COKE AND BY PRODUCT PLANT

Coke and byproduct plant of OJSC “ArcelorMittal Kryviy Rih” (CBP) is one of the biggest coke producers within Ukraine and the Eastern Europe. It was founded in January 1997on the base of the production facilities of by-product coke plant by including it into the composition of the Governmental Integrated Metallurgical Complex “Kryvorizhstal” of Kriviy Rih.

Coke and by-product plant began its history since 1936, when the first coke was produced.

An objective of CBP is to convert stone coal into quality products such as coke, coke gas and chemical coking products.

Coke and by-product production is designed for 10 coke batteries. At the present time 6 coke batteries are being exploited with total design capacity of 3 304 thous. tpy of gross coke with 6% moisture.

Total area of CBP makes 110,1 ha.

At the present time the composition of CBP consists of the following shops that provide production output:

♦ Coal preparation shop (CPS)
Output – coal charge for coke shops with production volume of 2 891 712 tones of coal for 2009;

♦ Coke shop 1 (CS 1):
Output – blast furnace coke (≥25 mm), coke nut (10-25 mm), coke breeze (0-10 mm). Overall production for 2009 made 2 364 806 t of gross coke with 6% moisture, 2 040 121 t of blast furnace coke, 32 486 t of coke nut and 150 311 t of coke breeze;

♦ Recovery shop (RS)
Output- coal tar, ammonium sulphate, raw coal benzol, hard recovery tar for the road construction (HRT). Overall production for 2009 made 82 440 t of coal tar, 34 258 t of ammonium sulphate, 19 553 t of raw coal benzol, 2 093 HRT.

♦ Desulphurization shop (DS):
Output – sulphuric acid, processed coke gas. Overall production for 2009 made 13 972 t of sulphuric acid, 977 570 t m3 of coke gas.

Realization of output

Almost all produced coke, sulphur acid and processed coke gas are used for own needs of the Enterprise.

Ammonium sulphate is realized in accordance with concluded contracts for the needs of agriculture, industry and for the export.

Crude benzol is shipped by coke and by-products plants in accordance with concluded contracts for further processing for customers’ needs and for the export.

Brief description of main CBP shops

Coal preparation shop

Acceptance, unloading, storage of coal concentrates as well as charge preparation and charging it into coal-storage bins of coke shop are the main objects of the shop.

Coal concentrate is unloaded by two VRS-93 type wagon dumpers. Charge coal is charged into the coal-storage bins by conveyor belts over charge conveyor lines. All objects of unloading, transportation, grinding, reloading of coal concentrate are equipped with dust and gas cleaning units with wet scrubbing system.

Project capacity of CPS for charge coal production makes 30,8 t/t per day. Stocking capacity of inside coal storage (ICS) makes 170 t/t. As per the project ICS consists of 68 silos.

Coke shop № 1

This shop is designed for producing coke and coke gas from charge coal, which is charged over conveyor lines of coal-conveying plant from coal preparation shop.

The coke shop includes 6 coke batteries №№1-6; 3 coal-storage bins, 3 quenching towers, 3 coke wharfs, 2 coke-screening plants.

Project capacity of CS №1 is 3304 thou. tpy of gross coke with 6% moisture.

The coke batteries №1-2, 3-4, 5-6 are used in blocks. Each coke battery block has its own equipment set such as coal-storage bins, coke quenching towers, coke wharfs and coke-screening plants.

Smokeless charge loading with application of steam injection method is provided on coke oven batteries № 1-2, 5-6 and on coke oven batteries № 3-4 with application of hydro injection method. Coke quenching is provided by purified water which passed biochemical treatment till the level of average normative indexes in this sphere of production. All facilities for transportation, sizing and screening of coke are equipped with dust trapping installations with wet cleaning system.

Dustless coke discharge was implemented on coke oven batteries № 3-4 and gastight doors of improved design were installed; the nitrogen inhibition of the atmospheric pollutant emission is applied at the ascension pipes of the coke batteries № 3-4. The deflectors were installed at the quenching house № 2. In the range of the modernization works at the facilities of the coke batteries № 3-4 a new coke-screening station was constructed with a crusher house for coke crushing of +80 mm.

Coke-Oven Gas Recovery Shop

The main purpose of the shop is to cool down the coke-oven gas, to recover coking products from it and to transfer it to the Desulphurization Shop.
The Coke-Oven Gas Recovery Shop design capacity for the quantity of the gas being cleared is 183 thou. m3 /hour.
The shop consists of the following sections:
♦ Section for the condensing and cooling of the coke-oven gas;
♦ Machinery room;
♦ Sulfate Section for the clearing of the coke-oven gas from the ammonia in the absorbers and the vacuum preparation of the ammonia sulfate in the evaporators;
♦ Benzene Section for the cooling and clearing of the coke-oven gas from the tar camphor in the final coolers and the recovery of the crude benzene in the wash-oil scrubber;
♦ Storage Facilities for tar, oils and benzene where the coal tar gets dewatered and prepared to be transported and also where tar, oils and crude benzene are stored.

Desulphurization Shop

The shop is intended for the clearing of the coke-oven gas from the hydrogen sulphide using the vacuum-carbonate process followed by the preparation of the technical sulfuric acid from the hydro-sulfuric gas using the wet catalysis process.

The Desulphurization Shop design capacity for the quantity of the gas being cleared is 200 thou. m3 /hour.

The shop reconstruction in 2004-2009 made it possible to keep on using the existing vacuum-carbonate process of the coke-oven gas clearing from the hydrogen sulphide by the modernization of the acting scheme with two stages of the recovery and regeneration with the installation of the sulfuric acid preparation as per WSA technology of the Dutch company “Haldor Topsoe”.

In 2009 the 2nd stage of construction was accomplished, during which the following works were carried out: constriction-installation works, pre start-up and adjustment works in order to provide the start-up of the equipment of new sulphuric acid department of DS by the WSA method. According to the order of the Enterprise dated 09.11.2009 №1034 the switching to sulphurated hydrogen gas of the new boiler furnaces and the new equipment for obtaining the sulphuric acid was carried out.

The designed cleaning of coke gas from sulphuraged hydrogen in amount 0.11 g/m3 was provided.

In 2009 within the frames of construction of the coke batteries set №3-4 and DS, the construction of exhausted solutions unit was carried out, the start-up of which is planned for 2010.

Actions for 2009

Aimed to fulfill the approved production and cost reduction program for the output goods in 2009 the following actions implemented at the site:
♦ Start-up and commissioning works for dosing bins №№ 31, 32 of the inside coal storage of the Coal Preparation Shop;
♦ Performance of the overhaul repair of coke oven batteries № 1-2, 5-6 in the Converter Shop №1;
♦ Performance of the overhaul repair of the ammonia sulfate dehydration unit, absorber №2 with catch basin, as well as the tube-type furnace №2 of the benzene section of the Recovery Shop
♦ Performance of construction works at sites of the reconstruction complex of coke oven batteries № 3-4, covering the Desulfurization Shop.

Aimed to improve the quality of the coal-tar resin, in 2009 there had been started the project implementation for construction of the tar scrubbing unit via desliming process. In 2009 had been performed the preparatory works (demolition of old foundations, rearrangement of the control room and operator’s room, layout of the concentrator unit), had been acquired “Flottweg” (Germany) tricanter centrifuge for tar cleaning and pumps.

Targets for implementation of this project:
- Carrying out of the requirements of technical conditions;
- Meet the requirements of the customers;
- To increase profitability from conversion of the tar into higher grade;
- To provide guaranteed sales of goods
Term for work completions is 2010.

The sources of emission in the atmosphere in RS of CBP are air vents of existing production equipment, which discharge pollutant agents (hydrogen cyanide, phenol, benzol, sulphurated hydrogen, ammonium, etc.) of 1-4th hazard class into the atmosphere.

Aimed to reduce the emissions of pollutant agents into the atmosphere in 2009 the following works had been carried out: works for installation and checkout of equipment and pipelines of ammonium section, tar and benzol storages, condensation section in order to combine the air vents and containers into common collector and connecting them to the gas pipeline of raw gas. The works for installation of devices and equipment of instrumentation and automation are carried out.

Realization of this project will allow:
- To reduce environmental impact;
- To fulfill the requirements of governmental legislation for environmental protection;
- To improve ecological situation in the city and region.
Completion date is planned for May 2010.

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OJSC "ArcelorMittal Kryviy Rih"
50095, Ukraine, Dnepropetrovsk region, Kryviy Rih, Ordzhonikidze st., 1
Tel: +38(0564) 78-53-09 Fax: +38(0564) 92-85-50 Press-service: +38(044) 284-04-91 E-mail: amkr.press-service@arcelormittal.com

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