Coke Oven Battery Solution

±10 °C

battery Temperature Stability

Radar Based

oven identification system

Level 2

heatitng control system

Improve + 5%

CSR

Eagle Coke™ is designed for the Coke Oven Batteries. The basic foundation of this platform is on strong framework of predictive analytics assisting in effective decision making for better Coke making.

The Platform has Following Major Modules:

Predictive Modelling of Coking Process
Constraint Based Dynamic Scheduling
Heating Process Management

The Eagle Coke™ platform is based on Industry 4.0 which includes Cyber-Physical systems, the internet of things and cloud computing. The complete system is pivoted around the data analysis, which is not only the central repository of information but also takes care of all the data for control modules to meet the different functional aspects.

The 'Analytics' uses statistical tools for different decision making for major functions like:

Cooking Process Management
Environmental Regulation
Energy Management and Estimation
Asset Management

The 'Analytics' uses statistical tools for different decision making for major functions like:

Cooking Process Management
Environmental Regulation
Energy Management and Estimation
Asset Management

Eagle Coke™ is an ideal platform to execute optimized energy balance, pollution accounting, high end coke quality with integrated asset management and safety controls. Above all with cloud-enabled platform user can opt for minimal IT infrastructure for an easy integration of IoT concept through smartphones and tablet. Modern coke making process involves the integration of oven battery with various machineries, IT hardware, software and multiple communication networks. Current Coke making process is facing new challenges like

Reducing energy consumption with high CSR
Adhering to environmental regulatory requirements
Increased safety at every phase of charging, pushing and quenching cycles

Reducing energy consumption with high CSR
Adhering to environmental regulatory requirements
Increased safety at every phase of charging, pushing and quenching cycles

ARE THESE THE CHALLENGES IN YOUR COKE BATTERY

Fluctuation in gas flow/pressure

Normal flow rate is 67000 to 75000 Nm3 / h which sometime goes as low up to 60000 Nm3/h
Normal Pressure range is 50-75 mbar which sometime goes as low as 35 mbar due to change in BF pressure

Fluctuation in CV

General range of operation in BF gas CV is 950-1020 kCal/nm3 but in our case it is typically varying in 1050 to 1120kCal/nm3 range
CV has to be maintained consistently is challenge as BF gas flow is also varying randomly

Wide change in pushing schedule

Normal: 90-93(with drop-out ovens 1 or 2 oven)

Demand change: +/-5 oven in day plan

Gas changeover: + /- 7 oven

The 'Analytics' uses statistical tools for different decision making for major functions like:

Cooking Process Management
Environmental Regulation
Energy Management and Estimation
Asset Management

EAGLE COKE™ SOLUTION OVERCOMING THE CHALLENGES

Control of COG flow to attain the desired mixed gas CV value
Based on the wide variation of pushing schedule, system is able to increase and decrease the heat input
Auto sequencing of Pushing schedule in case of out of sequence of oven charging
Attaining consistent CMT and battery temperature range

FUNCTIONAL ACHIEVEMENTS BY IMPLEMENTING EAGLE COKE™

Wide change in pushing schedule

EAGLE COKE™ stabilizes the coke oven heating temperature, the vertical flue temperature and effectively reduces the vertical flue temperature variation and put under control within ±10°C; inturn provides a guarantee for improving the coke quality effectively.

Increasing gas utilization rate and saving energy:

EAGLE COKE™ establishes a coke oven heating control model and controls the best heat supply to achieve the purpose of saving heating gas and adjusting oxygen content in waste gas (that is, controls to have a suitable excess air coefficient) to realize the best combustion. Energy balances reduces the carbon footprint by ensuring there is no waste or energy leakage.

Reducing emissions and pollution energy:

EAGLE COKE™ significantly reduce exhaust pollution, smoke and dust pollution from coke pushing and realizing environmentally friendly production of coke oven.

Increasing safety aspects of battery operation energy:

EAGLE COKE™ increases the safety aspect of battery operation with Mathematical modelling, closed looped systems and artificial intervention, increasing the work place safety.

VALUE DELIVERY RECOMMENDATION BY EAGLE COKE™

CSR improvement up to 5% as system will maintain the battery temperature in the desired limits. 1% CSR improvement will causes 3kg reduction in coke consumption for 1ton hot metal (THM) production
CO emission / Tons of Coke Production will further reduce due to maximize combustion of gases as system will ensure maximize combustion of gas
Consistency of Coke Quality will remain same even with irregular pushing’s also as system will take care of running the battery in the limits
Dynamic scheduling for Smooth transition from low pushing to high number of pushing or vice versa will optimize production to maximum levels.