jsw dolvi (2)oc4.tksranchi.in/49thoc4/presentations/session-1/jsw dolvi (2).pdf · sr. no. causes...
TRANSCRIPT
10-12-2018
1
49th Operating Committee | JSW Coke O en Dol i | 29 11 201849th Operating Committee | JSW Coke Oven Dolvi | 29.11.2018Reducing Coke Moisture & Improving Coke yield – Issues & Remedies
JSW Steel: Steel Manufacturing Facilities in India
CII EBA 2017_JSW Dolvi22
10-12-2018
2
DOLVI PLANT CONFIGIRATIONPellet Plant
ConArc
Iron ore Fines
Ladle Furnace
Current Capacity – 5 MTPA•Flat – 3.5 MTPA•Long – 1.5 MTPA
Ongoing expansion – 5 MTPA
Current Capacity – 5 MTPA
Ongoing expansion – 5 MTPA
Billet Caster Bar Mill
Coal
Coal InjectionPlant
HSMSponge Iron Plant
NGv
v
v
HRC
Jetty
Slab Caster
CII EBA 2017_JSW Dolvi33
Billet Caster Bar Mill
Sinter Plant
Coke oven
Blast furnace Pig Casting
Fluxes
TMT
CII EBA 2017_JSW Dolvi4
10-12-2018
3
Plant Details Coke oven # 1
SPECS DETAILS
Installed Capacity 1.0 MTPA
No of Batteries 2 ( Battery A & B)
Total No of Ovens 110 (2 x 55)
Coal Cake Dimensions 15000 mm x 5200 mm x 450 mm
Battery Type Stamp Charged
Quenching System Wet Quenching System
CII EBA 2017_JSW Dolvi5
Quenching System Wet Quenching System
Commissioning Date
Battery B : First Charging : 14th Feb 2014
First Pushing : 16th Feb 2014
Battery A : First charging : 25th Mar 2014
First pushing : 28th Mar 2014
PUSHER SIDE
OVERVIEW OF BATTERY AREA COKE # 1
COKE SIDE
CII EBA 2017_JSW Dolvi6
10-12-2018
4
Plant Details Coke Oven # 2 (Phase#1)
SPECS DETAILS
Installed Capacity 1.5 MTPA
No of Batteries 2 ( Battery A & B)
Total No of Ovens 124 (2 x 62)
Coal Cake Dimensions 17000 mm x 6250 mm x 450 mm
Battery Type Stamp Charged
Quenching System Wet Quenching System
CII EBA 2017_JSW Dolvi7
Commissioning Date
Battery A : First Charging : 11th June2018
First Pushing : 13th June 2018
Battery B : First charging : 12th Nov 2018
First pushing : 14th Nov 2018
PUSHER SIDE
OVERVIEW OF BATTERY AREA COKE # 2
COKE SIDE
CII EBA 2017_JSW Dolvi8
10-12-2018
5
Business Case
This project supports in meeting the business objective of improving the product quality for the
end user (Blast Furnace) resulting in less fuel consumption with substantial financial benefits
Problem Definition:
At present the Moisture
content in the coke is in
CII EBA 2017_JSW Dolvi 9
the range of 5.6 to 6.5%
resulting in higher fuel
consumption in Blast
Furnace
Daily Average Coke Moisture % Before Implementation
6.2 6.2
6.3
6.2
6.4
5.9
6.1
6
5.7
6.1
5.8
6
6.1
5.9
5.8
6.2
5.7
5.9
5.8
6
6.1
6.2
5.8
6
5.8
5.7
5.6
6
5.8
5.7
5.9
5.7
5.6
5.9
6.1
5.2
5.4
5.6
5.8
6
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
CII EBA 2017_JSW Dolvi
01‐12‐1
02‐12‐1
03‐12‐1
04‐12‐1
05‐12‐1
06‐12‐1
07‐12‐1
08‐12‐1
09‐12‐1
10‐12‐1
11‐12‐1
12‐12‐1
13‐12‐1
14‐12‐1
15‐12‐1
16‐12‐1
17‐12‐1
18‐12‐1
19‐12‐1
20‐12‐1
21‐12‐1
22‐12‐1
23‐12‐1
24‐12‐1
25‐12‐1
26‐12‐1
27‐12‐1
28‐12‐1
29‐12‐1
30‐12‐1
31‐12‐1
10
Date
Project Statement:
• Average coke moisture % data recorded from 1st Dec’17 to 31st Dec’17 and the analysis reflects coke moisture is in the range of 5.6 % to 6.3 %
10-12-2018
6
Causes Identified and Actions Implemented
Sr. No. Causes Suggested Solution Implementation Status
1Water seepage at wharf due to presence of river close to plant premises
Grouting work in wharf area
Yes
2Reduction in hot coke discharge at wharf Regulate quenching cycle Yes
3 Maximising draining of quenching water from wagon at Quenching Tower
Increase drain time after quenching
Yes
4Effective wharf management
Coke retention time at wharf increased
Yes
Increase in Coal Cake bulk
CII EBA 2017_JSW Dolvi
5 Coal cake bulk density density Yes
6 Usage of fresh coals in coal blendUsage on first come first use basis
Ongoing
Water Seepage at Wharf
CII EBA 2017_JSW Dolvi
Control Actions:
• Pressure grouting in wharf
• Till date 1st round and 2nd round of grouting work is completed
10-12-2018
7
1.Quenching car position is fixed while receiving hot coke of 27 tons from oven.
Quenching System Details
2.As per the coke distribution in wagon, four water distribution header valves were kept adjusted (last 2 valves are 5% open and middle 2 valves are 95 % open). Quenching time is 125 sec and auto pneumatic valve opening % is 53.Usable volume of tank is 364.47 cubic meter and according to quenching pump head value, flow of water is 200cubic meter per hour.
3.The static head of a pump is the maximum height and build pressure can be delivered by following the capabilitywhich can be read by Q‐H curve. However , For sufficient head,8.2 mt water level in quenching tank is ensuredbefore every quenching process, around 75 cubic meter water is required for each quenching and 13 cubic‐metert t d
CII EBA 2017_JSW Dolvi
get evaporated
4.Quenching tank filling time is 6.45 mins from tank overflow to overflow.
5.After quenching process , water drain time is 120 sec in wagon.
6.Interlocking provided for excess water drain time inside quenching tower after quenching. 13
Quenching System Details
6. Coke retention time in wharf is 25 to 30 min which releases vaporous and moisture.
7.Coke discharge from wharf as per wharf management according to even and odd chamber to conveyor7.Coke discharge from wharf as per wharf management according to even and odd chamber to conveyorthough discharging scrapper. Sampling point is before cutter by picking coke from belt of around one meterand analysis done by quartering after flattening cone method.
8. We maintained Quenching pond level at the channel level.
9.If level is low, than BOD operator is being informed to feed treated water and accordingly we inform BODoperator to stop supply of treated water after getting sufficient level.
CII EBA 2017_JSW Dolvi14
10.Grab crane is operated in every shift and coke breeze settled in the pond are removed.
However maintaining the above practices now we are not getting red hot coke in wharf after quenching (daily reports of coke quality parameters has been attached along with production for your reference please) hence we don't required hot spot quenching at this moment.
10-12-2018
8
Reduction in hot coke discharge at wharf
BEFORE AFTERAFTER
CII EBA 2017_JSW Dolvi
Control Actions:
Quenching car position is fixed while receiving hot coke
As per the coke distribution in wagon, water distribution header valves are adjusted
For sufficient head, 8.2 m water level in quenching tank is ensured before every quenching process
Quenching tank filling time is reduced to 6 minutes
CII EBA 2017_JSW Dolvi
For healthy condition of quenching pumps & valves fortnightly changeover is practiced introduced
Co-relation between quenching valve and quenching time is established
10-12-2018
9
Maximising draining of quenching water from wagon at Quenching Tower
Control Actions:
• After quenching process , water drain time increased to 120 sec
• For close monitoring of drain time LT interlock is introduced in quenching car i.e. quenching car will
not move for certain duration after start of quenching process
CII EBA 2017_JSW Dolvi
not move for certain duration after start of quenching process
Adjustment of Manual Delivery Valves.
Delivery line
Manual butterfly Valve 2Manual butterfly Valve 1
Manual Gate valve 1
Quenching Tank
Manual gate valve
Manual butterfly Valve 2
Pneumatic valve
Dis
trib
uti
on
H
ead
er
Manual butterfly Valve 1
Qu
ench
ing
No
zzle Un
it
Manual Gate valve 2
Manual Gate valve 3
Manual Gate valve 4
CII EBA 2017_JSW Dolvi18
Quenching Pond
Suction HeaderQuenching Pump Quenching Tower
10-12-2018
10
Effective wharf management
CII EBA 2017_JSW Dolvi
Control Actions:
• To increase coke soaking time in wharf, practise of dumping pushing in alternate wharf is introduced i.e. wharf no 1,3,5 will be
used for first 3 pushing followed by usage of wharf no 2,4,6 for next 3 pushing
• After establishment of this practice , 25-30 mins of coke retention time is achieved
Coal Cake Bulk Density
Control Actions:
Increase in nos of fall of hammer, achieved by increase in motor rpm.
Introduction of stamping time trends in DCS for close monitoring of stamping duration.
CII EBA 2017_JSW Dolvi
Ensuring healthy condition of working hammers by proper PM
10-12-2018
11
Coal cake bulk density
27.50
28.00
28.50
Action Results
24.00
24.50
25.00
25.50
26.00
26.50
27.00
Coke WT/Oven
CII EBA 2017_JSW Dolvi
01‐10‐17 08‐10‐17 17‐10‐17 26‐10‐17 07‐11‐17 19‐11‐18 28‐11‐17 05‐12‐17 13‐12‐17 21‐12‐17 30‐12‐17 07‐01‐18 17‐01‐18 27‐01‐18 05‐02‐18 12‐02‐1801‐10‐17 08‐10‐17 17‐10‐17 26‐10‐17 07‐11‐17 19‐11‐18 28‐11‐17 05‐12‐17 13‐12‐17 21‐12‐17 30‐12‐17 07‐01‐18 17‐01‐18 27‐01‐18 05‐02‐18 12‐02‐18 19‐02‐18 27‐02‐2018' 04‐03‐18 10‐03‐18 17‐03‐18 25‐03‐18 101‐10‐17 08‐10‐17 17‐10‐17 26‐10‐17 07‐11‐17 19‐11‐18 28‐11‐17 05‐12‐17 13‐12‐17 21‐12‐17 30‐12‐17 07‐01‐18 17‐01‐18 27‐01‐18 05‐02‐18 12‐02‐18 19‐02‐18 27‐02‐2018' 19‐11‐17 04‐
03‐18 10‐03‐18 17‐03‐18 25‐03‐18 9‐02‐18 27‐02‐2018' 04‐03‐18 10‐03‐18 17‐03‐18 25‐03‐18
23.50
Date
Daily Average Coke Moisture % (Gross) After Implementation
5 2 5 2 5 2 5 2
5.3
5 2
5.4
Average Daily Moisture %
5.1
4.9
5.1
4.8
5.2
4.6
5.2
4.7
5.1
4.6
4.8
5
4.7
4.8
4.6
4.9
5.2
4.8
5 5
4.8
5.1
5.2
4.9
4.8
5.1
5
4.7
5.1
4.9
4.2
4.4
4.6
4.8
5
5.2
CII EBA 2017_JSW Dolvi22
Project Statement:
From 26th March’18 to 25th April’18 data analysis reflects coke moisture is in the range of 4.6 % to 5.3 %
10-12-2018
12
Tangible Rs.20 Cr per annum for each percentage reduction in coke moisture
I t ibl E ti i k hi
Project Benefits
Project Milestones
Start Define Measure Analyze Improve Remark
Plan 10‐01‐18 11‐01‐18 17‐02‐18 25‐03‐18 25‐04‐18 Coke moisture is maintained
Intangible Expertise in coke quenching process
CII EBA 2017_JSW Dolvi
within the range
Actual 10‐01‐18 11‐01‐18 17‐02‐18 25‐03‐18 Ongoing
THANK YOU
CII EBA 2017_JSW Dolvi
THANK YOU
24