Thyssenkrupp IndustrialSolutions CokePlantTechnologies

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Jocelin Martin
5 years ago
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aswellasforoptimizingtheperformanceofcokingplants

1 Thyssenkrupp IndustrialSolutions CokePlantTechnologies ThevalueofengineeringforreductionofCAPEXandOPEX aswellasforoptimizingtheperformanceofcokingplants 25Anniversary of Polish NationalCokemaking Conference Koksownictwo 2017

2 Developmentofcokeplanttechnologies ~1980s LargenumberofcoalminesandcokeplantsinEurope Rapiddevelopmentofcokeplanttechnologies Innovationsconstantlyimplementedonnewplants Speedofinnovationslowingdownfrom1980s Page2 1990~ ~ ~now ConstantreductionofsteelandcokeproductioninEurope SupplyoflowcostcokefromChina Reducednumberofprojectsfornewplants Sharpreductionofspecialistsfordesign/R&Dprojects Enormousincreaseofcokeprice Boominconstr.ofnewandreplacementofagedplants Copiesofexistingdesignswithlittleinnovation LownumberofR&Dprojectsanddesignspecialists Over-supplyofsteelonworldmarket=>lowprofits Veryfewprojectsfornewplants Mainbuyingcriteriaislowestprice(ofengineering) Valueoftechnologyanddesignisnotrespected

3 Developmentofcokeplanttechnologies Example:increaseinovendimensions: Demandforlargerproductioncapacities. Limitedareaavailableforinstallation. Reductionofemissionsduetosmaller numberofcharging/pushingactions andovenclosures. Desiretodecrease manpowerfor 3.0 m operationand maintenance. 2.5 m 4.2 m 6.0 m 7.1 m 8.4 m Developmentslowing down Page3 3

Koppers 1974 Heinrich Koppers 1901 ThyssenKrupp EnCoke 1999 Takeover of Dr. C. Otto Dr. C. Otto & Comp.

4 HistoryofGermancompaniesforCokeMakingTechnology thyssenkrupp Industrial Solutions Coke Plant Technologies 2014 Uhde GmbH 2004 Krupp Uhde Krupp Chemie - anlagenbau 1961 Coke Oven Plants Division of Krupp Uhde Krupp Koppers 1974 Heinrich Koppers 1901 ThyssenKrupp EnCoke 1999 Takeover of Dr. C. Otto Dr. C. Otto & Comp Thyssen Still Otto Anlagentechnik 1993 Still Otto 1985 Firma Carl Still 1898 Didier OFU 1989 Didier Werke 1911 Page4

5 Developmentofcokeplanttechnologies Page5 Requirementsforfuturesustainabilityofcokingindustry Optimizationof operationalsafetyandplantperformance environmentalplantperformance workingconditionsintheplant costforoperationandmaintenance(opex) plantservicelife Combinedwithreducedcostofinvestment(CAPEX)! How can that be achieved??

6 ReductionofNOx-contentinwastegas Combiflame heatingsystem Combinationofairstagingandinternalfluegasrecirculation Page6

7 ReductionofNOx-contentinwastegas Combiflame heatingsystem Combiflame 2.0 heatingsystem Largely reduced NOx-formation Page7

8 ReductionofNOx-contentinwastegas Combiflame 2.0 providesfor: Reduction of NOx-formationatconstant heating flue temperatures Improved heat distribution over the height of heating flues Example from arecent project: Production capacity Limit of NOx-content in waste gas Copyofanexistingdesignrequires Averageheatingfluetemperature Optimizeddesignconceptrequires Averageheatingfluetemperature Page8 1,600,000 tons/year < 150 ppm 128ovens 1,250 C 120ovens 1,290 C Reduced number of ovens minus ~ 6.5% Withmuchmorepotentialaftervalidationofpresentcalculations

9 Optimizedovendimensions Methodologyofmainprocessengineeringsteps: SUGA-value (>100 hpa) oven pitch, chamber width W, chamber height H, roof thickness chamber length L oven volume coke production requirement oven number required coal-h 2 O max. heat flue temperature (NO x < xxx mg/nm 3 ) bulk density net coking time maximum machine operating cycle (pushes/d/set) chamber width regenerator, corbel area coal-vm, ash coke yield concrete wall thickness overall battery dimensions Page9

10 Optimizedovendimensions Methodologyofcostestimates: Total refractory quantities are calculated precisely based on the dimension of the battery. The quantities of all other equipment were compiled from completed plants and current project proposals, approximated by means of correlations with the battery dimensions. quantities of equipment civil structures refractory mechanical electric and instrumentation automation unit prices of equipment overall battery dimensions Unit prices for equipment and construction can be adjusted case by case depending on the country of manufacture / installation construction costs engineering total price Page10 10

11 Optimizedovendimensions Chamberlength Enlargingthechamberlengthcauses: linear increase of production capacity (or reduced number of ovens) linear increase in quantities of refractory almost no increase in mech. equipment & electric/instrumentation/automation coke throughput [t (d.b.)/a] 3,0E+06 2,5E+06 2,0E+06 1,5E+06 1,0E+06 5,0E chamber length [mm] chamber height [mm] Page11 11

12 Optimizedovendimensions Chamberlength Enlargingthechamberlengthcauses: linear increase of production capacity (or reduced number of ovens) linear increase in quantities of refractory almost no increase in mech. equipment & electric/instrumentation/automation Themosteconomicalwayofcapacityincrease! Page12 12

13 Optimizedovendimensions Chamberheight Enlarging the chamber height causes: almost linear increase of production capacity (or reduced number of ovens) increased oven pitch in order to keep the wall stability disproportionate increase in quantity of almost all equipment oven number required to for 2 mill. t (d.b.) coke/a chamber length [mm] chamber height [mm] Page13 13

14 Optimizedovendimensions Chamberheight Enlarging the chamber height causes: almost linear increase of production capacity (or reduced number of ovens) increased oven pitch in order to keep the wall stability disproportionate increase in quantity of almost all equipment Themostcostlywayofcapacityincrease! Page14 14

15 Optimizedovendimensions Chamberwidth Enlarging the chamber width causes: slight reduction of production capacity (or more ovens) reduction of numbers of pushes per day reduction of regenerator height reduction of corbel thickness reduction of sole flue height increase of oven pitch slight increase of material quantities gross coking time [h] chamber width [mm] Page15 15

Optimizedovendimensions Chamberwidth Enlarging the chamber width causes: slight reduction of production capacity (or more ovens) reduction of numbers of pushes per day reduction of regenerator

16 Optimizedovendimensions Chamberwidth Enlarging the chamber width causes: slight reduction of production capacity (or more ovens) reduction of numbers of pushes per day reduction of regenerator height reduction of corbel thickness reduction of sole flue height increase of oven pitch slight increase of material quantities Importantfactorforachievingtheoptimumnumberofcoke pushesperday! Page16 16

17 Optimumovendimensions Example from a recent project: Production capacity Copyofanexistingdesignrequires 1,600,000 tons/year 120ovens 105pushes/day Optimizations of chamber dimensions proposed by tkis: Increase of chamber length Reduction of chamber width Reduction of oven pitch Optimizeddesignconceptrequires 100ovens 104pushes/day Reduced weight of mechanical equipment minus 20% Reduced weight of refractory material minus 10% Page17 17

Highthermaldeflection Designwith wallprotection plate plussealing

18 Designimprovements Designofwallprotectionplates Page18 Designwith wall protection plate of cast iron Very heavy=>highcost Highthermaldeflection Designwith wallprotection plate plussealing membrane of mildsteel plate Lightweight =>low cost Easyadjustment Increased tightness

19 Designimprovements Locationofregeneratorslidingjoint Arrangementofslidingjoint betweenfireclayandsilica rightabovethesole flues: Lessregeneratorbracing Reductionofinvestment anderectioncosts Easierspringadjustment Page19 Sliding joint Fireclay Silica

sliding joint Many springs,highcost, difficult adjustment Page20 Lowlevel

20 Designimprovement Locationofregeneratorslidingjoint Sliding joint Regenerator Bracing Sliding joint Regenerator Bracing Highlevel of sliding joint Many springs,highcost, difficult adjustment Page20 Lowlevel of sliding joint Less springs,reduced cost, easier adjustment,reduced strains onbuckstay

waste gas Valve with 1Spindle With bettersealing

21 Designimprovements Typeofwastegasvalves Waste Gas Air Valve with 2spindles Leakages possible between air and waste gas Valve with 1Spindle With bettersealing between gasand waste gas(air between gasand waste gas) Page21

22 Designimprovements Typeofwastegasvalves Improved design with 2separateconnection pieces between valve and sole flues =>reduced cost for manufacturing Page22

23 Designimprovements Oven pressure control system EnviBAT 2.0 Old New Page23 Simplified connection to DCS

24 Designimprovements Oven pressure control system Currentpneumaticcabinet EnviBAT 2.0 Newpneumaticcabinetwith intelligentdatabus connection Page24

25 Designimprovements Oven pressure control system EnviBAT 2.0 Page25 Merits of EnviBAT 2.0 Simplified connection to DCS No RIOcabinets required Reduction of cables Simplified control cabinets Resulting inreduction of: Equipmentcost Erection cost Erection time Maintenancecost

26 Designimprovements Compensatorbetweenstandpipeelbowandgascollectingmain Page26 Easyinstallation,exchange and maintenance, more flexibility Less materialcost than fixed connection

27 Designimprovements Charging car rail chairs Heavycast-iron rail chairs: difficult alignment, expensivemanufacturing Simple,lightsteel rail chairs: easier alignment,cheaper manufacturing Page27

28 Designimprovements Example from a recent project: Production capacity Copyofanexistingdesignrequires Weightofmechanicalequipment Weightofrefractorymaterial Optimizeddesignconceptrequires Weightofmechanicalequipment Weightofrefractorymaterial 1,600,000 tons/year 120ovens 14,620tons 60,070tons 120ovens 13,470tons 59,490tons Reduced weight of mechanical equipment minus ~ 8% Reduced weight of refractory material minus ~ 1% Page28

29 EffectofreducedNOx-formation,designimprovements andoptimizedovendimensions Example from a recent project: Design concept Number of Weight of ovens mechanical refractory equipment material Copy of existing plant % 100% + NOx-reduction % 93.8% + design improvements % 92.9% + optimized oven % 84.6% dimensions Largesavings onequipment and construction! Page29

30 Effectsontotalinvestmentcosts(CAPEX) Evaluationofcostfactors: Engineering: 10% ~ 15% Equipment: 40% ~ 50% Construction: 35%~50%(relatedtoquantityofequipment) 85% ~ 90% of investment costs are related to the quantity of equipment Reductionofequipmentquantitiesismostimportantfor optimizationofinvestmentcost! Page30 30

31 Furtherdesignimprovements Optimizeddesignofregeneratorwalls Previous design Newdesignwith improved tightness dueto larger staggering of joints Page31

32 Furtherdesignimprovements Optimizeddesignofregeneratorfaces Previous design Newdesignwith improved tightness Reduced energy demand and Reduced emissions Page32

33 Furtherdesignimprovements Optimized heating wallquoin Previous design Newdesignwith improved tightness Page33

34 Furtherdesignimprovements Optimized oven roof design Previous design Page34 Newdesignwith grouting joints for improved tightness

35 Furtherdesignimprovements Lowemissionbleedersystem Safeignitionofthecrudegas Complete,soot-free, combustion LowNOx-emissions Lowthermalradiation Stableflamedirection,i.e.no strayingflamesduetowind impacts Page35

36 Further design improvements Low emission bleeder system Smokeless bleeder system inoperation Page36

37 CokePlantAutomation TheCOKEMASTER Suite Page37

38 Commissioning,plantadjustment and operator training Allsystemanddesignoptimizationswillonlybeeffectiveif theconstructionisexecutedinaccordancewiththespecifications theplantiswellcommissionedandadjusted theplantisoperatedandmaintainedproperly Supervisionofconstructionandpreciseplantadjustment areofhighvalue Trainingcoursesprovideahighmotivationtooperationand maintenancepersonneltouseandmaintaintheplantwell Page38

39 Resumee Anoptimizedtechnicalconceptconsideringtheavailabledesign improvementswillcauseanincreaseinengineeringcost, buthasalargepotentialforimprovementofthe: operationalsafetyandplantperformance environmentalplantperformance workingconditionsontheplant costofoperationandmaintenance(opex) plantservicelife andforconsiderablereductionsofcost forequipmentandconstruction Page39

40 Oil&Gas MineralProcessing FertilizerPlants CokePlants Naval Thankyouforyourinterestinourtechnologies! thyssenkrupp IndustrialSolutionsAG Friedrich-Uhde-Str Dortmund/Germany Page40

Controlling Particulate Emissons from Coke Oven Plants

Uhde Expertise in coke making Controlling Particulate Emissons from Coke Oven Plants Chicago, March 24 th & 25 th 2010 History Uhde Coke Plant Technologies The market leader of the western world emerged