Theme 1: Circular Economy & Resource EfficiencyWorld Steel Association – By-Product Workshop

Prepared by : By–Product Plant Team

Tata Steel Kalinganagar

2SlideTATA STEELBPP – TSK

INDEX

Slides 3-5

Introduction to By-Product Plant

Slides 6-11

Process Overview

Slides 12-17

Learnings & Issues

3SlideTATA STEELBPP – TSK

• By-Products Quality- FY’18

Tar • Average Moisture:

1.65%

• Average QI:0.8%

Sulfur • Purity >98%

• Bulk Density- 0.8-0.85gm/m3

• Moisture- 0.05-0.15%

• Ash Content- 0.19-0.23%

Co

ke

Ove

ns G

as • Calorific value-

4200KCal/Nm3

• CO Gas Quality maintained as per the design norms-NH3<0.04g/m3, H2S<0.5g/m3, Naphthalene<0.12g/m3,Tar fog<0.02g/m3.

Tre

ate

d W

ate

r • Quality as per the Environment Norms

• COD<250ppm, NH3<60ppm, CN<0.02ppm, Color<100PtCo, BOD<30ppm, TSS<100ppm, Phenol<1ppm

4SlideTATA STEELBPP – TSK

• By-Products – Uses

Ta

r • Soap, Shampoo & Ointment

• Medicinal applications

• Construction-Sealcoat Products

• Fuel- Firing of Boilers

• Paints, Synthetic dyes

• Photographic Materials

Sulfu

r • Vulcanization of Rubber

• Manufacturing of H2SO4

• Insecticide, Fertilizers

• Medicinal Applications

Co

ke

Ove

ns G

as • Fuel – Firing of

Boilers, Furnaces, Pumps, Blowers & other equipment

Tre

ate

d W

ate

r • Sent to CETP for further Treatment

• Used as Gardening, Fire Hydrant Water, Road Sprinkling for Dust Suppression

STEAM

NETWORK

BPP:PROCESS FLOW DIAGRAM

M

M

M M

MMM

M M M

M M M

M M M

M M M

MM

MM M M M

M M

M

M M M M

PGC#1 PGC#2 PGC#3

ETP#1 ETP#2 ETP#3

EXH#1 EXH#2 EXH#3

H2S

ScrubCombi

Scrub

Amm

ScrubNaph.

ScrubNaph.

Scrub

CHW System

CW System

STRIPP

ER

DEACI

DIFIER

Tar

Separat

or

Tar

Separat

or

FL

Pump

FL

Pump

Tar sludge

separatorsTar press pumpTar press pump

M

Soft water

Caustic soda solution

Stripped liquor

Lean liquorNAPHTHALENE

DISTILLATION

UNIT

GAS

DISTRIBUTION

NETWORK

1A 1B 2A 2B

COAL

WATER

TANK

COAL

WATER

TANK

COAL

WATER

FILTER

TAR

STORAGE

TANK

DEACI

DIFIERSTRIPP

ER

ENRICH

LIQUOR

TANKSOFT

WATER

TANK

CAUSTIC

SODA

TANK

Coal Water

Centrifuge Centifuge

SULP

HUR

TANK

Coal Tar

Flushing Liquor To Battery

Co

al

Wate

r T

o S

cru

bb

ers

Lean Caustic Soda Solution

Enrich Liquor

Claus Kiln

HP Boiler

Claus

ReactorSulphur

Condenser

Tail

Gas

P

D

6SlideTATA STEELBPP – TSK

• Process Overview – Coal Tar

• Gas cooling-Flushing Liquor

• Recovery from BPP Tanks (draining)

• Extraction of Max value

Coke Oven Gas

• Decanters-Settling

• Centrifuge- 3 Phase Separation

Coal Tar Recovery

• Naphthalene Addition

• Wash Oil Residue Addition

• Sold to External Customers

Coal Tar Storage

Tank

Tar Sludge – Mixed with Coal

Liquor/Water Drained sent to

Decanters

7SlideTATA STEELBPP – TSK

• Process Overview – Sulfur Recovery

• Scrubbers

• H2S, CO, CO2, NH3,HCN

• Sour Vapor

Coke Oven Gas

• Sulfur Recovery-Claus Process

• H2S Converted to Sulfur & SO2

• NH3 Converted to N2 & H2

Sour Vapor

• Fed again to the inlet of BPP Process

• Reuse/ Reutilization

• Better Recovery

Tail Gas

Tail Gas Recirculation

Sulfur pastilles Sold to External Customers

8SlideTATA STEELBPP – TSK

• Process Overview – Alternate / No Recovery

• Scrubbers

• H2S, CO, CO2, NH3

• Sour Vapor

Raw Coke Oven Gas

Flaring, FuelChoking Of Burners, Corrosion ,

SOx NOx EmissionsProcess Disruptions, Acid Rain,

Air Pollution,

9SlideTATA STEELBPP – TSK

• Process Flow – Alternate / No Recovery

• Scrubbers

• H2S, CO, CO2, NH3

• Sour Vapor

Coke Oven Gas

Flaring, FuelChocking Of Burners, Corrosion

, SOx NOx EmissionsProcess Disruptions, Acid Rain,

Air Pollution,

10SlideTATA STEELBPP – TSK

• Process Overview – Coke Oven Gas

• H2S, CO, CO2, NH3, HCN, BTX, Naphthalene, Tar Fog

• High Temperature

Raw Coke Oven Gas

• Primary Cooling

• Tar Fog Separation(ETP)

• Scrubbing of NH3, HCN, H2S, CO, CO2, Naphthalene

By-Product

Plant

• No Corrosion, Plugging/ Chocking

• Reuse/ Reutilization as Fuel

Clean Coke Oven Gas

Tail Gas & Naphthalene

Vapor Recirculation

11SlideTATA STEELBPP – TSK

• Process Overview – Treated Water

• Scrubbers

• H2S, CO, CO2, NH3, HCN, BTX, Naphthalene

• Rich Liquor

Coke Oven Gas

• Waste Water to BOD Plant

• Sour Vapor to Sulfur Recovery

Distillation/ Stripping

• Treated Water to CETP

• Reuse/ Reutilization

• Gardening, Fire Hydrant Water

BOD Plant

BOD Sludge – Mixed with

Coal

12SlideTATA STEELBPP – TSK

• Tar Recovery and Oil Depot Unit

13SlideTATA STEELBPP – TSK

• Coal Tar Quality Moisture %

G

O

O

D

2.40

5.00

1.65

1.66 1.72

1.16 1.18 1.26 1.20 1.25

2

3

2.71 2.62.36

3.082.9

3.1

3.7

2.57

1.43 1.51.85

1.028

0

1

2

3

4

5

6

0

1

2

3

4

5

6

FY'17Average

Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar FY'18(ABP)

FY 18Actual

Coal Tar Quality- Moisture %

FY 18 ABP(MT) FY 18 Actual FY 17 Actual

14SlideTATA STEELBPP – TSK

• Sulfur Recovery Unit and Packaging Building

15SlideTATA STEELBPP – TSK

• Sulfur Production-Learnings

Ineffective temperature monitoring: - Due to the lack of attention from operator like tiredness, loss of concentration etc. If the reduction in temperature is not monitored properly, it will lead to the sulphur plugging.

Presence of hydrocarbons (HC) in the molten sulphur :– Since SRU is a downstream plant, any malfunction in the upstream processing plant will lead to the presence of hydrocarbons in the molten sulphur, which ultimately lead to the plugging of sulphur in rundown lines .

Steam trap not working properly: – Steam traps may fail due to rust in metal parts.

Rain: – Sudden rain causes loss of heat from steam which leads to the formation of more condensate in the pipe, which cannot be removed by steam traps. This leads to reduction in temperature for the molten sulphur which ultimately results in the plugging of sulphur.

16SlideTATA STEELBPP – TSK

• Sulfur Plugging Pics

SL line below WHRBPipe Plugging in separator2

Valve Plugging in separator 1

Sulfur clinker

17SlideTATA STEELBPP – TSK

• By-Products – Future

Ta

r • High QI/Pitch

• Lower Moisture

Sulfur • Purity is always

related with the color which is not the case

• Plugged Sulfur Pipelines are quite difficult to clear out

Co

ke

Ove

ns G

as • Naphthalene and

Tar Fog complete removal from the Gas not possible

• Choking of Burners and Pipelines

Tre

ate

d W

ate

r • Maintaining Treated Water Parameters – CN, Color

• Bacteria Culturing with Sludge – New Varieties to curb CN and Color

• Activated Carbon For Color Treatment is a messier process