Experience in the repair of coke batteries 3 and 4 at OAO MMK

The cold repair of two coke batteries after operation for 24 and 37 years, respectively, is outlined, with complete and partial replacement of the upper lining structure.     

Atmospheric protection at coke plants

Atmospheric protection at coke plants is assessed on the basis of plant records and experimental data. Problems in addressing atmospheric emissions are often associated with poor inventories of emission sources. On the basis of research at OAO VUKhIN, a standard regarding the determination of atmospheric emissions is developed. This standard ensures objectivity of the data. Russian and European standards regarding atmospheric emissions are compared. It is clear that the planned introduction of a new system of technical standards for emissions requires the review of all atmospheric-protection measures and the introduction of new approaches.     

Using thermostable concrete in the hot repair of coke batteries

Practices in the United States and Germany regarding the use of thermostable concrete in the hot repair of coke batteries are assessed. Experience in furnace repair by means of thermostable concrete using a Russian method is described. The use of thermostable concrete in coke batteries has not been widely adopted, for lack of information. Experience shows that thermostable concrete can satisfactorily replace the fireclay lining of coke batteries. If the thermal conductivity and wear resistance of thermostable concrete can be improved, new prospects will appear for the replacement of brick battery linings by concrete blocks.     

Environmental management at coke plants

It is important to introduce an environmental management system in accordance with the ISO 14001 standard so as to improve the environmental safety of coke plants. Examples of reduced environmental impact show the effectiveness of the system introduced at OAO Koks.     

Reconstructing coke batteries 5 and 6 at OOO Mechel-Koks

At OOO Mechel-Koks, coke batteries 5 and 6 have been reconstructed. Besides the batteries themselves, associated systems such as the coal towers, the slaking towers, and the automation system were reconstructed. At coke battery 5, a control station for coke batteries 5–8 was installed, as well as a new coke-sorting system with a ramp and bunkers for large coke pieces.     

Using biochemically purified water at coke plants

The use of biochemically purified water in place of industrial-grade water for the exhaust-gas scrubbers in the drying department of the coal-enrichment shop and for irrigation of the cyclone washers in the coke shops at OAO ZSMK is considered. It is found that biochemically purified water may be used for 100% of the water needs in coke production. Using biochemically purified water in the dust-trapping equipment, the coaland coke-dust content of the atmospheric emissions may be reduced by 24.5%. Additional purification of wastewater by adsorption on coke and coal dust is possible.     

Propane-butane heating of coke batteries

Experience has been gained in propane-butane heating of the first coke batteries of a newly constructed coke plant, where no coke-oven gas or blast-furnace gas is available. Under the guidance of specialists at ZAO Ogneuporkoksservis (OKOS), five coke batteries have been successfully heated and put into operation. For the first time in global practice, a coke battery has been converted to continuous propane-butane heating. Propane-butane heating of the coke battery has been tested and confirmed as a reliable means of preparing the first batteries at a newly constructed coke plant for startup and production. In addition, experience shows that continuous propane-butane heating is possible for a battery with a limited supply of coke-oven gas for heating.     

Corrosion rates in water-circulation systems at coke plants

Means of improving the efficiency of water circulation of coke plants are considered. A systemic approach is adopted. The goal is to minimize corrosion in the water-circulation system by means of phenolic wastewater and corrosion inhibitors. The corrosion rate is investigated as a function of the dose of inhibitor and the operating parameters. On the basis of the models derived, the operation of the water-circulation system at coke plants may be better predicted.     

Hot repair of refractory linings in coke furnaces by means of surfacing mixtures

Constant repair of the refractory lining is required in the furnaces of any enterprise producing metallurgical coke. At OAO Zapadno-Sibirskii Metallurgicheskii Kombinat (ZSMK), coke batteries 3, 4, 5, and 6 exceeded their expected working lives in 1967, 1968, and 1971, respectively.     

Maintaining the production capacity of aging coke batteries at OAO MMK

Experience in maintaining the production capacity of nine coke batteries with a mean age of 35 years is outlined.     

Improved cost calculations of coke-oven gas at coke plants

It is important to develop new methods of determining the costs of individual products within a complex process, so as to determine, with maximum precision, the direct costs of each stage of the production process and better distribute the indirect costs. Means of improving cost calculations at OAO Zaporozhkoks are considered, for the example of coke-oven gas.     

Prospects for biotechnology in wastewater processing at coke plants

The prospects for biotechnology in wastewater processing at coke plants are considered, in conditions of nitrification and denitrification. Wastewater-processing systems employed at Russian and foreign coke plants are compared. The degree of purification is about the same in Russia and elsewhere. However, the treated water does not meet Russian standards for delivery to municipal treatment plants and reservoirs from which fish are taken to be cooked. The single-phase AO VUKhIN biotechnology permits the removal of 80–90% of the nitrate present without the addition of organic reagents, in contrast to classical nitrification and denitrification technology.     

Risk management in the byproduct shops at coke plants

Risk factors in the byproduct-trapping shop are identified. The need for quantitative and quantitative risk assessment is established. A method of estimating the probability of an accident in trapping-shop systems with different types of backup is developed. Calculations by the proposed method are presented. Recommendations for more stable shop operation are elaborated.     

Priorities in the design of chemical shops at coke plants

Recent trends in the design of chemical equipment at coke plants are described, through the lens of experience at Giprokoks. Some technological equipment is briefly characterized.     

EC-recommended best available techniques in wastewater purification at coke plants

At most coke plants, wastewater-purification equipment is far inferior to the available technology. Accordingly, pollutants are released into the workplace and into the atmosphere not only in wastewater purification but also in subsequent use of the water. At leading coke plants within the EU countries, releases are generally prevented by the use of the best available techniques. In collaboration with OAO Zaporozhkoks, ZAO Ekotekhnika has analyzed the best available techniques and is proposing to modernize biochemical systems for wastewater purification at coke plants.     

A mortar for lining coke batteries by zones

Conclusions A dinas mortar has been developed for lining coke batteries by zones, for the low-temperature zones with addition of 5% borax and for the high-temperature with addition of 2% borax.Deceased.Translated from Ogneupory, No. 8, pp. 22–24, August, 1993.     

Influence of ozonization on the hydrocarbon composition of raw benzene at coke plants

The influence of ozonization on the composition of raw benzene produced at coke plants is studied. Preliminary ozonization reduces the quantity of unsaturated hydrocarbons and sulfur-bearing compounds and correspondingly the proportion of benzene increases.     

Operation of the extreme heating channels in coke batteries

Defects in coke-oven linings of coke batteries are analyzed. In the course of operation, the properties of the Dinas brick change on account of the formation of silicate melts that move through a capillary system within the brick from hotter to cooler sections of the lining. Melt migrates from the vertical heating channels to the coke chambers. In contrast to most of the heating channels, significant temperature gradients arise between the extreme and adjacent heating channels on account of the great difference in the quantity of heating gas supplied. The temperature gradients facilitate melt migration in this zone not only from the vertical channel to the chamber but also between vertical channels. This factor accelerates lining wear at the extreme heating channels and must be taken into account in regulating the heating conditions at the extreme pairs of heating channels.