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HERALDING MERCHANT COKE MAKING IN INDIA VIA

RECOVERY S3 ROUTE

ABHIJIT SEN

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INTRODUCTION

• On behalf of the Coke making fraternity world over, We pay our deepest regard and tribute for two of most renowned names in coke making arena of yester years: 1) Louis Semet & 2) Earnest Solvay.

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TRIBUTE TO

LUIS SEMET AND EARNEST SOLVAY

• [1844-1920] • [1838-1922]

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PIONEERS OF BYPRODUCT COKE

• These two great men, one a scientist, an entrepreneur and inventor of Soda Ash process and another an engineer, the two, being related as brothers-in-law, both equally enterprising, together pioneered the most advanced of the coking technologies of all time till now i.e. The By-product Recovery type coke making process.

• Interestingly, the principal drive in the development of Semet-Solvay coking technology was not the need of coke but rather demand for one of its by-product –AMMONIA, needed by Ernest Solvay for his Soda Ash plant.

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SOLVAY PROCESS

• NaCl + CO2 + NH3 + H2O → NaHCO3 + NH4Cl (I)

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FIRST RECOVERY OVENS

• In 1876 Solvay gave the responsibility of developing a technology for getting Ammonia from Coal to Louis Semet.

• Semet after 6 years of experimentation built the first Recovery type coke oven plant with only 6 ovens of 5 mt charge capacity in 1882 in MONS , Belgium.

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THE TECHNOLOGY

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Semet Solvay & Sen (S3)

• With Semet-Solvay Ovens of enhanced 10 MT Charge capacity we have added a By-product Recovery plant of our own design along with mechanised oven machines, wet quenching tower and Coal and Coke processing units and, BOD plant & have named it as “Semet-Solvay & Sen”(S3) Coke plant

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CONSULTANCY PACKAGE

• We have a small consultancy organisation named Concept Consultants providing complete knowhow, basic & detailed engineering, erection supervision & commissioning of S3 By-product Coke Plant

• We are located at Kolkata, India

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VIEW OF AML PLANT, ROURKELA

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WHY

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GROWTH OF INDIAN STEEL CAPACITYIN COMING DECADES

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PROJECTED COKE DEFICIT

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INDIAN MERCHANT COKE MARKET

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Comparison 0F S3 with Equivalent capacity Merchant Bee-Hive Coke Plants

• Less cost of erection

• Less requirement of space

• Less requirement of refractory

• Less Carbonisation cycle time

• No burning Loss Hence higher coke yield

• By-products Coal tar, surplus COG etc.

• Life of Battery is almost double of Bee-hive coke ovens.

• Wide Capacity Range of 3000 tpm to 30000 tpm.

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Comparison 0F S3 with Equivalent capacity Conventional Recovery Coke Plants

• Advantages:1. Due to use of non-Silica refractory, cooling down is safe.

2. Huge cost saving for smaller capacity plants upto 0.4 mtpa capacity.

3. Easy to operate.4. Quality of Coke is good & comparable with that of conventional By-product

Recovery ovens.5. Highly suitable for smaller capacity / mini steel plants.

• Disadvantages:1. Non-Silica Refractory is less conductive wrt Silica, hence leads to higher

carbonisation cycle time of about 1.5 times that of a conventional Silica made By-product Recovery type coke plant.

2. However use of Silica bricks is not ruled out for willing Entrepreneurs.3. Not suitable for Large steel plants.

It is cost competitive on the whole.

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COMPARING COST OF PRODUCTION(BASIS: 1 MTPA )

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COST COMPARISION

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SEMET SOLVAY OVENS

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VIEW OF AML PLANT, ROURKELA

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OVEN TOP VIEW

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AML COO LIGHTING UP THE BATTERY HEATING

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PUSHER SIDE VIEW OF AML PLANT

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RED BRICK CHIMNEY UNDER CONSTRUCTION

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Conclusion

• The author feels that the new technology would immensely benefit the small and medium scale merchant coke makers in India and would go a long way in strengthening indigenous coke making technology in the developing economies throughout the world.

• The proposed S3 Recovery technology viz. “Semet Solvay & Sen” is a quite viable alternative coke making route that can replace the age-old Beehive ovens with lesser installation cost, higher gross coke yield and additional financial gain from sale of coal tar and use of surplus COG.

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• GODESS DURGA SYMBOL OF PROSPERITY WITH GODESS OF WEALTH LAXMI ON HER RIGHT AND GODESS OF KNOWLEDGE & EDUCATION SARASWATI ON HER LEFT.

• IN BOTTOM ROW WE HAVE GOD OF BUSINESS GANESHA ON HER RIGHT AND GOD OF DEFENCE & WARFARE KARTIKEYA ON HER LEFT.

• GODESS DURGA RIDES ON PROSPERITY SYMBOLISED BY THE LION. BUT SHE HAS TO FIGHT THE DEMON, WHICH SYMBOLISES ALL THE VICES THAT THREATEN CIVILISED SOCIETY LIKE LUST, ENEMITY, VIOLENCE , POVERTY,TERRORRISM , CORRUPTION, NEPOTISM, HATRED AND LAST BUT NOT THE LEAST ATMOSPHERIC POLLUTION