Improving Coke Strength by Optimizing Pre-carbonization Techniques and

Battery Operation
B Chakraborty, A. Gupta and A. Das*

Adoption of suitable pre-carbonisation techniques and optimizing battery operation has become
critical to the success of the coke making industry. Most low rank coals, such as Indian coals,
respond favourably to pre-carbonisation. However, these techniques are not universally
applicable to all coals and the suitability of these techniques have to be assessed in depth before
commercial implementation. Although some plants have adopted some technological innovations
in pre-carbonization techniques and battery operation, more emphasis is needed to adopt and
optimize these technologies to enable production of stronger coke using inferior coals.

1.0 Introduction

The Blast furnace process is becoming more and more intensive with a trend

towards lower coke rate and higher injection rates. Under these circumstances,

the role that coke is required to play in the blast furnace has undergone a subtle
1)
change . Some of its functions like being a source of heat and acting as a

reducing agent have become less important while its other functions like

maintaining gas permeability, resistance against alkali attack and metal

carburization have become decisive. Consequently, the strength of coke has

become critically important for blast furnace operation. Under Indian conditions,

and particularly in SAIL, the high ash content of coke coupled with relatively

inferior strength characteristics are two factors that need to be dealt with urgently

to facilitate the planned growth in steel production.

The strength of coke produced is dependent on many factors like input coal/coal

blend quality, pre-carbonisation techniques and battery operation.

*Research & Development Centre for Iron & Steel, Steel Authority of India Limited, Ranchi-834002

Corresponding author email: [email protected]

In the current scenario of global scarcity of good quality coking coals, the last two

factors assume further importance.

2.0 Pre-carbonisation techniques

Pre-carbonisation techniques mainly aim at improving the bulk density of the coal

charge and the resulting proximity of the coal particles during softening leads to a

stronger bond between the coke cells, thereby improving the coke strength. The

various pre-carbonisation techniques available include differential crushing,

selective crushing, oil addition, partial briquetting of coal charge, stamp charging

and pre-heating of coal charge. SAIL has opted for differential / selective

crushing, Partial Briquetting of Coal Charge (PBCC) and oil addition as pre-

carbonisation techniques.

In India, stamp charging was used in FCI, Sindri, where it faced frequent

breaking of coal cake. However, Germany perfected the stamping machine and

stamp charging was again introduced in Tata steel in 1989 where it worked

successfully. Stamp charging offers significant improvement in productivity and

quality of coke even with relatively inferior coals, making it particularly suitable for

the Indian Steel Industry. Coal preheating including Coal Moisture Control (CMC)

and Dry-cleaned and Agglomerated Pre-compaction System (DAPS) are the

other pre-carbonisation techniques, which have been developed by Nippon Steel

Corporation for increasing the usage of weakly and non-coking coals. These

techniques are yet to be introduced in India.

2.1 Differential crushing / Selective crushing

2.1.1 Need for crushing of coal

Coke plants use coking coals from a number of sources, which are characterized

by wide differences in their properties in terms of ash content, coking properties,

Hardgrove Grindability Index, vitrinite content and rank. In the context of SAIL,

indigenous coals, which constitute about 30% of the coal blend, are

characterized by high organic & inorganic inert content. The imported coals used

in the blend are characterized by comparatively low ash (9-10%), higher vitrinite

content (60-70%), high FSI values (7-8) and contain significant percentage (60-

65%) of -3 mm size fraction. Preparation of coal charge from such a

heterogeneous blend assumes significance from the point of view of preparing a

coal charge that is homogeneous in nature. Table-1 gives the typical properties

of coals used in SAIL plants.

Coal is a heterogeneous material. Coking coals are crushed to ensure

homogeneity of the coal blend, a prerequisite for producing good coke. Figure 1

presents the distribution of ash, volatile matter and dilatometric properties in

different size fractions of a typical coal blend obtained under industrial conditions

using conventional blend-crushing method. The ash content decreases from

coarser size fraction to finer size fraction. The difference in ash content between

+6 mm and –0.6 mm is 5.3%. Poor caking properties as shown by total dilatation

and lower volatile matter content characterize the coarser size fractions. While

the +6 mm size fraction shows a total dilatation of 6%, the –0.6 mm size fraction

shows a total dilatation of 67%. This is explained by the concentration of harder

and difficult-to-grind coals with inferior caking properties in the coarser size
fractions, leading to heterogeneity in the caking/ plastic properties of different

size fractions of coal charge. Due to difference in the shrinkage characteristics

between these particles and the remaining mass, cracks develop which reduce

the strength characteristics of coke.

2.1.2 Conventional crushing of coal

Under a conventional coal charge preparation system, the level of crushing (%

through 3mm) and the content of different size fractions of coal charge for a

particular moisture level of the coal blend, determine the bulk density of coal

charge in a coking chamber. An optimum level of crushing of the blend is

necessary keeping in view the following technological aspects 2) :

 Coarser crushing of inferior coals leads to generation of coarser particles

which are centers of weakness in the coke matrix. Due to difference in the

shrinkage characteristics between these particles and the remaining

mass, cracks develop which reduce the strength characteristics of coke.

 Finer crushing of coals leads to increased generation of micro fines (-0.6

mm) and decrease in bulk density. It also leads to increase in specific

surface area of coal grains which will increase the quantity of plastic

material required for wetting and enveloping the inert materials. The fines

lead to difficulties in conveying and charging of coal into the oven and also

lead to jamming of the off-takes/standpipes. The reduction in bulk density

affects the oven throughput.

Conventional blend crushing of all the coals together leads to heterogeneous

distribution of coal substance in the different size fractions of coal charge 3).
2.1.3 Differential crushing of coal

To optimise crushing of coals, differential crushing was developed by RDCIS,

SAIL, Ranchi. In differential crushing, the different coals are divided into two

groups based on grindability indices, caking/ coking properties and dilatation

properties of individual size fractions (Table-2). The two groups of coals are

crushed to different levels of crushing. Group I (softer) coals are crushed to lower

level and the crushing level of Group II (harder and inferior) coals is kept higher

to finely disperse coals with poor caking properties in the plastic mass.

Differential crushing was implemented at Bokaro Steel Plant Coke Ovens and

coke quality improved even with lower usage of imported coal in blend.

2.1.4 Selective crushing

In selective crushing, the –3mm fraction of coal which are richer in reactives is

separated out after the first stage of crushing using a pneumatic classifier and

only the inert rich coarser size fraction is crushed further in the second stage.

Pneumatic separation combined with re-crushing of coarse and mineralized coal

particles reduces the quality differences between the various size fractions in the

charge. It also facilitates a higher crushing level thus improving coke strength

without increasing the fines content. The effect of crushing level on coke strength

(M10 and M40) is shown in Figure 2 . The effect of different crushing methods on

coke strength (M10), using the same coal blend with different methods of coal

charge preparation is shown in Figure 3.

2.2 Partial briquetting of coal charge

Briquetting of coal with tar and pitch as binder is an exciting technique developed

originally in Japan, which utilizes the beneficial effects of high density of coal

charge and the swelling property of coal briquettes to improve coke quality.

Briquetting is an operation in which a press is used to effect cohesion and

compaction of fines possessing certain characteristics. Compaction during

briquetting brings particles in coal briquettes closer than in coal fines. It

intensifies caking action between particles. Briquettes expand with marked

evolution of gases and compress the surrounding coal fines to promote cohesion

of coal particles which also contributes to increase in coke strength. Apparent

density of briquettes produced are much greater than that of fine coal and this

results in increase in mutual contact areas of coal grains in the briquettes. High

density briquettes when carbonized along with fine coal exhibit strong swelling

power in plastic zone and exert comprehensive action as the softened blend,

thus accelerating the agglutination among grains not only of themselves but also

of the fine coal. Higher bulk density results in decrease in void volume of coal

charge thereby reducing the requirement of plastic material for the bonding

action. Use of coal tar pitch binder increases the caking substances. The

optimum percentage of briquettes is around 30%. Although the bulk density of

coal charge continues to increase beyond this point (Figure 4), the improvement

in coke strength (M10, M40) tapers off (Figure 5) and using more than 40% can

cause dangerous wall pressure. For maximum effect, the technology has to be

optimized in terms of size, shape, percentage and segregation of briquettes. For

reducing segregation, pillow shaped and tear drop shaped briquettes are
preferred over the oval shaped briquettes. Segregation can be controlled by use

of baffles (to avoid horizontal movement) and by controlling the level of coal

charge in the coal towers. A poor charging facility could also cause segregation

of briquettes & coal inside the oven and too much of segregation would result in

high wall pressure at certain points. The two well known systems in operation

are:

 Nippon Steel System – Here the briquettes are mixed with fine coal in a

larry car hopper through belt feeder.

 Sumitomo System – This system is called sumicol, where the briquettes

are pre mixed with fine coal and stored in the service bunker.

Apart from its effect on coke strength, PBCC results in a slightly lower yield of

gross coke (0.3 to 0.5%), higher yield of BF coke (4.1%) due to improved

strength of coke, increase in dry charge by 8.2% (at 30% briquette level),

increase in crude tar yield (0.5%) and marginal improvement in gas yield by

0.4%. The adoption of this technology in SAIL at BSP (1990 ) and RSP (1996 )

has improved M10 by 1 point and Coke Strength after Reaction (CSR) by 4-5

points. At Baoshan Steel works, China it was possible to produce coke with CSR

and CRI in the range of 57-65 and 26-30 respectively by adopting this

technology. Newcastle works of ISCOR, South Africa has also reported a marked

improvement in the M10 index and CSR of coke after the introduction of this

technology. A major advantage of this technology is that it can be easily

retrofitted to an existing coke oven plant with minimum interferences.

2.3 Coal Pre heating / Coal Moisture Control / DAPS:

High moisture content of coal adversely affects the bulk density of coal charge

and coke strength, increases thermal shock to coke oven refractory and

increases coking time. Coal moisture also reduces the flowability of coal charge,

resulting in jamming of transfer chutes etc. In the 1970s, a technology was

developed for reducing moisture by pre heating of coal before charging. In this

process, coal charge is preheated to as high a temperature as possible without

reaching the thermal decomposition threshold(above300 oC), not only to eliminate

the moisture completely, but also to raise the coal to an elevated temperature

before charging directly into the ovens. As a result, bulk density increases by 10-

12% while coking period reduces by 35%. Coke strength in terms of M10 & M40

both improve by up to 4 points. However, preheating technology in this form has

not sustained well in the world due to problems associated with the handling of

preheated coal which led to explosions one after another in almost all

commercial pre-heating set-ups.

2.3.1 Coal Moisture Control (CMC)

A modified preheating process (Figure 6) known as CMC was developed by

Nippon Steel and it started commercial operation at Oita works in 1983. In this

process, coal moisture is reduced from 9 - 10% to 5 - 6% utilizing the heat of the

exhaust gas from the ovens, and thus reduces the heat consumption of coke

making. The benefits achieved due to lower moisture content of coal charge are:

 Energy saving (~ 10%)

 Increased coke strength or usage of non or weakly caking coals

  Stabilized operation of Coke ovens due to less thermal shock

 Increased oven throughput due to higher bulk density.

2.3.2 Dry-cleaned and Agglomerated Preheating System (DAPS)

The reduction in coal moisture results in fine coal being emitted to the

environment during transportation and charging into coke ovens, and this leads

to problems such as the deterioration of work environment, operation troubles

due to carbon deposition on coking chamber walls and poor quality of tar,. This

led to the development of the DAPS process where dust occurrence is

suppressed to improve the environment friendliness of preheated coke making,

by separating fine coal from lump coal and forming the fine coal into

agglomerate. In the DAPS process, coal is dried in a fluidized-bed dryer, fine coal

grains (≤ 0.3 mm) are separated from coarser grains by the gas flow, collected by

a cyclone separator, formed into agglomerate by a roll compactor, mixed with the

coarser grains, and charged into coke ovens. The mass fraction of the fine grains

is approximately 30%. The charging density of coal is 0.80 t/m3; an even density

distribution in a coking chamber is maintained. In addition to suppressing the

dust occurrence, the DAPS has improved the caking property of fine coal by

increasing its bulk density. As a result, benefits achieved are:

 The strength of the DAPS coke is markedly better than that of the CMC

coke both in terms of cold as well as hot strength.

 The DAPS makes it possible to increase the use of non or slightly-caking

coals by 30% compared to the conventional wet coal charging process,

 and by approximately 20% compared to the CMC process, without

deteriorating the coke strength.

 The charging density of coal with the DAPS is approximately 0.80 t/m3,

and together with the reduction of coking time due to the decrease in coal

moisture, productivity of coke ovens improves by 21% compared with the

conventional wet coal charging process.

 The DAPS decreases the heat consumption of coke making due to lower

moisture content of coal and productivity. The heat consumption

decreases by approximately 15% compared to the conventional wet coal

charging process at the same production rate.

2.3.3 Super Coke Oven for Productivity and Environmental

Enhancement toward the 21st Century (SCOPE 21)

Coal pre-heating/ coal moisture control is also a part of the SCOPE 21 process.

The equipment is a next-generation eco-friendly coke oven that incorporates

unprecedented and innovative technologies to cope with raw material problems

through the increased use of low-grade coals, to conserve energy and reduce

CO2 emissions. The first commercial model of the SCOPE 21 coke oven has

been commissioned at the Oita Works of Nippon Steel Corporation in May 2009.

In this technology, coke making is divided in three steps namely, rapid

preheating, carbonization and coke upgrading and quenching. In coal rapid

preheating , the coal is heated slowly to 300°C in a fluidized bed dryer, and then

is heated rapidly to 380°C in a pneumatic pre-heater, and carbonized in the coke

oven. The effect of rapid preheating of coals on the coal chemical structures and
the resultant coke strength shows that the cracking reactions of the coals are

suppressed compared to slow preheating: the ratios of O/C and H/C in the

rapidly preheated coals were found to be almost identical to those of the

untreated coals4). An NMR study has revealed the enhanced mobility and

structural relaxation of the coal molecules due to the rapid preheating. The rapid

preheating of the coals improved the resultant coke strength. The enhanced

mobility of the coal molecules, is thought to improve the thermoplasticity of the

coals at the melting stage, which leads to improved strength of the resultant

cokes.

2.4 Stamp Charging

Stamp Charging technology was perfected by M/S Saarberg Interplan, Germany.

In this technology, fine coal is stamped into a cake outside the oven chamber and

introduced into the oven through the pusher side door by a special machine

known as Stamp Charging cum Pushing (SCP) machine. The coal blend is

gradually discharged from a bunker into the stamping box and a series of

hammers compact the coal mass into a solid cake. A stamping energy of 450-500

Nm/Kg is imparted to the coal mass having around 10% moisture to achieve a

typical bulk density of over 1100 kg/m 3 and the requisite cake stability. Stamp

Charging has a significant effect on M10 value of coke which is almost

independent of coal blend quality (Table 3) making it particularly suitable in the

Indian context. The improvement in coke strength (M10 and CSR) of coke by

Stamp Charging is shown in Figure 7. The current coal and coke quality from

stamp charged batteries at JSW and Tata Steel is given in Table 4.

For optimum and safe stamp charging operation, one needs to maintain correct

granulometry of coal , precise moisture control and control on rank of coal blend

(Ro<1.05) with adequacy of specific stamping energy.

2.5 Oil-water emulsion addition

Oil-water emulsion addition has been tried out at SAIL plants at DSP, BSP and

BSL (Figure 8). Apart from increasing the bulk density of coal charge, the

technology improves the flowability of coal particularly during monsoons. The

effect of addition of different oils on the bulk density is given in Figure 9.

However, if improvement in coke strength is desired, the percentage of oil in coal

charge has to be more than 0.3%.

A comparison of coke M-10 obtained using different pre-carbonisation

technologies is given in Figure 10.

3.0 Battery operation

Coke oven battery operation is basically a batch process in which individual

chambers are charged and the coal carbonized for a scheduled coking period

under a set heating regime. However, the process of oven charging and pushing

follows a particular sequence making it a continuous process where any sort of

interruption can be detrimental to coke quality and oven health. A harmonious

interaction between coal charging, maintenance of a proper heating regime and

coke pushing at the right time is a prerequisite for producing strong coke.
3.1 Coal charging

The coal charge should be uniform in terms of moisture content, granulometry

and bulk density. While charging, the proper sequence has to be maintained and

full charging of each oven chamber has to be ensured. Screw feeder based

charging mechanism should be preferred over conventional gravity charging.

Optimum amount of leveling should be done to ensure a level free space and

minimum spillage with compaction of the top layer. The straightness of the leveler

bar should be checked from time to time and if sagging is detected, corrective

action should be taken. Microwave based radar sensors for measuring the level

of coal in the coke oven can be installed for ensuring full charging. The sensors

are installed on the charging car to measure the pile height (±30mm accuracy)

after charging, and additional coal is automatically charged in order to achieve

the optimal charging level for each hole.

3.2 The heating system

The process of heating and regulation of coke ovens is of utmost importance with

respect to the strength of coke produced. An efficient heating system should

ensure:

1. Complete combustion of fuel gas with a minimum of excess air to ensure

optimum coke quality and specific heat consumption.

2. Uniform heat distribution throughout the oven such that coking proceeds

evenly in all parts of the oven.

3. Minimum time between pushing and charging of ovens.

In a majority of coke oven batteries in SAIL, conventional method of heating

control is followed. In conventional heating control, the heat required for coking is

considered the same for all ovens. The heating regime is dictated by the coke

production target based on which the average coking period and the average

heating wall temperature to be maintained are deduced. The heating wall

temperature is determined based on the manual measurement of the burner

base temperature of a few selected vertical flues (control verticals) with hand

held pyrometer once in a shift. Thus, conventional heating control is primarily

based on the control vertical temperatures. Although simple and practical,

conventional heating control is subjective and inefficient.

3.2.1 Automatic heating control of coke oven battery

The Coal cake inside the oven is a huge mass of about 14 -17 m. length, 0.4-0.5

m. width and 4-7 m. height. Bulk density of coal is also not uniform throughout. It

is estimated that bulk density beneath the charging hole is more than in between

charging holes and maximum bulk density occurs beneath coke side charging

hole. Obviously, if the driving force for coal carbonisation, i.e., the temperature in

heating canal is maintained same, all parts of coal charge is not likely to be

coked simultaneously. Hence, in order to avoid green pushing of the undercoked

portions, generally, coking period is maintained at a higher level thus overheating

coke at different locations and increasing specific heat consumption. A more

rational way of heating control is demand oriented heat input. For this, we must

have sufficient information about the heat demand. In other words, we must know

coal characteristics before it is charged, viz., charge weight, moisture content,

crushing index etc. Likewise, we must have sufficient information about heat
input parameters, viz., underfiring gas pressure, volume, calorific value etc.

Another aspect relates to the optimum coking period. It is known that

prolongation of coking period improves coke quality in terms of MI0 and CSR

values, though asymptotically, simultaneously requiring more underfiring gas.

Hence, an optimum carbonisation period has to be struck so as to meet both the

requirements of coke quality and reduced sp. heat consumption. Temperature

profile of coke oven gas measured at the gooseneck can help in optimizing the

coking period.

Automatic heating control systems which have come up during the last 10-15

years variously seek to measure the heat demand, follow the progress of

carbonisation, calculate and supply exact heat load, get feed back about the

product quality (in terms of temperature), and re-adjusts heat supply with the help

of the above monitoring system.

RDCIS, SAIL has also developed an indigenous automatic heating control

system known as the Integrated Coking Control System (ICCS). This system was

introduced in Battery 3, BSP and Battery 1, DSP and is under implementation in

Battery 4, BSP. The system consists of the following modules:

 Automatic Oven Identification which detects pushing and leveling

operation occurring in a particular oven of a battery. The system is based

on infra red/ RFID sensors .

 Heat demand model calculates the heat demand of ovens from heat

balance equations taking online data of charge coal quality parameters.

Surface heat losses and heat losses from waste gases are subtracted to

arrive at net heat demand of battery.

 Heat consumption model calculates heat consumed per reversal by

taking on-line data of heating gas fed per reversal and its calorific value.

Preliminary heat demand for the next reversal is computed from the above

and preliminary heating gas flow, pressure and draught for the next

reversal are predicted by the PC. These preliminary predictions are

modified depending on the values obtained from the feed back loops –

coking index & pushed out coke temperature.

 Coking index module is a critical part of the coking control system where

the temperature of the raw gas is measured on-line for each oven through

thermocouples inserted in the gas off-takes. The raw gas temperature

profile has a definite relationship with the progress of carbonisation and

distinctly indicates the time at which the carbonisation is completed. This

is indicated in the form of a temperature peak (Figure 11). After

carbonization is completed, some more time is given before the coke is

pushed. This additional time is known as the soaking period. The soaking

period that is required for optimum coke strength is specific to the coal

charge quality and battery condition. For a particular battery, it is specified

in the form of a ratio known as the coking index . The optimum range of

coking index for the battery is determined (Figure 12 ) and the model

ensures that the battery is operating under the specified coking index by

adjusting the heat input thus ensuring optimum coke quality and heat

consumption.

 Coke mass temperature module The coke mass temperature is an

important coke strength parameter which is measured by scanning the

 quenching car as it enters the quenching tower. The module appropriately

modifies these pre-quench temperatures to obtain the average coke mass

temperature.

The implementation of ICCS in SAIL resulted in the improvement of coke

strength in terms of M10 by 0.5 points.

3.2.2 Measurement of cross-leakage

Cross-wall leakage of gas from the coke oven chamber to the heating flues is a

major cause of inefficient combustion. It not only leads to a loss of coke oven gas

yield but it also significantly disturbs the pressure distribution throughout the

heating system and leads to chimney emissions. Conventionally, cross- leakage

has been visually estimated in terms of chimney smoking or vertical flue

inspection. However, these methods are qualitative and subjective in nature.

Recently, RDCIS, SAIL has developed a process for the quantification of cross-

leakage (patent pending) based on waste gas analysis. The process has been

successfully used to determine cross-leakage from selected ovens and all the

batteries at BSP (Table 5). The process is currently under implementation in all

coke oven batteries of SAIL.

4.0 Conclusion

Adoption of suitable pre-carbonisation techniques and optimizing battery

operation has become critical to the success of the coke making industry. Most

low rank coals, such as Indian coals, respond favourably to pre-carbonisation.

However, these techniques are not universally applicable to all coals and the
suitability of these techniques have to be assessed in depth before commercial

implementation. Although some plants have adopted some technological

innovations in pre-carbonization techniques and battery operation, more

emphasis is needed to adopt and optimize these technologies to enable

production of stronger coke using inferior coals.

References

1. Coke quality for a modern Blast Furnace; A. Babich, D. Senk et. al. ; Proc.

ICSTI, Nov, 2006, 351

2. Rational preparation of Indian coals for coke making; OS Morozov, RL

Sharma et. al. ; Steel India, vol5, No.1, April 1982, 1

3. Optimisation of preparation of coal charge for coke making; L

Parthasarthy, NK Ghosh et. al.; 21st Pittsburg coal conference, Sept., 2004

4. Effect of rapid preheating on coal structure and coke strength; M.

Matsuura et. al., Tetsu to Hogane, vol 89, No.5, 2003, 565

5. Monograph on coal & coke at Tata Steel; Edited by A. Chatterjee & PVT

Rao, 1992
Table 1 : Typical properties of Indian and foreign coals

Source Properties
Ash, % VM, % FSI Vitrinite, % MMR, %
Indigenous coals
Dugda 21.4 20.3 2 45.0 1.23
Bhojudhi 19.8 24.1 3 49.3 1.14
Sudamdih 18.5 24.0 3-3½ 45.6 1.18
Kargali 21.8 22.9 3-3½ 40.2 1.08
Kathara 19.6 25.9 2 41.8 0.96
Swang 20.6 27.8 3 47.7 0.95
Rajrappa 18.7 29.6 2-2.5 50.8 0.91
Foreign coals
Oaky Creek 9 24.2 8 69 1.25
German Creek 9 21.6 8 70 1.36
Gooneyella/B 9.1 23.4 7-8 62 1.22
Barwon 8.2 26 7.5-8 57 1.23
Malvern 9.2 22.8 7.5-8 57 1.25
Arco blend 7.5 25.5 7½ 56-60 1.16
New Zealand coking coal 3 29-30 9 92 1.19

Table 2: Grouping of coals

GroupSourceHGIGieseler’s
fluidity (ddpm)Ruhr Dilatometer
dilatationI
(Easy-to-grind with better
caking properties)Munidih
Kargali
Imported73.9
60.2
81.26966
4142
 5)
Table 3: Effect of stamp charging on coke strength (M10, M40)

Blend constitution, % Top charging Stamp charging

Imported Micum Indices Micum Indices
Jamadoba West Bokaro
coal M40 M10 M40 M10
25 55 20 82.6 9.2 84.5 6.1
40 40 20 83.3 9.0 83.4 6.0
50 50 - 80.6 9.2 84.6 6.4
43 57 - 79.8 10.6 82.6 6.4
34 46 20 82.0 9.8 85.9 6.1
30 40 20 81.0 9.0 82.7 6.3

Table 4: Stamp –charged coke quality at Tata Steel and JSW Steel

Parameter Tata Steel JSW Steel

Imp coal in blend, % 40.64 98.0

Coke moisture, % 4.3 6.0
Coke Ash, % 16.6 12.9
M40 82.8 86.8
M10 5.1 6.1
CRI 27.0 25.2
CSR 64.4 64.7

Battery No % cross-leakage % cross-leakage % cross-leakage

15.12.10 16.12.10 13.01.11

1 11.82 11.99 15.32

2 9.06 9.01 7.91
 3 7.85 7.62 8.27
5 3.40 3.59 3.06
7 12.72 12.73 12.19
8 10.03 9.96 8.76
9 6.03 6.30 6.58
10 5.95 6.15 8.27
Table 5: Cross-leakage from different batteries at BSP
Fig 1: Distribution of ash, VM and dilatation in coal size fractions
Fig 2 : Effect of crushing index on coke strength

Fig 2

1 – 6 : Differential crushing at different crushing levels of constituent groups

7 : Differential crushing with separation of fines
8 : Selective crushing
9 : Conventional blend crushing

Fig 3: Effect of different coal preparation methods on coke strength

Fig 4 : BD of coal charge as a function of the percentage of briquettes

Fig 5: Effect of addition of briquettes on coke strength

Fig 6: CMC process flow sheet
Fig 7: Effect of stamp charging on coke strength
Fig 8: Oil-water emulsion addition system

Fig 9: Effect of oil addition on bulk density

Fig 10 : Comparison of pre carbonization technologies
Fig 11 : Raw gas temperature profile
Fig 12: Effect of coking index on coke strength