High-Capacity Coke Oven Batteries Ralf Neuwirth, Frank Redemann Eurocoke Summit 2014 Edinburgh 29 April, 2014
High-Capacity Coke Oven Batteries
Ralf Neuwirth, Frank Redemann
Eurocoke Summit 2014 Edinburgh
29 April, 2014
High-Capacity Coke Oven Batteries
29 April 2014
Eurocoke Summit 2014 Edinburgh
2
High-Capacity Coke Oven Batteries Definition
High-Capacity Coke Ovens
=
Coke oven batteries for production of 1.5 to 2.5 million t/a
with one operating unit
Operating Unit
=
A number of coke oven batteries, which can be operated with
One set of service machines
One coal tower
One quenching system
High-Capacity Coke Oven Batteries
29 April 2014
Eurocoke Summit 2014 Edinburgh
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7 m
6 m
3 m
2.5 m
8 m
1900 1915 1925 1930 1985 2003
4 m
High-Capacity Coke Oven Batteries Development of Oven Height
High-Capacity Coke Oven Batteries
29 April 2014
Eurocoke Summit 2014 Edinburgh
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0
10
20
30
40
50
60
19001920
19401960
19802000
13 m³
32 m³39 m³
53 m³
76 m³
94 m³
tons of coke per oven
chamber volumes
0
10
20
30
40
50
60
19001920
19401960
19802000
13 m³
32 m³39 m³
53 m³
76 m³
94 m³
tons of coke per oven
chamber volumes
High-Capacity Coke Oven Batteries Development of Chamber Volumes
High-Capacity Coke Oven Batteries
29 April 2014
Eurocoke Summit 2014 Edinburgh
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Oven heightNumber of batteries
Number of ovens
Oven width
Useful volume p. oven
Numb. of pushes/charges p. day
Total length of sealings(doors, standpipes, charging holes)
Required space for the batteries
Sets of oven machines
Operation teams 3
2
1
3
2
5
55,000 m2
40,000 m2
50,000 m2
135 300 520
4.8 km 6.0 km 6.5 km
7.6 m 6.0 m 4.3 m2 4 5
140 220 325
76 m³ 34 m³ 20 m³
590 mm 450 mm 450 mm
High-Capacity Coke Oven Batteries Comparison for 2 Million Tons of Coke Per Year
Advantages of large ovens:
Reduced number of batteries / ovens
Reduced number of pushes/charges less emissions
Reduced length of sealings less emissions
Reduced plant space requirement
Reduced number of oven machines (and coal towers, quench systems, coke wharves)
Reduced number of manpower
High-Capacity Coke Oven Batteries
29 April 2014
Eurocoke Summit 2014 Edinburgh
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Reduced Manpower Requirement:
(Example from Germany)
Old coking plant 2.5 mill. t/a (oven heights : 4-6m, narrow chambers)
- Specific manpower : 336 persons / mill. ton
New coking plant 2.7 mill. t/a (oven height : 8.4m, width: 590 mm)
- Specific manpower : 106 persons / mill. Ton
High-Capacity Coke Oven Batteries Comparison of Manpower - Influence on OPEX
Reduced Maintenance Cost
due to decreased numer of batteries / ovens
High-Capacity Coke Oven Batteries
29 April 2014
Eurocoke Summit 2014 Edinburgh
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Typical number of pushes per oven during its service life World average / Maximum
12,000 15,000
Oven width : 450 mm
Coking time : 20 hr
Pushes per oven :
per day : 1.2
per year : 438
Oven width : 590 mm
Coking time : 27 hr
Pushes per oven :
per day : 0.9
per year : 324
Expected lifetime per oven ( average / maximum )
27 / 34 years 37 / 46 years
High-Capacity Coke Oven Batteries Comparison of Theoretical Service Life
High-Capacity Coke Oven Batteries
29 April 2014
Eurocoke Summit 2014 Edinburgh
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(more shrinkage = less pushing force) 0
1
2
3
4
5
6
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
coking time in h
co
al
sh
rin
kag
e i
n %
0
200
400
600
800
1000
1200
co
ke t
em
pe
ratu
re i
n °
C
450 mm chamber width 590 mm chamber width co
kin
g t
ime 4
50 m
m c
ha
mb
er
wid
th
co
kin
g t
ime 5
90 m
m c
ha
mb
er
wid
th
590mm
450mm
High-Capacity Coke Oven Batteries Comparison of Coal Shrinkage
High-Capacity Coke Oven Batteries
29 April 2014
Eurocoke Summit 2014 Edinburgh
9
High-Capacity Coke Oven Batteries Coke Oven Batteries - Design Criteria
Oven Length
Most economical dimension for increase of capacity Long ovens only in connection with wide chamber (higher shrinkage) Adjustment of heating media over the oven length complex for long ovens
Oven Height
Most expensive dimension for increase of capacity Large oven heights increase requirement for precise operation due to increased absolute shrinkage and tendency of carbon deposits Adjustment of vertical temperature distribution complex for high ovens
Oven Width
Almost no effect on plant capacity Wider ovens increase coking time; reduce number of pushes Less pushes cause less emissions Increased coking time causes increase coal shrinkage
High-Capacity Coke Oven Batteries
29 April 2014
Eurocoke Summit 2014 Edinburgh
10
Start-
up Client, Plant, Location Oven Type
Nominal
Capacity
[Mill. t/a]
No. of Batt. /
Ovens per
Battery
Dimensions
Height / Length / Width
[m]
Effective
Volume
[m³]
Remark
1984
&
2014
HKM, Hüttenwerke Krupp Mannesmann
Duisburg, Germany
COMBIFLAME
compound underjet 2.250 2 / 70 7.85 / 17.2 / 0.550 70.00
first battery
30 years old
2013 Hyundai Steel Comp. (HSC), Phase 3
Dangjin, Chungnam, South Korea
COMBIFLAME
compound underjet 1.800 2 / 70 7.63 / 18.0 / 0.590 76.25
2010 POSCO, Gwangyang Works, Phase 5,
Gwangyang, South Korea
COMBIFLAME
compound underjet 2.800 4 / 50 7.63 / 18.0 / 0.590 76.25
2 operating
units
2010
Zhangjiagang Hongfa Steelmaking
Co., Ltd. (SHAGANG)
Zhangjiagang, China
COMBIFLAME
compound underjet 2.000 2 / 70 7.63 / 18.0 / 0.590 76.25
2009 Hyundai Steel Comp. (HSC), Phases 1 + 2
Dangjin, Chungnam, South Korea
COMBIFLAME
compound underjet 3.300 4 / 60 7.63 / 18.0 / 0.590 76.25
2 operating
units
2009
Shougang Jingtang United,
Iron & Steel Company
Caofeidian, Hebei, China
COMBIFLAME
compound underjet 4.200 4 / 70 7.63 / 18.0 / 0.590 76.25
2 operating
units
2008 Wuhan Iron & Steel Corp. (WUGANG)
Wuhan, Hubei, China
COMBIFLAME
compound underjet 2.000 2 / 70 7.63 / 18.0 / 0.590 76.25
2006 Maanshan Iron & Steel Co. (MAGANG)
Maanshan, Anhui, China
COMBIFLAME
compound underjet 2.000 2 / 70 7.63 / 18.0 / 0.590 76.25
2006
&
2013
Taiyuan Iron & Steel Co. (TISCO)
Taiyuan, Shanxi, China
COMBIFLAME
compound underjet 3.300 3 / 70 7.63 / 18.0 / 0.590 76.25
2 operating
units
2003 Carbonaria / TK Schwelgern
Duisburg, Germany
TWINFLUE
compound gun flue 2.640 2 / 70 8.43 / 20.8 / 0.590 93.00 yes
High-Capacity Coke Oven Batteries Coke Oven Plants with Start-up in recent 10 Years
High-Capacity Coke Oven Batteries
29 April 2014
Eurocoke Summit 2014 Edinburgh
11
High-Capacity Coke Oven Batteries Coke Oven Batteries - Potential Coke Production Capacities
Battery
no. Oven no. Oven dimensions Volume
Coking
time
average heating
flue temperature
Pushes
per day
NOx - Limit
at 5%-O2
Total Coke
Production *)
[-] [-] [m] [m3] [h] [°C] [-] [mg/Nm³] [Mill. t/a]
2 100
7.63 / 18.0 / 0.590 76.25
~27.0
~1,275
89
< 350
1.400
2 120 ~27.0 107 1.680
2 140 ~27.0 124 1.960
For NOx value of < 500 mg/Nm3 with COG heating
Battery
no.
Oven
no. Oven dimensions Volume
Coking
time
average heating
flue temperature
Pushes
per day
NOx - Limit
at 5%-O2
Total Coke
Production *)
[-] [-] [m] [m3] [h] [°C] [-] mg/Nm3 [Mill. t/a]
2 100 7.63 / 18.0 / 0.590 76.25 ~26.0
~1,300
92
< 500
1.450
2 100 7.63 / 20.0 / 0.590 84.72 ~26.0 92 1.600
2 120 7.63 / 18.0 / 0.590 76.25 ~26.0 111 1.750
2 120 7.63 / 20.0 / 0.590 84.72 ~26.0 111 1.900
2 140 7.63 / 18.0 / 0.590 76.25 ~26.0 130 2.050
2 140 7.63 / 20.0 / 0.590 84.72 ~26.0 130 2.250
For reference plants in Korea
*) depending on coal data and number of operation days per year
*) depending on coal data and number of operation days per year
High-Capacity Coke Oven Batteries
29 April 2014
Eurocoke Summit 2014 Edinburgh
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Client: Hyundai Steel Corporation (HSC)
Location: Dangjin, South Korea
Capacity: Phase 1+2: 3,300,000 t/year of coke, 4 batteries, 60 ovens each,
Phase 3: 1,870,000 t/ year of coke,
2 batteries, 70 ovens each
7.63m chamber height Phase 1+2: Gas Treatment Plant with a capacity of 215,000 Nm3/hour
Phase 3: Gas Treatment Plant with a
capacity of 125,000 Nm³/hour
Start-up: Phase 1: 2009, Phase 2: 2010, Phase 3: 2013
Client: POSCO Group Location: Gwangyang, South Korea Capacity: 2,800,000 t/year of coke 4 batteries, 50 ovens each, 7.63m chamber height, Gas Treatment Plant with a capacity of 175,000 Nm3/hour Start-up: 2010
High-Capacity Coke Oven Batteries Reference Plants
High-Capacity Coke Oven Batteries
29 April 2014
Eurocoke Summit 2014 Edinburgh
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High-Capacity Coke Oven Batteries Reference Plant – Posco, Gwangyang, Korea
Battery
Coal Tower
Quenching facilities
Oven machines
Gas treatment plant
Coal treatment plant
High-Capacity Coke Oven Batteries
29 April 2014
Eurocoke Summit 2014 Edinburgh
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High-Capacity Coke Oven Batteries Reference Plant – Hyundai Steel (Phases 1+2), Dangjin, Korea
Battery
Coal Tower
Quenching facilities
Oven machines
Gas treatment plant
Coal treatment plant
High-Capacity Coke Oven Batteries
29 April 2014
Eurocoke Summit 2014 Edinburgh
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High-Capacity Coke Oven Batteries Coke Oven Batteries & Service Machines – Typical Design
PROven system
COMBIFLAME
Heat.-system
Underjet type
one-sided
Media supply
2/1 pushing cycle
Coke transfer car
& PECS
One spot
quench car
High-Capacity Coke Oven Batteries
29 April 2014
Eurocoke Summit 2014 Edinburgh
16
High-Capacity Coke Oven Batteries Coke Oven Batteries – Typical Design Criteria
Heating gas coke oven gas or compound oven
(availability of blast furnace gas)
COMBIFLAME waste gas recirculation & air stages
heating system for NOx reduction
Individual chamber - reduction of gaseous emissions
pressure control system - higher investment & maint. cost
Underjet oven or Underjet easy adjustment, basement req’d
gun type oven Gun type more equipment & refractory
one-sided or double-sided two-sided easier heating adjustment
media supply but higher investment cost
High-Capacity Coke Oven Batteries
29 April 2014
Eurocoke Summit 2014 Edinburgh
17
High-Capacity Coke Oven Batteries Project Execution Concept
Uhde+P: Uhde plus local partner
Start-
up Client, Plant Location Basic Eng. Detail Eng.
Process
relevant
Equipment
Refractory
Material
Bulk
Material Construction Commissioning
2014 HKM, Hüttenwerke Krupp Mannesmann
Duisburg, Germany Uhde Uhde Uhde Uhde Uhde Uhde Uhde
2013 Hyundai Steel Comp. (HSC), Phase 3
Dangjin, Chungnam, South Korea Uhde Uhde+P Uhde Uhde Uhde+P
Client
Uhde: SV
Client
Uhde: SV
2010 POSCO, Gwangyang Works, Phase 5,
Gwangyang, South Korea Uhde Uhde+P Uhde Uhde Uhde+P
Client
Uhde: SV
Client
Uhde: SV
2010
Zhangjiagang Hongfa Steelmaking
Co., Ltd. (SHAGANG)
Zhangjiagang, China
Uhde mainly
Client
mainly
Client Client Client
Client
Uhde: SV
Client
Uhde: SV
2009 Hyundai Steel Comp. (HSC), Phases 1+2
Dangjin, Chungnam, South Korea Uhde Uhde+P Uhde Uhde Uhde+P
Client
Uhde: SV
Client
Uhde: SV
2009
Shougang Jingtang United,
Iron & Steel Company
Caofeidian, Hebei, China
Uhde mainly
Client
mainly
Client Client Client
Client
Uhde: SV
Client
Uhde: SV
2008 Wuhan Iron & Steel Corp. (WUGANG)
Wuhan, Hubei, China Uhde
mainly
Client
mainly
Client Client Client
Client
Uhde: SV
Client
Uhde: SV
2006 Maanshan Iron & Steel Co. (MAGANG)
Maanshan, Anhui, China Uhde
mainly
Client
mainly
Client Client Client
Client
Uhde: SV
Client
Uhde: SV
2006
& 2013
Taiyuan Iron & Steel Co. (TISCO)
Taiyuan, Shanxi, China Uhde
mainly
Client
mainly
Client Client Client
Client
Uhde: SV
Client
Uhde: SV
2003 Carbonaria/TK Schwelgern
Duisburg, Germany Uhde Uhde
Client/
Uhde
Client/
Uhde
Client/
Uhde
Client/
Uhde
Client/
Uhde
High-Capacity Coke Oven Batteries
29 April 2014
Eurocoke Summit 2014 Edinburgh
18
High-Capacity Coke Oven Batteries Project Execution Concept
Remark:
Experience shows that the success of a project is deeply depending on the
right split of services and supplies and on the quality of communication,
trust and understanding between Buyer and Contractor.
Contractor’s minimum scope - complete engineering
(to secure guarantees for - process relevant equipment
process & performance) - supervision of construct. & comm.
Supply of refractories - crucial item for time schedule
(complex logistics and - special expertise required
quality control) - at least QC by contractor
Construction & commissioning - preferably by local contractors
Aspects of turnkey contracts - less project management by Buyer
- most costly solution
High-Capacity Coke Oven Batteries
29 April 2014
Eurocoke Summit 2014 Edinburgh
19
Thank you for your attention !
High-Capacity Coke Oven Batteries