is sent with
the tar slag to the mechanical ammonia sedimentation tanks (V81502A-D). After
sedimentation, the liquid separates into three layers; the top layer is ammonia; the
middle layer is tar, and the bottom layer is tar slag. The separated ammonia is sent to
the ammonia circulation tanks (V81503A, B) and then pumped with the ammonia
circulation pumps (P81501A-C) to the coke oven to cool the raw coal oven gas. The
circulated ammonia is pumped periodically to the upper section of the initial
condenser and the top of the electro tar precipitator for sprinkling use. The residual
ammonia is pumped with the ammonia circulation pumps (P81501A-C) to the residual
ammonia tanks (V81504A, B), and then pumped with the residual ammonia pump
(P81502A, B) to the desulphurization section for ammonia distillation. The separated
tar is sent to the intermediate tar tanks (V81505A, B) for further dehydration; the
precipitated ammonia enters into the liquid waste catch tank (V81511); the tar is
pumped periodically with the tar pumps (P81503A, B) to the tar tanks (V81506A-C);
if the tar is for sale, it is pumped with the tar pumps (P81503C, D) to the loading
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platform for shipment. The separated tar slag is conveyed to the small trolleys with
bin, and then transported periodically to the coal yard for mixing for coking.
The steam condensate from the equipment is sent to the condensate tank (V81510),
where the condensate is pumped with the condensing water pumps (P81506A, B) to
the boiler house.
The coal gas condensate from the blower system is exhausted to the water seal tanks
(V81508A-C) for blowers, and then pumped by the pumps (P81507A-C) to the
mechanical ammonia sedimentation tank.
The tar collected by the electro tar precipitator is discharged to the water seal tanks
(V81509A-C) for electric tar precipitation; the circulated ammonia after flushing and
sedimentation also enters into the water seal tank for electric tar precipitation, where
the tar and circulated ammonia are pumped with the submerged pumps (P81509A-C)
in the water seal tank to the mechanical ammonia sedimentation tank.
Furthermore, in order to prevent the tail gas containing ammonium in the storage tanks
from escaping, the tail gas from the storage tanks is centrally sucked by the exhaust blowers
(C81502A, B) to the exhaust gas cleaning tower (T81501), where the gas is washed with
circulating water and the exhausted. To ensure the washing result, the circulating water is
replenished continuously from the circulating water system for chemical production in the
plant, and a part of the circulating water is pumped continuously with the exhaust gas
cleaning pumps (P81510A, B) for biochemical treatment.
The liquid wastes to be discharged in the section is collected into the liquid waste
catch tank (V81511), and then pumped with the submerged pumps (P81508A, B) in
the liquid waste catch tank to the mechanical ammonia sedimentation tank for
sedimentation again.
The major equipment in condensing/blowing and electric tar precipitation section
include transverse pipe initial condensers (E81501A-E), centrifugal blowers
(C81501A-C), mechanical ammonia sedimentation tanks (V81502A-D), and electro
tar precipitators (X81501A-C).
1) The initial condenser is a transverse pipe cooler, with 3828m2 cooling area; each
initial condenser comprises upper and lower sections; five initial condensers are used
in parallel; when one of them is swept or serviced, the rest four initial condensers can
still meet the design requirement.
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2) The coal gas blower is a centrifugal blower with hydraulic coupler for speed
control; there are three blowers, in two-working and one-standby configuration. The
inlet flow per blower is 1000m3/min, the pressure boosting is 30kPa; the motor for the
blower is an explosion-proof motor with 800kW power.
3) Mechanical ammonia sedimentation tank
Four mechanical ammonia sedimentation tanks with 300m3 effective volume each
will be used; the standing and separation time can be up to 40min.
4) Electro tar precipitator
Three honey-comb electro tar precipitators will be used, with 38000~46000m3/h total
capacity. The electro tar precipitator employs carbon steel shell and stainless steel
precipitation electrodes, with high-voltage constant flow power supply unit. The three
electro tar precipitators operate under normal conditions; in case one of them is serviced
or fails, the rest two precipitators can meet the process requirement essentially.
Hourly consumption Remark
Normal Max.
1 Refrigerating water 16℃ m3 750 830 Continuous
2 Circulating water 35℃ m3 5020 5510 Continuous
3 Steam 0.5MPa(gauge) t 6.6 In winter
6.6kV kW 2000 Common
4
Electricity 240V kW 10 Common
415V kW 280 Common

Staff per shift
Operation
No. Name Production Assistant Total Remark
shift
worker worker
Operation Five-shift
4 3 20
room system
Total 20
3.5.8 Discharge/emission amount of the three wastes

Amount Remark
No. Name Discharge point State
Normal Max.
Mechanical ammonia
1 Tar slag Solid 300t/a 330t/a Continuous
sedimentation tank
Continuous,
Waste Exhaust gas cleaning
2 Liquid 5m3/h 7m3/h ammonium content
water pump
<300 mg/l
Exhaust gas cleaning ～970
3 Tail gas Gas Continuous
tower m3/h
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3.6 Desulphurization and sulfur recovery

3.6.1 General
3.6.1.1 Installation scale and composition
The section is a coal gas cleaning installation for the coking equipment producing
1,500,000t/a dry coke (nominal capacity). It comprises three parts: desulphurization,
sulfur recovery, and residual ammonia distillation. This section is mainly designed to
desulfurize hydrogen sulphide in the coal gas to below 300mg/Nm3, recover sulfur,
and distill the residual ammonia from the condensing/blowing section.
3.6.1.2 Production method and process characteristics:
The section employs a wet oxidizing desulphurization process, with the ammonium in
coke oven gas as the alkali source and PDS + tannin extract as the composite catalyst;
the process can remove not only H2S but also most of HCN and some organic sulfur,
featured with high desulphurization efficiency, without the need for external alkali
source, low salt content in the circulating liquid, without the need for salt abstraction,
and less liquid waste; in addition, the liquid waste can be added to the coal for coking
again; therefore, the process has advantages including low investment, low operation
cost, stable operation, and favorable environmental protection effect. The rich liquid
for desulphurization is regenerated in the regenerative tower; therefore, the process is
featured with high flexibility and continuous and stable operation. The sulfur is
recovered with the centrifugal machine; therefore, a great deal of steam can be saved.
The residual ammonia is distilled to produce ammonia steam with ~10%
concentration, which is cooled into ammonia and then replenished to the
desulphurization system, to increase alkalinity of the system and improve
desulphurization result.
3.6.1.3 Discharge/emission and treatment of the three wastes:
(1) The tail gas from the regeneration tower is exhausted to atmosphere from the
exhaust stack on tower top at 50m altitude, conforming to the national standard "Code
for Emission of Odor Pollutants" of P. R. China.
(2) The liquid waste produced during desulphurization is mixed into the coal for coking.
(3) The liquid waste from the ammonia distillation system is sent for biochemical treatment.
3.6.1.4 Production regime:
production.
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3.6. 2 Specifications and quantities of raw materials and products

1. Raw materials:
（1） The composition and quantity of coal gas are the same as those of the coal gas
from the condensing/blowing and electric tar precipitation section.
（2） The composition and quantity of the residual ammonia are the same as those of
the residual ammonia from the condensing/blowing and electric tar precipitation section.
（3） Composite catalyst: PDS + tannin extract
Consumption: 10t/a
（4） Liquid alkali:
Consumption: 2400t/a NaOH（40%）
2. Products
（1） Coal gas:
Quantity: 82206Nm3/h（dry）
Temperature: ～27℃
Pressure: ～0.0130MPa（gauge）
Impurity contents（g/Nm3）：
Tar Ammonia Hydrogen sulphide HCN Benzene Naphthalene
Trace amount 7.03 0.3 0.28 34.6 0.4
（2） Sulfur
Purity: ≥80%
Quantity: 2560t/a
（3） Liquid waste from ammonia distillation:
Water quantity: 30.9m3/h
Pressure: ～0.45MPa（gauge）
3.6.3 Table of major properties of hazardous substances in the section
Time Allowable
Maximum weighted concentrati
allowable average on for
Molecular Melting Boiling Flash Ignition Explosion limit in
No. Name concentrati allowable short-time
weight point ℃ point ℃ point ℃ point ℃ air (V%)
on concentrati indirect
mg/m3 on contact
mg/m3 mg/m3
～
1 Coal gas 10.1 640~650 ～5.5 H2S：10 CO：20 CO：30
30.0
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Time Allowable
Maximum weighted concentrati
allowable average on for
Molecular Melting Boiling Flash Ignition Explosion limit in
No. Name concentrati allowable short-time
weight point ℃ point ℃ point ℃ point ℃ air (V%)
on concentrati indirect
mg/m3 on contact
mg/m3 mg/m3
2 Sulfur 32 112.8 444.6 363
3 Ammonia 17 -77.7 -33.5 651 27.4 15.7 20 30
3.6.4 Layout of equipment

The principle for layout of the section is: smooth process, compact structure, small
footprint, easy to service and favorable for production organization, and conform to
applicable fire protection, explosion protection, and safe and health codes and standards.
Some equipment is deployed in open air at EL-0.150 elevation; the rest equipment is
deployed in the workshop in three-layer frame structure, with elevations as: ±0.000
for F1, EL+4.500 for F2, and EL+10.500 for F3.
Equipment in workshop: F1: solution circulation pumps (P82501A, B, C); F2:
centrifugal machines (M82501A, B, C); F3: sulfur foam tanks (V2506A, B, C); roof:
condensers/coolers (E82505A, B).
Equipment deployed in open air: pre-cooling tower (T82501), desulphurization towers
(T82502A, B), regeneration towers (T82503A, B), ammonia distillation tower
(T82504), water seal tanks for desulphurization tower (V82501A, B), solution
circulation tanks (V82502A, B), emergency tanks (V82503A, B), catalyst storage tank
(V82504), lower tank (V82505), raw ammonia filters (V82507A, B), waste water tank
(V82508), alkali discharge tank (V82509), alkali storage tank (V82510), water seal
tank (V82511), liquid waste tank (V82512), sprinkling liquid water seal tank
(V82513), lower waste water tank (V82514), alkali convey pumps (P82504A, B),
ammonia distillation waste water pumps (P82505A, B), liquid waste pump (P82506),
sprinkling liquid pump (P82507), solution heat exchangers (E82501A, B, C),
ammonia heat exchangers (E82503A, B), and waste water cooler (E82504).
The floor are of the installation is 73×50m.
3.6.5 Description of process flow
The coal gas from the condensing/blowing section enters into the pre-cooling tower
(T82501) first and is cooled by the refrigerating water to ~25℃; then, the coal gas
enters into the lower part of desulphurization towers (T82502A, B) in sequence and
contact with the desulphurization liquid (lean liquid) sprinkled from the tower top, so
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that the H2S content in the coal gas is reduced to 0.3g/Nm3; after sprinkling, the coal
gas is sent to the electro tar precipitation section to remove fog drops, and then sent to
the ammonia scrubbing section.
There are the following reactions in the desulphurization tower:
NH3 + H2O = NH4OH (1)
H2S + NH4OH = NH4HS + H2O (2)
NH4OH + HCN = NH4CN + H2O (3)
NH4OH + CO2 = NH4HCO3 (4)
NH4HS + NH4HCO3 + (X-1)S= (NH4) 2Sx+ CO2+ H2O (5)
The desulphurization liquid absorbing H2S and HCN from the desulphurization
towers (T82502A, B) flows through the liquid seal tanks (V82501A, B) for
desulphurization tower to the solution circulation tanks (V82502A, B), where the
liquid is replenished with strong ammonia produced from residual ammonia
distillation and mixed with catalyst from the catalyst storage tank (V82504); then, the
desulphurization liquid is pumped with the solution circulation pumps (P82501A, B,
C) to the solution heat exchangers (E82501A, B, C) to exchange heat with the
refrigerating water, so that the solution temperature is reduced to ~29℃; next, the
solution is fed to the regeneration towers (T82503A, B) for regeneration. The lean
desulphurization liquid after regeneration enters into the top of desulphurization
towers (T82502A, B) for sprinkling for desulphurization.
There are the following reactions in the regeneration tower:
NH4HS + 1/2O2 = S↓+ NH4OH (1)
(NH4)2Sx + 1/2O2 = Sx↓+ 2NH4OH (2)
The sulfur foams produced in the regeneration tower is discharged through the
enlarged portion on upper part of the regeneration tower to the sulfur foam tanks
(V82506A, B, C), and then flow by gravity to the centrifugal machines (M82501A, B,
C) to produce sulfur (moisture content <10%), which is for sale; the clear liquid from
the centrifugal machines flows by gravity into the liquid waste tank (V82512) and
then pumped periodically with the liquid waste pump (P82506) to the coal storage
yard and mixed back to the coal for coking.
Preparation of catalyst: catalyst has to be replenished during the production process;
the catalyst is prepared once a day; the preparation container is the catalyst storage
tank (V82504). First, softened water is filled into the tank, and then composite
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catalyst is added to the water and agitated to dissolve; then, the solution falls in drops
into the solution circulation tank (V82502A, B).
The residual ammonia from condensing/blowing section enters into the raw ammonia
filters (V82507A, B) and is filtered to remove impurities (e.g., tar) in the residual
ammonia; then, the residual ammonia enters into the ammonia heat exchangers
(E82503A, B) to exchange heat with the waste water produced in ammonia distillation
from the bottom of the ammonia distillation tower (T82504), so that the residual
ammonia is heated to ~98℃, and then sent to the ammonia distillation tower. The
ammonia distillation tower employs an indirect reboiler heating process; partial
ammonia enters from tower bottom into the reboiler (E82506) and exchanges heat
with the low pressure steam indirectly; the ammonia and the vaporized stream/water
mixture enters into the ammonia distillation tower and contacts with the residual
ammonia from the distillation section in counter flow for distillation. The distilled
ammonia steam enters into the ammonia dephlegmator (E82502) and cooled with
35℃ circulating water; the condensate enters into the top of the ammonia distillation
tower for backflow. The uncondensed ammonia steam part (containing ~10% NH3)
enters into the condensate cooler (E82505) and is cooled with 16℃ refrigerating
water into strong ammonia, which is sent to the solution circulation tanks (V82502A,
B) as replenishment for desulphurization; the excessive ammonia steam is sent to the
ammonia decomposition section. The waste water produced in ammonia distillation
and discharged from tower bottom exchanges heat with the residual ammonia in the
ammonia heat exchangers (E82503A, B), and then is sent to the waste water tank
(V82508); next, it is pumped with ammonia distillation waste water pumps (P82505A,
B) into the waste water cooler (E82504) and cooled with 35℃ circulating water to
~40℃, and sent for biochemical treatment.
The tar slag discharged from the bottom of ammonia distillation tower enters into the
tar tank (X82501), and then removed manually.
The procured NaOH (40%) solution is unloaded by tank wagons into the alkali tank
(V82509), and pumped by the submerged pump (P82503) in the alkali tank to the
alkali storage tank (V82510); next, the solution is pumped with alkali convey pumps
(P82504A, B) into the residual ammonia pipe before the ammonia distillation tower.
3.6.6 Overview of major equipment
The major equipment is described as follows:
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1） Desulphurization tower:
The tower is a packed tower with DN6400, H~40940 porcelain packing; the tower
body is made of carbon steel; the interior of the tower is treated for corrosion
protection. Two desulphurization towers will be used in cascade.
2） Regeneration tower:
The tower is a screen plate tower with 4 DN4600, H~49400 screen plates; the tower
body is made of carbon steel; the interior of the tower is treated for corrosion
protection; two regeneration towers will be used in parallel.
3） Ammonia distillation tower:
The ammonia distillation tower is a vertical screen plate tower with DN1600,
H~24850 screen plates; the tower body is made of 304. It employs an indirect reboiler
heating process to reduce discharge amount of waste water.
3.6.7 Consumption of raw materials and power
1) Consumption of materials
Consumption Remark
Day Year
Composite Industrial Wherein, PDS: 1600Kg/a;
1 Kg 27.4 10000
catalyst product tannin extract: 8400Kg/a
NaOH
2 Liquid alkali Kg 6575 2400000
（40%）
2) Power consumption
Service Hourly
No. Name Specification Unit Remark
condition consumption
Refrigerating
1 16℃ Continuous m3 311 (average)
water
Circulating
2 35℃ Continuous m3 322 (average)
water
3650 (under
Compressed 0.6MPa
3 Continuous m3 standard condition)
air (gauge)
(average)
10.0
0.5MPa 8.3 (average in
4 Steam Continuous t (average in
(gauge) summer)
winter)
5 Fresh water Intermittent m3 1.2
6600V 630 Common
6 Electricity Continuous kW installed
415V 113.25 capacity
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3.6.8Table of staffing
Staff per shift
No Operatio
Name Productio Assistant Total Remark
. n shift
n worker worker
1 Desulphurization 2 3 10 Five-shift system
2 Sulfur recovery 2 3 10 Five-shift system
Ammonia
3 1 3 5 Five-shift system
distillation
4 Total 25
3.6.9 Discharge/emission amount of the three wastes

Amount Remark
No. Name of pollutant Discharge point State
Normal Max.
Intermittent, to
Liquid waste from Liquid waste
1 Liquid 1.5m3/h 1.8m3/h coal preparation
desulphurization pump
section
Liquid waste from Ammonia Continuous, to
2 ammonia distillation waste Liquid 30.9m3/h 34m3/h biochemical
distillation water pump treatment section
Exhaust
Tail gas from Regeneration ～3650 ～4200
3 Gas continuously (at
regeneration tower m3/h m3/h
50m altitude)
3.7 Ammonia scrubbing and distillation, ammonia decomposition

3.7.1 Ammonia scrubbing and distillation
3.7.1.1 General
3.7.1.1.1 Design scale and composition of installation
The section is the third procedure of coal gas cleaning installation for the coking
equipment producing 1,500,000t/a dry coke (nominal capacity). The main purpose is
to scrub ammonia in coal gas with ammonia distillation waste water and softened
water; after scrubbing, the coal gas contains 0.1g/Nm3 ammonia, and then is sent to
the gas holders. The rich ammonia after scrubbing is distilled into strong ammonia
steam, which is sent to the ammonia decomposition section; the waste water after
ammonia distillation is partially returned to the ammonia scrubbing tower for
ammonia distillation, and the rest waste water is sent for biochemical treatment.
3.7.1.1.2 Production method and process characteristics:
The section employs ammonia distillation waste water to scrub ammonia in
conjunction with softened water, to attain 100mg/Nm3 concentration; the rich
ammonia is distilled through an indirect reboiler distillation process, which reduces
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not only steam loss but also discharge amount of waste water, favorable for water
balance in the project. The process is simple but leading, with matured and reliable
technique and stable operation.
3.7.1.1.3 Major environmental protection measures
The ammonia distillation waste water in this section is sent directly for biochemical treatment;
the ammonia containing naphthalene is sent to the mechanical ammonia sedimentation tank
in the condensing/blowing section; therefore, no waste water is discharged.
3.7.1.1.4 Production regime
365 days per year, five shifts prepared, with three shifts working for continuous production.
3.7.1.2 Quantities of raw materials and products
3.7.1.2.1 Raw materials
（1）The composition and quantity of coal gas are the same as those of the coal gas
from the desulphurization section.
（2）Consumption of softened water: 25 t/h
3.7.1.2.2 Products
（1） Coal gas:
Flow: 82206 Nm3/h (dry)
Temperature: ～30℃ Pressure: ～0.006MPa
Impurity contents（g/Nm3）：
Ammonia Hydrogen sulphide HCN Benzene Naphthalene tar
0.1 0.2 0.28 34.62 0.4 Trace content
（2）Yield of strong ammonia steam: 2840~3156 kg/h Concentration: 18%~20%
Temperature: 90℃ Pressure: ～0.012MPa
（3）Ammonia distillation waste water: 35 m3/h
Temperature: ～40℃ Pressure: ～0.4MPa
Ammonia content in ammonia distillation waste water: ≤ 200 mg/l
3.7.1.3 Table of major properties of hazardous substances in the section
Explosion limit Maximum
in air (V%) allowable
Melting Boiling concentration
Molecular Ignition
No. Name point point specified in
weight point ℃ Upper Lower
℃ ℃ national health
limit limit
standard
(mg/m3)
CO:30
1 Coal gas 10.1 640~650 30 5.5
H2S:10
2 Ammonia 17 -77.7 -33.5 630 27 15.8 30
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3.7.1.4 Description of process flow

The coal gas from the desulphurization section enters into the ammonia
scrubbing tower 1# (T816a01) first, and contact with the circulating
ammonia sprinkled from tower top in counter flow, so that the ammonia in
the coal gas is scrubbed; then, the coal gas enters into ammonia scrubbing
tower 2# (T816a02) and is scrubbed again with ammonia distillation waste
water; next, the coal gas enters into the cleaning section, where the
ammonia in the coal gas is further removed; finally, the coal gas is treated
in the fog precipitation section to remove fog drops, and then sent to the
gas holders.
The scrubbing water in ammonia scrubbing section in ammonia scrubbing
tower 1# (T816a01) is circulated ammonia. The circulated ammonia is
pumped from the ammonia circulation tank (V816a01A) by the ammonia
circulation pumps (P816a01AB). Some ammonia is pumped to the raw
ammonia tank (V816a02) as the raw material in ammonia distillation; the
circulated ammonia in ammonia scrubbing tower 1# (T816a01) is
replenished from ammonia scrubbing tower 2# (T816a02). The circulated
ammonia flows from the bottom of the ammonia scrubbing tower 1#
(T816a01) to the ammonia circulation tank (V816a01A) for circulation.
The circulated ammonia in ammonia scrubbing tower 2# (T816a02) comes
from the ammonia circulation tank (V816a01B); the circulated ammonia is
pumped by the ammonia circulation pumps (P816a01BC); wherein, some
ammonia enters into the ammonia scrubbing section in middle of the
ammonia scrubbing tower 2#, and is used with the softened water and
ammonia distillation waste water from the cleaning section at tower top to
sprinkle and scrub the coal gas; the rest is sent to ammonia scrubbing
tower 1# (T816a01). The ammonia scrubbing water flows from the bottom
of the ammonia scrubbing tower 2# (T816a02) into the ammonia
circulation tank (V816a01B) for circulation. The circulated ammonia is
replenished with the ammonia distillation waste water and softened water
after ammonia distillation. The softened water from boiler house is cooled
with refrigerating water in the softened water cooler if the temperature of
softened water is ≥25 ℃ ; then, the softened water is used as the cleaning
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water in the cleaning section, to ensure the ammonia content in coal gas is
up to the standard.
The raw ammonia is pressurized by the raw ammonia pumps (P816a02AB)
and enters into the ammonia/waste water heat exchangers (E816a03AB) to
exchange heat with the waste water; then, the raw ammonia enters into the
ammonia heater (E816a06) and is heated by steam to the boiling point;
next, the raw ammonia enters into the ammonia distillation towers
(T816a03AB); during normal production, the waste water is heated with
the reboilers (E816a02AB) for ammonia distillation; in case the reboilers
fail or are under service, the steam is used directly for ammonia distillation;
the steam in the top part of the ammonia distillation tower is cooled with
circulating water in the ammonia dephlegmators (E816a01AB); then, the
cooled liquid is fed into the ammonia distillation towers (T816a03AB)
directly; the uncondensed strong ammonia steam (containing 18%~20%
ammonium) is sent to the ammonia decomposition section. The ammonia
distillation waste water flows from the ammonia distillation tower into the
ammonia/waste water heat exchangers (E816a03AB) for heat exchange,
and then is sent to the waste water tank, and pumped with the ammonia
distillation waste water pumps (P816a03A, B) into the primary ammonia
distillation waste water coolers (E816a04AB), wherein the waste water is
cooled by circulating water to ~40 ℃ ; then, some waste water is sent to the
secondary ammonia distillation waste water cooler (E816a05) and is cooled
with refrigerating water to ~25 ℃ , and then sent to the ammonia cle aning
section in upper part of the ammonia scrubbing tower 2# (T816a02) for
ammonia cleaning; the rest waste water is sent for biochemical treatment.
The ammonia containing naphthalene overflowing from the ammonia
circulation tanks (V816a01AB) flows into the ammonia tank (V816a04) for
storage; when the ammonia in that tank reaches to a certain level, it is
pumped with the ammonia convey pump (P816a04) to the raw coal oven
gas pipe for coal gas sprinkling.
3.7.1.5 Layout of installation
The principle for layout of the section is: smooth process, compact layout, small
footprint, meet the requirements for production and service, and conform to applicable
fire protection and explosion protection codes and standards.
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The section is of 39mX 60m total floor area in single-layer structure; multi-layer
platforms are provided on ammonia scrubbing tower 1# (T816a01), ammonia
scrubbing tower 2# (T816a02), and ammonia distillation towers (T816a03AB).
Equipment deployed outdoor: ammonia scrubbing tower 1# (T816a01), ammonia
scrubbing tower 2# (T816a02), ammonia distillation towers (T816a03AB), ammonia
circulation tanks (V816a01AB), raw ammonia tank (V816a02), lower tank (V816a03),
naphthalene-rich ammonia tank (V816a04), waste water tank (V816a05), water seal
tank (V816a06), ammonium dephlegmators (E816a01AB), reboiler (E816a02),
ammonia/waste water heat exchangers (E816a03AB), primary ammonia distillation
waste water coolers (E816a04AB), secondary ammonia distillation waste water cooler
(E816a05), ammonia heater (E816a06), softened water cooler (E816a07), and
submerged pump (P816a05) in lower tank. Equipment deployed in pump room:
ammonia circulation pumps (P816a01ABC), raw ammonia pumps (P816a02AB),
ammonia distillation waste water pumps (P816a03AB), and naphthalene-rich
ammonia pump (P816a04). The pump room is in semi-enclosed structure, with 1m
high walls and a roof. The installation is also provided with an operation room and a
power distribution room.
3.7.1.6 Selection of major equipment
The major equipment in this section includes ammonia scrubbing towers (T816a01,
T816a02) and ammonia distillation towers (T816a03AB).
1) Ammonia scrubbing tower
Ammonia scrubbing towers 1# and 2# are packed towers; ammonia scrubbing tower
1# (ф5400H~35360mm) is packed with 125Y corrugated stainless steel orifice plates
in 3X5m height; ammonia scrubbing tower 2# (ф5400/ф4400H~39056mm) is packed
with 125Y corrugated stainless steel orifice plates in 2X5m+4m height and 250Y
corrugated stainless steel orifice plates in 1m height.
2) Ammonia distillation tower
There will be two ammonia distillation towers in “one working and one standby”
configuration; the ammonia distillation towers will be vertical screen plate towers
with high ammonia distillation efficiency; they will employ a reboiler heating process
to reduce discharge amount of waste water.
3.7.1.7 Power consumption
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Hourly consumption
No. Name Specification Service condition Unit
Average Max.
Circulating
1 35℃ Continuous m3 938 1030
water
Refrigerating
2 16℃ Continuous m3 160 180
water
3 Softened water ~40℃ Continuous m3 23 25
0.5MPa
4 Steam Continuous t 17.5 21
（G）
5 Electricity 415V Common kW 361
3.7.1.8 Table of staffing

Staff per shift
Operation
No. Name Production Total Remark
shift
worker
Ammonia scrubbing and Five-shift
1 2 3 10
distillation system
3.7.2 Ammonia decomposition

3.7.2.1 General
3.7.2.1.1 Installation scale and composition
The installation is one of the associated installations for the 1,500,000t/a coking plant.
The main purpose of the section is to decompose the ammonia from ammonia
scrubbing and distillation and desulphurization sections into N2 and H2 at high
temperature with catalyst, and produce steam as a byproduct with residual heat. The
mixture of hot decomposed gas and the burnt exhaust gas is cooled and then sent to
the raw coal oven gas pipe before the gas-liquid separator in the condensing/blowing
section; the steam byproduct is connected to the steam pipe network in the plant.
3.7.2.1.2. Production method and process characteristics
The ammonia steam is sent into the ammonia decomposition oven and is decomposed
into N2 and H2 with the nickel catalyst bed in the decomposition oven at high
temperature. The temperature in the oven is maintained by burning coal gas.
The hot tail gas about 1100℃ produced in the decomposition oven is recovered with
the waste heat boiler, with steam at 0.5MPa pressure (gauge) as the byproduct. The
tail gas is further cooled in the boiler water pre-heater and the decomposed gas cooler,
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and finally sent to the raw coal oven gas pipe before the gas-liquid separator in the
condensing/blowing section.
The principle for layout of the installation is: smooth process, compact structure,
small footprint, easy to service and favorable for production organization, and
conform to applicable fire protection, explosion protection, and safe and health codes
and standards.
3.7.2.1.3. Discharge/emission and treatment of the three wastes
The wastes from the installation mainly comprise waste water and waste slag. The
waste water is from the boiler and is discharged at a 250kg/h rate to the waste water
pipeline for central treatment. The waste slag is inactive catalyst (~12.3m3/3 years),
and is recovered to the catalyst plant.
3.7.2.1.4. Production regime
production.
3.7.2.2 Specifications and quantities of raw materials and products
a Raw materials
1）Coal gas: in the same composition as the coal gas from the ammonia scrubbing
section, volume: 1000Nm3/h.
2）Ammonia: volume: 4192kg/h, containing 671.6kg/h NH3, 646.4kg/h CO2, and
2944kg/h H2O.
3）Softened water: 5000kg/h, in the same specification as the boiler water.
4）Catalyst: 12.3m3/3 years
Major performance indexes:
① Appearance and dimensions: dark gray cylinder, φ18×19
② Stacking density: 1.5±0.1kg/l
③ Compression strength: ≥1000N/piece
④ Raw material of bearer: MgO, content ≥83%
⑤ Fire resistance: ≥1700℃
⑥ Content of active component Ni: ≥6.5%
⑦ Ammonia decomposition ratio: ≥99%
b Products
1) Steam byproduct: yield: 5000kg/h
Saturated steam at 0.5 MPa pressure (gauge)
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2) Decomposed gas: flow: 10555Nm3/h

Wherein: N2 34.2%, H2O 45.2%, CO2 6.4%, H2 14.2%
3.7.2.3 Table of major properties of hazardous substances in the section
Explosion Maximum
limit in air allowable
Boiling Flash
Molecular Melting Ignition (V%) concentration
No. Name point point Remark
weight point ℃ point ℃ specified in
℃ ℃ Upper Lower
national health
limit limit
standard
640～ CO：30mg/m3
1 Coal gas ～10.1 ～30 ～5.5
650 H2S：10mg/m3
2 Ammonia 17 630 27 15.5 30mg/m3
3.7.2.4 Layout of installation

The principle for layout of the installation is: smooth process, compact structure,
small footprint, easy to service and favorable for production organization, and
conform to applicable fire protection, explosion protection, and safe and health codes
and standards.
The installation is in three-layer frame structure, with elevations as: F1: EL-0.150; F2:
EL+5.000; F3: EL+10.000.
Equipment on F1: coal gas blowers (C816b01A, B), air blowers (C816b02A, B), and
boiler water pumps (P816b01A, B)
Equipment on F2: air pre-heater (E816b01), boiler water pre-heater (E816b02), and
decomposed gas cooler (E816b03).
Equipment on F3: deoxidation tank (V816b01), which can effectively prevent
cavitation in boiler water pumps.
Ammonia decomposition ovens (F816b01A, B) and waste heat boilers (F816b02A, B)
are deployed along the frame, to facilitate installation and service.
Floor area: 20×20.5m.
3.7.2.5 Description of system process flow
The ammonia steam from ammonia scrubbing and distillation section and
desulphurization section is metered and mixed, and then sent into the ammonia
decomposition ovens (F816b01A, B) in “one working and one standby” configuration,
and decomposed into N2 and H2 on the nickel catalyst bed at high temperature.
Phone: 0351-4171146 4157596
The temperature in the oven is maintained by burning coal gas. The coal gas from the
external pipe is pressurized by the coal gas blowers (C816b01A, B) and sent to the
combustor on the top of the decompose oven; the air is pressurized by the air blowers
(C816b02A, B), pre-heated to 130℃ in the air pre-heater (E816b01) with steam, and
sent to the combustor on the top of the decompose oven, wherein the air is mixed with
the coal gas and burns. Both the coal gas blowers and the air blowers are in “one
working and one standby” configuration.
The hot tail gas about 1100℃ produced in the decomposition oven is cooled to
~300℃ in the waste heat boilers (F816b02A, B) in “one working and one standby”
configuration, to produce steam at 0.5MPa pressure (gauge); then, the tail gas is
cooled by the boiler water pre-heater (E816b02) and the decomposed gas cooler
(E816b03) to ~80℃, and sent to the raw coal oven gas pipe before the gas-liquid
separator in the condensing/blowing section.
The boiler water is deoxidized water; the softened water from the boiler house enters
into the deoxidation tank (V816b01) and blown with steam and deoxidized to about
105℃; then, the softened water is heated in the boiler water pre-heater (E816b02) to
~130℃, and pumped with the boiler water pump (P816b01A, B) to the steam tank of
waste heat boilers (F816b02A, B).
3.7.2.6 Selection of major equipment
1）Ammonia decomposition ovens (F816b01A, B) (2 sets)
The equipment is φ3600×9660, filled with nickel catalyst; the oven body is made of
carbon steel, lined with fire resisting material; the ovens are in "one working and one
standby" configuration.
2）Waste heat boilers (with steam tank) (F816b02A, B) (2 sets)
The equipment is φ1600×~9400 (φ1800×~5500); the oven body is made of carbon
steel, lined with fire resisting material; the boilers are in "one working and one
standby" configuration.
3.7.2.7 Power consumption
Service Hourly consumption
condition Average Max.
1 Softened water 30℃ Continuous m3/h 6 7.5
2 Circulating water 35℃ Continuous m3/h 55 66
3 Coal gas 30℃ Continuous Nm3/h 1000
4 Water steam 0.5MPa（a） Continuous t/h 1.5 1.7
90 (common installed
5 Electricity 380V Continuous KW
capacity)
Phone: 0351-4171146 4157596
3.7.2.8 Table of staffing

Staff per shift
Operation
No. Name Production Assistant Total Remark
shift
worker worker
Ammonia Five-shift
1 2 3 10
decomposition system
3.7.2.9 Discharge/emission of the three wastes

No. Name Discharge point State Amount Remark
Ammonia decomposition 12.3m3/3
1 Catalyst Solid Recovered to plant
oven years
Boiler
2 waste Waste heat boiler Liquid 250kg/h To pipeline
water
3.8 Gas holder pressurization station

3.8.1 Overview and characteristics of the installation
The gas holder in this section is a 50000m3 dry gas holder for coal gas buffering and
storage; the coal gas is pressurized with three Roots blowers (two working, one standby).
The principle for layout of the section is: ensure safe operation and save floor area,
and follow relevant regulations in "Code for Fire Protection Design of Buildings"
(GBJ16-87).
The gas holder pressurization station is flammable and explosive; therefore, special
care shall be taken to fire safety. The gas holder is provided with lightning earth, with
earth resistance <10Ω.
The main purpose of the section is to settle the conflict between continuous and stable
production of coal gas and uneven coal gas usage; the gas stored in the gas holder can
also be used for short-time emergency use in case of failure.
3.8.2 Description of system process flow
The clean coal gas from the ammonia scrubbing and distillation section enters into the
dry gas holder (V86001), is pressurized to 0.011MPa by the Roots blowers
(C86001ABC), and then sent to the steel works through the gas pipe network.
1. Gas holder: 50,000m3 dry gas holder; the parameters are:
Pressure: 600mmH2O
Effective volume: 49500m3
Diameter: 37.715m
Height: 61.862m
Phone: 0351-4171146 4157596
2. Roots blowers: 3, two working, one standby, model ARH-700, motor power: 185KW.
3. Service equipment
As required for service, a SSQ-20 manual twin-beam hoist crane with 20t hoisting
capacity and 11m span is chosen in the pressurization workshop.
3.8.4 Power (water, electricity, steam) consumption norms and actual consumption
Consumption
No. Name Specification Service condition Unit
Normal Max.
1 Circulating water 0.4MPa Continuous T/h 2 3
2 Fresh water 0.3MPa Intermittent T/h 2 3
3 Electricity 415V Continuous KW 387 578
3.8.5 Staffing
Coal gas supply must be available uninterruptedly; therefore, the working day per
year for this section is 365 days, in three-shift system, 8h per shift.
Staff per shift
Operation
No. Name Air Pressurization Total Remark
shift
holder station
Gas holder Five shifts
1 1 1 3 10
pressurization station prepared
Phone: 0351-4171146 4157596

3.1 Coal Preparation 3.1.1 Design Job and Adopted Standards and Specifications

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3.1 Coal Preparation 3.1.1 Design Job and Adopted Standards and Specifications

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1,500,000t/a Coking Plant for JSW Steel Works, India·Preliminary Design processing

3.1 Coal preparation

3.1.3.2 Convey, storage and storage capacity of raw coal

moisture shall account for about 11%.

3.1.5 Selection of major production equipment

3.1.8 Power consumption

Staff per shift Persons

Staff per shift Persons

3.2 Coking and coke quenching

Total height of charring chamber: 4300mm

3.2.1.4 Specifications and quantities of raw materials and products

Consumption of washed fine coal (dry): 2009945t/a

80~25mm: 1386983t/a (Wet, moisture content =4%)

25~6.3 mm: 58253 t/a (Wet, moisture content =10%)

<6.3mm: 35703 t/a(Excluding dry coke breeze in powder-coke sedimentation tank:

No. Name Quantity Remark

Fresh water Continuous m3/hr 27 28

3.2.1.8 Table of staffing:

3.2.1.9 Flue gas emission:

Emission Emission Emission Composition of exhaust gas

Flue-gas temperature: ≤200℃

Flue gas valve at

Bag-type pulse dust

Dust convey Storage

Sound damper Humidification

3.3.4 Power consumption

3.3.5 Table of staffing

3.4. Coke screening/storaging

35703 98 4.08 Belt conveyor or trunk

3.4.3.3 Coke convey, storage, and storage capacity

(granularity>25mm) is unloaded by coke belt conveyor 8# (A83508A) into 7 coke

Staff per shift Persons

Staff per shift Persons

3.5 Condensing/blowing and electric tar precipitation

Component H2 CH4 CO CmHn CO2 N2 O2 Heat value (low) KJ/Nm3

% 56~60 23~27 5~8 2~4 1.5~3 3~7 0.3~0.8 17000~18000

Content of impurities in dry coal gas

Coarse Hydrogen Hydrogen

3.5.3 Major characteristics of hazardous substances

3.5.4 Overview of process flow

3.5.7 Table of staffing

3.5.8 Discharge/emission amount of the three wastes

3.6 Desulphurization and sulfur recovery

3.6. 2 Specifications and quantities of raw materials and products

Trace amount 7.03 0.3 0.28 34.6 0.4

3.6.4 Layout of equipment

3.6.9 Discharge/emission amount of the three wastes

3.7 Ammonia scrubbing and distillation, ammonia decomposition

3.7.1.4 Description of process flow

3 Softened water ~40℃ Continuous m3 23 25

5 Electricity 415V Common kW 361

3.7.1.8 Table of staffing

3.7.2 Ammonia decomposition

2) Decomposed gas: flow: 10555Nm3/h

2 Ammonia 17 630 27 15.5 30mg/m3

3.7.2.4 Layout of installation

3.7.2.8 Table of staffing

3.7.2.9 Discharge/emission of the three wastes

3.8 Gas holder pressurization station

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