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DryCoolingofCoke
PostedbySatyendraonApr25,2013inArticles|8comments
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DryCoolingofCoke
Drycoolingofcokeisknownascokedryquenching(CDQ)andisanalternativetothetraditionalwet
quenching.Duringwetquenchingofrunofovencoke,sensibleheatofthehotcokeisdissipatedintothe
atmosphereandislost.Inadditionthereareairborneemissions(0.5tonofsteampertonofcokeladenwith
phenol,cyanide,sulfideanddust)andalargequantityofwater(around0.6Cumpertonofcoke)isneededfor
wetquenching.Thecontaminantsinwaterarealsodischargedintheenvironment.InaCokeDryCoolingPlant
(CDCP)redhotcokeiscooledbyinertgases.Theheatenergyfromtheredhotcokeisrecoveredinawaste
heatboilerforuseassteam,resultinginenergyconservationaswellasareductionincokeparticleemissions.
Around80%ofsensibleheatisrecovered.TheCDCPprocessflowisinFig1.

Fig1ProcessflowinCDCP
History
Afterpilotandpilot/commercialtrialsthefirstfullscaleCDCPinstallationwascommissionedin1965atthe
CherepovetsIronandSteelWorksinthenUSSR.By1978around50CDCPmodulesof56tonsperhourwere
inoperationinthenUSSR.JapanpurchasedlicensefromUSSRandthreeJapaneseinstallationswere
commissionedin197677.InIndiaMECONpurchasedlicenseforGiprokoksdesignCDCPfromUSSRand
thefirst12chamberswereinstalledatVisakhapatnamSteelPlant.ThefirstCDCPplantwascommissionedin
September1989.Presently19chambersofthisdesignareinoperation.
ConceptofCokeDryCooling
HotcokeisbroughtfromthebatterytotheCDCPinbottomopeningbucketkeptonthequenchingcar.This
bucketisliftedattheCDCPbyahoisting/chargingdevicetothetopoftheCDCPchamberandredhotcokeis
dischargedinthechamberforcooling.Hotcoke(temperaturearound10001100degC)iscooledinthe
chamberbytheinertgas.TheinertgasinacontinuousrunningCDCPplantisamixgaswhichconsistsof
mainlynitrogen(70%75%)alongwithsmallamountsofCO2(0%15%),CO(8%10%),andH2(2%
3%).Inthechamberinertgasmovesupwardswhilethecokemovesdownwardbythegravity.Thecokeis
dischargedatthebottom.Thepassagetimeofthecokethroughthechamberisaround56hoursandtheflow
rateofinertgasisaround82,000NCumperhour.Thetemperatureofthecokeatthetimeofdischargefrom
thechamberisbelow200degC.Thehotinertgas,afterpickingheatfromthehotcoke,comesoutfromthetop
ataround800degCandisconveyedtothewasteheatrecoveryboiler(WHRB)wherethesensibleheatofthe
inertgasisusedtoproducehighpressure(around40Kgf/Sqcm)andtemperature(around440degC)steam
(25tons/hour).Thissteamproducespowerinabackpressureturbine.Thelowtemperaturecirculatinginertgas
attheWHRBexitispressurizedbyabloweranditscompositioniscorrectedbyadditionofnitrogengasand
thenthecoolinggasisinjectedatthebottomoftheCDCPchamber.Thetemperatureofthecoolinggasis
around170degC.OtherimportantequipmentinCDCParecutoffdeviceforcuttingoutthecokefromthe
chamber,dustremovingsystemforremovingthedustinthecirculatinginertgasandgasblower.
Primaryandsecondarydustcollectionsystemsareinstalledatthecokechargingandthedischargingareaas
wellasintheboilersection.Dustemissionsarereducedto50mg/NCuminabagfilterhousewhichisless
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than0.09Kgofdustpertonofdrycooledcoke.Sinecoolinggasisrecirculatedinaclosedsystemthereisno
airbornecokeemissionsfromgascooling.AlsonodustladensteamcloudsarereleasedbytheCDCP.This
helpsintheimprovementintheworkingenvironmentinthearea.
InamodernthreechamberCDCP,anominalcapacityof50tonsperhourisachievedperchamber.Normally
twochambersareinfulloperationandoneisinhotstandbystatus.CDCPisusuallyoperatedinsuchaway
thattwochambersandboilerworkatfullcapacityandthethirdiskeptinhotconditionbychargingat10%of
itscoolingcapacity.Thisstandbychamberisthusreadytoassumefulloperationincaseaproblemariseswith
eitheroftheoperatingtwochambers.Acokedrycoolingplantmoduleofcapacity56tonsperhourof
GiprokoksdesignisshowninFig2

Fig2Cokedrycoolingplantmodule.
Advantagesofcokedrycooling
1. MicumvalueM40ofthecokeisimprovedby3%to8%.MicumvalueM10ofthecokeisimproved
by0.3%to0.8%
2. CSRvalueofcokeimprovesbyaround2%.
3. Incokeproducedbydrycooling,thequalityofcokeismorestablebecauseoflowstandarddeviation
(usuallyaround1.25%).Auniformqualityofcokehelpsinblastfurnaceoperation.
4. Useofdrycooledcokereducesthecokerateintheblastfurnacebyaround2%2.5%.
5. Sincethehotcokeiscooledgraduallybytheinertgas,itisfreefromsurfaceporeandinternalcracks
normallypresentinthewetquenchedcoke.
6. Cokedrycoolingisenvironmentfriendlyascomparedtowetquenchingsincetheredcokeisquenched
byinertgasinaclosedsystemandisequippedwithefficientdustremovingfacilitiesandsuchavoidsthe
pollutionoftheatmosphere.
7. Cokedrycoolinggeneratesenergyfromwasteheat.Around1518MWofpowercanbegeneratedfrom
aCDCPhavingacapacityof100tonsperhour.
8. Sinceitrecoverssensibleheatofthecokethereisnetenergysaving.Energysavingisaround0.25G
cal/tonofcoke.
9. Sincethepowerisgeneratedbysteamfromwasteenergyinsteadofsteamfromfuelburningboiler,
emissionoftheequivalentamountofgreenhousegas(CO2)totheatmosphereissaved.Co2emissions
reductionisaround130Kg/tonofcoke.
10. Sincethemoisturecontentofcokeproducedbydrycoolingisaround0.2%ascomparedtothatof
around5%inwetquenchedcoke,ithelpsinreducingthecokerateinblastfurnace.Moistureinthecoke
needsadditionalheatintheblastfurnaceforevaporation.
11. CDCPhasbetterreliabilityandlowermaintenance.
12. Thereisconservationofwater.
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8Comments

1.

Apr26
brijeshkumardwivedi
Goodliteratureforcdqunderstanding.
Reply

2.

Apr26
SubhenduKumarDalai
Theoverallthermalefficiencyis8085%whichisaverygoodvalue.Thankyousirforthisuseful
article.
Reply

3.

Apr28
MilindThosar
DearSir,
GoodtechnicalliteratureforIndiaindustry.Keepitup.Ithelpseverybodystudent,engineersand
managers.
Yoursfaithfully,
MilindThosar
Reply

Apr30
KKGhosh
VisakhapatnamSteelPlant(VSP)underRashtriyaIspatNigamLimited(RINL)aNavaratnaPSU
isopeartingdryquenchingsuccessfullysinceearly90s.
Reply

4.

Apr30
KKGhosh
DearSir
Doyouhavedataofothersteelplantsgloballyregardinggenerationofcokedustpertonneofdrycoke?
Reply

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5.

DryCoolingofCoke|ispatguru.com

Apr30
subodhkumar
Veryinformativereport.
Maintenanceofconventionalcokeovensparticularlyinefficientcleaningofthecokeovendoorshad
beenthecauseofverypoorlifeofIndiancokeovenbatteries.Whatarethemaintenanceproblemsand
experienceinIndiawithdrycokequenching?
Reply

6.

Feb15
GCSharma
Veryinformativeanduseful.SailIspBurnpurhasinstalledthisplant.Thanksforsuchgoodwriteup
Reply

7.

May13
jai
Kindlyexplainthepotentialhazards.
Reply

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