ON

COAL CHEMICAL PLANT

(OBJECTIVES)

To clean Coke Oven Gas for using it as fuel

for heating Coke Oven Batteries and for
other consumers.

COAL CHEMICAL PLANT

(CLEANING PROCESS)

Co-gas coming out of Batteries has Tar,

Ammonia,Crude Benzol and gas rich in
Hydrogen and methane. The Tar ,Ammonia
and Crude Benzol is removed from Co-gas
before it is used as fuel in batteries.

COAL CHEMICAL PLANT

(CLEANING PROCESS- WHERE & HOW)

The Tar, ammonia and crude benzol is removed in Gas

Cleaning Plant (RECOVERY PLANT).
Tar is removed and sent to tar plant for the distillation to get
tar products.
Ammonia liquor is separated from tar and pumped back to gas
collecting mains.
Excess ammonical liquor is pumped to ammonia columns for
further treatment. After treatment it is sent to MBC.

COAL CHEMICAL PLANT

(CLEANING PROCESS- WHERE & HOW)

Ammonia is removed in gas cleaning unit

(Ammonium Sulphate plant). The gas
passed through the 4-5% Sulphuric Acid
Bath. Ammonia in Co-gas Reacts with acid
and forms ammonium Sulphate.
Crude Benzol is removed in Benzol
Recovery unit of gas Cleaning Plant.

COAL CHEMICAL PLANT

(SUB-SECTIONS)

RECOVERY
BENZOL PLANT
TAR DISTILLATION PLANT

RECOVERY
GAS CONDENSATION PLANT(GCP)
AMMONIUM SULPHATE PLANT
BENZOL RECOVERY PLANT
MBC PLANT

RECOVERY
seperator

ESP

PGC

EXH

Bat-1
Saturator
Amm-liquir

Bat-2
Bat-3

Tar

Fog
Tar

SLUDGE
TAR

Drier

Centrifuge

Amo- Slurry

Bagging

CO-GAS

DBO OIL FROM BDP

FGC

Sc-1

Sc-2
OIL

Co gas

To consumers

BO OIL

GAS CONDENSATION PLANT

(OBJECTIVES)

Exhaust Co-gas from Batteries.

Maintaining Constant Suction.
Condensation of TAR& Amm. liquor.
Continuous pumping of F.L to Batteries.
Separation of Tar, F.L & Sludge.

GAS CONDENATION PLANT

(EQUIPMENT)

PGCs
-10 no
ESPs
-06 nos
Exhausters-5 nos
F.L Pumps -6 nos
Decanters 8nos

-20,000 cum/hr.
-40,000 cum/hr.
-76,000 cum/hr.
- 1,500 cum/hr.
- 380 cum.

AMMONIUM SULPHATE PLANT

(OBJECTIVES)

To purify Co-gas
To recover Ammonia.
CAPACITY OF ASP unit

:-41,700 Ton / year

AMMONIUM SULPHATE PLANT

(EQUIPMENT)

Saturators
Centrifuges

-5nos.

-5nos-3.2 Ton/hr.
Drier
-2nos-8.0 Ton/hr.
Bagging Machine-2nos-10bags/min

BENZOL RECOVERY PLANT

(OBJECTIVES)

Recovery of slip Naphthalene from

Co-gas.
Enriching Tar with Naphthalene.
Recovery of Crude Benzol from
Co-gas.

BENZOL RECOVERY PLANT

Two Streams of Co-gas flow.
Each stream consists of
One Final Gas Cooler.
Two Benzol Scrubbers.

MBC PLANT
(OBJECTIVES)

Effluent Water treatment.

BENZOL PLANT
(OBJECTIVES)

To recover Crude Benzol from Benzolised

Oil.
To remove Impurities from Crude Benzol.
To produce Pure Products from C.B.

BENZOL PLANT
(SUB-SECTIONS)

Benzol Distillation Section.

Hydro Refining Unit.
Extractive Distillation Unit.
Crude & Finished Products Storage.

BENZOL DISTILLATION
SECTION
(OBJECTIVES)

To separate Crude Benzol from Benzolised

Oil.
To separate HCB from Crude Benzol.

BENZOL DISTILLATION
SECTION
(EQUIPMENT)

Two streams.
Each Stream consisting of
- Stripping column
-1No.
- Steam pre-heater
-2Nos.
-DBO Coolers-6Nos.
- Oil-Oil Heat Exchangers-3Nos.
- Oil Dephlegmators -2Nos.
- Water Dephlegmators -1No.
- Decanter
-1No.
Common for both streams-CB-1 Condensers
-2Nos.
-CB-1 Column
-1No.
-CB-2 Column
-1No.

BENZOL DISTILLATION UNIT

CRUDE BENZOL
CB-I

S
T
R
I

ONE

B.O

TO CFPS

COOLERS

N
G

C
O
L

TWO

CB-I

STEAM

L
U
M

LIVE STEAM

STEAM
CB-II

DBO TO SCRUBBERS

HYDROREFINING UNIT
(OBJECTIVES)

To remove Sulphour Compounds from

Crude Benzol.
To produce BTXS Raffinate for processing
in Extrative Distillation Unit.

HYDROREFINING UNIT
(FLOE SCHEME)
CB-1

De-Fronting agent
(For removal of CS2)
Heating by tharmal oil.

STAGE EVAPORATOR

Recycle gas mixing

Evaporation in stage.

PER-REACTOR
MAIN-REACTOR

Ni-Mo Catalyst

Styrene

H2

Ethyl Benzene

Co-mo Catalyst
Thiophene

H2 Butane+H2S

Condensation &seperation of RC gas

STRIPPER COLUMN
BTXS REFINATE

THERMAL TREATMENT

REMOVAL OF H2S

EXTRACTIVE DISTILLATION UNIT

(OBJECTIVES)

To separate non aromatics from benzene &

tolune.
To produce pure benzene, pure tolune, Light
solvent oil &still bottom oil from BTXS
Raffinate.

EXTRACTIVE DISTILLATION UNIT

(FLOW SCHEME)
XS Fr.

P.D COLUMN

LSN / SBO products.

BTXS

B/T Fr.
E.D COLUMN

NFM with dissolved H.C.

STRIPPING COLUMN
(VACUUM)
HC(B/T)

Batch Distillation for

BT SEPARATION
COLUMN

N- Formyl Morphiline solvent used for removal

of CH, MCH, from Aromatic Benzene, toluene.

NFM dissolves H.C.

N . A leaves as Vapours from top of column.

HC(B/T)

NFM Recycled to ED column.

BENZENE

TOLUENE

CRUDE &FINISHED PRODUCT

STORAGE UNIT
(OBJECTIVES)

To store crude benzol HCB and pure

products.
To despatch HCB and pure products to
customers by road tankers.

CRUDE &FINISHED PRODUCT

STORAGE UNIT
(EQUIPMENT)

Total Storage capacity

CB Tanks
-4Nos
PB Tanks
-4Nos
PT Tanks
-2Nos
LSO Tanks -5 Nos
NA Tanks
-2Nos
HCB Tanks -2Nos

-2800kl.
-2000kl.
- 400kl.
- 250kl.
- 100kl.
- 200kl.

TAR DISTILLATION PLANT

(SUB-SECTIONS)

Tar Distillation Section.

Pitch Cooling & Loading Area.
Naphthalene & Anthracene Fraction
Crystallization section (NAFC).
Tar & Oil Storage.

TAR DISTILLATION PLANT

Tar & oil storage

Decanter 1 no

Reciprocating
Furnace Fist stage
pump 2 no

Water

Reciprocating
pump 2 no

1st Evaporator
2 nd Evaporator
MH Pitch
Pitch Bays
For cooling

Collecting Tank

Furnace 2nd stage

Soft pitch
Reactor
Light Oil

Cutting & Bagging

Phenol
Naphthalene
Wash Oil
Anthracene I OIl

Anthracene II OIl

Distillation column

To NAFC

TAR DISTILLATION SECTION

Tar received from FGC unit to TOS unit.
From TOS tar is pumped to Decanter in TDS unit.
After removal of water from decanter moisture
content in tar reduces to 5-6%.
Tar is heated in the first stage of furnace to a
temp.of120-150 deg C and sent to first stage
evaporator.
In first stage evaporator complete demoisturisation is done.

TAR DISTILLATION SECTION

Tar after first stage evaporator is again heated in II
stage of furnace to a temp. of 330-350deg C.
In the second stage evaporator oil fraction is
separated from top of second stage evaporator(3540%) and soft pitch from bottom.
The oil fraction is sent to the distillation column,
where individual oil products are tapped , cooled
collected in storage tanks.

TAR DISTILLATION SECTION

THE PRODUCTS FROM DISTILLATION
COLUMN ARE AS FOLLOWS:Light oil
Phenol Fraction.
Naphthalene fraction.
Wash oil.
Anthracene oil-I & II.

PITCH COOLING AND

LOADING AREA
The soft pitch from second stage evaporator is sent
to reactors, where it is subjected to areation to
increase the softening point to get the Alluminium
grade pitch.
Al. grade Pitch is cooled in dumping yards. It cut,
bagged and dispatched to customers.
Part of the soft pitch is used to make PCM by
mixing it with Anthracene & Wash Oil mixture

NAFC
Naphthalene fraction is further processed in
NAFC unit to make Hot Pressed
Napthalene(35-40Kg Cakes). The cakes are
crushed, bagged and dispatched to customers.
Drained Naphthalene oil is also produced in
NAFC unit. It will have around 35-40%
Naphthalene.

TAR & OIL STORAGE

(OBJECTIVES)

To store crude Coal tar and Oil

products.
To despatch Tar, PCM and Oil products
to customers by road / rail tankers

PERFORMANCE -CCP
S.No

PARAMETERS

UNIT

APRIL'05

MAY'05

JUNE'05

JULY'05

AUG'05

SEPT'05

2004-05

Ammonium Sulphate Yield

Kg/Tdc

13.70

13.00

12.70

12.80

12.60

13.00

13.20

Crude Benzol Yield

Kg/Tdc

6.50

6.50

6.40

3.50

3.00

5.50

6.00

Crude Tar Yield

Kg/Tdc

31.50

31.60

31.70

32.00

31.80

32.10

31.80

NH3 Content in Raw Gas

g/Nm3

9.128

9.258

9.150

8.860

9.475

9.090

-----

NH3 Content in Clean Gas

gm/Nm3

0.039

0.034

0.031

0.022

0.035

0.034

-----

Benzol Content in Raw Gas

gm/Nm3

27.190

28.830

28.960

28.350

23.180

29.810

-----

Benzol Content in Clean Gas

gm/Nm3

9.190

11.360

9.770

11.360

18.940

11.040

-----

Naph.Content in Clean Gas

gm/Nm3

0.318

0.372

0.380

0.150

0.029

0.220

-----

Q I of Tar

2.394

2.304

2.473

2.200

2.320

2.620

-----

S.No

PRODUCTIONS

UNIT

JAN'0
5

FEB'05

MAR'05

APR'05

MAY'05

JUNE'05

JULY'05

AUG'05

SEPT'05

2004-05

Ammonium Sulphate

Ton

3299

3000

3414

3434

3345

3178

3287

3257

3150

37578

Crude Tar

Ton

8033

7257

8061

7890

8162

7951

8186

8197

7763

90379

Crude Benzol

Ton

1553

1358

1518

1422

1481

1400

785

705

1125

14750

C G Benzene

Ton

680

800

590

700

660

510

410

500

600

7433

N G Tolune

Ton

210

260

216

245

280

200

200

200

240

2220

Light Solvent Oil

Ton

65

133

105

130

145

120

90

110

125

1066

SOL-110(N.A)

Ton

130

175

165

145

210

185

150

164

158

1465

Heavy Crude Benzol

Ton

142

163

182

206

195

200

100

70

200

2319

Still Bottom Oil

Ton

20

15

12

15

10

15

10

15

18

247

H P Napthalene

Ton

270

190

260

186

170

205

157

167

108

2543

10

Coal Tar Fuel(PCM)

Ton

3180

3610

2450

3300

3570

2800

2930

2740

2540

39390

11

M H Pitch

Ton

2280

690

2820

1700

1220

2185

1345

1625

640

20430

TAR DISTELLED

Ton

6630

4700

7050

5800

5200

6300

4910

5200

3350

70590

CRUDE BENZOL
PROCESSED

Ton

1263

1580

1275

1400

1485

1170

980

1120

1215

13698

S.

NPRODUCTS
o

UNIT

JAN'0
5

FEB'0
5

MAR'0
5

APRIL
'
0
5

MAY'0
5

JUNE'
0
5

JULY'
0
5

AUG'0
5

SEPT'
0
5

2004-05

Ammonium Sulphate

Ton

3104

2865

2170

4226

3606

3112

3323

3532

3187

36309

Crude Tar

Ton

1957

1518

2797

956

1641

2476

2420

3438

4097

19774

H P Napthalene

Ton

252

174

245

200

51

303

145

201

127

2502

M H Pitch

Ton

1030

1161

2700

451

572

286

576

615

500

17561

Coal Tar Fuel(PCM)

Ton

12

77

71

84

20

WASH OIL

Ton

14

90

119

52

52

53

68

74

283

D.N.O

Ton

99

154

139

99

113

85

98

167

109

1241

Phenol Fraction

Ton

124

89

148

109

105

116

107

120

57

1312

10

Heavy Crude Benzol

Ton

140

153

127

186

132

171

142

81

152

1887

11

C G Benzene

Ton

587

869

590

341

618

928

321

164

701

8228

12

N G Tolune

Ton

161

240

239

228

308

218

205

182

246

2449

13

Light Solvent Oil

Ton

64

115

101

22

91

216

118

135

107

1159

14

SOL-110(N.A)

Ton

128

154

181

148

183

212

137

84

119

1491

15

Still Bottom Oil

Ton

10

19

20

10

20

126

##

SALES REVENUE

Crore

8.97

10.56

12.64

7.67

9.32

10.99

7.99

8.35

10.43

117.58

OUR SALEABLE CHEMICALS

Ammonium Sulphate
(PUSHKALA)
Crude Coal Tar
Hard Pitch
HP Naphthalene
Drained Naphthalene
Oil (DNO)
Phenol Fraction

CG Benzene

NG Toluene
Light Solvent
Naphtha
SOL 110
Coal Tar Wash Oil
Anthracene Oil
Coal Tar Fuel / PCM

AMMONIUM SULPHATE
(PUSHKALA)

Nitrogen by Wt.
Moisture by Wt.
Free Acidity by Wt.
Packing

20.60 % (min.)
1.00 % (max.)
0.04 % (max.)
50 Kg Bag

CRUDE COAL TAR

Grade - 1
Specific Gravity at 200C
Moisture % (max)
Viscosity ( E deg.) at 93 0 C

Grade - 2

1.16 1.20 1.16 1.20

4.00

4.00

1.70 2.50 1.70 2.50

Residue on Distillation (above

360 0 C) % min.

53

53

Benzene Insoluble % max.

14

15

Quinoline Insoluble % max.

HP NAPHTHALENE
Colour
White or Light Brown
Crystallization Point
78.500 C
Ash by Wt.
0.20 % (max)
Moisture by Wt.
0.50 % (max.)
Sulphur by Wt.
0.40 % (max.)
Benzene Insoluble
0.20 % (max.)

DRAINED NAPHTHALENE
OIL (DNO)
Specific Gravity
Moisture
Naphthalene

1.02 (max.)
4.00 % (max.)
30 - 50 %

PHENOL FRACTION
Specific Gravity 0.99 1.00
( at 20 deg C)

Distillation(0-2100C) 95.0 %
Phenol (%) 18 30
Naphthalene 30 % (max.)
Moisture 4% (max)

SOL 110
(NON AROMATICS)

Specific Gravity
(at

0.84 (min)

15 deg C)

Distillation Range
( 1 95 %)

55 - 1100C

COAL TAR WASH OIL

Specific Gravity at 380C
Moisture % (max)
Distillation------Up to 2300C % (max)
2300C- 3000C % (max)
Above 3000C % (max)
Naphthalene % (max)

1.04-1.08
4.00
10.00
85.00
5.00
15.00

TOLUENE (Nitration Grade)

Distillation Range

0.6 (Including 110.60C)

(1 - 96%)

Specific Gravity at 15/150C

Residue on Evaporation
H2S & Mercaptanes

0.870 - 0.874
5 mg/100 ml (max)
Negative

Purity (by GLC method)

99.2 % (min)

TOLUENE (Industrial Grade)

Distillation Range
Up to 1050C
Up to 1200C
Specific Gravity at 15/150C
Residue on Evaporation
H2S & Mercaptanes
Purity (by GLC method)

5 ml
90 ml
0.860 - 0.875
10 mg/100 ml (max)
Negative
92.0 % (min)

CG BENZENE
Distillation Range

0.6 (Including 80.1 0C)

(1 - 96%)

Specific Gravity at

0.879 - 0.886

15.6/15.60C

Residue on Evaporation
H2S & Mercaptanes
Total Sulphur (ppm max.)
Non Aromatics (ppm max)
Crystallization point (min)
Purity by GLC method

5 mg/100 ml (max)
Negative
2.0
500
5.30C
99.92% min

HARD PITCH

BALCO GRADE
Softening Point (R&B)
Coking Value (conradson)
Benzene Insoluble
Quinolene Insoluble
Ash

90 95 0 C
53 (min)
30% (min)
10% (max)
0.3% (max)

HARD PITCH

INDAL GRADE
Softening Point (R&B)
86 - 105 0 C
Coking Value (conradson) 52 (min)
Benzene Insoluble
27% (min)
Quinolene Insoluble
10% (max)
Ash
0.2% (max)

HARD PITCH

NALCO GRADE
Softening Point (R&B)
105-112 0 C
Coking Value (conradson) 52 (min)
Quinolene Insoluble
5-12% (max)
Ash
0.5% (max)

HARD PITCH

HINDALCO GRADE
Softening Point (R&B)
Coking Value (conradson)
Benzene Insoluble
Quinolene Insoluble
Ash

107-114 0 C
54 - 56
30 37 %
7 - 12%
0.5% (max)

HARD PITCH
GRADE # 1

Softening Point (R&B)

Coking Value (conradson)
Benzene Insoluble
Quinolene Insoluble
Ash

90 105 0 C
48 (min)
25% (min)
12% (max)
0.5% (max)

HARD PITCH
GRADE # 2

Softening Point (R&B) 101-115 0 C

Coking Value (conradson) 51 (min)
Benzene Insoluble
28% (min)
Quinolene Insoluble
12% (max)
Ash
0.5% (max)

ANTHARACENE OIL
Specific Gravity
at 200C (max)
Moisture % (max)
Distillation % (max)
up to 3000C

1.12
3.00
20.00

COAL TAR FUEL

(Pitch Creosote Mixture)

Moisture % (max)
Viscosity ( E0)
at 930 C

4.00
28

IN ADDITION TO ABOVE,
MEDIUM HARD PITCH
CAN ALSO BE MADE AS
PER THE CUSTOMERS
SPECIFICATION.

TOLUENE
Solvents
Artificial
Sweetening
Paint Industries
Rubber Industries
Rubber
Chemicals
Printing Ink.

Benzoic Acid
Sodium
Benzoates
Synthetic Fibers
Adhesives
Benzyl Chloride
Thinners &
Varnishes

HP NAPHTHALENE
Dye intermediates
Insecticides
Dispersing Agents
Tanning Agents
Beta Naphthol
Refined Naphthalene

BENZENE
Raw material for
various Drugs, Dyestuff, Synthetic
Rubber, Styrene.
Pesticides
Monochlorobenzene
Caprolactum
Phenol
DDT
LAB

Nitro Benzene
Aniline
Maletic Anhydride
Cumene
Cyclo-Hexavon
Nylon-6
Resin Intermediates
Nylon Intermediates
Styrene

HARD PITCH
Hard Pitch is used in Industries
requiring Pitch Carbon for
Electrodes and it is used by
Aluminium Industries.
It is also used for manufacturing
graphite and in blast furnaces
ladle repair.

AMMONIUM SULPHATE

Mainly used as Fertilizer due

to its nitrogen content.
Presently also used as a
Nitrogen bearing material in
mixed Fertilizer in Fertilizer
manufacturing plant.

LIGHT SOLVENT NAPHTHA

Solvents
Starting material for Dyes.
Printing Ink
Thinner

COAL TAR WASH OIL

Preservation of Wooden
Sleepers
Carbon Black Feed Stocks.
Disinfectant

ANTHRACENE OIL

Anthracene Oil is an
excellent material as a feed
stock for Carbon Black and
gives better yields and
quality of the finished
product.

DRAINED NAPHTHALENE OIL

Naphthalene bearing feed

stocks.
Naphthalene and Coal Tar
Oils are separated and used
for their specific end uses.