Stamp Charged Battery

A Case Study

Way forward--- Probable Action points

Objective

Why
Stampcoke
Charge
? using inferior coal
Improving
Quality
By Improving Bulk Density of Charge Coal
By Pre carbonizing technology

Oil addition
Controlled crushing
Coal moisture control (CMC)
Preheating
Briquette blending (PBCC)
Stamp Charging
Coke dry quenching
Scope 21

Objective

Pressing need in the field of coke making

Improved coke quality for bigger Blast Furnaces and high level
of PCI operation
More throughput per pushing-- pollution & productivity.
Preserve precious prime coking coal as reserve is limited
Exploitation of technology
Cost optimization --- Stamp Charged Coke is about 25 %
cheaper than Top Charged Coke -- through yield improvement --low blend VM & more sized coke elimination of coke cutter
Improved BF productivity

Example
Process

Stamp Charging

Top Charging

Low quality coals

80%

15%

High quality coals

20%

85%

Low quality coals @

$100

$100

High quality coals @

$130

$130

Typical coke oven

plant production

1,000,000tpy

1,000,000tpy

Required coal blend

1,340,000tpy

1,340,000tpy

Coal purchasing cost

$142,040,000

$168,170,000

Savings/y

$26,130,000

Coal Blend

Coal price

Justification

Decision Tool

Conventiona Briquett Coal

Controlle
Pre
l Top
e
Drying
d
hating
charging blending CMC
Crushing

Crushing fineness 78 - 80 %
78
78 80 78 80
78 - 80
(-3.2
80%
mm)
8 10% 0.2% 0.2% LDO
0.2% LDO
LDO
pitch &
tar
Moisture in coal
8- 9
6-8
6
8-9
0
(%)
Bulk density of
700 - 750
750 750 - 750 - 775 800 - 850
coal
800
800
charge (kg/m3)
M10 (Index)
10 - 11 8.5 - 9.5 8 - 9
8.5-9 .5 7.5 8.5
M40 (Index)
Carbonisation
time (Index)
Oven throughput
(Index)
Maintenance
need (Index)

77 - 80

79 - 81

78 - 79

78 - 79

100

105 110
105 110
105

100

100

100
100

79 - 81

Stamp
charging
89 91
(3.15mm
&
-0.5mm
48%)
8 - 11
1050 1150
5- 6.5
80 - 85

80 - 85 110 - 115

105

100- 105 110 - 115 115 - 125

105

100 - 105 150 - 175 110 - 115

Best Practices Adopted

Automatic Coal Moisture Control (close loop)

Auto positioning of machines through RFid

Laser Beam Centering of SCP machine

Self-sealing type Zero Leakage Oven Door

Charge gas transfer Car with HPLA system and pushing

emission control system for emission free charging

Laminar water spraying & semi-flood quenching for Low

Moisture Coke

CC TV for Safe Operation

Two stage crushing for correct granulometry

Best Practices Adopted

Mechanized handling of spillage.

High pressure Water Jet cleaning of doors at machines

Plough Extractors for automatic extraction of Coke

from Wharf. Coke scrapper in wharf.

Automatic CV Control and Injection for under firing gas.

Selective Remote Control Operation

Land based pushing and Charging emission Control

Coal Cake Profile measurement system

Auto flaring and auto ignition system in GC main

Coal Cake leveling device

Wall temp. Profile measurement in Pusher Ram.

CET measurement in coke guide cage

Best Practices Adopted

Auto heat pause control heating system.

Level 2 automation for process control

Web based On line data monitoring and analysis system

100% safety interlock system in process and all machines.

Online stack emission monitoring system by opacity meter

Specially designed quenching tower to reduce dust emission

Tar centrifuge to maintain tar quality

Desulphurization unit producing 99.5% pure sulphur pellets

Use of Boll Filter for flushing liquor with auto

backwashing
facility supplied by " Boll & Kirch Filterbau",
GmbH

Membrane tube type Coal Water Filter

Conclusion
Stamp Charging is a versatile coke making
technique coal cake making is a science --- Art as well.
cake stability/BD
Care need to be taken in selecting coals.
Prior testing of each coal and testing of blend in the
laboratory is recommended.
Measurement of wall pressure is important to
understand the blend.
Regular check of coal blend dilatation is important.
Use of non coking coal is possible and sometime
helps in reducing gas pressure.
Regular monitoring of pushing force is essential.
Cost of coke is lower than any other techniques.
Improvement in Blast Furnace performance is
positive factor

Way Forward
Increase Oven Size by improving coal cake
stability
Improve SUGA index of Battery to
withstand higher coking pressure
Increase Battery Life by plugging the
current deficiencies
Improve Coke Size (AMS) through
research/innovation
Eliminate Process Hazard through more
Automation
Introduce PROVEN/SOPRECO
Optimize Coal Blend Cost by using non
coking Coals