The light of heaven is crunched deep in to the interior of the mother Earth.

The
dark fire sources buried millions of years back at various depths as fossils have
paved way for progressive industrialization. These are nothing but the precious coal
reserves. Coking coal from various mines of multitude of graves arrive in railway
wagon at the coal preparation plant 2, there the wagons are tippled to unload coal on
subterranean bunkers. From here coal finds it way for the coke making to the number
of material handling processes. Different grades of coal are piled up separately in
the coal stock yard under the 2.5 Mt storage. Coal is handled through COAL
HANDLING PLANT 1, here the gantry crane is used for receiving and reclaiming
various grades of average coal from CPP2, from here coal is subsequently conveyed
to massive storage columns known as silos. Under the 4mt stage coal handling has
been augmented through incorporation of stacker cum reclaimer in CPP2. Here the
averaging of coal is done for minimizing the fluctuation and deviation in the quality
parameters due to inconsistency in the incoming coal quality, coal thus averaged is
sent to silos, these vertical storage columns have been classified to store prime
medium and imported coals separately. Depending upon the blend composition
required to produce blast furnace coke of definite quality parameters various grades
of coal are mixed to set proportions with the help of automatic proportioning devices
APDs, these APDs located at the bottom of the silos to automatically regulate the
coal discharge to form a predetermined coal blend, the coal blend is still not ready
for carbonization, the mixture is heterogeneous in terms of particle size, reactive
and invert components and thus will produce coke of weaker strength, coal need to
be crushed to the size of 3.2 mm to maximize homogeneity of various coal particles
and enhance coke strength in turn. Hammer crusher grinds the coal blend to the
required size the crushed coal blend is now ready for dispatch to coke over batteries
through a series of belt conveyors. The coal bled reaches the coal towers. The
charging car draws coal from each tower and drops subsequently in to the hot empty
ovens maintained at a temperature of 1050 to 1100 degree Celsius, at the end of coal
carbonisation the hot coke is pushed out of the hot ovens by the pusher car on to the
empty wagon of quenching car through a guide way provided by the coke guide car.
the hot coke is quenched with help of water at the quenching tower, subsequent
cooling coke is dumped on to the inclined ramp called coke wharf, from here coke
starts it journey towards the destination that is blast furnace, coal thus undergo
destructive distillation to give off volatile matter in the form of hydrocarbon rich
crude cokeoven gas and solid remnant in the form of coke. In route to the customer
end, coke is segregated at the coke handling plant using various equipment like role
gizzlers and vibrating squeeze. The gross coke is dividend in to bf coke of 25 to
80mm size, nut coke of 20 to 25 mm size and coke breeze of -20mm size. Nut coke
and coke breeze are used for layer charging in bfs and sinter making respectively.
At the bfs coke is loaded on to the skip and used for iron ore reduction along with
other burden materials. The raw coke oven gas coming from the oven chamber is
collected in the gas collecting mains of the battery and send to separator where the
crude gas separates out as gaseous part and the tar and ammonia liquor separates as
liquid part. The gas enters the primary gas cooler where it is cooled to ambient
conditions and is sent to various units for extracting and producing various products
like ammonium sulphate sold as RAJA KHAD, benzoyl products benzene, xylene
and toluene. Tar is processed for producing naphthalene and granulated pitch, finally
the coke oven gas stripped off all hydrocarbons and other condensates is sent to plant
wide network as clean gaseous fuel.