1. JSW STEEL LTD, SALEM WORKS
WELCOMES YOU ALL

2. ABOUT JSW SALEM PLANT
JSW Steel Ltd, Salem works, part of USD 11 Billion JSW Group, is India’s largest integrated special steel plant located in Salem, Tamilnadu with installed capacity of 1 MTPA

3. MAIN PRODUCTS Wide product ranges from 5.5 mm to 240 mm
Coils to 23.5 mm
Round Bars to 60 mm
Flats- 60 x 7 to 101 x 20 mm
Round Blooms-56 to 200 mm
Wide product ranges from 5.5 mm to 240 mm
More than 700 grades developed

4. OUR CUSTOMERS Products Key Customers As Cast
MSL, Karamtara, Wheels India, Lucchini, Italy
Flats
Jamna Industries, Soni Auto Ltd
Bars
Madhur Engineers Ltd, Southern Steel and Forgings
Coils
Aradhya Steel ltd, Mitco Wires Ltd
RR/RCS
Bharat Forge LTD, Happy Forge Ltd, Echjay Industries, MM Forgings…

5. REDUCTION IN COKE MOISTURE BY UTILIZING WASTE FLUE GAS &
IT’S EFFECT IN BF OPERATION
REJI MATHAI, V.RAVICHANDRAN, M.S. RAO, T.K. NAHA

6. INTRODUCTION
JSW Steel Limited (JSWSL), Salem Works, operates eco- friendly Coke oven plant, which Produces 0.5 million tons per annum of metallurgical coke through three Heat recovery batteries comprising of 120 ovens. And through waste heat recovery boilers 30 MW power is being generated.

7. SUMMARY OF COKE MAKING PROCESS
At JSW, Coke is manufactured by heating of the Suitable coal blend in the absence of or controlled air inside the Silica refractory lined oven at the temperature of 1250 to 1300 c for about 68 to 72 hours coking time. During the carbonization process all VM present in the coal is burnt and produce heat. The remnant solid mass after carbonization is called Hot Coke, which is pushed out and quenched with water, segregated in to various size for the BF use.

8. OBJECTIVE OF THE THEME
The sensible heat of the hot waste flue gas generated in the coke oven process which was partly being let out through the chimney is used to dry the coke
2 to 3 % Reduction in Coke moisture.

9. A NOVEL CONCEPT

10. HOT FLUE GAS ANALYSIS Sl.No. Parameter Unit Value 1 PM mg/Nm3 40.2 2
Sulfur die Oxide(SO2)
79.4 3
Nitrogen Oxide(NO2)
21.6 4
Carbon mono oxide (CO) %
0.2 5
OXYGEN O2
6.0 6
Carbon die oxide CO2
12.0

11. PROJECT IMPLEMENTATION
1500 TPD INHOUSE INSTALLATION OF
COKE DRYING UNIT
AN UNIQUE & FIRST OF IT’S KIND IN INDIA

12. OPERATING PARAMETER Sl. No Description Unit Actual 1 FD Fan RPM 1220 2
Gas flow
M³/Hr
110000 3
FD Fan Inlet temperature
° C 4
Coke Bunker Inlet Temperature 5
Coke Outlet Temperature 6
Suction
MMWC
96-120
Coke Dryer
FD Fan

13. COKE DRYING METHOD
The hot waste flue gas at temperature 1050 °C is extracted.
Diluted to 250°C by the atmosphere air .
Hot gas Blown to coke dryer bunker through FD fan.
The coke is retained for one and half hour .
The coke moisture content reduces from >5.5 to <2.5%.
The emergency vent & water spry system is provided .
Dust dust free environment is ensured during coke loading.

14. OUTCOME

15. MOISTURE EFFECT IN BF OPERATION

16. BF#1 RESULT – BEFORE AND AFTER
Coke Drying Unit
Fuel Rate
Kg/THM
Sinter %
Slag Volume
HBT
Deg.C
Steam
gm/Nm3
Coke Moisture
Corrected Fuel Rate
Before
591 73
355
977 20
5.49
593
After
588 74
377
988 31
2.34
582
Difference
3.14 11
Observations : Based on the data study, it was observed that for every 1% reduction in
coke moisture, there was a reduction of around 3.5 Kg/THM in fuel rate Note :
Shutdown and low production days data not considered for data study
Study was made on Corrected fuel rate to eliminate the effect of variations in sinter usage,
slag volume etc.

17. TANGIBLE BENEFIT Coke Moisture Reduction – 3.0%
Coke Saving – 10.5 Kg/THM (Approx)
Coke Cost – RS 13,000 /MT (Approx)
Hot metal Production – 75,000 MT/ MONTH
Cost Saving Per Year – Rs Cr/ Annum

18. CONCLUSION Coke moisture reduction > 2.5% consistently.
Significant Reduction in fuel rate at the BF.
An energy conservative initiation.
Recurring benefits .
Life & Safety of the chimney is enhanced by minimum let out of hot flue gas.

19. ACKNOWLEDGEMENT
The authors are very thankful to Mr. M S Pillai, Associate Vice-President and Mr. V. Ravichandran, Sr.Manager CPP-2 for Constant support and initiative to complete the coke dryer project.

20. THANKS