JSW Dolvi (2)oc4.tksranchi.in/49thOc4/Presentations/Session-1/JSW Dolvi (2).pdf · Sr. No. Causes...

10-12-2018

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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

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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


Billet Caster Bar Mill

Sinter Plant

Coke oven

Blast furnace Pig Casting

Fluxes

TMT


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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



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


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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



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


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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 %

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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


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


Control Actions:

• Pressure grouting in wharf

• Till date 1st round and 2nd round of grouting work is completed

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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


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.


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.

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Reduction in hot coke discharge at wharf

BEFORE AFTERAFTER


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


For healthy condition of quenching pumps & valves fortnightly changeover is practiced introduced

Co-relation between quenching valve and quenching time is established

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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


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


Quenching Pond

Suction HeaderQuenching Pump Quenching Tower

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Effective wharf management


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.


Ensuring healthy condition of working hammers by proper PM

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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


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


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 %

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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


within the range

Actual 10‐01‐18 11‐01‐18 17‐02‐18 25‐03‐18 Ongoing

THANK YOU


THANK YOU

24

JSW Dolvi (2)oc4.tksranchi.in/49thOc4/Presentations/Session-1/JSW Dolvi (2).pdf · Sr. No. Causes...

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