PRESENTATION

ON
COKE DRY COOLING
PLANT
(CDCP) BOILERS,
COKE OVENS ZONE
THERMAL
POWER
PLANT
By
M.SRINIVAS, A.M ,
E.NO:105358
CDCP Boilers,
T.P.P

Coke Dry Quenching Technology

Overview of CDQ (Coke Dry Quenching)

system_

The coke oven consists of plate-like carbonization chambers

alternately arranged in a sandwich form to achieve higher thermal
efficiency in carbonization.
Raw material placed in the carbonization chambers is heated to a
temperature between approximately 1100 and 1350oC through the
combustion of blast furnace /coke oven gas in the combustion
chambers,
which are located on both sides of the carbonization chambers
beyond the refractory brick.
The heated raw material is not exposed to air for approximately 12
to 14 hours to allow carbonization to proceed.
In this process, the fixed carbon contained in the raw material fuses
and solidifies to become redhot coke in the lower section of the
carbonization chambers.
The volatile component in the raw material vaporizes and
decomposes,
becoming gas. After escaping from the coke surface, the gas is
collected through a pipe located in the upper section of the
carbonization chambers.

When carbonization is complete, the red hot coke

(approximately 1,050oC) is discharged from the coke
oven and then carried to the top of the chambers.

The coke is then fed to the chambers and while it

descends through the chamber, is cooled with
circulating gas blown from the bottom of the chamber.
After it has cooled to approximately 200oC, the coke
is ejected from the bottom, while the circulating gas
that has been heated to 800oC or higher generates
high-temperature and high pressure steam in the
boiler.
The gas is purified by a dust collector and then sent
back to the chambers for recycling.
The generated steam is used as process steam or for
power

JUST LOOK AT THE OVERVIEW

OF COKE DRYCOOLING
PLANT

ADVANTAGES OF DRY COOLING

OF COKE

FEATURES OF OUR
CDCP

WE HAVE THREE CDCPS AND NEW CDCP NO 4

EACH CDCP HAS FOUR COOLING CHAMBERS WITH BIOLERS
EACH CHAMBER COOLING CAPACITY IS 50-52T/HR
TWO CHAMBERS ARE IN OPERATION
ONE CHAMBER IS ON HOT STAND BY
ONE MORE CHAMBER IS IN REPAIR
INCOMING COKE TEMPERATURE
:1000-1050 oC
COOLED COKE TEMPERATURE
:160-180 oC
STEAM PRESSURE
:40 ATA
STEAM TEMPERATURE
:440 oC
STEAM PRODUCTION OF EACH BOILER:25 T/Hr
CIRCULATING GAS COMPOSITION
:
CO2 : 6-12%, O2 : MAX 1%, CO : 6-14%, H2 : 3-5% , N2 :
REST
BOILER FEED WATER QUALITY
:
Ph value:9 to 9.5,Conductivity: <100 Micro Mhos, PO4: <
20 PPM, Si:<1 PPM< ,Total Dissolved Salts : <1 PPM.
POWER GENERATION
:11-14 MW

DRAWBACKS OF WET
QUENCHING

SENSIBLE HEAT LOSS TO ATMOSPHERE

AIR POLLUTION

WATER POLLUTION

COKE QUALITY DETERIORATION

WASTE HEAT RECOVERY BOILER

In waste heat recovery boiler the steam is
produced by utilizing waste heat in the
circulating gases coming out of cooling
chamber. The gases first pass through
superheater, then through evaporator
and then through economizer. The gases
after leaving the economizer pass
through cyclones and then re-circulated
to the chamber by running the mill fan.

G2, 4

BOILER DRUM

VENT

CDCP
SCHEMATIC
DIAGRAM

SAFETY VALVE
HOT COKE

DRUM LEVEL
NORMAL

TO
BPTS
CHAMBER

S
H
DCB
LOWER LEVEL

3TON

G1,3

E
V
E
P
O
R
A
T
O
R

E
C
O
N
O
M
I
S
E
R

CYCLONE

126 VALVE

N2
MILL FAN

Slime
Separater
FEED UNIT

CWPS

G2, 4

BOILER DRUM

VENT

CDCP
SCHEMATIC
DIAGRAM

SAFETY VALVE
HOT COKE

TO
BPTS

S
H
CHAMBER

DCB

3TON

G1,3

E
V
E
P
O
R
A
T
O
R

TO
3TON
BKR.
126 VALVE

E
C
O
N
O
M
I
S
E
R

CYCLONE

2TON

N2
MILL FAN

Slime Separater
FEED UNIT

CWPS

PROCESS DESCRIPTION

The waste heat recovery boiler used in coke dry

cooling plant is forced circulation type boiler. In
this the de-mineralized water after de-aeration
enters the feed pump, which pumps the water to
the feed unit, and then to the boiler. The purpose
of feed unit is to regulate the flow of water.
The water first enters into the economizer,
receives sensible heat from circulating gases
passing over the tubes, and then enters into drum.
The water from drum goes to circulating pump,
which pumps the water to evaporator through
slime separator. As the name indicates, the slime
separator separates the slime from water. The
slime from separator should be removed
periodically.

In evaporator the water at saturation

temperature receives latent heat of evaporation
from circulating gases passing over the tubes
and enters into the drum. In drum the steam
will be separated from water particles by steam
separators and the dry saturated steam goes to
the superheater and the water is circulated
again and again through circulating pump and
slime separator. The circulation ratio used here
is 5:1.
The dry saturated steam entering into the
superheater gets superheated by receiving heat
from circulating gases passing over the
superheater tubes. The superheated steam is
then supplied to BACK PRESSURE TURBINE STATION.

BACK PRESSURE TURBINE STATION

The back pressure turbine station is the name indicates, the steam in
which is expanding above the atmospheric pressure that steam can
be utilized as a process steam.
Generally in conventional turbines in thermal power plant the steam is
expanded up to condenser pressure in turbine. The same steam is
condensed and re-circulated. But here BPTS the steam is expanding
up to 2.5ata, after recovering the power in back pressure turbine.
There are two back pressure turbines for utilizing the steam produced
in all waste heat boilers.
After recovering the power by expanding steam in turbine, exhaust
steam is feed to chilled water plant-1 for refrigerating purpose (now
those are under shut-down, this steam is bleeding to atmosphere).
One controlled extraction (7ata steam) is provided after HP stages of
the turbine to supply process steam to coal chemical plant.
Speed of the turbine is reduced to generator to operating speed by a
reduction gear box.
Power generated at 11kv is feed to GSB-4 of electrical control room of
TPP and after getting stepped up to 220kv by transformer-4, it is
connected to grid.

Back Pressure Turbine Station parameters

Turbine Type :
EG 400-2
Make : BHEL
Capacity : 2 X 7.5 MW
No of Stages :
1+13+ 4
Steam Consumption : 70 tones/ hr per turbine at full load
Steam Pressure : 35ata (live steam pressure)
Steam Temperature : 430C
Extraction Steam Pressure : 7ata
Extraction Steam Temperature : 250C
Extraction Steam Flow : 45 tones/hr
Exhaust Steam Pressure : 2.5ata
Exhaust Steam Temperature : 163C
Exhaust Steam Flow : 25 tones/hr
Turbine Speed : 8083 rpm
Generator Speed : 3000 rpm
Stator Voltage : 11kv
Maximum Current : 492 Amps

BACK PRESSURE TURBINE STATION

COKE OVEN BATTERY COKE SIDE

COKE CAR

ROPE
TIE ROD

ROPE PULLEY

BUCKET
UPPER TRAVERSE
LOWER TRAVERSE

BUFFER

HOOKS
PEDASTRAL

LIFTING OF
BUCKET WITH HOT

MOTOR RESISTANCE BOXES R1, R2, R3, R4

R1

R2

GEAR COUPLING

R3

ROPE DRUM

DRUM
CONTROLER

THREE STAGE
GEAR COUPLING

GEAR BOX

M1

M2
BRAKES

R4

M3

M4

COOLING CHAMBER

Charging of hot coke in to

chamber

Waste Heat
Boiler

Cyclone
Separator

MILL FAN &AUXIALLARY FANS

MILL FAN or SMOKE FAN

RESERVE FAN

OLD DISCHARGING DEVICE

ROTARY DISCHARGING
DEVICE

ROTARY DISCHARGE

Rotary Discharge

Rotary Discharge

Rotary Discharge

No Gas Leakage

Conventional Discharging

Rotary Discharge

HYDRAULIC REGIME BEFORE ROTARY DEVICE

HYDRAULIC REGIME AFTER RORARY DEVICE

HOT AIR COMING

FROM CHAMBER
C
H
A
M
B
E
R

BOILER TUBES

DCB

WATER
COOLED
CYCLONES
02 NOS.
2T
BUNKER

127
128
LOCK
GATE

3T BUNKER
TO MILL FAN
2T BUNKER

DPT
STATION

FLOW DIAGRAM OF CDCP

MAIN PROCESS PARAMETERS IN

CDCP

01. Gross yield of coke/chamber (dry): 52 T/Hr.

02. Temperature of cooled coke: 180 200 C
03. Temperature of charged coke:
1000 1100 C
04. Temperature of Circulating gas before boiler : 600
800 C
05. Temperature of Circulating gas before
Chamber:180 200 C
06. Steam production for one chamber:22 25 T/Hr.
07. Pressure of Super heated steam:39 40 ata
08. Temperature of super heated steam:430 450 C
09. Amount of circulating gas/Tone of coke:14601540 Nm3
10. The load on exhauster:40 43 A

11. Residence time of coke in chamber:2 2.1 Hrs.

12. Pressure after exhauster:+ 260 MM of WC
13. Vacuum before exhauster:- 240 MM of WC
14. Capacity of main exhauster (smoke fan):160000
m3/Hr.
15. Capacity of Reserve exhauster:40000 m3/Hr.
16. Quantity of coke for each discharge:1.7 Tones.
17. Heating surface of Economizer:1180 m2
18. Heating surface of Evaporator :1250 m2
19. Heating surface of superheater:135 m2
20. Boiler drum parameters, :OD & L1600 MM, 5500 MM
21. Pressure reducing Desuperheater-I (PRDS-I):39/12
kg/cm2, 440/300 C
22. Pressure reducing Desuperheater-II: (PRDS-II)39/6
kg/cm2, 440/250O C
23. Pressure reducing Desuperheater-IV: (PRDS-IV)12/6
kg/cm2, 300/250O C

CHAMBER AND AUXILARY

UNITS

WAS

CIRCULATION WATER PUMPS &

PHOSPHATE SOLUTION PUMP

DEAERATOR

DEAERATOR

PRINCIPLE : A Deaerator is a device for air removal

and is used to remove dissolved gases from boiler
feedwater to make it non-corrosive.
Two basic types of deaerators exist today.
One type of deaerator includes a vertical domed
deaeration section mounted on top of a horizontal
cylindrical vessel which serves as the deaerated boiler
feedwater tank. This type is usually referred to as traytype (also cascade-type).
The second type of deaerator is constructed without the
trayed section. It has only one horizontal (or vertical)
vessel, in which one or more sprayers are placed to
vaporize the water. This more robust and less space
consuming form is referred to as spray-type deaerator.
An alternate for this way of deaeration would be the
use of water treatment chemicals. Costs and
environmental matters have to be observed

Our deaerator is (tray-type, with vertical, domed

aeration section and horizontal water storage
section)

Domed deaeration section (tray-type only)

At the top and in the mid portion of the feed tank an

inverted domed vessel of sufficient size as dictated, is
attached which is called the deaerator. This portion has
internals something like perforated trays to breakdown
the down flow of condensate water from the top into
fine globules to separate dissolved gases. The heating
steam, which is fed at the lower level of the dome,
passes upwards to give good intermixing. A small vent
pipe at the topmost point of this dome is provided for
venting out the dissolved gases. Some designs may
have a vent condenser to trap and recover any water
particles escaping through this vent. The typical vent
rate is in the range of 0.1% to 0.25% of total deaerator
capacity.
The deaerator dome therefore has connections for
condensate water inlet (at one side of the dome near
the top end) from previous LP feed heater and also a
connection for the deaerating steam from the bottom
of the dome (which also heats the feed water).

Storage section

This is generally a horizontally mounted cylindrical steel

vessel with dished ends, with internal and external fittings
and in the tray-type style with a dome on the top. The
size of the same depends on the unit capacity it is
associated with. The storage section acts as a buffer for
boiler feedwater supplying to the suction of the boiler
feed pumps from a pipe connected to the bottom of the
tank, generally in the mid portion.
During a cold start of the unit, it is possible that the water
in the feed tank may be cold. At that time, the water has
to be heated to bring it up to normal operating
temperature so as to expel the dissolved gases. For this, a
sparger pipe is provided inside the tank at the bottom
level. Low pressure steam supplied to the sparger pipe
provides the small amount of heat needed to increase the
temperature of the feedwater.
The storage tank is also provided with connections for the
injection of chemicals, level sight glasses, a drain, etc.

DEAERATOR
DEAERATOR COLUMN WITH STORAGE
TANK AND SAFETY DIVICE

DEARATOR TANK EFFECTIVE CAPACITY : 25 m3

D.M. WATER FROM NET WORK DEARATOR PIPE DIA :150 mm
DEARATED WATER FROM DEARATION TANK PIPE DIA : 200 mm

DEAERATOR

BOILER FEED PUMP

BOILER FEED PUMP

Feed pump is to supply the feed water to

boiler. The feed pump is run by a H.T.
motor coupled to it. The de-mineralized
water after getting de-aerated is supplied
to the boiler by the feed pump through
feed unit. The feed pump used is of
capacity 100 T/Hr. and discharge pressure
of 58 Kg/cm2. The water from feed pump
discharge goes to feed unit. Temperature
of bearings of pump is reduced by using
lubricating oil SS-32.

BOILER FEED PUMPS

BOILER FEED PUMPS &

MOTORS

BOILER FEED PUMP VIEWS

BOILER FEED PUMP

BOILER FEEDING SYSTEM

BOILER FEEDING SYSTEM

through feed unit. The feed unit has 3

lines. In those 3 lines, two lines are 100%
(one is main line and the other is bypass
line) aFeed water from feed pumps is
supplied to economizer nd the third line is
30% line. The bypass line i.e. standby line
serves the purpose, when the main line is
taken for any maintenance work. The 30%
line is used to fill the boiler drum at the
time of preheating the boiler or while
testing the boiler for its pressure
withstanding capacity i.e. hydraulic test.

BOILER FEEDING SYSTEM

WATER ECONOMISER

The economizer of waste heat recovery

boiler is of non-steaming type economizer.
This water economizer consists of 4 bundles
arranged in the second shaft, which is
having upstream gas flow. The input bundle
is arranged in the upper part and the output
bundle in the lower part and hence water
flows in down stream. Each bundle consists
of two similar transportable blocks. Blocks
of each bundle is supported and suspended
to the boiler frame by means of beams.
Each block consists of 32 coils of 28 x 3 mm
dia steel 20 connected in parallel.

Water economizer coils are designed as S

turns with the inlet holes and they are
arranged in pairs forming the pipe bundle
in staggered manner, S1 = 70 mm and S2
= 50 mm. Lower bundles are made of
pipe steel 15. The economizer chambers
are arranged in the path of gas flue at the
temperature zones of 170 O C approx. of
gases as input and at 300 O C approx. as
output. Water speed at the input of
economizer is 0.4 m/sec. with water
economizer heating surface is 1180 m2.

BOILER DRUM

BOILER DRUM

It is arranged over the roofing of the boiler and

positioned on two supports
Major diameter is 1600 mm, wall thickness is 40
mm, the drum active part length is 4400 mm,
overall length of cylindrical part is 5500 mm and
elevation of the drum axis is +23040mm.
Having separating devices i.e. to divide steam
and water, the phosphate introducing,
continuous blow down devices and emergency
discharge are arranged in the drum.
The water steam mixture is supplied to the drum
from two sides over whole length by 4 pipes,
branching at the inlet to the drum to from 8
inlets of 100 mm dia.

BOILER DRUM AND INTERNALS

The Separators inside the boiler drum are designed

using cyclones, which are installed in pairs of four
incoming ducts, which receive the steam / water
mixture. In these cyclones, the water and steam
will be separated, steam goes to the upper part of
drum and water falls to the lower part of drum.
The steam is then collected through the steam
trap, situated at the top inside the boiler drum, and
sent to the superheater. Feed water is supplied to
drum via economizer by means of the perforated
distribution pipe
Presidium Phosphate(Na3Po4)are introduced into
the drum through another perforated pipe. In the
lower part of the drum provision for permanent
purging is provided.

CIRCULATION PUMP

CIRCULATION PUMP

As the boiler is forced circulation type, circulation

pump is required for the circulation of water. In
natural circulation type boilers the water
circulation is due to density difference only. Here
the density difference is not sufficient for
circulation; hence the forced circulation is
preferred. The circulation ratio is 5:1. Two
pumps are provided for each boiler, one is in
running condition and other in emergency
standby. The pressure of circulating water is 3 4 Kg/cm2 more than that of actual drum pressure
and temperature is saturation temperature.

CIRCULATION PUMP

CIRCULATION PUMP

CIRCULATION PUMP - MECANICAL SEAL

Slime separator is a filter with a

SLIME
cylindrical mesh made of stainless steel.
SEPARATO
Water from the circulation
pumps is
supplied to the inner part of the
R mesh,
and goes out through the mesh walls.
Sludge falls down and is removed through
a periodical purging point. For cleaning
and replacing the net the lower bottom of
the slime collector body is manufactured
as removal flange.

EVAPORATOR

Evaporating surface for boiler

heating consists of two basic parts:
a. Upper radiation part, arranged in
the revolving gas flue of boiler before
steam superheater, and
b. Main part consisting of evaporator
bundles, situated below the steam
superheater.

The upper part of evaporating surface

consists of the outlets of the tubes
which rise from the main evaporating
surface. The outlet parts of the tube
are welded to the collecting mains which
are situated inside the brickwork of the
boiler walls at the boiler revolving gas flue
area. First four pipes, for the sake of
protection against wear out are made of
pipe 28 x 5. The size of others is 28 x 3.
Material of pipe is steel 20. The upper
evaporating part is the elongation of the
upper bundle at evaporating surface.

Blocks are composed of 200 coils

connected in parallel which are fixed on
the frame of the unit.
In input chamber of boiler
evaporating surface is fixed at lower
block frame. Block coils are made of 28
x 3 dia located in staggered manner
and from the staggered bundle S1 = 70
mm and S2 = 50 mm. The total area of
evaporating part is 1250 m2.

STEAM SUPERHEATER

Steam superheater is arranged in gas flue,

where the hot gas entered into the boiler. It
consists of two parts assembled in blocks
inter connected by 3 pipes. The first down
stream superheater part consists of the
saturated steam chamber, intermediate
chamber and of 48 coils, connected in
parallel 32 x 3 dia, steel-20. The second
down stream superheater part consists of
intermediate chamber, steam super heated
chamber and of 48 coils connected in
parallel 32 x 3 dia, steel 12

The temperature of super heated steam

is 430-440 O C. Heating surface of steam
superheater makes 135 m2. The
temperature of superheater steam is
controlled by the changing of
temperature of gases entering the boiler.
The quantity of cooled gases taken
behind from the boiler which are
necessary for controlling is supplied to
the gas flue before steam superheater by
means of the control valve and smoke
suction device. Temperature control limits
are 10 12C.

PHOSPHATE DOZING
SYSTEM

PHOSPHATE DOZING
SYSTEM

For this the equipment required is phosphate

mixer, solution filter, strong tank, phosphate
dozing pump and wash water tank. Phosphate
dozing is done to maintain pH of water. In this
system phosphate and hydrazine in specified
quantities are added to the water in the mixer
and thoroughly mixed, so that the solution was
prepared with equal concentration. Then the
solution was send to a storage tank through
suction filter. Whenever required this solution
was dozed by a pump called phosphate dozing
pump into the boiler drum. Wash water is
flushed into the mixer after mixing the solution
and into the dozing pump after dozing to flush
out lines. This is to avoid choking.

BLOW DOWN SYSTEM

Blowing down of water from boiler at various

stages is done in three modes.
CONTINUOUS BLOW DOWN: Here the water
from drum is blow down continuously to remove
silica deposit in the drum and reduce
conductivity of water. The increased
conductivity means, accumulation of dissolved
salts in water. This slag is bad conductor of
heat. By this is long run, the tubes will be
damaged. In keeping this view we should blow
down water from drum. It

CONTINUOUS BLOW DOWN

PERIODIC BLOW DOWN: As its name

indicates, the water is blow down
periodically. Usually 2-3 times in a shift
for 2-3 minutes. This is to be done to
remove un-dissolved salts in the water in
the pipelines. The purpose served by this
other than C.B.D. is, here water is blow
down from economizer (one point), slime
separator (one point) and evaporator (4
points). All these points are connected to
bubbler.

EMERGENCY BLOW DOWN The EBD

line is arranged to drum. Whenever
water level in the drum exceeds the safe
limit, the EBD valve
opens automatically and the water flows
down. The other end of EBD also
connected to the bubbler.

EMERGENCY BLOW
DOWN

BUBBLER

In bubbler all the water from CBD, PBD

and EBD is collected and cooled by
mixing some service water from outside
and then sent to the sump, from where it
is sent to sludge separation plant by a
centrifugal pump. The use of bubbler is
to reduce the temperature of water;
otherwise this high temperature causes
many problems.

CONTROL SYSTEMS IN CDCP

While operating coke dry cooling plant, the

following parameters should be controlled
in efficient manner. Automisation takes
vital role in recent plants, to reduce
manual alertness in processing. The
accuracy of this automisation can be
visualized by the added graphical trends
for the parameters drum level and steam
temperature.

GAS TEMPERATURE
CONTROL

Circulating gas temperature has to be controlled

due to the following reasons:
If the temperature of gas entering the chamber
is more than the rated temperature, overheating
of the superheater tubes takes place in turn
resulting in the increase of superheated steam
temperature.
If the temperature of gas before boiler is lesser
than the rated value then the production of
steam will be reduced.
The consumption of gas will be varied
depending on coke cooling rate.

The control of circulating gas temperature

is done by operating guide vane, which
controls the circulating gas flow through
the mill fan. In case the chamber running
with reserve fan (in case of failure of mill
fan) another guiding apparatus, with
controls the gas flow through reserve fan
will be operated. By opening the guide
vanes the gas flow will increase, which
causes the reduction in gas temperature
and by closing the guide vanes the gas
flow decreases causes increase in gas
temperature.

DRUM LEVEL CONTROL

Water level high in drum causes the water

entering into superheater and low level of
water may leads to starvation problem.
Drum level control is done by 3 element
control. These elements senses the actual
drum level of boiler, actual rate of steam
production, rate of feed water supply. The
drum level is then controlled by measuring
difference in steam production and feed
water supply and actual drum level.

STEAM TEMPERATURE
CONTROL

Steam temperature is to be maintained in the

rated limits. The control of steam temperature
can be done by two methods:
By operating guiding apparatus :- By operating
guiding apparatus, the gas temperature can be
controlled and by that steam temperature will be
controlled.
Bypassing the chamber :- Circulating gas will be
directly supplied to a point after dust catching
bunker by bypassing the chamber. This causes
the reduction in temperature of circulating gas
entering into the boiler and hence reduction in
steam temperature.

ROOF SPACE PRESSURE

CONTROL

While passing circulating gas at the time

of charging of coke the pressure in roof
space may increase. This pressure will be
controlled by opening the bleeder which
is arranged after mill fan. By this, some
gas will be let into atmosphere. By
closing the valve gas flowing out will be
reduced. This is to maintain roof space
pressure in safe limit.

PROTECTIONS & INTERLOCKS

Every waste heat boiler has protection

and signaling systems. Protection devices
are installed to increase safety of the
equipment. Also the boiler may be
operated with lesser personnel. If any
emergency arises, the personnel are
given signals in the form of alarms and
the boiler is stopped if the problem is not
rectified within the safe limits of working.

BOILER OVER FEEDING

PROTECTION

If this protection is not there the over feeding of

water causes the water entering into superheater
and in turn water enters the steam line and
thereby into turbine which causes damage to the
turbine blades. On receiving an impulse from
water level sensor of level rising in the boiler drum
by 100 mm higher than the normal level of 0-0,
the emergency discharge valve opens and passes
the signal to control room and this signal closes
the feed unit control valve. When level falls down
to +50 mm (upper permissible level) emergency
discharge valve is automatically closed. If the
water level rises up to +150 mm, second
protection is activated; and the boiler is stopped
through stoppage of main mill fan.

WATER LEVEL LOWER

PROTECTION

On receiving the pulse of the level

lowering in the drum by 150 mm lower
than the normal level the main exhauster
will trip. If this protection is not there,
and if steam generation is more than feed
water flow, the boiler starts emptying.
After continuous running like this, the
tubes become dry and due to hot gas
flow, the tubes get starved and this leads
to major breakdown of boiler.

LOW CIRCULATING WATER

PROTECTION

Low circulating water flow protection

protects the tubes of evaporating surface
from burning out as a result of stoppage
or lowering of water supply. Impulse
comes from all instruments measuring
water flow. Protection has two levels. If
flow falls to 100 m3/hr, first protection
switches on standby pump. If flow falls
further (65 m3/hr) second protection
switches off the main mill fan.

MAIN EXHAUSTER INTER

LOCKS

The interlocks are of two types as given below:

Starting interlocks
Tripping interlocks
FOR STARTING MAIN EXHAUSTER THE
FOLLOWING CONDITIONS ARE NECESSARY:
Boiler drum level should be within limits
Circulation water pump should run
Circulation water flow should be more than 100 T/Hr.
The guiding apparatus should be in closed condition
Feed water pressure should not be less than 48 Kg/cm2.
The main exhauster will trip in the following
cases
The drum level falls below 150 mm
If circulation water pump stopped and the standby
pump have not picked up
If circulation water flow falls below 65 T/Hr.
If boiler feed water pressure falls below 48 Kg/cm2.

DISCHARGING DEVICE INTERLOCKS

The discharging of cooled coke through discharging

device will be stopped automatically in following cases:
If main exhauster tripped.
If ventilation fan is not running.
If coke conveyor is stopped.
If discharged coke temperature raises above 200O C
If air gates for ventilation fan are closed
If coke level in the cooling chamber falls below
minimum level known as lower level.
If the conveyor to conveyor changeover is not opened
on the running conveyor.

OTHER INTERLOCKS

If main exhauster trips, the reserve

exhauster will start automatically.
The auto circulation pump starts
automatically when the circulation water
flow falls below 100 T/Hr. or when the
running circulation pump fails.
The coke bucket will not get lifted, if coke in
the cooling chamber reaches upper level.
The main exhauster will trip, if running
circulation pump tripped and standby
circulation water pump does not picked up.

HEAT BALANCE OF CDCP

No. of Coke oven Batteries

=3
No. of ovens per battery
= 67
Capacity of each oven
= 25 T
Temperature of charged coke = 1100 C
Temperature of cooled coke =200 C
Specific rate of steam production = 0.45
0.52 T/ton of coke
Pressure of steam
= 40 kg/cm2
Temperature of steam
= 440 C

Calculations
Coke pushed per oven = 25 T
Steam produced
= 0.45 * 25
= 11.25 T
Heat Inputs:
Heat content of hot coke:
Coke charged = 25 T = 25,000 kg
Specific heat of coke
= 0.383 kcal / kg
C
Temperature of hot coke = 1100 C
Heat content = m*c*t
= 25000 * 0.383
* 1100
= 10532.5 103 kcal

While transferring hot coke from oven to

chamber, hot coke reacts with air. This value
is taken as 4% of the total heat content.
Heat of reaction
= 0.4 * 10532.5 103
= 421.3 103 kcal
Sensible heat of de-aerated water:
Specific heat of water
= 1.03 kcal / kg C
Temperature of water
= 105 C
Mass of water = 11.25 T
= 11250 kg
Sensible heat = 11250 * 1.03 * 105
= 1216.7 103 kcal
Total heat input = H1 + H2 + H3
= 12170.5 103 kcal

Heat outputs:
Heat of steam produced
Pressure of steam
= 40 kg/cm2
Temperature of steam
= 440 C
Mass of steam = 11.25 T = 11250 kg
From steam tables, at 40 kg/cm2 & 440 C
Hsup = 784.15 kcal / kg
Heat of steam produced = Hsup * m
=
11250 * 784.15
= 8821.7
103 kcal
Sensible heat of cooled coke discharged:
Temperature of cooled coke discharged = 200 C
Amount of coke discharged
= 25 T =25000 kg
Sensible heat
= 200 * 25000 * 0.383
= 1915 103 kcal

Heat loss due to continuous blow down of water:

As per Russian standards 5% of feed water
supplied is blown down as CBD.
From steam tables,
Hf = 258.4 kcal / kg
Heat loss due to CBD
= 0.05 * 11250 *
258.4
= 145.35 103 kcal
Heat loss from bleeder:
As per Russian standards, heat loss due to
bleeding of steam is 2% of total heat,
Heat loss due to bleeding = 0.02 * 12170.5
103
= 243.41 103 kcal

Heat loss due to coke charging hole:

As per Russian standards, heat loss while
charging coke into chamber is taken as 1%
of the total heat.
Heat lost during charging = 0.01 *
12170.5 103
= 121.7 103 kcal
Heat loss due to radiation, periodical blow
down and other losses,
Other losses
= [12170.5 (8821.7 +
1915 + 145.35 + 243.41 + 121.71)] 103
= 923.33 103 kcal

HEAT BALANCE SHEET OF CDCP

Heat energy I/P
Sensible heat of hot coke
Heat of reaction
Sensible heat of feed water

kcal

Heat energy O/P

10532.5 Enthalpy of steam produced

421.3 Sensible heat of coke discharged
1216.7 Heat loss due to CBD

______
12170.5

kcal
8821.7
1915
145.35

Heat loss due to bleeding

243.41

Heat lost while charging coke

121.71

Other losses

923.33
______
12170.5

Thermal Efficiency of CDCP = Heat

content of steam produced
Heat input to plant
= 8821.7 100
12170.5
= 72.48 %

VARIOUS SECTIONS OF
CO&CCP

COKE OVEN SECTIONS

COAL PREPARATION
COKE OVEN BATTERY
COKE DRY COOLING OF HOT COKE
COKE SORTING

LAYOUT OF CO&CCP
LAYOUT OF CO&CCP

CO&CCP

PROCESS FLOW CHART

COKING COAL
FROM RMHP

COAL PREPARATION PLANT

COKE OVEN
BATTERIES
COKE

GAS
SEPARATOR

RUN OF OVEN
COKE (HOT)

FLUSHING
LIQUOR

COKE DRY
COOLING PLANT

RAW COKE
OVEN GAS
PRIMARY GAS
COOLER

TO GCM

STEAM

TO DECANTER

COOLED COKE

EXHAUSTER

BPTS
TAR DISTILLATION PLANT
COKE SORTING PLANT

BREEZE COKE
0-10 MM

NUT COKE
10-25 MM

BF COKE
25-80MM

TO
YARD
BURDEN HANDLING
SECTION(B.F)

SINTER
PLANT

COKE DUST
0-3 MM

LIGHT OIL
WASH OIL
HP NAPHTHALENE
ANTHRACENE OIL
PHENOL
PITCH
CT FUEL

TO
YARD

AMMONIUM
SULPHATE
FINAL GAS
COOLER
CLEAN COKE
OVEN GAS
CONSUMER

BATTERY
UNDER FIRING

TO
S.P
COKE SLUDGE
0-3 MM

CRUDE
BENZOL
BENZOL
RECTIFICATION PLANT

TO SALE

BENZENE
TOLUENE
H.B.F
SOL 110
SOLVENT NAPTHA
STILL BOTTOMS

COKE BUCKET
ALIGNMENT/LOWERING

Keep the selection in ground control

Centre the bucket properly

Close the hooks

Ensure proper closing of hooks on both the

sides

Change the selection to the lifter control

and then give signal to the lifter operator to
lift the bucket by pressing bell push button

COKE BUCKET

ALIGNMENT/LOWERING

Lower the bucket from RP-6 level

after ensuring proper alignment of
empty carriage with the stationary
guide until hooks are fully open.

Keep the selection switch in off

position.

SOP
LIFTER
Switch on the power to the respective lifter
Keep the selection in ground control
Wait for alignment operator signal (BUZZAR)
After receiving signal from Alignment operator,
change the selection to lifter mode and then charge
the circuit and lift the bucket in FOURTH notch
Observe for any abnormal sounds and inform to
S/IC
Ensure full lifting of bucket and then travel towards
chamber axis ,lower the bucket in FIRST notch after
ensuring hatch open and exact axis.

SOP OF LIFTER (contd.)

Ensure total discharge of coke from bucket

Check for any over lowering or hooks open and
if any inform to S/I or C/M to take necessary
action and lift the empty bucket in 2nd notch

Back travel the bucket after ensuring full

lifting of the bucket

Ensure hatch close and exact axis at well and

and check for arrows matching and then lower
the bucket in third notch

Ensure bucket stoppage at RP-6 level

After hooks are opened full , Switch off the

power of the lifter

Empty screen lifting

Ensure no loco movement below lifter

while lifting /lowering empty screen.
During empty screen lifting screen load(5
tons) is coming on screen chains. So, while
lifting the screen inching operation is
advised to be done till chains are
tightened to avoid sudden load on chains
Ensure chain healthiness and further lifting
is performed in first notch and stop lifting
around one meter below the actual lifting

Further lifting is to be done by

inching to avoid hitting of the rope
clamps.
After lowering of the empty screen
rope slackness is to be ensured by
the lifter operator.
During opening of the hooks
alignment operator should ensure
full opening of hooks and avoid loco
movement to avoid loco hitting with
the hooks

1.

2.
3.
4.
5.
6.

EMPTYING OF CDCP COOLING CHAMBER

Stop charging hot coke into cooling
chamber and inform to boiler people.
Open nitrogen ~300nm3 /hr
Continue discharging of coke up to lower
level.
Bypass lower level and temperature interlocks.
Keep guiding apparatus in manual mode at
50% opened.
Keep bleeder after mill fan in closed
condition.

EMPTYING OF CDCP
COOLING CHAMBER
7. Keep observer at DD area for
any
hot pieces.
8. Open water at conveyor gallery
on
running conveyor.
9. Completely empty the coke and
ensure
the same through triangular
manhole.
10.Stop mill fan and close nitrogen
and blank.

WORKING AT CHARGING DEVICE

Take shut down to lifter if required.

Stop charging and bring down coke
to lower level.
Bring down before boiler
temperature to~500degree C.
Maintain suction at roof space
--5mmwc minimum.
Open bleeder after mill fan full.
Run mill fan/reserve fan to maintain
suction as per requirement.
Open guiding apparatus full if
reserve fan is running.
Open guiding apparatus as per
requirement if mill fan is running .

WORKING AT DISCHARGING
DEVICE AREA

While working at discharging device area for opening

of manholes for inspection do as follows:

Stop charging and bring down coke level to lower level

o nly for long duration.

For urgent inspection stop charging and discharging

temporarily.

Close guiding apparatus and open bleeder after

mill fan in manual mode.
Open required manhole inspect and do the
needful and close manhole
For going inside discharging device check for
carbon monoxide presence.
For doing cutting or welding works inside
discharging device area bring down temperature
before boiler to~500degreeC.
Empty coke from gate3&4 and close gates above
the working area and take shutdown to discharging
device
.Check for carbon monoxide presence by EMD or
with our meter.

CHARGING HOT COKE INTO COLD

CHAMBER

ENSURE ALL MANHOLES ARE IN CLOSED CONDITION.

ENSURE BEFORE BOILER TEMPERATURE IS AT 90-100DEGREE C.

ENSURE COKE LEVEL MINIMUM SIX BUCKETS IN CHAMBER.

ENSURE ALL INTERLOCKS OF LIFTER AND DISCHARGING DEVICE.

ENSURE SMOOTH OPERATION OF LIFTER, CHARGING DEVICE, MILL

FAN, RESERVE FAN, BLEEDERS AND DISCHARGING DEVICE.

TAKE CLEARENCE FROM BOILER PERSONNEL BEFORE CHARGING HOT

COKE.

KEEP GUIDING APPARATUS AND BLEEDER AFTER MILL FAN IN CLOSED

CONDITION.

CHARGE ONE BUCKET OF HOT COKE IN COOLING CHAMBER AND KEEP

LID OPEN FOR 5-6 MINUTES.

OPEN GUIDING APPARATUS AND MAINTAIN

PRESSURE AFTER MILL FAN AT 60-70MMWC.

START DISCHARGING COKE AFTER ONE HOUR AS

FOLLOWS:
SNO HRS ROTARY TONNAGE PRESSURE
1
1ST
3TONS/HR
60-70MMWC
2
2ND
5 TONS/HR
80MMWC
3
3RD
7TONS/HR
100MMWC
4
4--6TH 8-12TONS/HR
110MMWC
5
7-10TH 3TONS/HR TO RAISE 120MMWC
6
11-13TH 25 TONS/HR
150MMWC
7
14TH 30 TONS/HR
175MMWC
8
15TH 35TONS/HR.
AUTO MODE

AT THIS STAGE BOILER MAY BE

CONNECTED TO HEADER AND PUT IN TO NORMAL
OPERATION. IN ROTARY DD INCREASING IS TO BE
DONE GRADUALLY EVERY 15MTS ONCE AND NOT
ONCE IN ONE HOUR.

WEDING OR CUTTING AT
CIRCULATING GAS TRACK

Stop charging and, discharge coke up to lower level

Bring down temperature before boiler upto 400425degreeC.

Start reserve fan and stop mill fan.

Close guiding apparatus of reserve fan after some

time Open bleeder after mill fan fully in manual mode.

Open nitrogen at dust catching bunker ~300400cu.meter/hr.

Keep minimum gap of charging to welding work ~2-3

hrs.
If reserve fan is running before give more gap of 3-4
hrs.
Close nitrogen after work is completed. Normalize
system after work is completed
Ensure reserve fan guiding apparatus and bleeder
after mill fan are normalized
Then only give protocol for start of work for safe work.

MAINTENANCE AT MILL
FANS/RESERVE FANS

1.. FOR ONLY MAN HOLES OPENING

a) Stop charging and bring down coke to lower level
b) Stop mill fan after bringing the temperature before boiler
to ~500degreeC.
c) Keep open bleeder after mill fan 100%.
d) See that opening of manhole and previous charging gap
at least 2hrs.
e) Close guiding apparatus of reserve fan to avoid gas
leakage.
f) For opening manhole at mill fan suction side only
open guiding apparatus of mill fan) Open the
manhole, check for any gas leak.

h)Change the gasket etc. or inspect inside if any.

i) Close manhole properly and normalize system.
j) If reserve fan man hole is to be opened stop reserve fan
also
2. FOR DOING CUTTING OR WELDING WORKS (On
the body etc.)
a) Stop charging and bring down coke level to lower level.
b) Stop mill fan after bringing the temperature before
boiler to ~400degreeC.
c) Open nitrogen at DCB by 300-400 cub. meters/hr half
an hour before
Work and close after work is completed.

d)

Keep open bleeder after mill fan 100%.

e)

Before stopping mill fan take sample for explosive

mixture by EMD people.
f)

Close guiding apparatus of reserve fan while doing

welding works.
g)

Normalize the system after work is completed.

FLAMES IN DISCHARGING DEVICE

Reasons:
1.Insufficient air supply and green coke
charging leading to high CO&Hydrogen
Action to be taken:
1. Stop discharging
2. Close the guiding apparatus
3. Restore air supply, if required open extra
lid
4. Wait for some time and normalize the
chamber slowly

IN CASE OF DUST AND

GAS EMISSIONS AT DD

Check the rotary bleeder for its

opening
Check the running of the ventilation
fan and opening of its guiding
apparatus
Check the opening of the air-gates
Check the ventilation line for any holes

Flames at charging device

Reasons:

1. Improper seating of lid

2. Malfunction of MF bleeder

3. Potential boiler leakage

4. Safety flap burst

Action to be taken
1.
Break the prechamber bleeder water seal if required
2.
Rectify the abnormality found

BLEEDERS

1. After MF bleeder- For maintaining the

hydraulic regime. For healthy chamber
bleeder opening should not be more than
30%
2. Pre-chamber Bleeder- It acts as a safety
valve when high pressures are devoleped at
roof space.
3. Rotary Bleeder- To maintain suction at the
discharging device
Purging Bleeder- To ventilate circulating gas
during emergency situations like total power
failure and heavy boiler leakage

DPT SYSTEM

Dust is carried by circulating gas during

cooling process must be separated in order to
prevent chamber equipments i.e. impeller
vanes,ducts,boiler tubes etc. from erosion.
DPT is used to transport the dust collected
from DCB
And cyclones to red bunker at DPT station
SOP
Find the bunkers which are full with dust by
hammering runner pipes or moving sensors.
Empty the 3-T bunkers first then 2-T bunkers
after having necessary instructions from shift
I/Cor shift C/M

CONCLUSION

The various modifications suggested in coke dry

cooling plant for increasing the boiler life are as
follows:
1. PROVISION OF S.S. SHIELDS AT THE
ENTRANCE OF ECONOMISER, EVAPORATOR
AND SUPER HEATER IN GAS FLOW PATH
2. Stop modification for dust collection at
the bottom of second path of gas (i.e.
below economiser) or provided vibration
at boiler bottom.
3. Closing of all gaps in economiser
bundle area where low resistance path or
preferential path are created
4. PROVISION OF PH CHECKING IN
CONTROL ROOM AT OPERATORS DESK