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High-Capacity Coke Oven Batteries Ralf Neuwirth, Frank Redemann Eurocoke Summit 2014 Edinburgh 29 April, 2014

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Page 1: High-Capacity Coke Oven Batteries€¦ · High-Capacity Coke Oven Batteries 29 April 2014 Eurocoke Summit 2014 Edinburgh 2 High-Capacity Coke Oven Batteries Definition High-Capacity

High-Capacity Coke Oven Batteries

Ralf Neuwirth, Frank Redemann

Eurocoke Summit 2014 Edinburgh

29 April, 2014

Page 2: High-Capacity Coke Oven Batteries€¦ · High-Capacity Coke Oven Batteries 29 April 2014 Eurocoke Summit 2014 Edinburgh 2 High-Capacity Coke Oven Batteries Definition High-Capacity

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

Page 3: High-Capacity Coke Oven Batteries€¦ · High-Capacity Coke Oven Batteries 29 April 2014 Eurocoke Summit 2014 Edinburgh 2 High-Capacity Coke Oven Batteries Definition High-Capacity

High-Capacity Coke Oven Batteries

29 April 2014

Eurocoke Summit 2014 Edinburgh

3

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

Page 4: High-Capacity Coke Oven Batteries€¦ · High-Capacity Coke Oven Batteries 29 April 2014 Eurocoke Summit 2014 Edinburgh 2 High-Capacity Coke Oven Batteries Definition High-Capacity

High-Capacity Coke Oven Batteries

29 April 2014

Eurocoke Summit 2014 Edinburgh

4

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

Page 5: High-Capacity Coke Oven Batteries€¦ · High-Capacity Coke Oven Batteries 29 April 2014 Eurocoke Summit 2014 Edinburgh 2 High-Capacity Coke Oven Batteries Definition High-Capacity

High-Capacity Coke Oven Batteries

29 April 2014

Eurocoke Summit 2014 Edinburgh

5

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

Page 6: High-Capacity Coke Oven Batteries€¦ · High-Capacity Coke Oven Batteries 29 April 2014 Eurocoke Summit 2014 Edinburgh 2 High-Capacity Coke Oven Batteries Definition High-Capacity

High-Capacity Coke Oven Batteries

29 April 2014

Eurocoke Summit 2014 Edinburgh

6

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

Page 7: High-Capacity Coke Oven Batteries€¦ · High-Capacity Coke Oven Batteries 29 April 2014 Eurocoke Summit 2014 Edinburgh 2 High-Capacity Coke Oven Batteries Definition High-Capacity

High-Capacity Coke Oven Batteries

29 April 2014

Eurocoke Summit 2014 Edinburgh

7

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

Page 8: High-Capacity Coke Oven Batteries€¦ · High-Capacity Coke Oven Batteries 29 April 2014 Eurocoke Summit 2014 Edinburgh 2 High-Capacity Coke Oven Batteries Definition High-Capacity

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

Page 9: High-Capacity Coke Oven Batteries€¦ · High-Capacity Coke Oven Batteries 29 April 2014 Eurocoke Summit 2014 Edinburgh 2 High-Capacity Coke Oven Batteries Definition High-Capacity

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

Page 10: High-Capacity Coke Oven Batteries€¦ · High-Capacity Coke Oven Batteries 29 April 2014 Eurocoke Summit 2014 Edinburgh 2 High-Capacity Coke Oven Batteries Definition High-Capacity

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

Page 11: High-Capacity Coke Oven Batteries€¦ · High-Capacity Coke Oven Batteries 29 April 2014 Eurocoke Summit 2014 Edinburgh 2 High-Capacity Coke Oven Batteries Definition High-Capacity

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

Page 12: High-Capacity Coke Oven Batteries€¦ · High-Capacity Coke Oven Batteries 29 April 2014 Eurocoke Summit 2014 Edinburgh 2 High-Capacity Coke Oven Batteries Definition High-Capacity

High-Capacity Coke Oven Batteries

29 April 2014

Eurocoke Summit 2014 Edinburgh

12

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

Page 13: High-Capacity Coke Oven Batteries€¦ · High-Capacity Coke Oven Batteries 29 April 2014 Eurocoke Summit 2014 Edinburgh 2 High-Capacity Coke Oven Batteries Definition High-Capacity

High-Capacity Coke Oven Batteries

29 April 2014

Eurocoke Summit 2014 Edinburgh

13

High-Capacity Coke Oven Batteries Reference Plant – Posco, Gwangyang, Korea

Battery

Coal Tower

Quenching facilities

Oven machines

Gas treatment plant

Coal treatment plant

Page 14: High-Capacity Coke Oven Batteries€¦ · High-Capacity Coke Oven Batteries 29 April 2014 Eurocoke Summit 2014 Edinburgh 2 High-Capacity Coke Oven Batteries Definition High-Capacity

High-Capacity Coke Oven Batteries

29 April 2014

Eurocoke Summit 2014 Edinburgh

14

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

Page 15: High-Capacity Coke Oven Batteries€¦ · High-Capacity Coke Oven Batteries 29 April 2014 Eurocoke Summit 2014 Edinburgh 2 High-Capacity Coke Oven Batteries Definition High-Capacity

High-Capacity Coke Oven Batteries

29 April 2014

Eurocoke Summit 2014 Edinburgh

15

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

Page 16: High-Capacity Coke Oven Batteries€¦ · High-Capacity Coke Oven Batteries 29 April 2014 Eurocoke Summit 2014 Edinburgh 2 High-Capacity Coke Oven Batteries Definition High-Capacity

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

Page 17: High-Capacity Coke Oven Batteries€¦ · High-Capacity Coke Oven Batteries 29 April 2014 Eurocoke Summit 2014 Edinburgh 2 High-Capacity Coke Oven Batteries Definition High-Capacity

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

Page 18: High-Capacity Coke Oven Batteries€¦ · High-Capacity Coke Oven Batteries 29 April 2014 Eurocoke Summit 2014 Edinburgh 2 High-Capacity Coke Oven Batteries Definition High-Capacity

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

Page 19: High-Capacity Coke Oven Batteries€¦ · High-Capacity Coke Oven Batteries 29 April 2014 Eurocoke Summit 2014 Edinburgh 2 High-Capacity Coke Oven Batteries Definition High-Capacity

High-Capacity Coke Oven Batteries

29 April 2014

Eurocoke Summit 2014 Edinburgh

19

Thank you for your attention !

High-Capacity Coke Oven Batteries