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Dry Quenching of Hot Coke
Satyendra April 25, 2013 9 Comments
CDCP, CDQ, Coke Rate, CSR, CWQ, Drum Index, Micum
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Dry Quenching of Hot Coke
Coke dry quenching (CDQ) is an energy saving process used during the
production of coke in the coke oven battery. A CDQ plant is also called
coke dry cooling plant (CDCP). In the traditional CWQ (coke wet
quenching) process, the red-hot coke which is pushed from the coke oven
is cooled by spraying water on the hot coke. The water used for cooling is
vapourized and released into the atmosphere. An issue with this
conventional system is the energy loss when the thermal energy of the
red-hot coke is converted into the steam which is vapourized and released
unused. Another drawback is that the CWQ process also produces
airborne coke dust, and hence, the CWQ process is associated with high
CO2 emissions and thermal energy loss.
During the CWQ process for cooling of the run of oven coke, sensible heat
of the hot coke is dissipated into the atmosphere and is lost. In addition,
there are air borne emissions (0.5 ton of steam per ton of coke, which is
laden with phenol, cyanide, sulphide and dust) and a large quantity of
water (around 0.6 cum per ton of coke) is needed for wet quenching. The
contaminants in water are also discharged in the environment. Tab 1
shows the comparison of typical properties of coke produced by the CWQ
process and the CDQ process.
Tab 1 Comparison of typical properties of coke produced by CWQ and CDQ processes
Sl. CWQ CDQ
Parameters Units
No. process process
1 Water content % 2-5 0.1-0.3
2 Ash content % 11.35 11.39
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3 Volatile components % 0.5 0.41
4 Average particle size mm 65 55
Coke breeze rate (after cut at
5 % 10 13
-15 mm)
6 Porosity % 49 48
7 Drum index % 83.5 85
Coke strength after reaction
8 % 58 60
(CSR)
In the CDQ process, the red-hot coke is cooled by gas circulating in an
enclosed system, thereby preventing the release of airborne coke dust.
The thermal energy of the red-hot coke, which is lost in the conventional
CWQ process, is collected and reused as steam in the CDQ system. This
technology uses less fossil fuel and results in lower CO2 emissions,
thereby contributing to the prevention of global warming. Nowadays, CDQ
plants have gathered a lot of attention from the world due to its e cient
energy recovery and the characteristic of reducing the environment
pollution. They are being regarded as an essential facility for the counter-
measure against environmental problems like global warming by CO2 and
air pollution. In a study, in which the energy saving calculation has been
carried out based on the operation of an existing CDQ process, it has been
shown that 85 % of the waste heat generated during coal carbonization is
being recovered by the CDQ process.
History
The CDQ technique was introduced in Switzerland by the Sulzer brothers in
the 1920s. A few decades later, an improved conception of the CDQ
process for continuous operation was produced by the Giprokoks Institute
in Russia. After pilot and pilot/commercial trials, the rst full scale CDQ
plant installation was commissioned in 1965 at the Cherepovets Iron and
Steel Works in the then USSR. By 1978 around 50 CDCP modules of 56
tons per hour were in operation in the then USSR. Over the last two
decades, the CDQ process has been gradually accepted, although the CWQ
process is still popular. However, a large numbers of CDQ plants are
operating in many countries. Fig 1 shows a CDQ plant module of
Giprokoks design is having a capacity of 56 tons per hour.
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Fig 1 CDQ plant module of Giprokoks design is having a capacity of 56
tons per hour
Japan purchased license from USSR in 1975 and three Japanese
installations were commissioned in 1976 – 77. Since production capacity
of coke ovens is increasing in recent years, CDQ capacity also have been
demanded to adapt to this changing trend. In order to follow this tendency
and satisfy various customer requirements, the development of large-
scale CDQ plant comprising single chamber (single-chamber CDQ) for
quenching a large quantity of coke has taken place in Japan. For single-
chamber CDQ, availability is very important factor because there are no
spare facilities. In order to achieve high availability, stable operation is
essential. For inexperienced operator, however, it is di cult to achieve the
stable operation by adjusting various parameters. In recent years, a new
automation technology for CDQ plants has also been developed.
Progressive increase in the capacity of CDQ chambers since 1975 is
shown in Fig 2.
Fig 2 Progressive increase in the capacity of CDCP chamber since 1975
CDQ process
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Hot coke after its pushing is brought from the coke oven battery to the
CDQ plant in bottom opening bucket kept on the quenching car. This
bucket is lifted at the CDQ plant by a hoisting/charging device to the top of
the CDQ chamber and red hot coke is discharged into the pre-chamber by
the charging device. Hot coke (temperature around 1000 deg C to 1100
deg C) is cooled in the chamber by the circulating gas. In the chamber the
circulating gas moves counter-current to the coke movement, i.e. the
circulating gas moves upwards while the coke moves downward by the
gravity.
The circulating gas in a continuous running CDCP plant is a mixed gas
which consists of mainly nitrogen (N2) along with small amounts of
carbon di-oxide (CO2), carbon mono-oxide (CO), and hydrogen (H2). The
typical composition of the circulating gas is N2 – 70 % to 75 %, CO2 – 10
% to 15 %, CO – 8 % to 10 %, and H2 – 2 % to 3 %. The hot coke, while
descending in the chamber, is cooled to a temperature which is less than
200 deg C by the circulating gas blown from the lower zone of the cooling
chamber and is discharged from the discharging facility at the bottom of
the chamber. The passage time of the coke through the chamber is around
5 hours to 6 hours. The typical operating parameters for a CDQ plant of 56
tons/hour capacity are given in Tab 2.
Tab 2 Typical parameters for CDQ plant of 56 tons/hour capacity
Sl. No. Parameter Unit Value
1 Capacity ton/hour 56
2 Coke charge temperature deg C 1,000 – 1,050
3 Coke output temperature deg C 200
4 Gas inlet temperature deg C 170
5 Gas outlet temperature deg C 800 -850
6 Steam generation ton/hour 25
7 Steam pressure kg/sq cm 40
8 Steam temperature deg C 440
9 Total gas volume N cm/hour 84,000
The high-temperature circulation gas (at around 800 deg C to 850 deg C)
after a heat exchange process in the cooling chamber passes through the
primary dust catcher and is supplied to the boiler. The circulation gas after
a heat exchange process in the boiler is cooled down to around 180 deg C.
The steam generated in the boiler is used either as a general-purpose
process steam, or converted into super heated high pressure steam for the
generation of electric power through a turbine generator.
The circulating gas passes through the secondary dust catcher into the
gas circulation blower, by which its pressure is boosted, and its
composition is corrected by addition of N2 gas and then the circulating
gas is injected at the bottom of the CDQ chamber. If necessary, a sub-
economizer is installed to decrease the temperature of circulation gas to
around 130 deg C, improving the cooling e ciency of the cooling
chamber.
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There are some auxiliary facilities which include cut off device for cutting
out the coke from the chamber, dust removing system for removing the
dust in the circulating inert gas, and the secondary dust catcher installed
before the circulation blower. The process ow of CDQ process is shown
in Fig 3.
Fig 3 Process ow of the CDQ process
Bene ts of CDQ process
CDQ process has many advantages in comparison with conventional CWQ
process. Major advantages are described below.
Utilization of the sensible heat of hot coke – The electric power can be
generated by dry quenching of coke without the consumption of the fossil
fuels. This leads to the reduction of the CO2 emissions. As an example
(Fig 4), CDQ with 200 tons per hour (t/h) capacity can generate around 36
MW of electric power. For the generation of the same electric power with a
heavy oil red boiler, 12 t/h of heavy oil is needed and this results into 36
t/h of CO2 emission to the atmosphere. Hence, a CDQ plant provides both
the economical as well as the environmental advantages. Since it recovers
sensible heat of the coke, there is net energy saving. Energy saving is
around 0.25 Gcal/ton of coke. CDQ process thus enables effective
utilization of energy which is dispersed into the atmosphere in the CWQ
process.
Protection of environment – In CDQ, there is no white smoke which is
normally seen coming out of the quenching tower in case of CWQ process.
This white smoke has a high content of dust. The absence of white smoke
in case of CDQ process is because all the processes are totally enclosed.
As a result, the working environment around CDQ equipments is improved.
In general, with the CWQ process, large quantity of coke dust (around 300
g/t of coke to 400 g/t of coke) is emitted which is contained in the steam
emitted to the environment. The recently developed process of ‘coke
stabilizing quenching (CSQ) reduces the dust emission volume. But the
CDQ process is still more e cient in prevention of dust emission. The dust
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emission volume from CDQ is less than 3 g/t of coke (Fig 4). This value
has improved further with the continuous improvements of the CDQ
process which is taking place.
The CDQ process is also environment friendly with respect to water
pollution and water conservation. This is since no water is used in the CDQ
process as against CWQ process where the quenching medium is water.
Fig 4 Bene ts of the CDQ process
Contribution of CDQ process in productivity improvement at BF – The
improved quality of coke produced by the CDQ process leads to the
productivity improvement at the blast furnace (BF). As regards the coke
produced by the CDQ process, it has got two excellent features in
comparison to the quality of coke produced by the CWQ process. These
features are (i) higher mechanical strength of the coke, and (ii) very low
moisture content in the coke (almost zero). These features provide certain
bene ts at the BF which are described below.
The fuel consumption in BF is reduced by a few percent since the extra
heat energy is not needed for the evaporation of moisture contained in the
coke. It also contributes to the CO2 reduction at BF, and an improvement
of power generation at TRT (top pressure recovery turbine) due to the
increasing of the temperature at the top of BF.
By using the coke quenched with CDQ process, the permeability in BF is
improved because of the high coke strength. Higher permeability in the BF
improves the e ciency of reduction reaction in the BF, and this improves
the hot metal productivity of the BF. BFs using coke produced by the CDQ
process has comparatively more stable operation. Further, as the coke
strength is increased, interior of BF can maintain the su cient
permeability and hence higher rates of pulverized coal injection can be
achieved at the BF.
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Improvement of coke quality – The quality of coke is improved by the CDQ
process compared to the coke produced by the CWQ process. The quality
of coke is more stable because of the low standard deviation (usually
around 1.25 %). A uniform quality of coke helps in the BF operation. This is
because the coke is cooled gradually by the circulating gas in the CDQ
chamber instead of fast quenching by the spaying of water with water jets
in case of the CWQ process. Also, the water-gas reaction is avoided. The
improvement expected in the mechanical strength (drum index) is around
1.5 % and improvement in the coke strength after the reaction (CSR) is
around 2.5 %. This improvement is since the hot coke which is cooled
gradually by the circulating gas, is free from surface pores and internal
cracks which are generally present in the wet quenched coke.
It is generally observed that the increase rate of coke strength is relatively
less, in case there is high percentage of high-grade coking coal in the coal
blend used for coal carbonization. The higher use of low coking coal in the
coal blend provides additional cost advantage by the CDQ process.
Technical
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Comments on Post (9)
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brijesh kumar dwivedi
Good literature for cdq understanding.
Posted: 26 April, 2013 at 02:45 am Reply
Subhendu Kumar Dalai
The overall thermal e ciency is 80-85 % which is a very good value. Thank
you sir for this useful article.
Posted: 26 April, 2013 at 11:25 am Reply
Milind Thosar
Dear Sir,
Good technical literature for India industry. Keep it up. It helps everybody
student, engineers and managers.
Yours faithfully,
Milind Thosar
Posted: 28 April, 2013 at 11:43 am Reply
KK Ghosh
Visakhapatnam Steel Plant (VSP) under Rashtriya Ispat Nigam Limited
(RINL) – a Navaratna PSU is opearting dry quenching successfully since
early 90s.
Posted: 30 April, 2013 at 07:56 am Reply
KK Ghosh
Dear Sir
Do you have data of other steel plants globally regarding generation of
coke dust per tonne of dry coke ?
Posted: 30 April, 2013 at 07:53 am Reply
subodh kumar
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17/06/2020 Dry Quenching of Hot Coke – IspatGuru
Very informative report.
Maintenance of conventional coke ovens particularly ine cient cleaning
of the coke oven doors had been the cause of very poor life of Indian coke
oven batteries. What are the maintenance problems and experience in
India with dry coke quenching?
Posted: 30 April, 2013 at 15:18 pm Reply
Technologies for improvement in Coking process in Byproduct Coke Ovens
| ispatguru.com
GC Sharma
Very informative and useful . Sail-Isp Burnpur has installed this plant .
Thanks for such good write up
Posted: 15 February, 2014 at 09:48 am Reply
jai
Kindly explain the potential hazards.
Posted: 13 May, 2014 at 17:38 pm Reply
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