29 SEP Presentation

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    W E L C O M ER A S H T R IY A IS P A T N IG A M L IM IT E D

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    Vizag Steel Plant

    COAL BLENDING MODEL

    ON COST OPTIMIZATION

    AT VIZAG STEEL

    S.K.SEET

    D.S.SASTRY

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    TOPIC

    % Introduction

    %Coke Requirement vis--vis BlastFurnace operation

    %Challenges for Steel Industry for coke

    %Opportunity & Alternatives

    %Efforts at Vizag steel

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    introduction

    % Steel industry is highly energy intensive having 5 to 8Gcal/tls in Indian scenario. Where as in other part of theworld it is around 4.5 to 5.5 Gcal/tls. Out of this 60 to 70 %is contributed from energy being consumed in iron makingthrough coke oven blast furnace route. To day 50 to 60 % ofsteel is made through this route, which is still a dominanttechnology. In this energy consumption coke is the maincontributor & many a time redefining coke qualityrequirement remains the crux of the subject The redefinitionof coke quality takes in to cognizance several factors thatput the biggest challenges as well as opportunity to the cokemaking technology. They include designing of suitable cokingblend against constraints such as; economic, logistic and

    pollution. A targeted coke quality production against theseconstraints has been the major driving force to developvarious alternate technology of coke making, blendformulation with cost optimization, coke making withenergy efficient and environment friendly route.

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    BLAST FURNACE SHOP

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    PROCESS OF COKE QUALITY

    DETERMINATION

    Blast

    Furnace

    Volume, operating regime

    Extent of auxiliary fuel

    Productivity requirement

    Coking coal availability/Cost/Logistics

    Up stream Fuel gas requirement

    CokeQuality

    specification

    Coke Chemical requirementCoke Physical requirement

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    CONSTRAINTS BEFORE

    STEELMAKERS TODAY

    % CRUDE STEEL PRODUCTION BY 2019-20 WILL BEARROUND 110 MT AS PER NSP

    % SHARE OF HOT METAL THROUGH BF ROUTEWILL BE 65 MT

    % COKING COAL CONSUMPTION WILL THEN

    INCREASE FROM PRESENT LEVEL OF 25 MT TO70 MT

    % INDIAN COKING COAL ARE INFERIOR INQUALITY

    % INSPITE OF VARIOUS AUXILLARY FUEL

    INJECTION IN BF THE DEMAND FOR MET COKEWILL INCREASE

    % INDIA TODAY HAS NO OPTION BUT TOHEAVILY DEPENDANT ON HARD COKINGCOAL IMPORT

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    1 8

    C o k in g C o a l R e q u ire m e n t

    P re s e n t & o n P la n t e x p a n s io n( In M i l l io n T o n n e s )

    0 . 4 9 20 . 4 2 0- -P C I

    7 . 5 2 54 . 9 2 53 . 5 9 8T o t a l

    0 . 6 9 10 . 6 7 50 . 5 3 8M e d i u m

    - -- -0 . 5 4 0S o f t

    6 . 3 4 23 . 8 3 02 . 5 2 0H a r d

    1 0 .0 M T b y

    2 0 1 2 - 1 32 n d P h a s e

    6 .3 M T b y

    2 0 0 8 - 0 91 s t P h a s e

    P r e s e n t

    2 0 0 6 - 0 7C o k in g C o a l

    COKING COAL REQUIREMENT AT VIZAG STEEL

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    2 6

    L o c a lA v e r a g e1 0S m a l l

    V o l u m e s o f

    e v e r y t h i n g

    M a in l y

    u n d e r g r o u n d

    I n d i a

    E u r o p e /

    U S A /

    A r g e n t i n a

    A v e r a g e1 5H a r d a n d

    s e m i- s o f t

    M a in l y

    u n d e r g r o u n d

    , s m a l l

    m i n e s .

    In d u s t ry i s

    s t i ll e v o l v i n g

    C o lo m b i

    a

    L o c a l , s o m e

    to J a p a n ,

    K o r e a , B r a z i l

    A v e r a g e4 0 0 / 2 0 0

    ( 5 0 % l o s s o n

    w a s h i n g )

    - d o -M a in l y

    u n d e r g r o u n d

    , s m a l l a n d

    la r g e

    s a f e t y fa c t o r

    a q u e s t io n

    m a r k

    C h i n a

    J a p a n ,

    E u r o p e ,

    B r a z i l

    - d o -5 0- d o -- d o -C a n a d a

    J a p a n ,

    K o r e a , I n d i a ,

    B r a z i l

    E x c e l l e n t1 0 0H a r d , S e m i -

    s o f t & S o f t

    O p e n c a s t &

    U n d e r g r o u n d

    la r g e m in e s

    A u s t r a l i a

    P r i n c i p a l

    M a r k e t s

    L o g is t ic s &

    P o r t s

    A p p r o x .

    a n n u a l Q ty .

    (M T )

    T y p e o f C o a lT y p e &

    N a t u r e o f

    M in in g

    C o u n t r y

    World Coking Coal at a Glance

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    3S e m i-

    f t

    e r re n e z e l

    E u r eE x c e l l e n t3S e m i-

    f t

    O p e n c a s tS o u t

    f r i c a

    L o c a l , s o m e t o

    a p a n o re a

    T e r r i le5 0- o -- o -R u s s i a

    E u ro p eA v e ra g e3 0H a r ,

    S e m i s o f t

    /s o f t

    n d e rg ro u n d -

    la rg e m in e s

    P o l a n d

    5 5 6T

    ot a l

    a p a n , E u ro p eE x c e l l e n t5 0- d o -n d e rg ro u n d

    O p e n c a s t

    S A

    L o c a l E u ro p eA v e ra g e3 0H a rd ,s e m is o f t

    / S o f t

    n d e rg ro u n d la rg e m in e s

    a n d re s e rv e s

    d e p l e t i n g

    U k ra in e

    L o c a l , s o m e t o

    c h i n a

    T e r r i le5H a rdU n d e rg ro u n dN o r t h

    o re a

    L o c a l o n lT e r r i le1 0H a rd /

    S e m i-

    s o f t

    U n d e rg ro u n d -

    la rg e m in e s

    K a z a k h s t a

    n

    P r in c i p a l M a rk e tsL o g is t i c s

    P o r ts

    A p p ro x .

    a n n u a l

    t . ( M T )

    T y p e o f

    C o a l

    T y p e N a t u re

    o f M in in g

    C o u n try

    World Coking Coal at a Glance

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    CONSTRAINT IN CONVENTIONAL

    COKE MAKING

    %AGEING OF BATTERY

    %USE OF HIGH COST COKINGCOAL

    %HIGH ENERGY CONSUMPTION

    %HIGH LEVEL OF POLLUTION

    %MODERATE PRODUCTIVITY

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    1. Explore new & emerging technology to meet

    environmental and energy constraints

    2. To utilize indigenous coal quality

    3. To enhance battery life4. Measure on low cost blend and energy

    conservation to make the coke making

    technology more cost effective

    5. Bring about an clarity of understanding onexact nature of coal to coke transformation vis-

    -vis coal quality and operating parameters.

    ISSUES TO BE RESOLVE

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    Popular Routes of Iron making

    Primary Secondary

    Blast FurnaceDirect Reduction

    a. DRI

    b. MIDREX

    Smelting Reduction

    a. COREX

    b. FINEX

    c. ROMELT

    d. HISMELT

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    D E V E L O P E D B Y M / s V A I , I T IS

    T H E F IR S T C O M M E R C I A L

    S M E L T IN G R E D U C T IO NP R O C E S S .I T C A N U S E L U M P I R O N O R EA N D N O N C O K I N G C O A L S

    R E Q U I R E M E N T : L O W A S H (8 - 1 2% )

    H I G H V .M . ( 20 - 2 5% )N O N C O K I N G C O A LO X Y G E N 5 0 0 - 60 0 m 3 /T h m

    J V S L S C O R E X F U R N A C E I S

    O P E R A T I N G W IT H 1 0 0 %IM P O R T E D C O A L .

    C O R E X P R O C E S S

    S m e ltin g R e d u c t io n

    OPPORTUNITY TO REDUCE MET COKE DEMAND

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    D E V E L O P E D

    P O S C O A N D

    M/ V A I,

    I O N S I S T S O FT W O S T A G E S

    I T P E R M I T S P R O D U C T I O N O F

    H O T M E T A L W I T H C H E A P

    & A B U N D A N T O R E F I N E S

    A N D N O N - C O K I N G C O A L S .

    T H E F I R S T A N D O N L Y P L A N TU S I N G T H I S P R O C E S S I S A T

    P O S C O . I T S T A R T E D I N M A Y

    2 0 0 3 , W I T H A N A N N U A L

    C A P A C I T Y O F 0 0 , 0 0 0 T O N S .

    F I N E X E S S

    OPPORTUNITY TO REDUCE MET COKE DEMAND

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    D E V E L O P E D B Y JIS F.

    I T IS A 2/ 3 S T A G E

    S M E L T I N G R E D U C T I O N

    P R O C E S S I R O N O R E F I N E S A N D H IG H

    A S H , H IG H V M C O A L S C A N

    B E U S E D IN T H IS P R O C E S S .

    A P IL O T P L A N T O F

    C A P A C IT Y 0 0 T/ D A Y W A S

    C O M M I S S IO N E D I N 9 9 3 I N

    J A P A N

    Y E T T O S T A R T L A R G E S C A L EC O M M E R C I A L P R O D U C T IO N

    D I O S O C E S S

    OPPORTUNITY TO REDUCE MET COKE DEMAND

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    ALTERNATE TO COKE MEKING

    TECHNOLOGY

    %JUMBO COKE OVEN

    %

    MIXED PROCESS WITHALTERNATE USE OF COG

    %HEAT RECOVARY OVENS

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    JUMBO COKE OVEN

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    ALTERNATIVE PROCESS SCHEME IN AN INTEGRATED

    STEEL PLANTWITH VARIOUS USE OF COG

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    COAL BLOCK CHARGING IN HEAT

    RECOVARY OVEN

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    21

    SLOT OVEN VS HEAT RECOVARY

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    ENABLERS OF COKING

    TECHNOLOGY AT VIZAG STEEL

    %PHYLOSOPHY OF BLEND DESIGN

    %BLENDING MODEL ON COSTOPTIMIZATION

    %ECO FRIENDLY COKE MAKING%OPERATING DISCIPLINE TO

    ENHANCE BATTERY LIFE

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    COKE GAS

    LIGHT OIL

    WASH OIL

    HP NAPHTHALENE

    ANTHRACENE OIL

    PHENOL

    PITCH

    CT FUEL

    BENZENE

    TOLUENE

    H.B.F

    SOL110

    SOLVENT NAPTHA

    STILLBOTTOMS

    COKING COALFROM RMHP

    COKE OVEN

    BATTERIES

    RUN OF OVEN

    COKE (HOT)

    COKE DRY

    COOLING PLANT

    STEAM

    BPTS

    COOLED COKE

    COKE SORTING PLANT

    BREEZE COKE

    0-10 MM

    NUT COKE

    10-25 MM

    BF COKE

    25-80MM

    COKE DUST

    0-3 MM

    BURDEN HANDLINGSECTION(B.F)

    TOS.P

    SINTER

    PLANT

    COKE SLUDGE

    0-3 MM

    TO SALE

    COAL PREPARATION PLANT

    TO

    YARD

    TO

    YARD

    SEPARATOR

    FLUSHING

    LIQUOR

    RAW COKE

    OVEN GAS

    PRIMARY GAS

    COOLERTO GCM

    TO DECANTER EXHAUSTER

    AMMONIUM

    SULPHATE

    FINAL GAS

    COOLER

    CLEAN COKE

    OVEN GAS

    CONSUMER

    BATTERYUNDER FIRING

    CRUDE

    BENZOL

    BENZOL

    RECTIFICATION PLANT

    TAR DISTILLATION PLANT

    PROCESS SCHEME OF COKE

    MAKING

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    Tippler

    house

    Jn-1

    Track

    hopper

    Ground

    Hoper

    Jn-3 Jn-4 Jn-5

    B O I LE R C O A L

    B O I LE R C O A L

    B O I LE R C O A L

    B O I LE R C O A L

    C -5

    S O F T C O A L

    IC C 2 C OA L

    IC C 1 C O A L

    M C C C O A L

    IC C 3 C OA L

    IC C 2 C OA L

    S O F T C O A LB E L T C O N V E Y O R

    B E L T C O N V E Y O R

    B E L T C O N V E Y O R

    B E L T C O N V E Y O R

    B E L T C O N V E Y O R

    B E L T C O N V E Y O R

    T OT hermal

    Power

    Plant

    Jn-1 8

    Jn-1 9 CokingCoa l

    T o Coa l

    Preparation

    P lan t

    Tail

    end

    Drive

    end

    SCHEME OF COAL HANDLING & STORAGE

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    SHEMATIC VIEW OF COKE OVEN

    OVENCH

    I

    M

    N

    E

    Y

    GCM GCM

    S

    PS

    P

    PUSHER SIDECOKE SIDE

    STEAM

    CROSS OVER MAIN

    SUCTION MAIN

    BF GAS LINE

    CO GAS LINE

    BUS FLUE

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    CARBONIZATION PROPER( PROCESS PARAMETER OF CARBONIZATION)

    %

    DRY COAL CHARGED 8300 TONS/DAY% MICROFINES CONTENT IN CHARGE 30% MAX

    % MOISTURE CONTENT IN CHARGE 7-9%

    % VOLATILE MATTER IN CHARGE 25-27%

    % MMR OF CHARGE UP TO 1.15

    % VERTICAL SHRIKAGE OF CHARGE > 5%

    % AVERAGE COKING PERIOD 16-18 HRS

    % CONTROL VERTCAL TEMPERATURE 1250-1330 OC

    % FREE SPACE TEMPERATURE < 800 OC

    %PRI & CRI > 0.96

    % COEFFICIENT OF HEATING UNIFORMITY(Kb) > 0.9

    % ALL EMMISIONS LEVEL BELOW STIPULATED NORM

    % RARE INSTANCE OF HIGH PUSHING AMPERAGE

    CONTD.

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    % Strict control on coal blend quality such as; MMR, VM, Moisture,granulometry etc, to avoid chance of higher coking pressure.

    % Blend composition, CO gas quality is monitored every shift.

    % Micro fines were allowed as low as possible in the blend alongwith strict vigilance on Q.I content of coal tar

    % Batteries were operated at a fixed coking time as far as possible

    % GCM pressure is maintained at 16 mmwc with an aim to achievepositive sole pressure at the end of coking time

    % Ascension pipes, door, doorframe are cleaned every day

    % Inspection of oven, stand pipes, charging hole & door leakage byoperator after every pushing

    %

    Lutting of lids and immediate adjustment of knife sealing of doors% Coking hours variation is kept within 30 minutes (max )

    % Gas temperature, GCM Pressure, pushing amperage, steam flow,heating gas flow, Flue temperature were monitored and loggedthrough computer

    CARBONIZATION PROPER( PROCESS PARAMETER OF CARBONIZATION)

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    Fugitive Emission Stack Emission

    Parameter PLD PLO PLL SPM SO2 NOX

    Norm

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    B O I

    C H A M B E R D C B

    C Y C L O N E

    C O N V E Y E R

    1 ,

    2

    IL L

    N

    S A F E T Y V A L V E

    H O T C O K E

    N 2

    2 T O N

    3 T O N

    T O

    3 T O N B K R .

    T O

    B P T S

    E

    C

    O

    N

    O

    M

    I

    S

    E

    R

    E

    V

    E

    P

    O

    R

    A

    T

    O

    R

    S H

    1 2 6 V A L V E

    G 1 , 3G 2 , 4

    C D C PS C H E M A T I C

    D I A G R A M

    A i rA i r

    CDCP- ENVIRONMENTAL AND ENRGY EFICIENT

    COKE MAKING PRACTICE

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    %LESS POLLUTION

    %POWER GENERATION 12 MW

    %LESS WATER IN COKE

    %HIGHER STABILITY OF COKE

    %HIGHER CSR OF COKE

    CDCP- ENVIRONMENTAL AND ENRGY EFICIENT

    COKE MAKING PRACTICE

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    % CHEMICAL REQUIREMENT OF COKE

    % PHYSICAL REQUIREMENT OF COKE

    % REQUIREMENT OF CARBONIZATION YIELD

    % REQUIREMENT OF BATTERY LIFE% CONSIDERATION FOR COAL WEATHERING

    % INCORPORATION OF LOW COST SEMICOKING COAL COMPONENT

    % COST OPTIMIZATION OF BLENDING OPTIONS% LOGISTICS

    CONTD.

    BLENDING PHYLOSOPHY

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    J n - 1 9C o a lF r o m

    R M H P

    F o r e i g nO b j e c t

    S e p a r a t i o n

    ( F O S )

    J n -2

    1

    3

    5

    7

    9

    1 1

    1 3

    1 5

    2

    4

    6

    8

    1 0

    1 2

    1 4

    1 6

    C o a l

    C r u s h i n g

    - 3 m m

    J n -3C o a l

    to e r

    C h a r g e d

    T o b a t t e ry

    1 6 n o s

    S i l o

    T o

    S t o r e

    D i ff e r e n tC a t e g o r y

    o f c o a l s

    F o r

    b l e n d i n g

    W e ig h f e e d e r

    D e s i g n a t e d

    b l e n d

    D e s i g n a t e d

    b l e n d

    THE COAL BLENDING PROCESS

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    ROUTINE TEST

    % PROXIMATE

    % ULTIMATE

    % CSN/FSI

    % LTGK

    % ALKALI

    % ASH BASICITY INDEX

    % DEGREE OF OXIDATION

    % PHYSICAL TESTS ON

    COKE STRENGTH MICUM TEST

    CRI/CSR (AS PER ASTM

    D 5341)

    SPECICIAL TESTS ADDED

    % MMR & PETROGRAPHY

    % PILOT OVEN TESTFACILITY

    %

    PLASTOMETRY

    CONTD.

    CHARACTERIZATION OF COAL

    AND MET COKE

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    MMR & PETROGRAPHY

    TESTINGFACILITY AT VIZAG STEEL

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    BLEND COAL SAMPLE SHOWING

    VARIOUS MACERALS

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    3

    capacity--- 250kg

    length of oven --- 920mm

    idth of the oven --- 405mm

    height of the oven --- 1035mm

    useful volume --- 0.32 m3

    movable heating all TYPE

    SALIENT FEATURE OF PILOT OVEN

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    PILOT TEST RESULT OF PLASTIC &

    ANTHRACITE

    Parameter

    B end coal+

    Plast c

    5%

    Ant racite

    % V.M 0.62 0.62

    % A H 6.3 16.3

    % F.C 3.08 83.08

    M- 40 78.0 79.0

    M- 10 11.0 10.0

    C 27.0 23.0

    C 56.2 63.0

    1. 5% use of anthracite in the blend is tested

    and found to be suitable

    2. Use of plastic in the coal blend gave resultwhich is encouraging

    3. Use of low ash Non-Coking coal in the blend

    is under progress

    4. A systematic difference to the tune of 5 to 7

    points in CSR value is observed between

    pilot and actual battery.

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    F

    x

    g!

    f" ! #

    e q$

    a% &

    y by BF

    B % e '

    g a% &

    e(

    a& )

    e 0

    B % e ' g a % & e ( a & ) e 0 0 a & 0 fy g

    Te " 1 " a % " ( & e ( a

    Be0 &

    B% e '

    g Op& ! 0

    B 2 e 3 4 C 5 a 2 q 6 a 2 7 8 y

    5 9

    De@

    7 g 3 C 9 7 8 e 9 7 a

    CSR/CSR0 &

    a b % & y/ 1 a( '

    e0 0

    A0 1 A 0 $ % p 1 $ ( A a 0 1 ba 0 " & y &a % # a %

    Ex 0 &

    g p( ! "

    e0 0

    fa" % &

    y

    L &

    e(

    a& $ (

    e0 $ ( )

    e y

    P % ! & " ! B B e ( " a % ! ) e & ( a % f! ( B a & !

    Ba& &

    e ( y p ( e 0 0 $ ( e &" ! #

    g p ( e 0 0 $ ( e

    Fa) ! (

    a b % e% !

    g 0 & "

    C! 0 &

    ! p& B

    za& !

    & e " 1 q $ e /LP & e " 1 q $ e

    Pilot Testing of the model

    output blend

    Decision to go for commercial

    trialBlend for regular use

    PROCESS OF BLENDING DECISION

    AT VIZAG STEEL

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    CONCLUSION

    %

    Dependence on imported coal is likely to increase in which case the coal selection andblend formulation will require focused attention. Vizag steel has started few efforts inthis direction and one among them is development of a cost optimized blend designmodule.

    % Handling of coal storage and proportioning in port and plant need augmentation.

    % An improvement in the conventional system of coke making includes high capacityovens. They will provide cost savings, better stability & lifetime, operational performanceand less environmental problems

    %

    In total CO2 emission in China is no-2 and India is in no-5 position. Hence ecology isgoing to be the biggest concern for Indian steel industry in future. A suitable selection ofcoke making alternative fulfilling the future environ mental requirement will beprudent to keep coke production on sustainable basis.

    % As Met coke will remain the most critical input to the Steel Industry sustainable long-term strategy is necessary. In this regard modern HR coke oven offers economical,environmental friendly and technologically viable solution to feed future coke demand.It should be the Technology For The Future. However for integrated steel plant it needa judicious mix of both by-product recovery and HR type

    % World coals generally fall into broad categories resembling high fluidity USA coal or lowfluidity high ash and sulfur of Australian type. High fluidity coal generally predominatesin Columbia, Russia, China, and New Zealand regions. Low fluidity coals are common inAustralia, Canada, and India & CIS regions. A judicious mix of both categories with useof cheaper addition of reverts, low rank coal with the adoption of coal blending modeldeveloped at Vizag Steel can help in addressing this issue.

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    Questions

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