HEATING REGIME

HEATING BY EITHER CO GAS OR MIXED

GAS
.

AIR REQUIRED FOR COMBUSTION ENTERS

AND WASTE GASES GENERATED ARE
DISPOSED, THRU WHBOX by the DRAFT of
CHIMNEY
AIR QUANTITY IS REGULATED WITH THE
HELP OF FINGER PLATES, FLAP
OPENING,LOWER BANANA,DRAFT DAMPER
AND CHIMNEY GATES.

CO GAS FROM NETWORK

PREHEATED TO 65 DEG C AND
SUPPLIED TO ALL 68 RISERS EACH ON P/S
& P/S
EACH GAS RISER IS EQUIPPED WITH
ISOLATION COCK
& REVERSING COCK

WHAT IS REVERSAL
ONCE FOR EVERY 20 MTS HEATING
CHANGES FROM GREEN TO RED
(OR) RED TO GREEN TAKES PLACE
WHICH IS CALLED REVERSAL
THIS IS TO ATTAIN UNIFORM
HEATING.

GREEN REVERSAL
ODD FLUES OF ODD H/W
&
EVEN FLUES OF EVEN H/W

HEATING SYSTEM IN GREEN REVERSAL

OVEN
150

E O

H/W150

REG REG
149 149

H/W

H/W151

E E

HH

OVEN
151

H/W152

O E

REG REG
150 150

REG REG
151 151

WHB
150

WHB
151

REG REG
152 152

CONCRETE FLUE GAS TUNNEL

RED REVERSAL
EVEN FLUES ODD H/W
&
ODD FLUES OF EVEN H/W

F
L
A
S
H

Y
10

C = X-(Y+10) = 159 165 mm =

= 156 160 mm =

P
L
A
T
E
T in case of F Series
T in case of D - Series

HEATING SYSTEM IN RED REVERSAL

OVEN
150

E O

H/W150

REG REG
149 149

H/W

H/W151

E E

HH

OVEN
151

H/W152

O E

REG REG
150 150

REG REG
151 151

WHB
150

WHB
151

REG REG
152 152

CONCRETE FLUE GAS TUNNEL

Flue connection in adjacent h/ws in one

reversal(h/w 150 , 151)

H/w 150

H/w 151

Flue connection in G/R reversal

150

150

PAUSE
SMALL INTERMISSION PROVIDED AT
CHANGEOVER FROM ONE HEATING TO
ANOTHER
FACILITATES EVACUATION OF
RESIDUAL GASES
30 SECONDS IN BAT1&2
0 SEC. IN BAT3

REVERSING WINCH
Reversing winch mechanism is meant for
reversing the heating system from RED heating to
GREEN heating and vice versa to attain uniform
heating of the battery
This consists of a motor and gear box.

Drives provided are electrical, and Pneumatic

Manual Provision is also given in case of total
power failure
Minimum air pressure required forpneaumatic
drive is 4 kg/sq.cm
All the WHBoxes and heating gas reversing
cocks are connected to this system.
Condition of the ropes and pulleys is to be
ensured.

INTERLOCKS OF REV.
WINCH
To ensure the safety of the system, some
interlocks are provided such that
Rev.winch goes to pause position (along with hooter)
when reg .draft in both the streams goes below
5mmwc
When h/gas pressure goes below 50mmwc
When air rope snaps
Rev. winch remains in the same position (but hooter
comes) when gas rope snaps

AFTER REV COCK,

SYSTEM IS BIFURCATED
INTO TWO :
RED & GREEN

EACH SUB SYSTEM AFTER REV.COCK IS

PROVIDED WITH A CYLINDER ADJUSTED
IN ORIFICE

THEN EACH SUB SYSTEM IS

CONNECTED TO A MANIFOLD

THE MANIFOLD IS CONNECTED TO

THE FLUES BY RUBBER HOSE.

OTHER END OF THE HOSE IS

CONNECTED TO WASHER HOLDER
AND RISER UNIT.

FOR EACH FLUE, WASHER OF

PRESCRIBED SIZE IS PROVIDED IN THE
WASHER HOLDER
GAS FLOW FOR ENTIRE HALF SECTION
OF H/W IS REGULATED BY CYLINDER.
GAS FLOW FOR EACH FLUE IS
REGULATED BY WASHER

AIR ENTERS THRU WHB , BUS

FLUE AND REGENERATOR
CO GAS AFTER RISER UNIT
PASSES THRU CERAMIC
RISER
AIR AND GAS UNDERGOES
COMBUSTION

REGENERATOR
THE HEAT IN THE WASTE GAS
IS ABSORBED by CHECKERS
DURING DOWN- STREAM AND
GIVEN AWAY to AIR DURING UPSTREAM

LOWER BANANA SCHEME P/S(mm)

1 2 3

4 5 6 7 8 9 10 11 12

13 14 15 16

00

35

35

35

35

35

35

35

00

34

32

30

28

26

24

22

00

34

32

30

28

26

24

22

00

35

35

35

35

35

35

35

LOWER BANANA SCHEME C/S(mm)

17 18 19 20 21 22 23 24 25 26 27

28

29 30 31 32

35

35

35

35

35

35

35

00

34

34

34

34

34

34

34

00

34

34

34

34

34

34

34

00

35

35

35

35

35

35

35

00

MEANS FOR FLAME

LENGTH ADJUSTMENT
UPPER BANANA
DEFLECTOR
RECIRCULATION WINDOW
RESERVE BRICKS.

CONTROL VERTICAL TEMP(6/28

OR 9/23
MEASUREMENT TO BE STARTED 5 MTS
AFTER REVERSAL
MESUREMENT TO BE STARTED FROM
101 C/S UP TO 101 P/S IN A U FASHION

*MEASUREMENT

TO BE
DONE IN NON BURNING
FLUE
*MEASUREMENT TO BE
COMPLETED BY REVERSAL
END.

CORRECTION FACTOR for

CVT
VALID FOR A PARTICULAR CP
TO COMPENSATE THE DROP IN TEMP
WITH TIME OF MEASUREMEN
BROADLY CLASSIFIED INTO 4 TEMP
ZONES
STARTS FROM C/S 101 AND ENDS WITH
P/S 101

 TEMP DIFF. BETN P/S AND

C/S CONTROL VERTICALS IS 35-45
DEG C(1.5 DEG C BETN. ADJACENT
FLUES)
DIFF. BETN. EVT&FLUE TEMP NEXT
TO EV NOT TO EXCEED 30 DEG C
DIFF . BETN. EVT & CVT NOT TO
EXCEED 100 DEG C.

CROSS WALL TEMP (CWT)

(1-32 FLUES)
TAKE 10/11 H/WS AS ONE SET
MEASURE IN TOTAL 4 REVERSALS
(5 H/WS IN 2REV
START MEASUREMENT FROM C/S
AND MOVE IN AZIG-ZAG WAY

WASHER SCHEME
( H/WALLS-102 TO 167 / H/WALLS 101 ,168)
1

10 11 12 13 14 15 16

21.9

16.9

16.4

16.2

16.1

16.1

16.1

16.1

16.2

16.2

16.2

16.2

16.3

16.3

16.4

16.4

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
16.5

16.5

16.6

16.6

16.7

16.7

16.7

16.7

16.8

16.8

16.8

10 11 12 13 14 15 16

21.4

17.1

14

13.5

13.4

13.4

13.4

13.5

13.6

13.6

13.6

16.9

13.6

16.9

13.7

17.3

13.7

18.8

13.7

22.3

13.7

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
13.7

13.7

13.8

13.8

13.8

13.8

13.8

13.8

13.9

13.9

13.9

13.9

14.7

15.5

19

22.6

END VERTICAL TEMP

(1&32 VERTICALS)
MAX EVT- 1250/1300 DEG C

EVT AT EXTENDED CP 1140/1180

DEG C

COEFFICIENT OF BATTERY(KB)
(indicates temp uniformity)
KB= (66-0p) + (66-0k)
2*66

= 1.0( ideal)

66 = no of h/ws considered
0p= no of h/ws deviated from p/s day average temp by
more than + 20 DEG.C
0k = no of h/ws considered from c/s day average temp by
more than +20 deg C

KC= no of avgs deviated by

more than 7 deg c from the
respective target
total no of avgs in the day(6)
Kc =6/6=1(ideal)

COEFF OF EXCESS AIR

(theoretical 1.3)
ALPHA = 1 + K (O2-0.5 CO)
CO2+CO
K for co gas 0.42
K for BF gas 2.59

FREE SPACE TEMP

This is the temp measured in the free
space of the oven at 2/3 of coking period
thru p/s and c/s charging holes with the
help of the thermocouples.
This temp should be in the range of 780800 deg C.

Higher FST results in cracking of

aromatics and unwanted graphite
deposition which affects tar fluidity and
also gas track jamming.
lower FST results in non readiness of
coke mass

CHARGE LEVEL
MEASUREMENT
Coal level to be measured in the oven
immediately after charging with the help
of a tool provided exclusively for it.
The free space should be around 250-300
mm.
To be measured thru all three charging
holes.

SHRINKAGE
MEASUREMENT
It is measured in the oven thru all charging holes 15
mts before the end of coking period.
The shrinkage is 250-300 mm
% shrinkage = shrinkage in mm * 100
6700 mm(coal level after charging)
DESIRABLE VALUE= 5%(approx.)
less shrinkage results in more wall pressure
more shrinkage is the result of more volatile matter

DRAFT
Suction created by the chimney
Amount of suction created depends on chimney height,
waste gas temp, climatic conditions etc.
Draft facilitates inletting of air and out letting of waste
gases into atmosphere.
Draft is mantained with the help of chimney gates in
auto mode.

Indication for good draft is slightly positive pr.at

vertical top, strong flame and alpha @1.3-1.4.
Draft should be uniform throught the battery for
better temp uniformity
.Uniformity of draft is to be attained by regulating
draft dampers at waste heat boxes atleast
twice/month
Draft regulation is done with the help of
INCLINTED MANOMETER.

VERTICAL TOP PRESSURE

VTP to be mantained as slightly positive so as to prevent
infiltration of air into the system
CROSS LEAKAGES
These are mainly raw gases from oven to heating system
cross leakages are the indication of bad refractory
condition
Cross leakages always to be kept at check
High waste gas temp is the indication of cross leakages

OVEN SOLE PRESSURE

GCM Pr. = Sole pr. + 1.2 h
h = height betn. Oven sole and
GCM( 10 mtrs in our case)
Desired sole pressure= 0.51.0mm

COKE MASS TEMP

COKE MASS TEMP MEASURED THRU ALL
CHARGING HOLES AT 4 LEVELS ALONG
OVEN HEIGHT
MEASURED WITH THERMOCOUPLES
INSERTED AT 7-8 HRS OF CP
DESIRABLE COKE MASS TEMP.AT 30 MTS
BEFORE THE END OF CP- 1050 deg C

GENERAL PROBLEMS

BUFFING:
CHIMNEY CROSS LEAK:
CHIMNEY SMOKING WHITE
CHIMNEY PUMPS NOT WORKING
WASTE GAS TEMP HIGH ETC

***REASONS , INDICATIONS AND

REMEDIES