th 49 operating committee meating jspl...
TRANSCRIPT
11/12/2018
1
49th
OPERATING COMMITTEE MEATING JSPL Raigarh
Confidential and Privilege
JSPL Raigarh.
November ’2018November 2018Members:
M. Raman , Mgr Umesh Nayak, Jr. MgrRahul Rana, Executive
Plant Configuration
Name of the Plant Recovery type stampcharged coke oven plant
Technology Adopted China Shougang International trade
Plant Capacity 0.85 MTPA
Short Description 2×64 , 4.3m Stamp ChargeShort Description 2 64 , 4.3m Stamp Charge
Total length of Carbonising Chamber 14.08 m
Height of Carbonizing Chamber 4.30 m
Effective Height 4.00 m
Average width of Carbonising Chamber 500 mm
Carbonising Chamber centre distance 1200 mm
Conical degree of Carbonising Chamber 20 mm
Number of vertical flues 28
BHUSHAN STEEL
Number of vertical flues 28
Standard flue temperature P/S 1290
Standard flue temperature C/S 1310
Raw material used Imported Coal
Final Product Coke
By – Products Tar, BTX, Ammonium Sulphate
11/12/2018
2
Deriving Benefits Of Automation to Promote Battery Health
PRI & PC Value
Pushing Current
Technological Cleaning
Machine Positioning and Oven Identification
Pushing and Charging with Uniform Coking Period
Anti – Collision Machine
Ch i L l C t l
BHUSHAN STEEL
Charging Level Control
Door Optimization
Gas Emission Controlling
PRI & PC Value
lPRI- Percentage of ovens pushed with in ±20 min of the average coking period.
lPC- Percentage of ovens pushed with in ±15 min of the schedule pushing time
BHUSHAN STEEL
11/12/2018
3
Pushing Current
lAutomation help us to Collect, store and compile pushing current data from pusher car.
lIdentify abnormalities in pusher ram drive mechanism.
lAnalyze coke quality.
lJudge Coal blends Performance.
lEvaluate coking cycle time.
lExplore Oven Sole Abnormalities.
BHUSHAN STEEL
Technological Cleaning
lCollecting data of technological cleaning like door cleaner and
lframe cleaner from machines.
lMonitor and Improve surrounding environment.
lMaintain PLD as per Safety Environment norms.
BHUSHAN STEEL
11/12/2018
4
Machine Positioning and Oven Identification
lControl Room To Machine Connectivity.
l Equipment Protection (Anti Collision & wrong pushing).
l Machine To Machine Connectivity.
l Alignment Of Machines.
Avoid Wrong Pushing
BHUSHAN STEEL
l Avoid Wrong Pushing.
l Wireless system needs less maintenance.
Pushing and charging with Uniform Coking Period
lAutomation System facilitate us to maintain uniform
lcoking period of ovens.
lIt is Paperless and less time consuming and zero
lhuman error process.
lPushing schedule display in HMI in all machines which
i h l f l f t t f ll hi h d l
BHUSHAN STEEL
l is helpful for operators to follow pushing schedule
l without any error.
11/12/2018
5
Anti-collision Mechanism
lKeep desired gap between two machines avoid collision of machines and derailing of machines on
l both ends of tracks.
lWarning signal and collision system in HMI of both Machine and LT speed reduction to 1st notch.
lWhen machines come closer, LT supply goes off and machines come to halt avoiding collision.
lWhen individual machines move to either ends, warning and collision signal is shown in HMI and the LT speed is reduced to 1st notch
BHUSHAN STEEL
lspeed is reduced to 1st notch.
lWhen the machines reach closer to end stoppers then LT supply goes off and machine comes to halt.
Charging Level Control
lIndividual Hammers level control.
lControl Different Stamping Units.
lFix Coal Cake Height.
lSafe Stamping Operation.
lAvoid Breakdowns.
lIndividual coal feeders control.
BHUSHAN STEEL
f
11/12/2018
6
Gas emission control
Introduced 4.3m Coke Oven Battery wet de dusting system for controlling of gas emission in battery, during
pushing and charging
BHUSHAN STEEL
Working Principle
Sucking the smoke from the hole of the coke and mix some air to facilitate the emission toSucking the smoke from the hole of the coke, and mix some air to facilitate the emission to burn and then passing through Venturi separator, and under Suction force of the fan to emitthe clean air into atmosphere.
Meanwhile the door head emission will be collected by door top fume hood and flow into the main pipe under the suction force of the auxiliary fan, by same procedure of top emission, the fume from door head will be burnt and washed, then emitted into atmosphere.
BHUSHAN STEEL
p
11/12/2018
7
Coke Oven By Product PlantIn order to make raw coke oven gas suitable for use as a fuel gas at the coke oven battery and else where in the steel making facility the by-product plant must:
1.Cool the Coke Oven gas to condense out water vapor and contaminants.2. Remove tar aerosols to prevent gas line/equipment fouling .3. Remove ammonia to prevent gas line corrosion.4. Remove naphthalene to prevent gas line fouling by condensation. 5. Remove light oil for recovery and sale of Crude Benzol.
Other duties include:
BHUSHAN STEEL
1. Remove Hydrogen Sulfide (H2S) to meet local emission regulations governing the combustion of coke oven gas.
Block Diagram Of By-Product
Coke Oven Fl hi
Excess for distillation
Batteries
Gas liquorSeparator
Primary gas Cooler (PGC)
Electrostatic tarprecipitator (ETP)
Decanter Sludge
Flushingliquor tank
Liquor To Coal yard
Tar Storagetank
To marketTar Separator
BHUSHAN STEEL
precipitator (ETP)
DesulphurizationUnitExhauster
SuctionAmmonium
SulphateUnit
Crude Benzol unitGas
holder
ConsumerConsumers
11/12/2018
8
Coke Oven‐1 By‐Product
Cold Blast Section(AREA -1)
•GLS (Gas Liquor Separator)
•PGS (Primary Gas Cooler)
•ETP (Electrostatic Tar Precipitator)
Ammonium Sulphate & Crude Benzol Unit
(AREA – 2)
•Ammonia Stripper•Ammonium sulphate•Saturator•Crystallizer•Centrifuge
BHUSHAN STEEL
•Exhauster
•Refrigeration Unit (Chiller & Cooling Tower)
•Decanter & Tar Separator
g•Vibrating bed Dryer•Crude Benzol •Benzol Washer•Distillation Column•Tube Type Furnace
Flow Sheet of Crude Benzol Recovery Plant
BHUSHAN STEEL
11/12/2018
9
Simple Block Diagram of Benzol Recovery Plant
BHUSHAN STEEL
Problem Statement
Quality of Crude Benzol i:e; %age of Benzene in the BTX is lowered to 63%.
We contacted our customers for the problem they are facing in final product extraction from theCrude Benzol i;e Benzene.
We have received following response from them
1. They have to do Double Distillation for 99.15% Benzene over Single Distillation2. They are incurring a excess cost of Rs.3 over other Crude Benzol distillation (Increase of 60% in
cost)
BHUSHAN STEEL
cost).
11/12/2018
10
Therefore we spend some time and many sessions on figuring out the related factors affecting the percentage of Benzene in the Crude Benzol.
500
Pareto Analysis of Out of Norm. parameters
CountOthe
r
pressur
e
perature
pressure
moutl
et
peratur
e
peratur
e
peratur
e
500
400
300
200
100
0
100
80
60
40
20
0
Para
met
ers
Perc
ent
BHUSHAN STEEL
Parameters 108 106 85 75 29 21 17 20Percent 23.4 23.0 18.4 16.3 6.3 4.6 3.7 4.3Cum % 23.4 46.4 64.9 81.1 87.4 92.0 95.7 100.0
column t
op pre
column t
op tempe
column b
ottom pre
steam
rich oil in
let te
mpe
column botto
m tempe
rich o
il outl
et tempe
First we start to tackle the superheated steam temperature which fluctuated a lot at that period of time.
Superheated Steam Temperature fluctuated between 340°C to 350°C
We tried to increase the temperature to 370°C without affecting the Tube Type furnace Parameters by much.
did h b dj i h b i i h b d bl
BHUSHAN STEEL
We did that by adjusting the combustion in the Tube Type Furnace and now we are able to attain a temperature of 365°C and above.
11/12/2018
11
Process Characterization
Upper spec *Target *Lower spec 360
Customer Requirements
Low High
0 6
Z actual = 4 41
Z potential = 5.36
Capability Analysis for Steam Out TemperatureSummary Report
How capable is the process?
Mean 373.74Standard deviation (overall) 3.1141
Actual (overall) capability Pp * Ppk 1.47 Z.Bench 4.41 % Out of spec 0.00 PPM (DPMO) 5
Process CharacterizationZ actual = 4.41
LSL
parts from the process that are outside the spec limits.• The defect rate is 0.00%, which estimates the percentage of
Actual (Overall) CapabilityAre the data above the limit?
Comments
BHUSHAN STEEL
380376372368364360
shifts and drifts were eliminated.Potential (within) capability is what could be achieved if process Actual (overall) capability is what the customer experiences.
Then we diverted our attention to increase the Washing Oil temperature and in the process increasing the bottom temperature of the Distillation Column.
Increased the temperature of the oil to 190°C (at the inlet to the Distillation Column) and hence thetemperature of Distillation Column bottom increased to 179°C to 182°C and the top temperature ismaintained at 94°C.
Maintaining these parameters showed us a very positive result in the Benzene content of the Crude Benzol.
Initial improvements are:
BHUSHAN STEEL
Initial improvements are:1. Total BTX content in the product increased from 87% to 90%.2. Quantity of Crude Benzol also increased by 0.5 ton per shift.
11/12/2018
12
At present we are attaining a Benzene percentage of around 72% - 74% and that to very consistently in the last month without any loss in the productivity .
Customer RequirementsReduction in % Out of Spec
Before/After Capability Comparison for Benzene perc vs Benzene %ageSummary Report
Customer Requirements
68 * *Lower Spec Target Upper Spec
Process Characterization
Mean 67.362 70.311 2.9492StDev(overall) 6.5816 1.0675 -5.5141
Actual (overall) capability Pp * * * Ppk -0.03 0.72 0.75 Z.Bench -0.10 2.17 2.26 % Out of spec 53.86 1.52 -52.34 PPM (DPMO) 538613 15188 -523425
Statistics Before After Change
97%
Yes No
0 0.05 0.1 > 0.5
P = 0.032
Yes No
0 0.05 0.1 > 0.5
P < 0.001
Reduction in % Out of Spec
to 1.52%.% Out of spec was reduced by 97% from 53.86%
Was the process standard deviation reduced?
Did the process mean change?
BHUSHAN STEEL
BeforeLSL
After and drifts were eliminated.Potential (within) capability is what could be achieved if process shifts Actual (overall) capability is what the customer experiences. • The process mean changed significantly (p < 0.05).0.05).• The process standard deviation was reduced significantly (p < Before: Benzene perc After: Benzene %age
Actual (Overall) CapabilityAre the data above the limit?
Comments
THANK YOU
BHUSHAN STEEL