EPA-650/2-74-062-0
SEPTEMBER 1974
Environmental Protection Technology Series







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                           EPA-650/2-74-062-a
     COKE  OVEN CHARGING
       EMISSION  CONTR01
         TEST  PROGRAM  -
SUPPLEMENTAL  OBSERVATIONS
                   by

           R. W. Bee and R. W. Spcwak

             The Mitre Corporation
             Westgate Research Park
             McLean, Virginia 22101
            Contract No. 68-02-0650
             ROAP No. 21AFF-004
           Program Element No. IAB013
        EPA Project Officer:  R. V. Hcndriks

           Control Systems Laboratory
       National Environmental Research Center
     Research Triangle Park,  North Carolina 27711
                Prepared for

      OFFICE OF RESEARCH AND DEVELOPMENT
      U.S. ENVIRONMENTAL PROTECTION AGENCY
           WASHINGTON, D.C. 20460

               September 1974

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This report has been reviewed by the Environmental Protection Agency
and approved for publication.  Approval does not signify that the
contents necessarily reflect the views and policies of the Agency,
nor does mention of trade names or commercial products constitute
endorsement or recommendation for use.
                                  ii

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                              ABSTRACT






    The larry car, developed jointly by the American Iron and Steel




Institute and the Environmental Protection Agency, was tested at the




Jones and Laughlin Pittsburgh Works by The MITRE Corporation during




the Spring and Summer of 1973.  The purpose of these tests was to




demonstrate the improvement in atmospheric conditions that can be ob-




tained while charging a slot type coke oven.  New larry cars having




both similar and contrasting features are currently in operation on




other slot type coke ovens, and their effectiveness should logically




be assessed as an adjunct to the J & L car evaluation process.  This




report describes the procedures used to gather comparative operational




information at the Weirton Steel Corporation, Division of National




Steel Corporation, Brown's Island Coking Plant, where two charging




cars, similar in several ways to the J & L car, are in production




operation.
                                  iii

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                          ACKNOWLEDGEMENTS






     The observations recounted in this paper were performed by The




MITRE Corporation under the sponsorship of the Office of Research and'




Development, U. S. Environmental Protection Agency.  The effort was




carried out as an adjunct to Project 0750 at the direction of




Mr. R. V. Hendriks, Project Officer for EPA.



     The authors would like to express their appreciation for the




splendid cooperation and support of Weirton Steel personnel, particu-




larly Mr. Houston Woods, Director of Environmental Control; Mr. Gene




Current, Assistant Director of Environmental Control; Mr. Thomas




Emmerth, Assistant Superintendent of Brown's Island Coke Plant; and




their respective staff members.  The task of gathering the required in-




formation was aided immeasurably by the help of these gentlemen.



     The design of the particulate sampling equipment represents the




adaptation of an earlier MITRE design to the unique problems en-



countered in the proposed observations.  Mr. Andrew Wallo III, played a




major role in the adaptation and fabrication of the particulate




sampling equipment used and described in this report.
                                  iv

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                         TABLE OF CONTENTS
LIST OF ILLUSTRATIONS                                           vi

LIST OF TABLES                                                  vi

1.0  CONCLUSIONS                                                 1

2.0  INTRODUCTION                                                9

3.0  SYSTEM DESCRIPTION                                         11
     3.1  Historical Background                                 11
     3.2  Oven Description                                      12
     3.3  Charging Car Description                              15

4.0  CHARGING OPERATIONS                                        25
     4.1  Coking Cycle                                          25
     4.2  Charging Sequence                                     25
     4.3  Leveling Procedure                                    29
     4.4  Collecting Mains                                      30
     4.5  Coal Description                                      31

5.0  CHARGING OBSERVATIONS                                      32

     5.1  Reporting Procedures                                  32
     5.2  Summary of Performance Observations                   34
     5.3  Functional Operating Times                            39
     5.4  Particulate Sample Collection                         40
     5.5  Gas Constitutent and Concentration Measurements       51

6.0  LARRY CAR WORK HISTORY                                     56
     6.1  Work and Maintenance Schedule                         56
     6.2  Significant Events                                    57
     6.3  Operator Performance                                  59
     6.4  Future Modifications                                  59

APPENDIX A - CHARGING OBSERVATION LOG SHEETS                    61

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                       LIST OF ILLUSTRATIONS


Figure                                                         Page


  1    Weirton Car Arrangement                                  15

  2    AISI/EPA Car Arrangement                                 17

  3    Overhead View of Oven Positions in the Charging
       Sequence                                                 26

  4    Simplified Schematic Diagram                             43

  5    Particulate Sampler in Simulated Use                     44

  6    Sampling Head                                            45

  7    Orifice Assembly for Sample Flow Measurement             45

  8    Bypass and Fan Arrangement                               47

  9    Typical Area of Greased Slide, Charge to Oven C-22
       on 3/13/74                                               47

 10    Typical Filter Element Area, Charge to Oven B-13
       on 3/26/74                                               49

 11    Typical Filter Element Area, Charge to Oven C-24
       on 3/15/74                                               49

 12    Typical Filter Element Area, Charge to Oven A-ll
       on 3/26/74                                               50



                          LIST OF TABLES

Table                                                          Page

  1    Display of Weirton Charging and Dampering Sequence       27

  2    Observed Operation Times                                 41
                                 vi

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1.0  CONCLUSIONS




     Information was gathered on the design and operation of the new




charging cars operating on the Brown's Island battery of the Weirton




Steel Division, National Steel Corporation.  A comparative analysis




with the AISI/EPA charging car demonstration of the ability to re-




duce emissions due to charging was then performed.  A direct com-




parison was made in areas where the similarities between the Weirton




cars and AISI/EPA car designs are strong.  In areas where contrasting




features or procedures were observed, assessment of their success




relative to design intent and EPA objectives is reported.




     The strong similarities between the two designs are:  basic




automation of the coke oven top side activities, specifically control




of the damper, steam and ascension pipe caps, ascension pipe cleaning,




and lid removal-replacement; improved operator environment; improved




coal handling systems to control coal flow and contain emissions.  An




integral part of the improvements in emissions containment is the im-




proved drop sleeve-to-oven port seals and aspiration of the ovens to




the collection main during charging.  These features are considered




part of the charging system.




     Both systems appear to have had reasonably good success in auto-




mation of the oven controls.  Although the Weirton car has a somewhat




more complex set of functions (dual collection mains), both cars per-




formed required functions with only an occasional malfunction, usually




caused by misalignment of the actuating or control arms.  Both cars




had lid lifting mechanisms which adequately performed the required

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functions.  Both cars experienced similar .problems with the lid lift-




ing electromagnets and their associated wiring.  The rerlidding cycle




for the Weirton car was a few seconds slower than the AISI/EFA car,




but this appears to be a function of the control system adjustment




rather than a basic difference in the design capability.  The ascen-




sion pipe cleaning device on the Weirton car appears to work quite




well.  There is still, however, an occasional need to manually clean




the ascension pipe goosenecks.  The original design of the cleaner




for the AISI/EPA car was unsuccessful, reportedly because of align-




ment problems.  We have not observed the operation of the replacement




unit so we cannot comment on its operation.  We understand, however,




that its design is similar to the Weirton unit.  If so, similar




results should be expected.



     Both cars have had reasonable success in the improvement of



operator environment.  This comment is not based on quantitative data,



but rather on conversations with several operators and "in the cab"




observations.  There were, however, some comments at both locations




to the effect that the cab placement and configuration makes direct



observation of the car operation and oven conditions difficult, if




not impossible.  Such restrictions of view may represent a safety




as well as an operational problem.




     The two cars employ contrasting approaches to coal flow control.




The Weirton car uses a screw feed transfer conveyor, while the




AISI/EPA car depends on gravity to feed the coal directly from the

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hopper down through the drop sleeve into the oven.  The screw feed




arrangement controls coal flow by stopping or starting the screw




transfer unit.  The gravity feed is controlled by a butterfly valve




in the drop sleeve assembly.  We understand that screw or turntable




feed is generally recognized as providing better coal flow control,




but that coal hopper clearance restriction on some batteries may pre-




vent the consideration of these designs for retrofit or replacement




cars.  This was a major consideration in the choice of the gravity




feed system for the AISI/EPA demonstration car.  A detailed analysis




of system performance is somewhat beyond the scope of this paper, but




observations to date would tend to substantiate the superiority of




the screw and possibly the turntable feeds over gravity feed.  It does




appear that correction of certain proven design problems, such as




drop sleeve packing and side wall angle may substantially improve the




performance of the AISI/EPA gravity feed car.



     Both the AISI/EPA and Weirton cars represent substantial improve-




ments in emission control compared to older cars observed.  While the




AISI/EPA car seems more capable of sealing the emissions during the




charge, it is less consistent in overall emission control than the




Weirton car.  The relief (coking) stacks on the Weirton car appear to




be the source of 50% of more of its emissions, especially near the




end of the charge.  The AISI/EPA car, on the other hand, seems more




able to reduce emissions during this period, assuming that the drop




sleeves have properly seated in the ports.  The Weirton car drop

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sleeve seal usually exhibits some leakage, but the rate (i.e., the




seal) is fairly consistent.  The AISI/EPA car seal exhibits a more




"very good" or "very bad" tendency, perhaps because of its weight and



resistance to movement sometimes necessary to seal alignment.  It was




concluded, however, that both the AISI/EPA  and Weirton charging car




drop sleeve-to-oven port seals represent considerable Improvement




over older types of drop sleeves in the areas of both coal spillage




reductions and emission containment.




     Containment of the emissions during the charging process at




both J & L and Weirton is heavily dependent upon the reduction of




oven pressure through steam aspiration.  The original concept for




improvement of aspiration at J & L involved the replacement of steam




ejectors and the raising of steam pressure supplied to the ejectors




to 175 pounds.  Marginal Improvements were obtained using the higher



pressure and the potential problem of increased coal carry over was



recognized.  Experimentation showed that a reasonable compromise could




be achieved by running approximately 120 pounds pressure to the new




ejectors.  It has been reported that further improvements have been




accomplished through the installation of jumper pipes between existing




"smoke holes."  This has the effect of connecting two oven aspirating




systems in parallel and supplying an off take passage at both ends



of the oven as in a dual collection main system.  Substantial improve-




ments in oven aspiration have been reported.

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     The double collection main system at Weirton has performed well




under most charging conditions.  Improvement has been attempted by




raising steam pressure to the ejectors, but coal carry over problems




were experienced causing some pressure reduction.  The system is now




operating at an acceptable level and generally holds the oven close




to neutral during charging.  A major portion of emissions for both




cars occurs after the drop sleeves have been raised for re-lidding




and are thus beyond the control of the car itself.  The elimination




of these emissions will depend primarily on oven aspiration, leveling




procedures, and to a much lesser extent, the details of how the coal




was placed in the oven.




     We recognize the impossibility of generalization as to production




rates for all battery conditions, much less production rates for other




batteries, but investigation and observations indicate that a rate of




40 to 45 ovens per 8 hour shift from a single set of functional ma-




chines would represent a reasonable production goal.  On batteries




where operating units must be shared, this rate may be substantially




altered.  Such sharing is praticed at J & L, but is not currently




practiced at Weirton.  Observations and associated discussions of the




Weirton and AISI/EPA car indicate that the Weirton car has never been




and is not expected to be pacing unit of the battery under present




operating practices.  This conclusion is consistent with the average




observed charging time of five minutes for the Weirton car.  The




AISI/EPA car has displayed a tendency to be the pacing factor,

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particularly when operations are running behind the normal production



schedule.  This statement is consistent with observed charging times



ranging from 7 to 10 minutes.  The situation might be affected sub-



stantially, however, by changes in operating practice, such as the



adoption of stage charging (i.e., the cars might be more closely



matched).



     Both cars provide flexibility in their opreation through the use



of independent/step controls for each function.  This flexibility



allows the adoption of modified procedures, such as stage charging or



the circumvention of problem areas when mechanical or electrical prob-



lems occur.  Judging from discussions with maintenance and operating



personnel, the Weirton car has undergone more extensive additions



and modifications to the control system than the AISI/EPA car.  The



changes, most of which have been initiated by the local supervisory



and maintenance personnel, have for the most part proved to be useful



in both maintenance and operation under conditions of malfunction.



     The training of operators to run the Weirton car has not pre-



sented a problem in terms of production rates or lost production.



The new operators go through a break-in period during .which time they



work in parallel with an experienced operator.  The operators we spoke



to did not express any problems In learning the operation of the new




cars.

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     Based on discussions and observations, the Weirton car has few




problems in the area of operability/dependability.  With the excep-




tion of the two instances reported here, involving some damage by




fire, no lost oven production was attributable to the Weirton charg-




ing cars.  During the observations, one car operated 24 hours a day




for five straight days without any malfunctions which caused produc-




tion delays or loss of production.  We feel that much of this record




can be attributed to the mechanical arrangement of the Weirton car.




Elements of the hydraulic and electrical system are positioned away




from the drop sleeve, open charging port and potential flame and




heat.  We also feel that the relatively light weight of the drop




sleeve assembly contributes to the lack of mechanical/hydraulic




problems.  An additional factor which we feel has a significant im-




pact is a thorough understanding of car operation and control by




individual operators.  This certainly reduces the incidence of equip-




ment damage caused by improper or negligent operation.




     Equipment malfunctions will inevitably occur, but their impact




can be magnified by delays in remedial actions.  An important factor




which tends to reduce the time required for resolution of maintenance




problems is the centralization of responsibility for initiation and




control of necessary work.  At Weirton, the electrical department is




totally responsible for all equipment maintenance work except for the




heaviest mechanical work that may require special assistance.  All




necessary trades are included in the make up of electrical department

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personnel.  When outside help is required, they operate under the




centralized direction of the electrical department.  These factors



improve coordination, reduce worker availability delays and generally



expedite required repairs.




     One final point should be made to help place the comparison of




the two cars in perspective.  That is, that the AISI/EPA car repre-




sents the retrofit of a new car to an older oven (P4 battery is




nearing 20 years of age), while the Weirton car is a new car designed




for and placed on an entirely new battery.  Many of the problems




experienced by the AISI/EPA car can be traced to battery equipment




wear and misalignment problems.  The difficulty experienced in pre-



dicting relative position changes caused by oven expansion, wear,




and modifications, tend to indicate that equipment intended for



retrofit should be designed to provide the maximum tolerance to




"misalignment" practical, and consistent with emission control, and




that new equipment should be given similar consideration in order to




minimize maintenance and operating problems as it ages.

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2.0  INTRODUCTION




     The larry car, developed jointly by the American Iron and Steel




Institute and the Environmental Protection Agency, was tested at the




Jones and Laughlin Pittsburgh Works by The MITRE Corporation during




the Spring and Summer of 1973.  The purpose of this testing was to




demonstrate the improvement in atmospheric conditions that can be ob-




tained while charging a slot type coke oven.  New larry cars having




both similar and contrasting features are currently in operation on




other slot type coke ovens, and their effectiveness should logically




be assessed as an adjunct to the J & L (AISI/EPA) car evaluation pro-




cess.  This report describes the procedures used to gather comparative




operational information at the Weirton Steel Corporation, Division of




National Steel Corporation, Brown's Island Coking Plant, where two




charging cars, similar to the AISI/EPA car, are in production operation.




     MITRE observed these two charging cars in production operation




in March and April of 1974 using observers familiar with the coke




oven environment and the operation of the AISI/EPA car during the




original test period.  This report presents three general subject




areas for which information was obtained.  The first area concerns a




description of the Weirton coking system, including oven configura-




tion, larry car operation, and the coke oven charging procedures in




general.  The second area involves the actual observation of the two




Brown's Island larry cars during the coal charging operation, which




involved recording of emission characteristics and electro-mechanical

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performance.  The last area discussed is a brief work history of the




two larry cars obtained through interviews with coke plant personnel




responsible for the operation of the larry cars.
                                 10

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3.0  SYSTEM DESCRIPTION




3.1  Historical Background




     One of the newest slot type coking facilities in the United




States is located at the Weirton Steel Division of National Steel




Corporation in Weirton, West Virginia.  The battery, comprised of 87




ovens, is located on Brown's Island in the Ohio River adjacent to the




main plant facility.  At this time, the ovens and their associated




by-product recovery facility are the primary activities on the island.




     Work on the construction of the Brown's Island facility was




started in August 1970.  The oven was brought to a point where con-




struction of the charging cars could commence in August of 1972.  The




oven first produced coke on May 31 of 1973 having experienced some




delay caused by a gas explosion during initial firing of the facility.




The ovens were considered to be in regular production operation at




that time and have been operating continually since that time.




     The break-in period of the facility is defined as the time from




the first production of coke until the establishment of routine




operational and maintenance procedures with the associated substantial




reduction of production delays caused by nonfamiliarity with the new




equipment and procedures.  Based on discussions with supervisory




operating personnel, reasonably smooth operation of the charging car




was achieved in December of 1973.  Although occasional problems arise




which cannot be immediately resolved, supervisory maintenance
                                 11

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personnel say they now feel confident in their ability to understand




the machine operation, and to solve problems in a timely manner as




they occur.



3.2  Oven Description




     The Brown's Island facility employs some of the most recent coke




oven technology, including an enclosed pushing and quenching capa-




bility.  The pushed coke is received by a closed refractory-lined



hopper car which is connected via ducts to a car mounted scrubber.




The hopper car is unloaded through bottom gates into stationary re-




fractory lined hoppers beneath the track.  These hoppers in turn




feed the hot coke to the enclosed quench units.  The resulting gases




are cleaned prior to release to the atmosphere.




     The ovens are of the tall (20 feet) configuration and utilize a



double collection main by-product recovery system.  Each oven charge



contains approximately 70,000 pounds of coal.  The oven is charged



through four ports spaced unequally across the width of the oven.



     The port design features a tapered oven top seat contoured to




accept and seal the lower portion of the larry car drop sleeve (boot)




and a matching lid which uses a "sharp edge" seal especially suited




for "setting" by rotation by the car mounted automatic lid lifter




mechanism.  The cast iron lid has a sealing edge diameter of ~19-3/4




inches and the oven port has a minimum diameter of ~17-3/4 inches.




This diameter extends downward through the brickwork for a distance




of approximately 1 to 1-1/2 feet where the passage fans out laterally




to a width of 3 to 5 feet at the oven inner roof.





                                  12

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     During the oven charging cycle, aspiration of the ovens is ac-




complished using steam ejectors.  The ejectors located in the collection




main side of the ascension pipe bend are of standard configuration.




They are currently operated at 100 pounds pressure and approximately




400°F+ steam.




     During recent periods of operation at higher pressures, problems




were encountered in the by-product primary cooler spiral heat ex-




changers.  The excessive coal carry over caused fouling of the liquor




side of the spiral heat exchanger. In addition, this problem was




aggravated by the cooling unit water having a high iron content




which in turn caused excessive scale to be deposited on the water side




of the spiral heat exchangers.  The two problems combined to produce




high by-product input temperatures that came very close to causing




facility shutdown.  The improvement of cooling water quality and the




reduction of aspirator steam pressure are credited with the current




solution to this problem.




     During discussions of the carry over problem with Weirton personnel,




they voted some continuation of excessive coal carry over build ups




in the liquor traps and on damper valves.  As a result, they found it




necessary to initiate more frequent trap clean outs.  Although J & L




operating personnel reported no problems with by product cooling units,




they also reported a requirement to clean the traps at more frequent




intervals as compared to operation with lower ejector steam pressures.




A possible explanation for the differences in operating experiences
                                  13

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between the two sites is that the Weirton coal preparation process




produces a higher proporation of fines than the J & L process.  This




could allow a higher preparation of cool dust to pass the trap and




potentially foul the cooler units.  This situation is being investiga-




ted and appropriate action will be taken.




     The seal of the ascension pipe caps is an area in which problems




are frequently encountered.  The design of the cap is similar to the




charging port design in that a sharp edge seal is employed.  The cap




is allowed to "float" with respect to the hinge mechanism to provide




a self-centering seating action.  Considerable leakage around caps




was observed immediately after a charge, with many continuing to




leak for several hours into the coking cycle.



     It appears that the relatively short "leak path" around the




"sharp edge" seal is not readily plugged by the self-sealing action



of condensing and hardening tars and carbon build-up.  An investiga-




tion of the problem is currently under way by Koppers and two new cap



configurations are undergoing tests on operating ovens.  A solution




to the problem is important, since observation indicates that the cap



leaks account for a substantial portion of the ambient background




emissions (conditions between charging operations).  Also, cap leaks




occurring during charging and aspiration diminish the vacuum capacity




available at the charging ports.  Although probably not sufficient to




make the difference between a negative and positive port condition,




the lost capacity would allow emissions to the atmosphere which would




otherwise be contained by the recovery system.




                                  14

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3.3  Charging Car Description




     The two charging cars operating on the Brown's Island Battery




utilize some of the most significant improvements in modern coke oven




technology.  The cars are of the basic screw feed design, but several




features have been added to improve car operation and the conditions




in which the machine operators work.  These features are discussed in




the following .section.




     The charging car coal handling system (Figure 1) for each of the




four charging sleeves is comprised of a car mounted hopper, a screw




type conveyor fed by gravity from the hopper, a "slide plate" valve,




a "drop-boot", and a device for mechanically removing and replacing




the charging port lids.  The significant difference between this coal




handling system and the system used on the AISI/EPA car (Figure 2)




is the use of the screw conveyor to control the coal flow as opposed




to an oscillating "butterfly" valve in the lower portion of the "drop




sleeve" on the AISI/EPA car.




     The coal is gravity fed from the main hopper to the screw con-




veyor which can be stopped or started using separate controls in the




control cab.  The slide valve at the drop sleeve end of the screw




conveyor is not used to control the primary coal flow.  Its primary



 function is  to seal the drop sleeve after  the charge and also  to pre-




 vent coal tailings  from the conveyor tube  from falling on the  oven




 surface or the lid  lifting mechanism.   This  arrangement provides a




 positive coal  feed  through the screw to a  point above the slide plates,




 From this point,  the coal drops loosely through the open slide plate,




 through the drop sleeve assembly, and into  the open charging port.  In






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                RELIEF  STACK

                (ON 12 and #3 SLEEVES)
                                                                                                                   COAL HOPPER
                                                                                                       HYDRAULIC  LID
                                                                                       LID OSCILLATOR   LIFTER
                                                                                       MECHANISM
SLIDE VALVE
HYDRAULIC CYLINDER
                                                                                                                        CARRIAGE MOVEMENT
                                                                                                                        HYDRAULIC CYLINDER
              MOVEABLE CARRIAGE


                     BOOT ASSEMBLY
                                                                FIGURE 1
                                                      WEIRTON CAR ARRANGEMENT

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OSCILLATING "BUTTERFLY  VALVE"
                                                                                      COAL HOPPER
                                                                             HYDRAULIC DROP SLEEVE LIFTING CYLINDER
                                                                        LID LIFTER MECHANISM
                                                        FIGURE 2
                                                J & L CAR ARRANGEMENT

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contrast, the coal in the AISI/EPA car Is fed by gravity to the drop



sleeve assembly.  The flow of coal is controlled by the butterfly



valve in the lower portion of the sleeve which oscillates back and



forth to allow the coal to feed past it into the open charging port.



The AISI/EPA car is designed to maintain some coal on top of the



butterfly valve to improve the sealing function of the drop sleeve



after the charge.  The intent of both systems is to seal the lower



portion of each drop sleeve after the hopper has emptied until the



re-lidding sequence can be initiated.



     The Number 2 and Number 3 sleeves on the Weirton car are equipped



with relief stacks connected to the  system at the drop sleeve end of



the screw conveyor above the slide plate valve.  The other two sleeves



(Number 1 and 4) also have attachment points for similar stacks but



these are blocked off by cover plates installed at the time of car



fabrication.  During the latter portion of the charge when Number 3



and Number 2 hoppers have emptied, the stacks vent emissions caused



by oven back pressure until slide plate valve closure is initiated.



If emissions caused by oven back pressure are present on sleeves 1 or




4, and the slide valve is not closed, the emissions are vented through



the screw conveyor and up through the empty hopper.  Closure of the



slide plate valves effectively stops emission venting through both



the stacks and  the empty hoppers.



     The lid lifting mechanism on the Weirton car utilizes an electro-



magnet to secure the port lid to the lifting mechanism.  The lifting
                                  18

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and lateral motion is supplied by a combination of hydraulic piston




cylinders.  When the lid is replaced after a charge, the lifter




mechanism rotates the lid in its oven-top seat to improve the lid




seal.  This rotating action is supplied by a hydraulic rotary actuator.




     The lid lifting mechanism is mounted on a wheeled carriage along




with the drop sleeve assembly.  The drop sleeve or "boot" is fairly




light in weight.  It is composed of two interlocking sections with a




self-aligning inner seal ring.  The horizontal movement of the car-




riage places either the drop sleeve or the lid lifter over the charg-




ing port on which the car is spotted.  The complete carriage unit




moves beneath and is independent of the slide plate valve.  The action




of each sleeve carriage can be controlled independently or they can




be operated as part of the automatic master charge sequence.




     The horizontal carriage motion is controlled by a cylinder lo-




cated at the extreme end of the track assembly.  The vertical lifting




motion for both the drop sleeve and lid lifter are supplied by a




cylinder located on the back end of the moveable carriage.  Because




the same lift cylinder is used for the lid lifter and the drop sleeve,



they move up and down  in unison regardless of which  is in current




functional use.  The lid rotating motion  is supplied by an actuator




forming a part  of  the  vertically moveable portion  of  the lid  lifting




unit.  It is located behind  the  lid magnet and  is  connected  to  it by




two  operating rods.  The arrangement  described  maintains maximum




separation of system hydraulic components from  the area directly above




an open charging port.
                                   19

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     The major difference between these functional systems on the




Weirton car and the AISI/EPA car is the separation of the drop sleeve



assembly from the moveable carriage.  On the AISI/EPA car, the drop



sleeve is raised to allow the lid lifter mechanism to move horizon-




tally under it.  The lifter mechanism is lowered to secure and lift




the cap.  It _is then retracted to allow the drop sleeve to be lowered




for the charge.  No horizontal movement of the drop sleeve is necessary




during the sequence.  The drop sleeve is quite heavy on the  AISI/EPA



car.  Added to this is the weight of the coal being gravity fed into




the top of it.  This weight is utilized to achieve seat alignment and




seal integrity in the oven top port during the charging operation.



The separate hydraulic cylinder used to raise the drop sleeve assembly




is located on a heavy frame along the upper side of the sleeve



assembly.




     The Weirton car is designed to minimize the requirements for



oven top workers.  The lid lifting and re-lidding mechanism performs




one of the functions normally handled by these personnel.  A second



function, the control of the collecting main damper and the steam




ejectors, is accomplished through the use of operating arms attached




to hydraulic rotary actuators mounted on the car.  Eight such arms



are used, four on either side of the car to operate the pusher and




coke side ascension pipe controls.  The arms operate in pairs, one to




open the damper and one to close it; one to open the ascension pipe




caps and one  to close them and simultaneously turn on the ejector




steam.  The steam can also be turned off by the proper operation of




                                  20

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the arms.  All arms operate on controls of the oven on which the car




is spotted.  All control functions can be performed on this oven




without moving the car.




     The chore of ascension pipe cleaning (normally handled by the




car operator) is performed by two car mounted mechanical cleaning




devices controlled from within the cab.  The units rotate outward from




the car to contact the edge of the open ascension pipe.  An interlock




prevents the completion of the operation unless the caps are open and




the frame of the device is properly seated on the edge of the open




pipe.  When seated, the device extends a shaft into the open pipe.  A




serrated scraper known as a "cookie cutter" mounted on the end of the




shaft cleans the sides of the ascension pipe bend.  At the end of the




outward stroke, the scraper is automatically retracted and raised




back to the stored position on the car.  The complete cleaning system




is operated hydraulically.




     The functions of ascension pipe control and cleaning are achieved




in a similar manner on the AISI/EPA car.  A few operational differences




are, however, worthy of mention.  The AISI/EPA car employs a single




operating arm to control the functions on the oven to be charged.  A




second operating arm is positioned so as to control the lid and dam-




per on an oven to be charged in the next sequence.  The car mounted




ascension pipe cleaner is positioned to operate on the same oven.




     The ascension pipe cleaner on the AISI/EPA car was originally de-




signed to employ a rotary flail-type cleaner, however, recent changes
                                  21

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 in design have modified  this  concept.   It  is  understood  that  a  scrap-




 ing action  similar  to  the Weirton device will be utilized on  the new




 system.




      The original design of the Weirton cars  did not  call for vibra-




 tors on the hopper  units to assist in  coal flow.   After  experiencing




 some occasions where wet coal clung to the hopper  side,  the decision




 was made to install and  test electro-mechanical hopper visbrators on



 the car. Two such  units were attached to  the sides of hoppers  2 and



 3.  A manual control switch for the two vibrators  was installed on




 the control panel in the cab.  The switch  is  connected in such  a way




 as to allow vibrator operation only during a  charging sequence.




      During the  normal .operation of the car (as observed during the




 two week period), the  vibrators were not used.  On two occasions in




 which the car capabilities  were being  demonstrated to new operators,




 the vibrators were  turned on for a short period.   Operating personnel



report that the vibrators are needed only during the most severe "wet




coal" conditions and are generally capable of clearing the hoppers




with only a short burst of operation.  We were told that  no plans had




been made to install vibrators on all the hoppers  at this time.




     The occasional use of vibrators on the Weirton car  is  in contrast




to the programmed use of vibrators on the AISI/EPA car.   The vibrators




are automatically controlled as part of the AISI/EPA car  charging se-




quence and operate for a set period of  time.  Controls on the cab




panel do, however, allow the operator to turn off  the vibrators.
                                  22

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     The control of the Weirton car during a charging operation is




accomplished through the use of electro-mechanical timers and relay




logic circuitry.  Solid state circuitry is utilized only in the trac-




tion drive motor proportional control units.  In addition to the




normal relay logic circuitry, a number of circuits which bypass certain




logic interlock strings have been added.  These bypasses which have




limited access and are not used in normal operation, provide an




emergency capability to clear the car functions and allow it to move




or be moved along the top of the battery.  It is also possible using




certain types of these bypasses to manually operate some of the car




functions should a malfunction occur in the normal control logic.  It




was reported that this bypass capability has been responsible for




maintaining production in several instances when malfunctions occurred




and the spare car was not immediately available for relief operation.




Operation of the car using these circuits generally requires a second




operator  in the car equipment room and close coordination between




the cab operator and the bypass operator.




     No method is provided on the Weirton car for the indication of




coal level in the hoppers or coal flow in the system.  The initiation




of an automatic charge cycle starts timing devices which open the




slide valves and sequentially start the conveyor screws.  The screws




continue in operation until the timed sequence runs out or the car




operator judges that the hoppers are empty.  The operator uses several




observations to aid him in this decision.  They include elapsed time




from the start of the charge, observed activity around each drop
                                 23

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sleeve, the position of the leveler bar, flow of smoke from the 2 and




3 sleeve stacks, and the observed drop in screw motor current when




the hoppers go empty.  The operator can also leave the cab and visually




check the coal level in the hoppers through ports cut in the side of




each hopper.  This, however, is seldom necessary.




     The lack of level sensing devices is in contrast to the multi-




point level sensing system used on the AISI/EPA car.  The charging con-




trol system senses the "20% remaining" level signal and interrupts




the coal flow at this time to start the leveling sequence.  Coal flow




is started again when the pusher operator confirms the start of




leveling.  The lower level sensor ("hopper empty") is responsible for




stopping the coal flow to insure the presence of a coal plug above



the butterfly valve.



     The last feature of note is the improvement of the operating cab




environment.  The cab is closed and was observed to be generally free




from charging emissions during relatively heavy smoke conditions.  An




air conditioning unit in the cab seems to be quite effective.  In




addition to this unit, a second unit has been added to"the cars elec-




trical equipment room to hold its temperature at a lower level.  The




operators seemed quite pleased with the conditions compared to those




generally associated with the operation of a larry car.

-------
4.0  CHARGING OPERATION




4.1  Coking Cycle




     As in most plants, the coking time is a function of several




variables including product demand, coal characteristics, manpower




availability and raw material availability.  During the two weeks of




observation, the coking time had been raised to 23.5 hours because of




shortages of delivered coal.  The longer cycle decreased the plant




production rate, and thus the number of charging operations performed




in a shift.




     The operating pace had been slowed to 30 ovens per 8 hour shift.




We were told that a rule of thumb for a normal production rate change




is to add or drop 1 over per 8 hour shift.  Their normal production




pace utilizes between a 17 and 18 hour coking cycle.  .To this date,




the Brown's Island Battery has reached and maintained a maximum of




39 ovens per shift.  It is expected to be able to maintain a maximum




production schedule somewhat above this rate.




4.2  Charging Sequence




     After  the  larry car fills its hoppers at the coal bin, it then




proceeds to the oven that is scheduled  to  charge (A-l in this example),




A sequential numbering system is used in which the  87 oven batteries




are divided into three equal sections; A,  B and C.  Figure 3 presents




a small portion of Section A to clarify the discussion of the charg-




ing sequence, while Table 1 displays a portion of the Weirton charg-




ing and dampering sequence.  The first operation the larry car opera-




tor performs is to spot the larry car over the oven to be charged.




He accomplishes this by aligning pointers  on the larry car with  the






                                   25

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         CHARGING PORT
             o     o.    o     o
o      o     o      o      o
O      O     O      O      Q
o      o     o      o      o
                                                                 -LARRY CAR

                                                                 TRACKS
  A-l
               A-2
                            A-3
                            A-4
A-5
 CHARGE
HALF DAMPER    LIDS REMOVED
                                                 FULL DAMPER
                                   FIGURE 3

               OVERHEAD VIEW OF OVEN POSITION IN THE CHARGING SEQUENCE

-------
                   TABLE 1




DISPLAY OF WEIRTON CHARGING AND DAMPERING SEQUENCE
Charge
A-l
B-l
C-l
A-3
B-3
C-3
A-5
B-5
C-5
A- 7
B-7
C-7
A-9
B-9
C-9
Half -Damper
A-2
B-2
C-2
A-4
B-4
C-4
A-6
B-6
C-6
A-8
B-8
C-8
A-10
B-10
C-10
Remove Lids
A-3
B-3
C-3
A-5
B-5
C-5
A- 7
B-7
C-7
A-9
B-9
C-9
A-ll
B-ll
C-ll
Damper
A-5
B-5
C-5
A-7
B-7
C-7
A-9
B-9
C-9
A-ll
B-ll
C-ll
A-13
B-13
C-13
                      27

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oven flue caps two ovens behind.  Once this is done, the operator



activates the automatic gooseneck cleaner buttons, and the necks of




the ascension pipes are purged automatically.  The larry operator is



now ready to charge, and waits for the go ahead signal from the pusher




car.  Upon receiving the signal, the operator activates the actuator




arm which closes the ascension pipe caps and turns the collecting




main steam on simultaneously.  When these tasks are complete, the




operator  presses the master charge button which initiates the actual




charge.  The larry car now operates automatically until the end




of the charge, at which time the lid return cycle is initiated by




the automatic timers, or by the operator, depending on the selected




mode of operation.  After the charge is over, the operator backs




up and half dampers oven A-2 to stop cross flow across the oven




caused by unequal pressures in the collecting mains.  Next the




operator removes the lids from the oven being pushed, A-3, which will




undergo a decarbonlzation cycle of approximately 40 minutes.   The




operator then backs up to the next oven to be pushed, A-5, and full



dampers it, while also opening the ascension pipe caps.   During the




week of March 24-29, the lids were left on the charging ports during




decarbonization in order to build up a layer of carbon at the top of




the oven.  Because of this, lids had to be removed just prior to the




gooseneck cleaning step in the ordinary charging sequence.  As a re-




sult of a lid lifter malfunction, an indicator lamp signaled that a




lid had been removed when it had not.  The operator, thinking he had



a clear port, initiated the charge into a closed port.   This caused




considerable coal spillage on the oven top before the condition was




                                   28

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detected and the feed stopped.  This problem had reportedly occurred
several times on the night shift.  No problem was discovered in the
lid lifter mechanism, but in order to insure proper removal of the
lids, the larry car operator would come off his spot following the
lid lifter operation, to visually check lid removal.  The car was then
respotted and the charge was performed in the normal fashion.  This
practice added several seconds to the normal time required for a
charge, but the larry car was generally ahead of the other elements
of the operation.
4.3  Leveling Procedure
     After the larry car has charged the oven with about 80% of its
coal, the leveling sequence begins.  The pusher car receives a signal
in the form of aloud buzz from the larry car.  This buzz is activated
by a timer in the master charge button electronic control circuitry.
Leveling is then initiated in the pusher car by pushing the automatic
leveling sequence button.  All leveling from this point in time is
automated.  The leveling is performed with the coal flowing from the
number 2 drop sleeve.  This was a very consistent leveling practice
at Weirton, and no deviations from this scheme were observed.
     There has been a problem at the Brown's Island Battery involving
coal spillage during the leveling procedure.  During the earlier
operation of the Brown's Island Battery, the leveler bar had been in-
serted into the oven considerably earlier in the charge, and was
leveling for some longer period of time.  The Weirton personnel ob-
served excessive amounts of coal spillage during this time, and as
a result, the leveling sequence was altered.  A shorter leveling
                                 29

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 period was initiated and the coal spillage was decreased because of




 the lower number of leveler bar strokes, each of which drags some



 coal out of the chuck door.  This represents a trade-off of changing



 of the leveling time to prevent coal spillage against the fact that




 waiting a longer period of time to level causes the open gas passage




 to both ascension pipes to be reduced.




     There having been two alternative coal spillage reduction methods




proposed at Weirton.  The first was the use of air hoses to blow the




coal wedged between the leveler bar baffles loose to keep the leveler




bar operating at peak efficiency through each leveling stroke.  Heat




seemed to be a problem as far as hose maintenance was concerned, and




the idea was abandoned.  Another proposed solution was the use of a




chain to dcag along the top of the leveler bar to knock the coal



loose between the  leveler bar baffles in its reverse stroke.



4.4  Collecting Mains



     The Brown's Island Battery utilizes a double off-take collecting




main system to service each four charging port oven.  The coke side




and pusher side collecting mains are interconnected by two overhead




cross-over pipes that span the oven approximately at one third and




two thirds of the oven's distance lengthwise.




     The standard pressure and temperature at which the mains operate




are 11 mm and 72°, respectively.  These are variable controls and are




increased and decreased as the coke plant superintendent deems nece-




ssary during different coking schedules and special situations.






                                   30

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4.5  Coal Description




     The Brown's Island Battery is equipped with its own separate coal




preparation plant which is divorced from the mainland coal preparation




plant.  The coal is currently sized at 72% passing an 1/8 inch screen.
                                   31

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5.0  CHARGING OBSERVATIONS




5.1  Reporting Procedures




     Direct observations of the larry car performance in production




operation were made by personnel familiar with details of the charg-




ing operation, and the coke oven environment.  In order to make the




observations simple and efficient, no instrumentation was employed to




measure emission quantities.  The observation scheme relied instead




upon the judgement of the observer to assess the relative quantities




of observed emissions from some pre-defined points on the larry car.




The observer characterized the emissions from each designated point




as either a blank box (none observed), L (light flow), M (medium flow),




or H (heavy flow).  The basis for this Judgement was developed by



watching several typical charges by the car and moderating the obser-




vations based on recalculations of emissions flows on the J & L cars,



including the AISI/EPA car.  In addition to the flow information re-



corded, other observations such as the general color of emission, the




presence of flame at a point, and the dynamic flow characteristics




(puffy, increasing, decreasing, changing to) were also noted.




     The points designated for observation were the areas around and




immediately above each drop sleeve (boot) seal, the four hopper tops,




and the stacks attached to the number 2 and 3 sleeves.  It is esti-




mated  that these points account for at least 90% of the emissions




through the car during a charging operation.  All of these points are




visible from a point on the oven surface approximately 50 feet in
                                  32

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front of the car.  The observer remained at this approximate position




throughout the charging operation under observation.  From this point,




it is generally possible to differentiate emissions from sources




other than the car and to judge the flow characteristics.




     During the charging operation, a record was made of observations




at IS second intervals.  This interval was found to provide a reason-




ably accurate account of the charging conditions.  This interval was




too short to allow the observer to record information directly on the




form, so a portable tape recorder was used to record the observer's




verbal commentary.  This technique allowed the inclusion of sufficient




detail and added commentary to provide a basis for completion of the




observation form.  The completed forms are included as Appendix I of




this report.




     A hand-held stop watch was used by the observer to provide




timing information on the various segments of the charging operation.




An overall time for just the charging operation (coal flow start to




last lid on) was obtained for each of the observed charges.  In addi-




tion, other segments and combinations of segments were timed to pro-




vide a comprehensive picture of the cars' operational pace.  The total




operation during the week of March 11-15 was on a reduced production




schedule, therefore, steps involving operator initiated operations may




not have been performed in the shortest practical time.
                                  33

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     During the period of the observations, the general weather con-




ditions remained relatively constant.  No rain was experienced and




the temperature ranged from the 50's up to the 70's.  Due in part to




the location of the oven (unshielded by adjacent structure on an




island in the middle of a river), a constant breeze was present,




ranging from a light 2-4 mph to continuous 15-18 mph wind.  This wind




was responsible for the rapid dispersal of emissions as they rose from



the top of the oven or car stacks.




5,2  Summary of Performance Observations




     The basic impression obtained from the observations is that -the




larry car is very consistent in its operation.  For example, the ob-



served charging times for 57 operations was between 1 minute,




30 seconds and 1 minute, 50 seconds with an average time of 1 minute,




39 and 2/10 seconds.  Most of the observed spread in time can be ac-




counted for by variations in the start of the operator initiated re-




lidding cycle.  A second example is the occurrence of a small puff of




emissions from number 2 stack during the first 10 seconds of the




charging operation.




     Examination of the reporting forms shows that the first 30




seconds of the charge is fairly free from emissions except for this




puff.  Certainly this is due in part to the mechanical timer control,




but the overall consistency of charge quality (emission level) cannot




be achieved unless all goes smoothly, such as coal flow, leveling,




re-lidding and oven control operation.  The dependability was further
                                  34

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attested to by the fact that the lid man spent much of his time riding




in the larry car cab.  When a malfunction did occur, such as a lid not




seating properly, he came down, quickly fixed the problem and returned




to the cab.  Discussions with the car operators confirmed the fact




that little trouble has been encountered with coal flow.   They also




related a feeling of overall dependability, with some commenting that




this car was more complicated than the other cars they had operated




but that it worked well "in spite of this."  In general,  the mechan-




ical problems observed were minor in nature and were handled by the




car operator and lid man on duty at the time.




     The spotting of the car on an oven is accomplished by aligning




a car mounted pointer with flue caps set in the oven top.  This is




done by sighting down through a window on either side of the control




cab.  The system appears to provide the needed accuracy and it is




simple to use.  The only observed problem with the system was the




visibility of the pointer and cap during certain light conditions.




Late in the afternoon, the sunlight would strike the surface of the




cab window in such a way as to obscure the spotting pointer and cap.




The condition was similar on both sides of the car.  It appears that




the problem could be eliminated by shading the lower windows in an




appropriate manner.




     The drop sleeve units appear to have little problem in seating




properly in the open charging ports.  The lower portion of the unit




can be canted considerably before a reasonable seal is lost.
                                  35

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Mis-spotting of the car can, however, cause a visible gap in the




boot-to-oven seal.  This seemed to occur primarily when the car was




being respotted after a check to insure that all lids had been re-




moved.  No explanation was obvious since the same spotting facilities




are used for both the initial and re-spotting operations.



     The ascension pipe cleaners worked well during  the period of obser-




vation.  No malfunctions were observed and their cleaning ability




appeared adequate.  It was reported that on two occasions the scraper,



or "cooky cutter," had fallen off the end of the ram into the collec-



tion main.  In order to prevent this, a steel cable has been fastened




around the scraper and to the ram shaft.   The reported production



delay caused by a malfunction of the cleaner involved the premature



extension of the ram as the  uiit was swung down to the operating




position.  This was traced to a sticking interlock switch in the logic



circuit.  The event has not been repeated, and no remedial action is



felt to be necessary.



     The lid lifters performed well during observation.  The only




problem involved two occasions in which two separate units failed to




remove lids.  On an occasion, the unit was recycled and operated pro-




perly on the second try.  On the other occasion, the lid was removed




by the lid man without a second try by the lifter.  On both occasions,




the lifters worked without further problems on succeeding charges.



We were told that occasionally the lid detector interlock switch does




not actuate when in contact with the lid, and the magnet does not






                                   36

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energize.  We were told that on one occasion, the magnet picked up a




flue cap cover instead of the port cover.  The cap detector interlock




was made, and a charge was attempted with the lid in place.  This re-




sulted in a considerable coal spill before the coal could be stopped.




     No serious problems in unit operation were observed or reported




but it was noted that the electrical connections for this unit show




rapid deterioration and are reported to be difficult to keep in good




repair.  No problems were observed in the unit hydraulic system, but




it was reported that flexible elbows and couplings in the system had




shown some tendency to leak prematurely.  A more durable replacement




for these units is being sought.




     It seemed that the rotating action of the lifter is slow in com-




parison to the operation of the AISI/EPA car.  The time between a rota-




tion in one direction and a reverse rotation is long.  This caused no




observed problems but a "ready to travel" car condition might be




achieved a few seconds earlier if the delay could be shortened.




     The car mounted actuators which control steam, ascension pipe




cap closure, and damper action, performed with only minor malfunctions




during the periods of observation.  On several occasions, the lid




failed to travel over center when closure was attempted.  Recycle of




the system did not solve the problem and the cap was closed manually




by the lid man.  On two occasions, the actuator arms became jammed




in the control levers and had to be freed manually using a long pry




bar.  We were told that the control levers are occasionally bent






                                  37

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causing misalignment of the arms.  It was reported that this problem




is solved by occasionally checking the levers and re-aligning them




using a sledge hammer and wooden wedges.  No serious delays have been




reported as a result of control misalignment.




     The screw conveyor and slide plate valve functioned normally dur-




ing the observation period.  No malfunction in their mechanical oper-




ation was observed, however, a coal plug did occur once on number 4




drop sleeve.  It was reported that the coal had plugged in the charg-




ing port and caused a packing action back through the system.  It took



about 5 to 10 minutes to clean the plug in the port and complete the




charge.  During a discussion following the incident, operating and




supervisory personnel did not feel that any car associated malfunction




had caused the problem.  It was suspected that the possibility of late



leveler bar entry had caused or contributed to the problem.




     During observed activities, attempts were made at timely closure




of the slide valves based on an observed drop in screw feed motor



operating current.  The slight drop in current proved hard to detect




and coordination of the activity was difficult to accomplish.  The re-




sults of the trial runs did, however, indicate the value of timely




valve closure by the observed reduction in emissions through the stacks.




It appears that a valid and perhaps easier-to-implement approach would




be the monitoring of coal flow in the sleeve just above the slide




valve.  When the detector indicates the end of flow, the valve can be




closed immediately and the screw stopped.  The sensor might be






                                   38

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arranged to mechanically operate a switch which would provide a sig-




nal or initiate closure of the slide plate valves automatically.




     The electro-mechanical vibrators were not used in connection with




normal charging during the observation periods.  They were turned on




twice to demonstrate their use to new car operators and they were




turned on once as a demonstration for the observer.  Conversation with




car operators and supervisory operating personnel indicate that the




vibrators are dependable in their operation and effective in removing




coal clinging to the sides of the hoppers.




5.3  Functional Operating Times




     As a part of observation activity, various segments of the charg-




ing cycle were timed to determine the cars' current operating pace.




This section presents the results of this activity.




     During each charge for which an observation record was made, a




time for the charge was taken.  The total charging time as observed




by MITRE was defined as the time period between the initiation of the




coal screw feed and the completion of the lid replacement cycle.  This




"total charging time" was recorded for 57 individual charges, and the




average was found to be 1 minute and 39.2 seconds.  The maximum charg-




ing time observed was 1 minute, 50 seconds, while the minimum was




found to be 1 minute, 30 seconds.  The occurrence of the coal plug on




number 4 sleeve appears in this average as the time elapsed to the




first re-lidding.  No time was recorded for the clearance of the port




and the completion of the charge to the number 4 port.






                                  39

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     In addition to the standard time taken for each observed charge,




segments of the total charging operation were timed.  A summary of




these times appears in Table 2.  The terms "return to travel" and




"ready to travel" refer to a condition in which the car is moving or



ready to move to some other location on the oven.




     Based on the cycle time from car spotting to travel to the coal




bin of 3 minutes, 30 seconds, and the hopper filling time of 1 minute,




an 8 minute complete cycle time does not seem unreasonable.  The 39




oven per 8 hour shift pace that has been maintained on occasion in



the past, represents an average cycle time of 12.3 minutes.  It ap-



pears, however, that the pacing production system may be the coke side




door machine which has a planned operating cycle time of a little



over 10 minutes.



5.4  Particulate Sample Collection




     As a part of the observations of oven charging activities, a num-



ber of particulate samples were taken around the number 2 and 3 drop




sleeves and in the free emission plume around the bottom of the




charging car.  The device used to obtain these samples was designed




and constructed by MITRE to perform this specific sampling task.  A




description of the device and test results is contained in this section.




     During the course of testing at the J & L facility, considerable



difficulty was encountered in obtaining a particulate sample which




could provide meaningful data on the physical characteristics of the




emitted material.  These problems gave rise to the development by






                                  40

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                               TABLE 2

                      OBSERVED OPERATION TIMES



Approximate Time To Fill The Hoppers In the Coal Bin     1 Minute
Ascension Pipe Cleaning Cycle
Lid Removal/Complete Cycle
Lid Lifting Cycle/Timed From The Sleeve Raise Until
The Lid Was Replaced
Lid Lifter Oscillation And Return To Travel Ready
Status
Slide Valve Closed To Lid Lifter Ready
Drop Sleeves Down To Ready Travel
Lids On, Half And Full Damper To Ready Travel
Spotting Of Car For Charge Through Half And Full
Damper Cycle To Coal Bin
30 Seconds
16 Seconds
8 Seconds
9 Seconds
32 Seconds
2 Minutes, 10 Seconds
53 Seconds
3 Minutes, 30 Seconds

-------
MITRE of a direct impaction particulate collection device dubbed the
MITRE Carrousel.  The device was configured to pass glass microscope
slides through the emission duct opening.  The slides, one surface of
which was coated with silicon grease, collected particle samples for
direct viewing and analysis under an optical microscope.  Details of
this device and its operation are reported in MITRE WP-10480 and the
coke oven testing program final report.
     A similar approach was selected for use in collecting particle
samples during the observations at Weirton.  The two major differences
were that sample flow through the sampling device was controlled by a
fan and the smaller material not deposited on the greased microscope
slide was collected on a filter element through which the entire
sample flow passed.  A simplified schematic of the device is shown in
Figure 4, and Figure 5 pictures the device in simulated use.
     The intent of the device is to draw a representative sample
through the first orifice in the sampling head at a velocity approxi-
mating the concentrated emission plume velocity in free air.  The
value of this velocity was selected based on in-duct and free space
velocity measurements made during the coke oven tests at J & L and
was nominally  10 ft/sec.  The stream from this orifice is directly
perpendicular against the greased surface of the microscope slide
shown in Figure 6.  The slide is held in clips in a chamber in such a
way that the sample flow can pass around all four edges.  The sample
flow continues through an exit orifice at the rear of the chamber and

                                  42

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•SAMPLE  INLET
          •GREASED SLIDE


                   -FILTER'HOLDER AND FILTER


                       ORIFICE  FLOW  METER
                         BY-PASS AND BY-PASS VALVE
             ORIFICE
AXIAL FAN-
                                       FIGURE 4
                            SIMPLIFIED SCHEMATIC DIAGRAM

-------
              FIGURE 5




PARTICULATE SAMPLER IN SIMULATED USE

-------
                  FIGURE 6
               SAMPLING HEAD
                  FIGURE 7
ORIFICE ASSEMBLY FOR SAMPLE FLOW MEASUREMENT
                     45

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into a filter element holder.  The filter element which restricts




particle passage down to approximately .7 y is pre-weighed to allow




measurement of the deposited material.  From the filter, the air flow




passes into a 1-1/2 inch tubular passage which serves two functions;



a handle extension, and a housing for an orifice flow meter (Figure 7).




The flow meter provides a facility for measuring sample volume flow




and thus the capability for determining sample velocity at points of




interest in the system.  In order to adjust the flow through the




sampling system, a controllable bypass circuit is provided, as shown




in Figure 8.



     The following is a brief description of the samples collected




based on visual observations of the greased slides, the filter ele-




ments, and the loose particulate catches.  No detailed analysis of



these elements has been undertaken at this time, but this brief




summary will indicate the success of the sampling technique and



equipment.



    The material deposited on the slides was fairly uniform in size




characteristics.  An area of one of the greased slides is shown in




Figure 9.  The deposits, as expected, are concentrated in about a




3/4" circle corresponding to the inlet orifice position and size.




Some of the larger particles are located on the periphery of the slide




indicating some reentrainment or "particle bounce."  Many of the




larger particles did not adhere to the slide and were caught in the




filter element.  This would seem to indicate that although they

-------
                        FIGURE 8
               BYPASS AND FAN ARRANGEMENT
                                 	9.2 jj/div.^
                        FIGURE 9
TYPICAL AREA OF GREASED SLIDE, CHARGE TO OVEN C-22 ON 3/13
                           47

-------
Impacted on the slide, their larger size and aerodynamic resistance
caused them to be dislodged and blown off the greased surface.
     One of the cleanest charges observed was made while the particu-
late sampler was in use.  This was a charge to Oven B-13, at approxi-
mately 11:25 a.m. on 3/26/74.  Examination of the slide showed a
very light deposit of uniformly distributed particles.  Few extremely
large particles were found on the slide or on the filter holder.
There was a minimal amount of loose material found in the system.
One point of interest is the brownish color of the filter element as
opposed to the black color of sample filters from other tests.  The
filter element pictured in Figure 9  had the lowest sample weight
for filter deposits recorded for the seven tests.
     Two of the filter elements exhibited a shiny black surface
characteristic and fairly heavy sample weights.  The surface of the
filters as shown in Figure 10 appears to have been wiped with a rather
thick liquid.  The deposits show a pool like characteristic which
produces the shiny surface.  This is in contrast to the surface of
the other four samples, example in Figure 11 , which show a large
number of distinguishable particles.  The only obvious differences
between the two groups of charges was that there was considerably
more visible fire on the two tests on which the filters with the
shiny surfaces were obtained.  The sampler was not operated in the
direct flame but the heat may have had a polishing or melt/flow effect
on the filters or it may have changed the characteristics of particu-
late material emitted.
                                  48

-------
                         FIGURE 10




TYPICAL FILTER ELEMENT AREA, CHARGE TO OVEN B-13 ON 3/26/74
               *   !



                          FIGURE 11




 TYPICAL FILTER ELEMENT AREA,  CHARGE TO OVEN C-24 ON 3/15/74







                            49

-------
                         FIGURE 12




TYPICAL FILTER ELEMENT AREA,  CHARGE TO OVEN A-ll ON 3/26/74
                             50

-------
     No further analysis of the samples is planned at this time, but




they will be preserved should there be further interest in information




which they may provide.




5.5  Gas Constituent and Concentration Measurements




     During the week of 3/11/74 to 3/15/74, gas constituent and concen-



tration data were obtained for a select group of pollutants.   The




pollutants measured were as follows:






         Pollutant                 Detector Tube Concentration Range




           N02                               0.1-50 PPM



           CO                                10-3000 PPM




           CO                                .001-.!%




           co2                               .01-10%




           H2S                               1-800 PPM






The gas measurement was performed with an MSA universal tester using




MSA detector tubes.




     The gases were measured in the plume surrounding the drop sleeve



during the charging operation, and also on the oven top during



ambient conditions when a charge was not taking place near the




measurement area.




     The gas concentrations that were obtained proved to be incon-



sistent, which in turn made it difficult to draw any meaningful con-




clusions from them.  The reasons for this difficulty were the wind




conditions that prevailed at the oven top at Brown's Island coupled
                                  51

-------
with the relatively low order of emissions to be measured.  These




conditions contributed to a highly dispersed and rapidly dissipated




emission condition.




     These emission plume characteristics were in contrast to the




emission plumes at Jones and Laughlin Pittsburgh Works, where the




emission plumes were less dispersed and slower to dissipate.  The




concentrations that were obtained are as follows:






                            Weirton Steel



Ambient Air Data - Oven Top




             NO.   -   No Response




             H_S   -   No Response




             C02   -   .07%



             CO    -   .002%



             CO    -   10 PPM






Plume Data - Drop Sleeve During 3/11/74 Charge



             NO.   -   No Response




             CO-   -   No Response




             H2S   -   25 PPM




             CO    -   .01%




             CO    -   50 PPM




             CO    -   75 PPM




             HS   -   5 PPM
                                  52

-------
Plume Data - Drop Sleeve During 3/12/74 Charge




             H.S   -   No Response
             N02   -   .1 PPM




             C02   -   .08%




             CO    -   .005%




             CO    -   125 PPM






Plume Data - Drop Sleeve During 3/13/74 Charge




             N02   -   .4 PPM




             C02   -   .3%




             H2S   -   10 PPM




             CO    -   100 PPM




             CO    -   .02%






Ambient Air Data - 3/11/74 (Battery Top)




             NO.   -   No Response




             H.S   -   No Response




             C02   -   .07%




             CO    -   .001-.1   -   .002%




             CO    -   10-3000 PPM   -   10 PPM
                                  53

-------
Plume Data - 3/11/74

             NO. - Around Drop Sleeve   -   No Response

             CO. - Around Drop Sleeve   -   No Response

             H_S - Around Drop Sleeve   -   25 PPM

             CO - Around Drop Sleeve   -   50 PPM

             CO - Around Drop Sleeve   -   75 PPM
                     Oven B-24

             H9S - Around Drop Sleeve   -   5 PPM
              *      Oven C-24


Plume Data - 3/12/74

             H,S - Around Drop Sleeve   -   No Response
              *•        Oven C-22

             NO, - Around Drop Sleeve   -   .1 PPM
               Z       Oven A-24

             CO- - Around Drop Sleeve   -   .08%
                       Oven B-24

             CO - Around Drop Sleeve   -   .005%
                      Oven C-24

             CO - Around Drop Sleeve   -   125 PPM
                      Oven A-20


Plume Data - 3/13/74

             NO, - Around Drop Sleeve,  -   .4 PPM
                      Oven B-28

             CO. - Around Drop Sleeve  -   .3%
                      Oven C-28

             H,S - Around Drop Sleeves  -   10 PPM
               *       Oven A-l

             CO - Around Drop Sleeve   -   100 PPM
                      Oven B-l

             CO - Around Drop Sleeve   -    .02%
                      Oven C-l

                                  54

-------
     After careful examination of the data presented here, it was




decided that no meaningful conclusions could be drawn regarding emis-




sions produced during the charging operation.  The ambient data does,




however, provide some quantitative information of possible use on




oven top conditions.  Any application of this data should, however,




take into account its short comings in quantity and the highly variable




conditions.
                                55

-------
6.0  LARRY CAR WORK HISTORY
6,1  Work and Maintenance Schedules
     In discussions with supervisory personnel, we were told that no
formalized arrangement for rotation of the oven equipment has been
established.  The philosophy which prevails is to let the shift
foreman select the equipment to be used.  This usually means the con-
tinual use of one car until either a malfunction occurs or the car is
placed in standby to be checked by the motor inspector.
     The motor inspector will generally notify the foreman the day
before he intends to check the car.  The foreman can then set the car
out at the beginning of the shift during which the car is to be in-
spected.  The actual time of inspection during the shift is based on
the inspector's work load.  In conversations with the "greasers," we
were told that they normally grease the car on a daily basis while
it is in operation.  This is usually accomplished during periods when
the car is in the coal bin being filled.  The daily greasing is con-
fined to 36 hand fittings and operation of the central lubrication system.
     In addition, the greasers try to catch each car out of service
at least once a week to check all machinery requiring lubrication.
This complete check requires from 1-1/2 to 2 hours and includes such
items as the checking, cleaning, and lubricating of semi-exposed
gearing and other hard to reach rotating machinery.  The hydraulic
systems are also checked at this time.
     One fact which allows flexibility in scheduling is that the
electrical department is responsible for all maintenance and repair
work on oven machinery.  They have the capability within their shop
                                  56

-------
to handle all but the heaviest mechanical repair jobs.  It is their




responsibility to coordinate work on those jobs for which they require




assistance.  This seems to provide prompt attention to problems as




they arise and centralizes the responsibility for their resolutions.




This arrangement is in contrast to the situation which existed at




J & L in which the foreman or car supervisor was responsible for co-




ordination of the various craft shops needed for a repair job, such




as millwrights, riggers, electrical, line and wire, pipe fitters, etc.




The crafts in turn would then schedule work priorities based on




minimization of production disruption.  In some instances, this caused




delays when one craft was not available and other work could not pro-




ceed until their segment of the job was complete.




 6,2  Significant Events




      As a part of the observation activity, a compilation of signifi-




 cant events such as breakdowns causing loss of production,  was under-




 taken.  We were told that no formalized reporting system on specific




 events is established, but that information of this type could be




 obtained from operating supervisors based on their personal recollec-




 tions and notes.  This approach was pursued through informal talks




 with these individuals.




      The conversations disclosed only two occasions during which pro-




 duction was lost because of larry car problems.  The first occasion




 involved the loss of 4 to 6 hours of production when one of the cars




 became immobilized over an open port.  This resulted in damage to




 drop sleeve hydraulic systems and one ascension pipe cleaner and






                                    57

-------
associated control system.  Analysis of the event indicated that the



following sequence of events may have occurred.




     1.  At the end of a charge, the operator observed an unusually



heavy concentration of flame from around one drop sleeve.




     2.  He reacted in a proper manner by attempting to move the car




away from the flaming port.  In his attempt to clear the car for




motion, the operator accidentally pushed the ascension pipe cleaner




actuating button.   The cleaner extended and became wedged between




ascension pipes as the car moved.




     3.  The operator stopped the car when he realized what had hap-




pened, but its proximity to the open flaming port caused considerable




damage before the lid could be replaced.




      Some portion of the cleaner assembly had to be cut away before




 the car could be moved off the oven.  In addition, the second car was




 undergoing maintenance at that time and was not ready for immediate



 service.  Work necessary to get the standby car into service was



 rushed to completion and production was resumed with certain functions




 being operated manually in the bypass mode.




      The car which had burned was repaired to a point where it could




 perform production charging in approximately 8 to 10 hours.  Several




 of its functions would have had to be operated in the bypass mode




 and the damaged ascension pipe1 cleaner was inoperable.



      The second event occurred when an interlock switch on the ascen-




 sion pipe cleaner failed causing the ram to be extended prematurely.



 The extended ram contacted the overhead trolly track as the unit swung




 down to the operating position.  Power was lost and a portion of the





                                 58

-------
"hot rails" was badly damaged.  It required approximately 1/2 hour to




resolve the problem and resume production.  The standby car could not




operate until the hot rail was cleared.




6.3  Operator Performance



     The larry car operator performance at Weirton seemed to be of a




highly consistent level.  This can be attributed to the fact that the




Brown's Island Battery is highly automated, and the larry car opera-




tors' performance is limited  to the  task  of driving and spotting the




larry car, and operating  the  charging/aspirating mechanisms with the




aid  of automated control  circuitry.  The  fact  that the car is



automated leaves relatively few decisions to the individual discretion




of the driver, since he follows a predescribed charging scheme for-




matted by the oven superintendent.




6.4  Future Modifications




     As far as MITRE could ascertain from its experiences on the oven




and conversations with battery personnel, the Brown's Island Battery




is being modified in every area that seems to need further design and




planning.  At the present time, attention is being given to three




specific areas; leaking ascension pipe caps, level sensing in the




charging car hoppers, and increased aspiration in the collecting main




system.




     Experimentation is currently taking place concerning the ascen-




sion pipe caps in order to discover new methods of reducing the emis-




sions that occur immediately after the charging operation.  Various




materials and seating configurations are being implemented experi-




mentally on the oven, and are being observed during normal operating




conditions so  as to  determine the advantages and disadvantages of each.





                                 59

-------
     The Brown's Island Battery is also working on a method for
sensing the coal level in the larry car coal hopper.  The reason  for
this is to signal the larry car operator when all coal has been dis-
charged through the drop sleeve into the oven.  Prior to this, the
larry car operator had been using his own judgement as to the empti-
ness of the hopper, or allowing the automatic charging cycle to
initiate slide valve closure.  As a result, the slide plate valve is
left open for an undetermined amount of time after the coal discharge
is complete.  It is this undetermined period of time that allows
charging emissions to escape to the atmosphere via the open slide
plate and coking stack.  The Brown's Island personnel feel that a
reduction in charging emissions would be accomplished if the slide
plates were closed immediately following the emptying of coal, and as
a result, are presently devoting attention to this problem.  During
the week of March 24th, the electrical department was experimenting
with a current sensing device attached to the drive motor of the screw
that feeds coal to the drop sleeve during the charging operation.
Theoretically, when the screw feed cylinder of the larry car is free
of coal, the operating load of the motor, which is normally 15-20 amps
during the coal feeding sequence, is decreased by 2-4 amps.  This
reduction could be sensed by the current sensing device.  This drop
in the current load could then be used as a signal for the larry car
operator to close the slide plate valve, thus closing the charging
emission escape route.
     Experiments are also under way concerning oven aspiration and
steam ejector operation.  Different ascension pipe plumbing configur-
ations are being considered and tried experimentally on the oven
during normal charging conditions.
                                    60

-------
       APPENDIX I




LARRY CAR OBSERVATION LOGS
           61

-------
                               LARRY CAR OBSERVATION LOG
COMPANY
   PLANT-
BATTERY
National Steel
Weirton Steel
Brown's Island
                                                                         3/11/74
DATE-
TIME
OVEN
3; 40
C-22
CHARGE

IS SEC.

30 SEC.

45 SEC.

1MIN.

1MIN.1SSEC.

1MIN.30SEC.

1 MIN. 45 SEC.

2MIN.

2 MIN. 15 SEC.

2 MIN. 30 SEC.

2 MIN. 45 SEC.

3 MIN.

END OF CHARGE

LID REPLACED
  TOTAL
  CHARGING
  TIME
PUSHER SIDE

HOPPER















1:50
I
OflOP
SLEEVE


MF

L










CENTER
2
HOPPER/
STACK

PS



MS-*
MS








DROP
SLEEVE


MF
LF
F
F
F








CENTER
3
HOPPER/
STACK





MS
MS








DROP
SLEEVE


MF
LF •
F
F
F








COKE SIDE
4
HOPPER















DROP
SLEEVE















f - INCREASING ^ DECREASING -+ CHANGING TO
S - STACK HP - HOPPER F - FIRE
                                   L - LIGHT FLOW
                                  BL - BLACK
                                           M  -  MEDIUM FLOW
                                           V  -  YELLOW
         H -  HEAVY FLOW
         P •  PUFFY
WEATHER .
                                                  MANUALGAS
                                                               .01 Concentration of CO.
                                                               Reading Taken at 02
                                                               Drop Sleave
REMARKS:.
 MITRE
MCF 2495 12/73
                                                                       OBSERVER
                                             62

-------
                                LARRY CAR OBSERVATION LOG
          National Steel
          Weircon Steel
COMPANY
  PLANT
BATTERY  Brown's Island
       DATE
       TIME
       OVEN
                                                                        3/11/74
                                                                        3:55
                                                                        A-24
CHARGE
IS SEC

30 SEC
45 SEC

1 MIN
1 MIN IS SEC

1 MIN 30 SEC

1 MIN 45 SEC
2 MIN

2 MIN IS SEC
2 MIN 30 SEC

2 MIN 45 SEC
3 MIN

END OF CHARGE
LID REPLACED
 TOTAL
 CHARGING
 TIME
PUSHER SIDE

HOPPER





LPF









1:35
1
DROP
SLEEVE















CENTER
2
HOPPER/
STACK

SPF



LS









DROP
SLEEVE

MBL
M
L
F










CENTER
3
HOPPER/
STACK





MS









DROP
SLEEVE

F*MBL
FL
L
F










COKE SIDE
It
HOPPER















DROP
SLEEVE















f - INCREASING | DECREASING -fr CHANGING TO
S • STACK HP • HOPPER F - FIRE
WEATHER .
                                    L -  LIGHT FLOW
                                   BL -  BLACK
                                                       M
                                                       V
MEDIUM FLOW
YELLOW
H - HEAVY FLOW
P - PUFFY
                                                   MANUAL GAS
                                                               25  PPM of H.S at 92
                                                               Drop Sleeve	
REMARKS.
                                           63

-------
                                LARRY CAR OBSERVATION LOG
COMPANY-
  PLANT:
BATTERY.
National  Steel
Weirton Steel
Brown's Island
           DATE
           TIME:
           OVEN
                                                                         3/11/74
B-24
CHARGE
IB SEC.
30 SEC.
4BSEC

1MIN.
1 MIN. IB SEC.
1MIN.30SEC.

1 MIN. 45 SEC.
2 MIN.

2 MIN. IS SEC.
2 MIN. 30 SEC.
2 MIN. 45 SEC.
3 MIN.

END OF CHARGE
LID REPLACED
 TOTAL
 CHARGING
 TIME
PUSHER SIDE
1
HOPPER















1:32
DROP
SLEEVE


L

L-+M











CENTER
2
HOPPER/
STACK

SF


LS










DROP
SLEEVE

LP
LF
LF+
F










CENTER
3
HOPPER/
STACK




L-+SF










DROP
SLEEVE

LF
LF
LFP
F










COKE SIDE
4
HOPPER















DROP
SLEEVE















f - INCREASING ^ DECREASING -fr CHANGING TO
S - STACK HP - HOPPER F - FIRE
                                    L
                                   BL
                             LIGHT FLOW
                             BLACK
M - MEDIUM FLOW
Y - YELLOW
                                                                            P -  PUFFY
WEATHER:-
                                                   MANUALGAS
                                                     75 PPM of CO at  92
                                                     Drop Sleeve	
REMARKS:.
 MITRE
MCF 2495 12/73
                                                                        OBSERVER
                                              64

-------
                               LARRY CAR OBSERVATION LOG
COMPANY

   PLANT

BATTERY
           National  Steel
           Welrton Steel
           Brown's Island
DATE
TIME
OVEN
                                                                        3/11/74
4:18
CHARGE

15 SEC

MSEC

45 SEC

1 MIN

1 MIN 16 SEC

1 MIN. 30 SEC

1MIN 45 SEC

2 MIN

2 MIN 15 SEC

2 MIN 30 SEC

2 MIN 45 SEC

3 MIN

END OF CHARGE

LID REPLACED

 TOTAL
 CHARGING
 TIME
PUSHER SIDE

HOPPER















1:32
1
DROP
SLEEVE















CENTER
2
HOPPER/
STACK

SP



MS









DROP
SLEEVE

LF
LFP
LFP
L+FP










CENTER
3
HOPPE R/
STACK





MHP MS









DROP
SLEEVE

LF
LFP
LFP
L+FP










COKE SIDE
4
HOPPER















DROP
SLEEVE















f - INCREASING | DECREASING -» CHANGING TO
S - STACK HP - HOPPER F - FIRE
                                   L -  LIGHT FLOW
                                  BL -  BLACK
                                                      M -  MEDIUM FLOW
                                                      Y •  YELLOW
         H -  HEAVY FLOW
         P •  PUFFY
WEATHER .
                                                  MANUAL GAS
                                                               5 PPM of H2S at 02
                                                               Drop Sleeve
REMARKS
            The numDer three drop sleeve malfunctioned, and the lid did not release.
            Recycling of the lid lifter  mechanism In the manual mode corrected  th
            problem.

 Ml
m^m
MCF 2495 12/73
                                            65

-------
                                LARRY CAR OBSERVATION LOG
COMPANY
   PLANT-
BATTERY-
National  Steel
Weirton Steel
Brown's Island
DATE.
TIME:
OVEN:
                                                                           3/12/74
C-18
CHARGE
15 SEC.
30 SEC.
45 SEC.

1MIN
1 WIN. 15 SEC.
1 MIN. 30 SEC.

1 MIN. 45 SEC.
2 MIN.

2 MIN. 15 SEC.
2 MIN. 30 SEC.

2 MIN. 45 SEC.
3 MIN.

END OF CHARGE
LID REPLACED
 TOTAL
 CHARGING
 TIME
PUSHER SIDE
1
HOPPER















1:40
DROP
SLEEVE
















CENTER
2
HOPPER/1
STACK

SP



MS









DROP
SLEEVE

M
MF
M
M










CENTER
3
HOPPER/
STACK





MS









DROP
SLEEVE

MF
MF
LJ?
Ft
F









COKE SIDE
4
HOPPER















DROP
SLEEVE




F










f • INCREASING ^ DECREASING -» CHANGING TO
S - STACK HP • HOPPER F - FIRE
                                    L - LIGHT FLOW
                                   BL - BLACK
                                             M - MEDIUM FLOW
                                             Y - YELLOW
         H - HEAVY FLOW
         P • PUFFY
WEATHER:.
                                                    MANUALGAS
REMARKS:.
MCF 2495 12/73
                                               66

-------
                                LARRY CAR OBSERVATION LOG
 COMPANV
   CLANT
 BATTERY
National Steel
Weirton Steel
Brown's Island
       DATE
       TIME
       OVEN
                                                                         3/12/74
2:10
                                                               B-20
 CHARGE

 IS SEC

 30 SEC

 45 SEC

 1 MIN

 1MIN 16 SEC

 1 MIN. 30 SEC

 1 MIN 45 SEC

 2 MIN

 2 MIN 15 SEC.

 2 MIN 30 SEC.

 2 MIN 45 SEC

 3 MIN

 END OF CHARGE

 LID REPLACED
 TOTAL
 CHARGING
 TIME
PUSHER SIDE

HOPPER















1:35
1
DROP
SLEEVE




M










CENTER
2
HOPPER/
STACK





MS









DROP
SLEEVE

M
LF
LF
M
F









CENTER
3
HOPPER/
STACK




LS
MS









DROP
SLEEVE

MF
F
F
L
F









COKE SIDE
4
HOPPER















DROP
SLEEVE















f - INCREASING ^ DECREASING — •> CHANGING TO
S - STACK HP - HOPPER F • FIRE
                                   L - LIGHT FLOW
                                  BL - BLACK
                                             M
                                             Y
MEDIUM FLOW
YELLOW
  H -  HEAVV FLOW
  P •  PUFFY
WEATHER   Pry Bulb 46 RH 702
	Strong North Wind
                                        MANUAL GAS
REMARKS.
 MITRE
MCF 2495 12/73
                                           67

-------
                                LARRY CAR OBSERVATION LOG
COMPANY
   PLANT
BATTERY-
National Steel
Weirton Steel
Brown's Island
DATE:
TIME.
OVEN-
                                                                         3/12/74
                                                              C-20
CHARGE
15 SEC.
30 SEC
45 SEC.
1MIN.
1MIN IS SEC.
1 MIN. 30 SEC.
1 MIN. 45 SEC.
2 MIN.
2 MIN. IS SEC.
2 MIN. 30 SEC.
2 MIN. 4B SEC.
3 MIN.
END OF CHARGE
LID REPLACED
 TOTAL
 CHARGING
 TIME
PUSHER SIDE

HOPPER















1:38
I
DROP
SLEEVE



L











CENTER
2
HOPPER/
STACK





FS









DROP
SLEEVE

fi'II
M
LFt











CENTER
3
HOPPER/
STACK




MS
FS









DROP
SLEEVE

MF
F
Ft











COKE SIDE
4
HOPPER















DROP
SLEEVE















f - INCREASING | DECREASING -» CHANGING TO
S - STACK HP - HOPPER F - FIRE
                                   L -  LIGHT FLOW
                                   BL -  BLACK
                                            M • MEDIUM FLOW
                                            V > YELLOW
         H -  HEAVY FLOW
         P -  PUFFY
WEATHER:.
REMARKS:    MITRE particulate teat run.
                                                  MANUAL GAS
 MITRE
MCF 2495 12/73
                                             68

-------
                                LARRY CAR OBSERVATION LOG
COMPANY
   PLANT
BATTERY
National  Srggl
Weirton Steel
Brown's Island
DATE
 TIME
OVEN
                                                                           3/12/74
2:35
A-22
CHARGE

IS SEC

30 SEC

OS SEC

1MIN

1MIN IS SEC

1MIN 30 SEC

1 MIN 45 SEC

2MIN

2 MIN 15 SEC

2 MIN 30 SEC

2 MIN 45 SEC

3 MIN

END OF CHARGE

LID REPLACED
 TOTAL
 CHARGING
 TIME
PUSHER SIDE
1
HOPPER















1:44
DROP
SLEEVE















CENTER
2
HOPPER/
STACK
SP




MS









DROP
SLEEVE

M
M
M
Mt

F








f - INCREASING
S « STACK
CENTER
3
HOPPER/
STACK





MS









DROP
SLEEVE

M-+LF
LF
FP
MF

F








COKE SIDE
4
HOPPER















DROP
SLEEVE




F

F








^ DECREASING -fr CHANGING TO
HP » HOPPER F • FIRE
                                    L - LIGHT FLOW
                                   BL - BLACK
                                              M  -  MEDIUM FLOW
                                              V  -  YELLOW
         H - HEAVY FLOW
         P - PUFFY
WEATHER .
REMARKS
                                                    MANUAL GAS
 MITRE
MCF 2495 12/73
                                              69

-------
                                LARRY CAR OBSERVATION LOG
COMPANY
   PLANT
BATTERY-
National  Steel
Welrton Steel
Brown's Island
                                                                   DATE  3/12/74
 TIME:
OVEN-
      2:47
B-22
CHARGE

IS SEC.

30 SEC.

45 SEC.

1MIN

1MIN. IS SEC.

1MIN.30SEC.

1 MIN. 43 SEC.

2MIN.

2 MIN. IS SEC.

2 MIN. 30 SEC.

2 MIN. 4S SEC.

3 MIN.

END OF CHARGE

LID REPLACED
 TOTAL
 CHARGING
 TIME
PUSHER SIDE

HOPPER















1:35
L
DROP
SLEEVE

F
FP
LFP
Ft










CENTER
2
HOPPER/
STACK
SP














DROP
SLEEVE

I/+MF
LFP
LFP
L+Ft






•



CENTER
3
HOPPER/
STACK





MS









DROP
SLEEVE

I/+MF
LFP

L+F+ '










COKE SIDE
4
HOPPER





HP P






•


DROP
SLEEVE















f - INCREASING ^ DECREASING -» CHANGING TO
S - STACK HP - HOPPER F - FIRE
                                    L  -  LIGHT FLOW
                                   BL  -  BLACK
                                             M  >  MEDIUM FLOW
                                             Y  -  YELLOW
         H
         P
       HEAVV FLOW
       PUFFY
WEATHER:.
                                                   MANUALGAS
REMARKS..
 MITRE
MCF 2495 12/73
                                             70

-------
                               LARRY CAR OBSERVATION LOG
COMPANY
   PLANT
BATTERY
National Steel
Weirton Steel
Brown's Island
DATE
TIME
OVEN
                                                                         3/12/74
2:58
C-22
CHARGE

IS SEC

30 SEC

«S SEC

1 MIN
1MIN 15 SEC

1MIN 30 SEC

1MIN 45 SEC

2 MIN

2 MIN 15 SEC

2 MIN 30 SEC

2 MIN 45 SEC.

3 MIN

END OF CHARGE

LID REPLACED
 TOTAL
 CHARGING
 TIME
PUSHER SIDE

HOPPER















1:34
1
DROP
SLEEVE















CENTER
2
HOPPER/
STACK
SP




MS+HP









DROP
SLEEVE

M
M
MY
L-+M










CENTER
3
HOPPER/
STACK





MS+HP









DROP
SLEEVE

MF
LF
F
F










COKE SIDE
4
HOPPE R















DROP
SLEEVE















f - INCREASING ^ DECREASING — » CHANGING TO
S ' STACK HP - HOPPER F - FIRE
                                   L - LIGHT FLOW
                                  BL - BLACK
                                             M - MEDIUM FLOW
                                             Y - YELLOW
         H -  HEAVY FLOW
         P -  PUFFY
WEATHER .
REMARKS
                                                  MANUAL GAS
 MITRE
MCF 2495 12/73
                                                                       OBSERVER
                                            71

-------
                                LARRY CAR OBSERVATION LOG
 COMPANY
   PLANT
 BATTERY
          National Steel
          Weirton  Steel
          Brown's  Island
DATE
 TIME:
OVEN
                                                                          3/12/74
3:10
A-24
 CHARGE

 IS SEC.

 30 SEC

 45 SEC.

 1MIN

 1 MIN. IB SEC.

 1MIN.30SEC.

 1 MIN. 45 SEC.

 2 MIN.

 2 MIN. IB SEC.

 2 MIN. 30 SEC.

 2 MIN. 45 SEC.

 3 MIN.

 END OF CHARGE

 LID REPLACED
 TOTAL
 CHARGING
 TIME
PUSHER SIDE

HOPPER















1:30 .
1
DROP
SLEEVE















CENTER
2
HOPPER/
STACK















DROP
SLEEVE















CENTER
3
HOPPER/
STACK















DROP
SLEEVE















COKE SIDE
it
HOPPER















DROP
SLEEVE















f* - INCREASING ^ DECREASING — » CHANGING TO
S - STACK HP - HOPPER F • FIRE
                                   L - LIGHT FLOW
                                  BL - BLACK
                                                       M - MEDIUM FLOW
                                                       Y - YELLOW
         H -  HEAVY FLOW
         P •  PUFFY
WEATHER:-
                                                  MANUAL GAS
                                                               .1 PPM Reading NO? On
                                                               02 Drop Sleeve	
REMARKS.  Routine of larry operator  s*»gma
                                                                 lflrrv gflr
         spot he ha If -     red inm-pa
                                           waiting
 MITRE
MCF 2495 12/73
                                                                       OBSERVER
                                           72

-------
                                LARRY CAR OBSERVATION LOG
           National Steel
 COMPANY 	
   PLANT _
 BATTERY   Brown's  Island
Weirton Steel
DATE
TIME
OVEN
                                                              3/12/7A
                                                              3:28
                                                              B-24
 CHARGE

 IS SEC

 MSEC

 45 SEC

 1MIN

 1MIN 15 SEC

 1MIN 30 SEC

 1IMIN 4BSEC

 2MIN

 2MIN IS SEC

 2MIN 30 SEC.

 2MIN 45 SEC

 3MIN

 END OF CHARGE

 LID REPLACED
 TOTAL
 CHARGING
 TIME
PUSHER SIDE

HOPPER















1:32
1
DROP
SLEEVE



F











CENTER
2
HOPPER/
STACK
LSP




SP









DROP
SLEEVE

LFP
M
L

F









CENTER
3
HOPPER/
STACK





MS









DROP
SLEEVE

M
F
F

F









COKE SIDE
I
HOPPER















.
DROP
SLEEVE

F













f - INCREASING ^ DECREASING — » CHANGING TO
S - STACK HP - HOPPER F - FIRE
                                   L - LIGHT FLOW
                                  BL - BLACK
                                           M - MEDIUM FLOW
                                           V - YELLOW
         H -  HEAVY FLOW
         P -  PUFFY
WEATHER .
                                                  MANUAL GAS
REMARKS  Half damper after charge,  then unlid. then full damper.   Vibrators were
          used as a demonstration  for new larry operator.	
 MITRE
MCF 2495 12/73
                                                                       OBSERVER
                                            73

-------
                               LARRY CAR OBSERVATION LOG
COMPANV

   PLANT

BATTERY
National Steel
Weirton Steel
Brown's Island
DATE
TIME.
OVEN
                                                                         3/12/74
3:38
                                                               C-24
CHARGE

15 SEC

30 SEC

45 SEC

1MIN

1MIN 15 SEC.

1 MIN 30 SEC

1MIN.4SSEC.

ZMIN.

2 MIN 15 SEC.

ZMIN 30SEC.

2 MIN 45 SEC.

3 MIN.

END OF CHARGE

LID REPLACED
 TOTAL
 CHARGING
 TIME
PUSHER SIDE

HOPPER















1:43

1
DROP
SLEEVE















CENTER
2
HOPPER/
STACK
SP




LS
MS








DROP
SLEEVE

M
LPP
LFP
L+FP
L









CENTER
3
HOPPER/
STACK





LS
MS








DROP
SLEEVE

MFP
LFP
LFP
L+FP










COKE SIDE
4
HOPPER















DROP
SLEEVE















f - INCREASING ^ DECREASING -» CHANGING TO
S - STACK HP - HOPPER F - FIRE
L - LIGHT FLOW M - MEDIUM FLOW H - HEAVY FLOW
BL - BLACK V - YELLOW P - PUFFY
WEATHER-.
                                                  MANUAL GAS
                                                               .005% CO at 02 Drop Sleeve
REMARKS  Regular  sequence after charge.  The overall charge looked very good,
          with very  light smoke from the stacks.	
MCF 3495 12/73
                                            74

-------
                               LARRY CAR OBSERVATION LOG
 COMPANY
   PLANT
 BATTERY
National Steel
Weirton Steel
Brown's Island
DATE
 TIME
OVEN
                                                                          3/12/74
3:59
                                                               A-26
 CHARGE

 IS SEC

 30 SEC

 45 SEC

 1MIN

 1MIN 16 SEC

 1MIN 30 SEC

 1 MIN 45 SEC

 2MIN

 2 MIN 16 SEC

 2 MIN 30 SEC.

 2 MIN 45 SEC

 3 MIN

 END OF CHARGE

 LID REPLACED
 TOTAL
 CHARGING
 TIME
PUSHER SIDE

HOPPER















1:35
1
DROP
SLEEVE




H










CENTER
2
HOPPER/
STACK
LSP














DROP
SLEEVE

LF
LFt
L+F











CENTER
3
HOPPER/
STACK




MS










DROP
SLEEVE

LF
LF+
L+F











COKE SIDE
t
HOPPER




L HP P






.



1
DROP
SLEEVE















f - INCREASING ^ DECREASING — *• CHANGING TO
S - STACK HP - HOPPER F - FIRE
                                   L  -  LIGHT FLOW
                                  BL  -  BLACK
                                            M - MEDIUM FLOW
                                            V - YELLOW
         H -  HEAVY FLOW
         P -  PUFFY
WEATHER
                                                  MANUAL GAS
                                                               125  PPM CO  at 02 Drop Sleeve
REMARKS  Normal sequence after charge.  End of charge looked cleaner  than usual.
 MITRE
MCF 2495 12/73
                                             75

-------
                               LARRY CAR OBSERVATION LOG
          National  Steel
          Weirton Steel
 BATTERY   Brown's Island
COMPANY
  PLANT
DATE-
TIME:
OVEN
                                                                         3/12/74
4:32
                                                                         026
CHARGE

15 SEC

30 SEC
45 SEC

1MIN
1MIN 15 SEC

1 MIN. 30 SEC.

1 MIN. 45 SEC.

2 MIN

2 MIN. 15 SEC.
2 MIN. 30 SEC.

2 MIN. 45 SEC.

3 MIN.

END OF CHARGE
LID REPLACED
 TOTAL
 CHARGING
 TIME
PUSHER SIDE

HOPPER















1:40
I
DROP
SLEEVE















CENTER
2
HOPPER/
STACK





MS









DROP
SLEEVE

L
LFF
L+
LF










CENTER
3
HOPPER/
STACK















DROP
SLEEVE

LFP
LFP
u
LF










COKE SIDE
4
HOPPER















DROP
SLEEVE















f - INCREASING ^ DECREASING —*• CHANGING TO
S - STACK HP - HOPPER F - FIRE
                                   L • LIGHT FLOW
                                  BL - BLACK
                                                           MEDIUM FLOW
                                                      Y  -  YELLOW
         H -  HEAVY FLOW
         P -  PUFFY
WEATHER:.
                                                  MANUALGAS
REMARKS: Long wait before charge.  Electrical Department looked over the bottom of
          the car but did nothing.  	
 MITRE
MCF 2495 12/73
                                                                       OBSERVER
                                            76

-------
                               LARRY CAR OBSERVATION LOG
COMPANY
  PLANT
BATTERY
National Steel
Weirton Steel
Brown's Island
DATE
TIME
OVEN
                                                                        3/13/74
5:02
                                                              C-l
CHARGE

15 SEC

30 SEC

45 SEC

1MIN

1 MIN 15 SEC

1MIN 30 SEC.

1 MIN. 45 SEC

2 MIN

2 MIN. IS SEC

2 MIN 30 SEC

2 MIN 45 SEC

3MIN

END OF CHARGE

LID REPLACED
 TOTAL
 CHARGING
 TIME
PUSHER SIDE

HOPPER





MH









1:40
L
DROP
SLEEVE





FL-*I









CENTER
2
HOPPER/
STACK
SP




MS









DROP
SLEEVE

L
L
LFP
LI
M









CENTER
3
HOPPE R/
STACK





MS









DROP
SLEEVE

L
LF
LFP
L4-FP










COKE SIDE
It
HOPPER















DROP
SLEEVE















f - INCREASING | DECREASING -» CHANGING TO
S - STACK HP • HOPPER F - FIRE
                                   L -  LIGHT FLOW
                                  BL -  BLACK
                                            M -  MEDIUM FLOW
                                            Y -  YELLOW
         H •  HEAVY FLOW
         P -  PUFFY
                                                 MANUAL GAS
                                                              .02% CO at 02 Drop  Sleeve
REMARKS  4:10 complete cycle
 MITRE
MCF 2495 12/73
                                             77

-------
                                LARRY CAR OBSERVATION LOG
 COMPANY
   PLANT
 BATTERY
National Steel
Weirton Steel
Brown's Island
DATE
TIME.
OVEN
                                                                         3/15/74
10:25
                                                              A-20
 CHARGE

 IS SEC

 30 SEC

 45 SEC.

 1MIN

 1MIN. IS SEC.

 1MIN.30SEC.

 1 MIN. 45 SEC.

 2MIN

 2 MIN. 15 SEC.

 2 MIN. 30 SEC.

 2 MIN. 45 SEC.

 3 MIN.

 END OF CHARGE

 LID REPLACED
 TOTAL
 CHARGING
 TIME
PUSHER SIDE

HOPPER















1:45
1
DROP
SLEEVE
MF

F
M
M
F









CENTER
2
HOPPER/
STACK




M
Mi









DROP
SLEEVE
M
Mt
U
U
M
L









CENTER
3
HOPPER/
STACK




M
Mt









DROP
SLEEVE

Mt
MF
MF
MfF
F









COKE SIDE
4
HOPPER















DROP
SLEEVE


L
L
L
L









f - INCREASING ^ DECREASING -*• CHANGING TO
S - STACK HP - HOPPER F - FIRE
                                   L - LIGHT FLOW
                                  BL - BLACK
                                            M -  MEDIUM FLOW
                                            Y -  YELLOW
         H •  HEAVY FLOW
         P •  PUFFY
WEATHER .
                                                  MANUALGAS
REMARKS- *" ascension pipe, lid did not come down,  and as a result, the smoke at  the
	drop  sleeves was worse than usual.   Smoke from stacks stopped quicker than
          usual.   Car was run in the manual mode.      	
 MITRE
MCF 2495 12/73
                                                                       OBSERVER
                                            78

-------
                                LARRY CAR OBSERVATION LOG
COMPANY
   PLANT
BATTERV
National  Steel
Weir ton Steel
Brown's Island
DATE
 TIME
OVEN
                                                                          3/15/74
10:55
C-20
CHARGE
15 SEC
30 SEC
45 SEC
1MIN
1MIN 16 SEC
1MIN 30 SEC
1 WIN 45 SEC
2MIN
2MIN IS SEC
2MIN 30 SEC
2 MIN 45 SEC
3IMIN
END OF CHARGE
LID REPLACED
  TOTAL
  CHARGING
  TIME
PUSHER SIDE

HOPPER





M









1:43
1
DROP
SLEEVE




M










CENTER
2
HOPPER/
STACK
SP





SMt








DROP
SLEEVE

FM
FM
FM+
FM
HF+









CENTER
3
HOPPER/
STACK















DROP
SLEEVE

MF
MtF
M+F
LFt
LF
MF








COKE SIDE
4
HOPPE R















DROP
SLEEVE















f - INCREASING | DECREASING -» CHANGING TO
S - STACK HP - HOPPER F - FIRE
                                    L  -  LIGHT FLOW
                                   BL  -  BLACK
                                             M >  MEDIUM FLOW
                                             V -  YELLOW
         H -  HEAVY FLOW
         P -  PUFFY
WEATHER .
REMARKS
                                                   MANUAL GAS
 MITRE
MCF 2495 12/73
                                                                        OBSERVER
                                              79

-------
                                LARRY CAR OBSERVATION LOG
 COMPANY

   PLANT
 BATTERY
National Steel
Weirton Steel
Brown's Island
DATE-
 TIME-
OVEN.
                                                                           3/15/76
11:15
                                                                 A-22
 CHARGE

 IS SEC

 30 SEC.

 45 SEC

 1MIN.

 1 MIN. 16 SEC.

 1 MIN. 30 SEC.

 1 MIN. 45 SEC.

 2 MIN.

 2 MIN 15 SEC.

 2 MIN. 30 SEC.

 2 MIN. 45 SEC.

 3 MIN.

 END OF CHARGE

 LID REPLACED
 TOTAL
 CHARGING
 TIME
PUSHER SIDE
1
HOPPER















1:42

DROP
SLEEVE




L
L
L








CENTER
2
HOPPER/
STACK
MP




M









DROP
SLEEVE

MB
Mt
Ht
Mt
M+
L+








CENTER
3
HOPPER/
STACK





SH
SH








DROP
SLEEVE

MB
Mt
Mt
Mt
M
HY








COKE SIDE
4
HOPPER















DROP
SLEEVE


L
L
L+

L








f • INCREASING | DECREASING -» CHANGING TO
S - STACK HP - HOPPER F - FIRE
L - LIGHT FLOW M - MEDIUM FLOW H - HEAVY FLOW
BL - BLACK Y - YELLOW P - PUFFY
WEATHER.
                                                   MANUAL GAS
REMARKS:.
 MITRE
MCF 2495 12/73
                                                                        OBSERVER
                                             80

-------
                               LARRY CAR OBSERVATION LOG
COMPANY
   PLANT
BATTERY
National Steel
Weirton Steel
Brown's Island
DATE
TIME
OVEN
                                                                         3/15/74
11:30
B-22
CHARGE

IS SEC

30 SEC
 1 MIN

 1MIN 15 SEC

 1MIN 30 SEC

 1 MIN 45 SEC

 2 MIN.

 2 MIN 15 SEC

 2 MIN 30 SEC

 2 MIN 45 SEC

 3 MIN

 END OF CHARGE

 LID REPLACED
 TOTAL
 CHARGING
 TIME
PUSHER SIDE

HOPPER















1:47
L
DROP
SLEEVE




L
U









CENTER
2
HOPPER/
STACK




L
L









DROP
SLEEVE
MF
L


L
Mt









CENTER
3
HOPPER/
STACK




M
M+









DROP
SLEEVE
MF
LF
LFP
Ft
Ft
HF









COKE SIDE
It
HOPPER















DROP
SLEEVE
LF
F
LP
Ft
LFP
FL+









f • INCREASING 4 DECREASING -» CHANGING TO
S - STACK HP - HOPPER F - FIRE
                                   L -  LIGHT FLOW
                                  BL -  BLACK
                                            M - MEDIUM FLOW
                                            Y - YELLOW
         H -  HEAVY FLOW
         P -  PUFFY
WEATHER
                                                 MANUALGAS
REMARKS  MITRE particulate test run.  Heavy fire on Number 3 Drop Sleeve
 MITRE
MCF 2495 12/73
                                            81

-------
                                 LARRY CAR OBSERVATION LOG
 COMPANY
   PLANT
 BATTERY
National  Steel
Weirton Steel
Brown's Island
DATE:
 TIME-
OVEN:
                                                                             3/15/74
11:40
                                                                  C-22
 CHARGE

 15 SEC

 30 SEC.

 45 SEC.

 1MIN

 1MIN  IS SEC.

 1MIN 30 SEC.

 1 MIN. 45 SEC.

 2MIN.

 2 MIN.  15 SEC.

 2 MIN. 30 SEC.

 2 MIN. 45 SEC.

 3 MIN.

 END OF CHARGE

 LID REPLACED
 TOTAL
 CHARGING
 TIME
PUSHER SIDE

HOPPER















1:37
1
DROP
SLEEVE





L
L








CENTER
2
HOPPER/
STACK
HP




M
M








DROP
SLEEVE

MB
MtH
M
L
M
F








CENTER
3
HOPPER/
STACK





M
M








DROP
SLEEVE

MBF
MF
LF
Ft
M









COKE SIDE
4
HOPPER















DROP
SLEEVE

FP
F

F
FL









f - INCREASING | DECREASING -» CHANGING TO
S - STACK HP - HOPPER F - FIRE
                                    L - LIGHT FLOW
                                   BL - BLACK
                                             M - MEDIUM FLOW
                                             V - YELLOW
         H • HEAVY FLOW
         P - PUFFY
WEATHER.
                                                   MANUAL GAS
REMARKS:.
MCF 2495 12/73
                                                                         OBSERVER
                                              82

-------
                               LARRY CAR OBSERVATION LOG
COMPANY

   PLANT

BATTERY
National Steel
Weirton Steel
Brown's Island
DATE
 TIME
OVEN
                                                                         3/15/74
11:52
A-24
CHARGE

IS SEC

30 SEC

45 SEC

1MIN

1MIN 15 SEC

1MIN 30 SEC.

1MIN 45 SEC

2MIN

2MIN IS SEC

2MIN 30 SEC.

2MIN 4SSEC

3MIN

END OF CHARGE

LID REPLACED
 TOTAL
 CHARGING
 TIME
PUSHER SIDE

HOPPER



P











1:38
L
DROP
SLEEVE





L










CENTER
2
HOPPER/
STACK
SUP




LS









DROP
SLEEVE


MB
L
Mt
FL









CENTER
3
HOPPER/
STACK




MS
MS









DROP
SLEEVE

FLB
FL
LFP
F

MF








COKE SIDE
4
HOPPER




P










DROP
SLEEVE





Lt









f • INCREASING ^ DECREASING -» CHANGING TO
S - STACK HP • HOPPER F - FIRE
                                   L - LIGHT FLOW
                                  BL - BLACK
                                            M -  MEDIUM FLOW
                                            V -  YELLOW
         H -  HEAVY FLOW
         P •  PUFFY
WEATHER .
                                                  MANUAL GAS
REMARKS.
 MITRE
MCF 2495 12/73
                                            83

-------
                                LARRY CAR OBSERVATION LOG
COMPANV    National Steel
   PLANT.   Welrton Steel
BATTERY.   Brown's Island
           DATE-
            TIME:
           OVEN
                   3/15/74
12:10
B-24
CHARGE

IS SEC

30 SEC

45 SEC

1 MIN

1MIN IS SEC.

1 MIN. 30 SEC.

1 MIN. 45 SEC.

2 MIN.

2 MIN. 15 SEC.

2 MIN. 30 SEC.

2 MIN. 45 SEC.

3 MIN.

END OF CHARGE

LID REPLACED
 TOTAL
 CHARGING
 TIME
PUSHER SIDE

HOPPER















1:38
1
DROP
SLEEVE

F













CENTER
2
HOPPER/
STACK
LSP




SM+
SM+








DROP
SLEEVE

FM
H
FM
M+
M









CENTER
3
HOPPE n/
STACK





SM+
SM








DROP
SLEEVE

Mt

HY
M+
M









COKE SIDE
4
HOPPER















DROP
SLEEVE




M
L









T - INCREASING ^ DECREASING — * CHANGING TO
S - STACK HP - HOPPER F - FIRE
                                    L -  LIGHT FLOW
                                   BL -  BLACK
M - MEDIUM FLOW
V - VELLOW
 H - HEAVY FLOW
 P - PUFFY
WEATHER:.
                                                   MANUAL GAS
REMARKS:.
 Mr
MCF 2495 12/73
                                              84

-------
                           LARRY CAR OBSERVATION LOG
COMPANY

  PLANT
BATTERV
National Steel
Weirton Steel
Brown's Island
DATE

TIME
OVEN
                                                              3/15/74
12:21
                                                     C-24
CHARGE

IS SEC

30 SEC

45 SEC

1MIN

1MIN 15 SEC

1MIN 30 SEC

1 MIN 45 SEC

2MIN

2 MIN IS SEC

2 MIN 30 SEC.

2 MIN 45 SEC

3 MIN

END OF CHARGE

LID REPLACED
 TOTAL
 CHARGING
 TIME
PUSHER SIDE
1
HOPPER















1:38

DROP
SLEEVE





L









CENTER
2
HOPPER/
STACK
SP



M+
H









DROP
SLEEVE

MF
MF
LF
M
H









CENTER
3
HOPPER/
STACK




M+HP










DROP
SLEEVE

MF
MF
LF
MF
F









COKE SIDE
4
HOPPER





P









DROP
SLEEVE




L
L









f • INCREASING | DECREASING -» CHANGING TO
S • STACK HP - HOPPER F • FIRE
L - LIGHT FLOW M - MEDIUM FLOW H - HEAVY FLOW
BL - BLACK Y • YELLOW P • PUFFY
WEATHER.
REMARKS  MITRE Particulate Test Run
                                           MANUAL GAS
 MITRE
MCF 2495 17/73
                                             SWir
                                      85

-------
                                LARRY CAR OBSERVATION LOG
COMPANY-
   PLANT
BATTERY
National  Steel
Weirton Steel
Brown's Island
                                                                   DATE  3/15/74
       12:39
 TIME-
OVEN:  A"26
CHARGE

IS SEC

30 SEC.

45 SEC

1 MIN.

1 MIN. IS SEC.

1 MIN. 30 SEC.

1 MIN. 45 SEC.

2 MIN.

2 MIN. IB SEC.

2 MIN. 30 SEC.

2 MIN 45 SEC.

3 MIN.

END OF CHARGE

LID REPLACED
 TOTAL
 CHARGING
 TIME
PUSHER SIDE

HOPPER






Ht








1:39
I
DROP
SLEEVE



L
L










CENTER
2
HOPPER/
STACK
SP





SM








DROP
SLEEVE

M+
M
M
M
MY
L








f - INCREASING
S - STACK
CENTER
3
HOPPER/
STACK






SM








DROP
SLEEVE

M+
fr^H
H
H '
MY
L








COKE SIDE
4
HOPPER












•


DROP
SLEEVE






L








| DECREASING -» CHANGING TO
HP - HOPPER F - FIRE
                                    L •  LIGHT FLOW
                                   BL -  BLACK
                                             M -  MEDIUM FLOW
                                             V -  YELLOW
         H - HEAVY FLOW
         P - PUFFY
WEATHER-.
                                                   MANUAL GAS
REMARKS:.
 MITRE
MCF 249512/73
                                                                        OBSERVER
                                             86

-------
                                 LARRY CAR OBSERVATION LOG
 COMPANY
   PLANT
 BATTERY
National Steel
Weirton Steel
Brown's Island
DATE
TIME
OVEN
                                                                          3/15/74
12:54
                                                               B-26
 CHARGE

 15 SEC

 30 SEC

 45 SEC

 1 MIN

 1MIN IS SEC

 1MIN 30 SEC

 1 MIN 45 SEC.

 2 MIN

 2 MIN IS SEC

 2 MIN 30 SEC.

 2 MIN 45 SEC

 3 MIN

 END OF CHARGE

 LID REPLACED
 TOTAL
 CHARGING
 TIME
PUSHER SIDE
1
HOPPER















1:40
DROP
SLEEVE

F
FP












CENTER
2
HOPPER/
STACK
LSP




MS
M+








DROP
SLEEVE

M
M
Mt
F

F








CENTER
3
HOPPER/
STACK





MSt
M








DROP
SLEEVE

LF
LF
F
FP

F








COKE SIDE
4
HOPPER





HP P









DROP
SLEEVE















f - INCREASING ^ DECREASING -» CHANGING TO
S - STACK HP - HOPPER F - FIRE
                                    L - LIGHT FLOW
                                   BL - BLACK
                                             M -  MEDIUM FLOW
                                             V -  YELLOW
         H -  HEAVY FLOW
         P -  PUFFY
WEATHER ,
                                                   MANUAL GAS
REMARKS   Patching door jam.
MCF 2495 12/73
                                              87

-------
                               LARRY CAR OBSERVATION LOG
          National  Steel
          Weirton Steel
COMPANY .
  PLANT _
BATTERY.   Brown's Island
DATE.   3/15/7A
TIME-   1:36
OVEN.
 CHARGE

 15 SEC

 30 SEC.

 45 SEC

 1MIN.

 1MIN IB SEC

 1MIN.30SEC

 1 MIN. 45 SEC.

 2MIN.

 2 MIN. IB SEC.

 2 MIN. 30 SEC.

 2 MIN 45 SEC.

 3 MIN.

 END OF CHARGE

 LID REPLACED
 TOTAL
 CHARGING
 TIME
PUSHER SIDE

HOPPER















1:37

I
DROP
SLEEVE





F









CENTER
2
HOPPER/
STACK
LSF




LS









DROP
SLEEVE

L
LPF
L

L
L








CENTER
3
HOPPER/
STACK





MtS









DROP
SLEEVE

MF
LPF
LF
F
L
L








COKE SIDE
4
HOPPER















DROP
SLEEVE















f - INCREASING | DECREASING -» CHANGING TO
S - STACK HP - HOPPER F - FIRE
L - LIGHT FLOW M - MEDIUM FLOW H - HEAVV FLOW
BL - BLACK V - VELLOW P - PUFFY
WEATHER:.
                                                  MANUAL GAS
REMARKS-  Very clean  charge..   Good coordination demonstrated  between larry car and
	pusher  car.   Leveling bar went in on signal from  larry car.	
 MITRE
MCP 2499 12/73
                                                                      OBSERVER
                                            88

-------
                               LARRY CAR OBSERVATION LOG
           National Steel
 COMPANY
   PLANT
 BATTERY     Brown's Island
Weirton Steel
                                                                        3/15/74
DATE .
TIME .
OVEN  A-28
1:52
 CHARGE
 IS SEC
 MSEC
 45 SEC

 1MIN
 1 MIN 16 SEC

 1MIN.30SEC

 1 MIN 45 SEC.
 2 MIN

 2 MIN IB SEC
 2 MIN 30 SEC.

 2 MIN 45 SEC
 3 MIN

 END OF CHARGE
 LID REPLACED
 TOTAL
 CHARGING
 TIME
PUSHER SIDE

HOPPER















1:33
1
DROP
SLEEVE















CENTER
2
HOPPER/
STACK



L
L
L









DROP
SLEEVE

L













CENTER
3
HOPPER/
STACK




M
Li









DROP
SLEEVE

LF
FP
FL
FL
L









COKE SIDE
4
HOPPER















DROP
SLEEVE















V • INCREASING | DECREASING -» CHANGING TO
S - STACK HP - HOPPER F • FIRE
                                   L - LIGHT FLOW
                                  BL • BLACK
                                           M - MEDIUM FLOW
                                           V - YELLOW
         H -  HEAVY FLOW
         P •  PUFFY
WEATHER .
                                                  MANUAL GAS
REMARKS  Very good  charge
 MITRE
MCF 2495 12/73
                                            89

-------
                               LARRY CAR OBSERVATION LOG
COMPANY   national  Steel
   PLANT   Weir ton Steel
BATTERY   Brown's Island
           DATE:   3/26/74
                  9:58
            TIME:
           OVEN-  B-9
CHARGE

IS SEC

30 SEC.

45 SEC

1MIN

1MIN IS SEC.

1 MIN. 30 SEC.

1 MIN. 45 SEC.

2 MIN.

2 MIN. IB SEC.

2 MIN. 30 SEC.

2 MIN. 45 SEC.

3 MIN.

END OF CHARGE

LID REPLACED
 TOTAL
 CHARGING
 TIME
PUSHER SIDE

HOPPER





M









1:40
I
DROP
SLEEVE





F










CENTER
2
HOPPER/
STACK
LSP




MSMHP









DROP
SLEEVE

LFP
LF+












CENTER
3
HOPPER/
STACK





MS









DROP
SLEEVE
LFP
LF+



F









COKE SIDE
4
HOPPER















DROP
SLEEVE





F









f - INCREASING ^ DECREASING — ^ CHANGING TO
S - STACK HP - HOPPER F - FIRE
                                   L - LIGHT FLOW
                                  BL - BLACK
M - MEDIUM FLOW
Y - YELLOW
H - HEAVY FLOW
P - PUFFY
WEATHER-.
                                                  MANUAL GAS
REMARKS: Fairly clean charge.  Very little smoke during middle of  charge.  Hopper
          smoke.                                             	
 MITRE
MCF 2495 12/73
                                                                       OBSERVER
                                             90

-------
                                LARRY CAR OBSERVATION LOG
COMPANY
   PLANT
 BATTERY
National Steel
Weirton Steel
Brown's Island
DATE   3/26/74
       10:08
 TIME
OVEN
C-9
CHARGE
15 SEC
30 SEC
45 SEC

1MIN
1 MIN 15 SEC

1 MIN 30 SEC

1MIN 45 SEC
2 MIN.

2 MIN. 15 SEC
2 MIN 30 SEC

2 MIN. 45 SEC

3 MIN

END OF CHARGE
LID REPLACED
 TOTAL
 CHARGING
 TIME
PUSHER SIDE

HOPPER















1:40
I
DROP
SLEEVE















CENTER
2
HOPPE R/
STACK
LSP




MS









DROP
SLEEVE

LFP
LtFP
L4-

F4-









7 - INCREASING
S - STACK
CENTER
3
HOPPER/
STACK





MS









DROP
SLEEVE

FP
FP
FP

F+









COKE SIDE
4
HOPPER















DROP
SLEEVE















^ DECREASING — ^ CHANGING TO
HP - HOPPER F - FIRE
                                    L -  LIGHT FLOW
                                   BL -  BLACK
                                             M - MEDIUM FLOW
                                             Y - YELLOW
         H -  HEAVY FLOW
         P -  PUFFY
WEATHER.
                                                  MANUAL GAS
REMARKS
En<*
                  charge was very  clean,  with very little  smoke around drop
          sleeves.   Stack smoke was  unusually light.
MCF 2495 12/73
                                                                       OBSERVER
                                             91

-------
                                LARRY CAR OBSERVATION LOG
          National  Steel
COMPANY. .
   PLANT .
BATTERY  Brown's  Island
Weirton Steel
DATE-
TIME-
OVEN
                                                                         3/26/76
10; 23
                                                              A-ll
CHARGE

15 SEC.

30 SEC.

45 SEC

1MIN

1 MIN. IS SEC.

1MIN.30SEC.

1 MIN. 45 SEC.

2 MIN.

2 MIN. 16 SEC.

2 MIN. 30 SEC.

2 MIN. 45 SEC.

3 MIN.

END OF CHARGE

LID REPLACED
 TOTAL
 CHARGING
 TIME
PUSHER SIDE
1
HOPPER






L








1:40
DROP
SLEEVE





F









CENTER
2
HOPPER/
STACK
HSP




MSt
LHP








DROP
SLEEVE

MF
M+FP
MF
LF+
F









CENTER
3
HOPPER/
STACK





MSt
LHP








DROP
SLEEVE

MF
M+FP
MF
LF+
F









COKE SIDE
4
HOPPER















DROP
SLEEVE















f - INCREASING | DECREASING -» CHANGING TO
S - STACK HP - HOPPER F - FIRE
                                   L - LIGHT FLOW
                                   BL - BLACK
                                             M - MEDIUM FLOW
                                             V - VELLOW
         H -  HEAVV FLOW
         P •  PUFFY
WEATHER..
                                                  MANUAL GAS
REMARKS: MITRE particulate- test run.   End of charge had more smoke than usual.
 MITRE
MCF 2495 12/73
                                                    /Mr

-------
                               LARRY CAR OBSERVATION LOG
 COMPANY
   PLANT
 BATTERY
National Steel
Weirton Steel
Brown's Island
DATE
TIME
OVEN
                                                                       3/26/74
10:45
                                                             B-ll
 CHARGE

 15 SEC

 30 SEC

 4SSEC

 1MIN

 1MIN 15 SEC

 1 MIN. 30 SEC

 1 MIN 45 SEC

 2 MIN

 2 MIN. 15 SEC.

 2 MIN 30 SEC

 2 MIN. 45 SEC

 3 MIN

 END OF CHARGE

 LID REPLACED
 TOTAL
 CHARGING
 TIME
PUSHER SIDE

HOPPER















1:40
1
DROP
SLEEVE





F









CENTER
2
HOPPER/
STACK
LSP




MS









DROP
SLEEVE

LFP
LFP
FP

F









CENTER
3
HOPPER/
STACK





MS









DROP
SLEEVE

FP
LFP
FP

F









COKE SIDE
4
HOPPER















DROP
SLEEVE





F









f • INCREASING | DECREASING -» CHANGING TO
S • STACK HP - HOPPER F • FIRE
                                   L  -  LIGHT FLOW
                                  BL  •  BLACK
                                            M - MEDIUM FLOW
                                            Y • YELLOW
         H -  HEAVY FLOW
         P •  PUFFY
WEATHER.
                                                 MANUAL GAS
REMARKS  Lid lifter  on Number 4 drop sleeve did not operate,  the lid was  removed
	manually^ Ji₯the li.dman«  A one minute IQSS IB rgaUgpd if  lid—lifter	
          doesn't work.   Relidding operation was normal.
 MITRE
MCF 2495 12/73
                                            93

-------
                                LARRY CAR OBSERVATION LOG
COMPANY   Maflnnni  fit-gel
   PLANT   Weirton Steel
BATTERY   Brown's Island
           DATE.  3/26/74
 TIME.
OVEN-
                  10:54
                  Oil
 CHARGE

 15 SEC.

 30 SEC.

 45 SEC

 1MIN.

 1 MIN. 15 SEC.

 1MIN.30SEC

 1 MIN 45 SEC.

 2 MIN.

 2 MIN. 15 SEC.

 2 MIN. 30 SEC.

 2 MIN. 45 SEC.

 3 MIN.

 END OF CHARGE

 LID REPLACED
 TOTAL
 CHARGING
 TIME
PUSHER SIDE
1
HOPPER





LHP









Not
Recorded
DROP
SLEEVE





F









CENTER
2
HOPPER/
STACK
MSP




LHPMS









DROP
SLEEVE

L+FP
LFP

LFP










CENTER
3
HOPPER/
STACK





MS









DROP
SLEEVE

L+FP
LFP

LFP
F









COKE SIDE
4
HOPPER







i







DROP
SLEEVE















f - INCREASING | DECREASING -fr CHANGING TO
S • STACK HP - HOPPER F - FIRE
                                   L - LIGHT FLOW
                                  BL - BLACK
M - MEDIUM FLOW
Y - YELLOW
         H -  HEAVY FLOW
         P -  PUFFY
WEATHER:.
                                                  MANUAL GAS
R EM ARKS: Takes  approximately 15—20 seconds  to move off spot, check lids, and
          re-spot.   Smoke was heavier  than usual on mnnhor two stack.	
 MITRE
MCF 2495 12/73
                                                                       OBSERVER
                                              94

-------
                               LARRY CAR OBSERVATION LOG
          Nat-lnnal Stgel
COMPANY
   PLANT
BATTERY   Brown's Island
Weirton Steel
DATE  3/26/74
TIME
OVEN
                                                             11:07
                                                             A-13
CHARGE
IS SEC
MSEC
45 SEC

1MIN
1MIN IS SEC
1 WIN. 30 SEC.

1 MIN 45 SEC
2MIN

2 MIN 15 SEC
2 MIN 30 SEC.

2 MIN. 45 SEC
3 MIN.

END OF CHARGE
LID REPLACED
 TOTAL
 CHARGING
 TIME
PUSHER SIDE

HOPPER















1:38
L
DROP
SLEEVi

FP
F

F










CENTER
2
HOPPER/
STACK
HSP



MS










DROP
SLEEVE

MFP
MF
MF
F
F









CENTER
3
HOPPER/
STACK




MS










DROP
SLEEVE

FP
F
F
F
F









COKE SIDE
It
HOPPER















DROP
SLEEVE















f - INCREASING ^ DECREASING — * CHANGING TO
S - STACK HP - HOPPER F - FIRE
                                   L -  LIGHT FLOW
                                  BL -  BLACK
                                            M -  MEDIUM FLOW
                                            Y -  YELLOW
         H -  HEAVY FLOW
         P -  PUFFY
WEATHER .
                                                  MANUAL GAS
REMARKS  Lid operation satisfactory, larrv car appeared to be mis-spotted.
 MITRE
MCF 2495 12/73
                                            95

-------
                                LARRY CAR OBSERVATION LOG
 COMPANY-
   PLANT
 BATTERY-
National Steel
Weirton Steel
Brown's Island
           DATE  3/26/74
            TIME:
                 11:20
           OVEN:  B-13
 CHARGE

 15 SEC.

 30 SEC.

 45 SEC.

 1MIN.

 1 MIN IS SEC.

 1 MIN. 30 SEC.

 1 MIN. 45 SEC.

 2 MIN.

 2 MIN 15 SEC.

 2 MIN. 30 SEC.

 2 MIN. 45 SEC.

 3 MIN.

 END OF CHARGE

 LID REPLACED
 TOTAL
 CHARGING
 TIME
PUSHER SIDE

HOPPER















1:45
1
DROP
SLEEVE















CENTER
2
HOPPER/
STACK
MSP




MSt









DROP
SLEEVE

MF
LFP
L+FT

M









CENTER
3
HOPPER/
STACK





MSt









DROP
SLEEVE

MF
LFP
L+FT


F








COKE SIDE
4
HOPPER















DROP
SLEEVE •















f - INCREASING ^ DECREASING -> CHANGING TO
S - STACK HP - HOPPER F - FIRE
                                   L - LIGHT FLOW
                                  BL - BLACK
M > MEDIUM FLOW
Y - YELLOW
                                                                H - HEAVY FLOW
                                                                P - PUFFY
WEATHER:.
                                                  MANUAL GAS
REMARKS. MITRE particulate test run.  Charge looked fairly clean.  Light  flow from
          stacks.   Number two drop sleeve seemed to hold a negative pressure  for
          most of the charge.
 MITRE
MCF 2495 12/73
                                                                       OBSERVER
                                            96

-------
                               LARRY CAR OBSERVATION LOG
COMPANY
   PLANT
BATTERY
National Steel
Weirton Steel
Brown's Island
                                                                  DATE  3/26/74
 TIME
OVEN  C-13
CHARGE

15 SEC

30 SEC

45 SEC

1MIN

1MIN 15 SEC

1 MIN 30 SEC

1 MIN 45 SEC

2 MIN

2 MIN IS SEC

2 MIN 30 SEC

2 MIN. 45 SEC

3 MIN"

END OF CHARGE

LID REPLACED
 TOTAL
 CHARGING
 TIME
PUSHER SIDE
1
HOPPER















1:45
DROP
SLEEVE















CENTER
2
HOPPER/
STACK
LSP




MS









DROP
SLEEVE

M
M
LET
HYP










CENTER
3
HOPPER/
STACK





MS









DROP
SLEEVE

M
M
LFP











COKE SIDE
4
HOPPER















DROP
SLEEVE















f - INCREASING | DECREASING -» CHANGING TO
S - STACK HP - HOPPER F - FIRE
                                   L - LIGHT FLOW
                                  BL - BLACK
                                            M  -  MEDIUM FLOW
                                            Y  -  YELLOW
         H -  HEAVY FLOW
         P -  PUFFY
WEATHER .
                                                  MANUAL GAS
REMARKS  Lid  lifter  operation satisfactory, but larry man checked lids.  Car re-
	spotted  poorly,  drop sleeves misaligned.   Poor seal on number one drop
	sleeve appeared  to have caused poor suction on number one and two ports.
                                             97

-------
                                LARRY CAR OBSERVATION LOG
 COMPANY

   PLANT

 BATTERY
National  Steel
Weirton Steel
Brown's Island
DATE.  3/26/74
      i i .. eo
TIME:
                                                                  OVEN:
                                                              A-15
 CHARGE

 15 SEC


 30 SEC.

 45 SEC.


 1MIN

 1 MIN. 15 SEC.

 1 MIN. 30 SEC.


 1 MIN. 45 SEC.

 2 MIN.


 2 MIN. 15 SEC.

 2 MIN. 30 SEC.

 2 MIN. 45 SEC.

 3 MIN.


 END OF CHARGE

 LID REPLACED

 TOTAL
 CHARGING
 TIME
PUSHER SIDE

HOPPER















1:40
1
DROP
SLEEVE

MF
F

LF










CENTER
2
HOPPER/
STACK
MSP














DROP
SLEEVE

MF
MF
M
LF
F









CENTER
3
HOPPER/
STACK





MS









DROP
SLEEVE

MF
MF
M
LF
F









COKE SIDE
4
HOPPER















DROP
SLEEVE

MF
FP


F









f - INCREASING 4 DECREASING -» CHANGING TO
S - STACK HP - HOPPER F - FIRE
                                   L - LIGHT FLOW

                                  BL - BLACK
                                             M - MEDIUM FLOW

                                             V - YELLOW
        H - HEAVY FLOW

        P • PUFFY
WEATHER:.
                                                  MANUAL GAS
REMARKS: Ascension pipe lid did not  come down in the automatic cycle, closed

	manually bv lid man.  nils  caused a delay of about  one minute.- Car
           leaked badly around all sleeves.
                                             98

-------
                                LARRY CAR OBSERVATION LOG
 COMPANY  National Steel
   PLANT  Weir ton Steel
 BATTERV  Brown's Island
           DATE   3/26/7A
            TIME   1;24
           OVEN   A-19
 CHARGE

 15 SEC

 3O SEC

 45 SEC.

 1MIN

 1MIN 15 SEC

 1MIN 30 SEC

 1MIN 45 SEC

 2MIN.

 2MIN 16 SEC

 2 MIN. 30 SEC

 2MIN.45SEC

 3 MIN

 END OF CHARGE

 LID REPLACED
 TOTAL
 CHARGING
 TIME
PUSHER SIDE

HOPPER





L









1:38
1
DROP
SLEEVE















CENTER
2
HOPPER/
STACK
MS














DROP
SLEEVE

LFP
L+FP

L+FP
L+F









CENTER
3
HOPPER/
STACK















DROP
SLEEVE

LFP
L+FP

L+FP
MtF









COKE SIDE
4
HOPPER















DROP
SLEEVE















f - INCREASING | DECREASING -» CHANGING TO
S - STACK HP • HOPPER F • FIRE
                                   L - LIGHT FLOW
                                  BL - BLACK
M • MEDIUM FLOW
Y - YELLOW
H • HEAVY FLOW
P • PUFFY
WEATHER .
REMARKS.
                                                  MANUAL GAS
 \TTTRE
MCF 2495 12/73
                                            99

-------
                               LARRY CAR OBSERVATION LOG
          National Steel
COMPANY
   PLANT.
BATTERv   Brown's Island
Weirton Steel
                                                       DATE:  3/26/74
                                                        TIME:
                                                       OVEN:  B-19
CHARGE

15 SEC

30 SEC.

45 SEC.

1MIN.

1 MIN. IB SEC.

1 MIN. 30 SEC.

1 MIN. 45 SEC.

2 MIN.

2 MIN. IB SEC.

2 MIN. 30 SEC.

2 MIN. 45 SEC.

3 MIN.

END OF CHARGE

LID REPLACED
 TOTAL
 CHARGING
 TIME
PUSHER SIDE

HOPPER















1:40

I
DROP
SLEEVE

F
P
F












CENTER
2
HOPPER/
STACK
LPS



MS










DROP
SLEEVE

L+F
LF
LF
F










CENTER
3
HOPPER/
STACK




115










DROP
SLEEVE

L+F
LF
LF
F










COKE SIDE
4
HOPPER















DROP
SLEEVE

F

F











f - INCREASING | DECREASING -» CHANGING TO
S - STACK HP - HOPPER F • FIRE
L - LIGHT FLOW M - MEDIUM FLOW H - HEAVY FLOW
BL - BLACK V - YELLOW P - PUFFY
WEATHER:.
                                                  MANUALGAS
REMARKS:
Larry car appeared  to be misaligned on the charging ports.  A lot of smoke
and fire at  the beginning of the charge.  Drop sleeves were tilted.
two and .number four lids were cocked and burning.	
                                                                                 Number
 MITRE
MCF 2495 12/73
                                                                      OBSERVER
                                            100

-------
                               LARRY CAR OBSERVATION LOG
COMPANY
   PLANT
BATTERV
National Steel
Weirton Steel
Brown's Island
DATE  3/26/74
TIME  1:54
OVEN  C-19
CHARGE

IS SEC

30 SEC

45 SEC

1MIN

1MIN IS SEC

1MIN 30 SEC

1 MIN 45 SEC

2MIN

2 MIN 15 SEC

2 MIN 30 SEC

2 MIN 46 SEC

3 MIN

END OF CHARGE

LID REPLACED
 TOTAL
 CHARGING
 TIME
PUSHER SIDE

HOPPER















1:43
I
DROP
SLEEVE

MtF
F

F4-
M
F








CENTER
2
HOPPER/
STACK
MSP














DROP
SLEEVE

M+F
MF
L+F
F+
LF









CENTER
3
HOPPER/
STACK















DROP
SLEEVE

M+F
MF
L+F
F+
LF









COKE SIDE
4
HOPPER















DROP
SLEEVE





H
F








f - INCREASING | DECREASING -» CHANGING TO
S • STACK HP - HOPPER F • FIRE
                                   L  -  LIGHT FLOW
                                  BL  -  BLACK
                                            M - MEDIUM FLOW
                                            V - YELLOW
        H - HEAVV FLOW
        P - PUFFY
WEATHER .
                                                 MANUAL GAS
REMARKS  Number one  and  four  drop sleeves had heavy smoke.  Car was spotted okay.
 MITRE
MCF 2495 13/73
                                             101

-------
                               LARRY CAR OBSERVATION LOG
          National  Steel
 COMPANY-
   PLANT
 BATTERY   Brown's  Island
Weirton Steel
DATE:
TIME:
OVEN-
                                                             3/26/74
                                                             2:18
                                                             A-21
 CHARGE
 15 SEC.
 30 SEC.
 45 SEC
 1MIN.
 1 MIN. IB SEC
 1 MIN. 30 SEC.
 1 MIN. 45 SEC.
 2 MIN.
 2 MIN. 15 SEC.
 2 MIN. 30 SEC.
 2 MIN 45 SEC.
 3 MIN.
 END OF CHARGE
 LID REPLACED
 TOTAL
 CHARGING
 TIME
PUSHER SIDE

HOPPER















1:38

1
DROP
SLEEVE

Ft
FP












CENTER
2
HOPPER/
STACK
HSP



MS










DROP
SLEEVE
HP
FP
MF
LF
F










CENTER
3
HOPPER/
STACK




MS










DROP
SLEEVE
HP
FP
MF
LF .
F










COKE SIDE
4
HOPPER















DROP
SLEEVE




F










f - INCREASING | DECREASING -» CHANGING TO
S - STACK HP - HOPPER F - FIRE
L - LIGHT FLOW M - MEDIUM FLOW H - HEAVY FLOW
BL - BLACK Y - YELLOW P • PUFFY
WEATHER-
                                                  MANUAL GAS
REMARKS:  MITRE particulate test run.  Operation was ahead of  schedule and larry
	    car was detained in coal bin.       	
 MITRE
MCF 2495 12/73
                                                                       IBSERVER
                                            102

-------
                               LARRY CAR OBSERVATION LOG
COMPANY
   PLANT
BATTERY
NaMnnal Sfpgl
Weirton Steel
Brown's Island
DATE
TIME
OVEN
                                                                        3/26/74
3:09
                                                              A-23
CHARGE

15 SEC

30 SEC

45 SEC

1MIN

1 MIN 15 SEC

1MIN. 30 SEC

1 MIN 45 SEC

2 MIN

2 MIN 15 SEC

2 MIN 30 SEC

2 MIN 45 SEC

3 MIN

END OF CHARGE

LID REPLACED
 TOTAL
 CHARGING
 TIME
PUSHER SIDE

HOPPER




M










1:40
1
DROP
SLEEVE

MF
MF
M+FP











CENTER
2
HOPPER/
STACK
HPP



MS










DROP
SLEEVE

MF
MF
M+P
FP
F









CENTER
3
HOPPER/
STACK




MS










DROP
SLEEVE

MF
MF
MIP
F
F









COKE SIDE
4
HOPPER















DROP
SLEEVE















f - INCREASING ^ DECREASING -» CHANGING TO
S - STACK HP - HOPPER f - FIRE
                                   L - LIGHT FLOW
                                  BL - BLACK
                                            M - MEDIUM FLOW
                                            Y - YELLOW
         H -  HEAVY FLOW
         P -  PUFFY
WEATHER .
                                                  MANUAL GAS
REMARKS  Heavy  smoke at start of charge,  car  appeared to be properly spotted.
	More smoke from drop sleeves than  usual.	
 MITRE
MCF 2195 12/73
                                             103

-------
                                LARRY CAR OBSERVATION LOG
          national Steel
 COMPANY .
   PLANT -
 BATTERY-  Brown's Island
Weirton Steel
DATE:  3/26/74
TIME:  3;20
                                                        OVEN:  B-23
 CHARGE

 15 SEC.

 30 SEC.

 45 SEC.

 1MIN

 1 MIN. 16 SEC.

 1 MIN. 30 SEC.

 1MIN 48 SEC.

 2 MIN.

 2 MIN. IB SEC.

 2 MIN 30 SEC.

 2 MIN. 45 SEC.

 3 MIN.

 END OF CHARGE

 LID REPLACED
 TOTAL
 CHARGING
 TIME
PUSHER SIDE

HOPPER















1:41
I
DROP
SLEEVE

MFP+













CENTER
2
HOPPER/
STACK
LFS




MS









DROP
SLEEVE

NF
UP
FP
LFP
F







•

CENTER
3
HOPPER/
STACK





MS









DROP
SLEEVE

MF
L+F
FP
LFP
F









COKE SIDE
4
HOPPER
i














DROP
SLEEVE





F









f - INCREASING ^ DECREASING -» CHANGING TO
S - STACK HP - HOPPER F • FIRE
                                   L - LIGHT FLOW
                                  BL - BLACK
                                             M • MEDIUM FLOW
                                             V - YELLOW
        H - HEAVY FLOW
        P • PUFFY
WEATHER .
                                                  MANUAL GAS
REMARKS: Larry operator is- still checking to make sure lids are off.   Car
          appears to be off soot, sleeves are tilted.	
 MITRE
MCF 2493 12/73
                                                                       OBSERVER
                                            104

-------
                               LARRY CAR OBSERVATION LOG
COMPANY
   PLANT
BATTERY
National Steel
Weirton Steel
Brown's Island
DATE
TIME
OVEN
                                                                      3/26/74
3:33
                                                            C-23
CHARGE

IS SEC

30 SEC

45 SEC

1 MIN

1 MIN 15 SEC

1 MIN. 30 SEC

1 MIN AS SEC

2 MIN

2 MIN. 15 SEC

2 MIN 30 SEC

2 MIN 45 SEC

3 MIN.

END OF CHARGE

LID REPLACED
 TOTAL
 CHARGING
 TIME
PUSHER SIDE
1
HOPPER















1:42
DROP
SLEEVE





LP









CENTER
2
HOPPER/
STACK
MSP














DROP
SLEEVE

MFP
MF












CENTER
3
HOPPER/
STACK





MS









DROP
SLEEVE

MFP
MF

F+










COKE SIDE
4
HOPPER















DROP
SLEEVE















f - INCREASING ^ DECREASING -» CHANGING TO
S - STACK HP • HOPPER F - FIRE
                                  L - LIGHT FLOW
                                 BL - BLACK
                                            M -  MEDIUM FLOW
                                            V -  VELLOW
         H • HEAVY FLOW
         P - PUFFY
WEATHER .
                                                 MANUAL GAS
REMARKS  Good negative aspiration observed on number  two  and number  three drop sleeves.
	fire was being drawn in.  Drop sleeve alignment  appears  to  be better  the	
          first tltne they are lowered rather  than  the  second time.	
 "MITRE
MCF 2495 12/73
                                           105

-------
                               LARRY CAR OBSERVATION LOG
          National Steel
          Melrton Steel
 BATTERY.  Brown's Island
COMPANV:
  PLANT:
DATE.  3/26/74
T.ME:
                                                                 OVEN:
                                                                       A-25
CHARGE

15 SEC

30 SEC.

45 SEC.

1MIN.

1 MIN. IB SEC.

1 MIN. 30 SEC.

1 MIN. 43 SEC.

2 MIN.

2 MIN. IB SEC.

2 MIN. 30 SEC.

2 MIN. 45 SEC.

3 MIN.

END OF CHARGE

LID REPLACED
 TOTAL
 CHARGING
 TIME
PUSHER SIDE

HOPPER















Not
Recordei
I
DROP
SLEEVE

F
F
F
F
F
F








CENTER
2
HOPPER/
STACK















DROP
SLEEVE

F
F
F
F
F
F








CENTER
3
HOPPER/
STACK







1







DROP
SLEEVE

F
F
F .
F
F
F








COKE SIDE
4
HOPPER















DROP
SLEEVE



F
F
F
F








f - INCREASING | DECREASING -» CHANGING TO
S • STACK HP • HOPPER f • FIRE
                                   L - LIGHT FLOW
                                  BL - BLACK
                                                      M - MEDIUM FLOW
                                                      V - YELLOW
        H - HEAVY FLOW
        P - PUFFY
WEATHER-.
                                                  MANUALGAS
REMARKS. First charge of new shift, auction appeared  to be malfunctioning, although
          the lid man disagreed•   Much more fire  than  usual in the drop sleeves.	
 MITRE
MCF 2495 12/73
                                                                       OBSERVER
                                             106

-------
                               LARRY CAR OBSERVATION LOG
COMPANY
   PLANT
BATTERY
National Steel
Weirton Steel
Brown's Island
                                                                  DATE  3/26/74
 TIME
OVEN
       4:19
B-25
CHARGE

IS SEC

30 SEC

«S SEC

1MIN

1MIN IS SEC

1 MIN 30 SEC

1 MIN 45 SEC

2 MIN

2 MIN 15 SEC

2 MIN 30 SEC

2 MIN 45 SEC.

3 MIN

END OF CHARGE

LID REPLACED
 TOTAL
 CHARGING
 TIME
PUSHER SIDE

HOPPER















1:39
L
DROP
SLEEVE

MFP
UFP












CENTER
2
HOPPER/
STACK





LS









DROP
SLEEVE

MFP
UFP

F4-










CENTER
3
HOPPER/
STACK





MS









DROP
SLEEVE

MFP
L+FP

F*










COKE SIDE
4
HOPPER


•












DROP
SLEEVE















f - INCREASING | DECREASING -» CHANGING TO
S - STACK HP - HOPPER F - FIRE
                                   L - LIGHT FLOW
                                  BL - BLACK
                                             M - MEDIUM FLOW
                                             Y • VELLOW
         H -  HEAVY FLOW
         P -  PUFFY
                                                  MANUAL GAS
REMARKS  Good charge.
 MITRE
MCF 2195 12/73
                                             107

-------
                                LARRY CAR OBSERVATION LOG
 COMPANY-

   PLANT-

 BATTERY-
National  Steel
Weirton Steel
Brown's Island
DATE   3/26/76
 TIME.
OVEN
4;34
                                                               C-25
 CHARGE

 IS SEC.

 30 SEC.

 45 SEC

 1MIN

 1 MIN. IS SEC.

 1 MIN. 30 SEC

 1 MIN. 45 SEC.

 2 MIN.

 2 MIN. 16 SEC.

 2 MIN. 30 SEC.

 2 MIN. 45 SEC.

 3 MIN

 END OF CHARGE

 LID REPLACED
 TOTAL
 CHARGING
 TIME
PUSHER SIDE
1
HOPPER















1:39
DROP
SLEEVE


P+



L








CENTER
2
HOPPER/
STACK
MSP














DROP
SLEEVE

FP
LFP
F+

HP
F








CENTER
3
HOPPER/
STACK






L








DROP
SLEEVE

FP
LFP
F+
F

F








f - INCREASING ^ DECREASING
S - STACK HP - HOPPER
COKE SIDE
4
HOPPER















DROP
SLEEVE

F4-













-»• CHANGING TO
F - FIRE
                                    L -  LIGHT FLOW
                                   BL -  BLACK
                                             M -  MEDIUM FLOW
                                             V •  YELLOW
         H -  HEAVY FLOW
         P -  PUFFY
WEATHER..
                                                   MANUAL GAS
REMARKS..
 MITRE
MCF 2495 12/73
                                                                        OBSERVER
                                              108

-------
                                LARRY CAR OBSERVATION LOG
COMPANY
   PLANT
BATTERY
National Steel
Weirton Steel
Brown's Island
DATE
 TIME
OVEN
                                                                         3/27/74
3:34
                                                              A-25
CHARGE

15 SEC

30 SEC

45 SEC

1MIN

1 MIN 15 SEC

1MIN 30 SEC

1 MIN 45 SEC

2 MIN

2 MIN 15 SEC

2 MIN 30 SEC

2 MIN 45 SEC

3 MIN

END OF CHARGE

LID REPLACED
 TOTAL
 CHARGING
 TIME
PUSHER SIDE

HOPPER





HP









1:40
1
DROP
SLEEVE




M










CENTER
2
HOPPER/
STACK
MSP




MS









DROP
SLEEVE

LFP
LIFP
FP
F










CENTER
3
HOPPER/
STACK





MS









DROP
SLEEVE

LFP
L4-FP
FP
F










COKE SIDE
4
HOPPER















DROP
SLEEVE















f - INCREASING | DECREASING -fr CHANGING TO
S - STACK HP - HOPPER F - FIRE
                                   L - LIGHT FLOW
                                  BL - BLACK
                                             M - MEDIUM FLOW
                                             Y - YELLOW
         H -  HEAVY FLOW
         P -  PUFFY
WEATHER.
                                                  MANUAL GAS
REMARKS
          Coke side  ascension pipe lid failed  to close.  Lid man closed  it manually.
MCF 2495 12/73
                                              109

-------
                               LARRY CAR OBSERVATION LOG
COMPANY

   PLANT
BATTERY
National Steel
Weirton Steel
Brown's Island
DATE.  3/27/74
TIME:
OVEN-
B-25
CHARGE

15 SEC.

30 SEC.

45 SEC.

1MIN

1 WIN. 15 SEC.

1MIN. 30 SEC.

1 MIN. 46 SEC.

2MIN.

2 MIN. IS SEC.

2 MIN. 30 SEC.

2 MIN. 45 SEC.

3 MIN.

END OF CHARGE

LID REPLACED
 TOTAL
 CHARGING
 TIME
PUSHER SIDE

HOPPER















1:42
I
DROP
SLEEVE

M
MFP
F+
LFP










CENTER
2
HOPPER/
STACK
MSP




MS









DROP
SLEEVE
Mi
MFP
MFP
MIFF
LFP

FP








CENTER
3
HOPPER/
STACK





MS









DROP
SLEEVE

MFP
MFP
M+P
LFP

FP








COKE SIDE
4
HOPPER





L









DROP
SLEEVE















f - INCREASING | DECREASING -» CHANGING TO
S - STACK HP - HOPPER F - FIRE
                                   L - LIGHT FLOW
                                  BL - BLACK
                                            M -  MEDIUM FLOW
                                            Y -  YELLOW
         H -  HEAVY FLOW
         P -  PUFFY
WEATHER-
                                                  MANUAL GAS
REMARKS: More  smoke than usual at the beginning  of  the charge.  Smoke especially
          heaw on drop sleeves one, two, and  three.   Charge R"pned normal	
           toward  the end•
 MITRE
MCF 2495 12/73
                                             110

-------
                               LARRY CAR OBSERVATION LOG
          National  Steel
          Weircon Steel
 BATTERY   Brown's  Island
COMPANY

  PLANT
           DATE

           TIME
           OVEN
                                                                         3/27/74
                                                                         4:06
                                                                        C-25
CHARGE

15 SEC

30 SEC

45 SEC

1MIN

1MIN 15 SEC

1 WIN 30 SEC

1 MIN 45 SEC

2MIN

2 MIN 15 SEC

2 MIN 30 SEC

2 MIN 45 SEC

3 MIN

END OF CHARGE

LID REPLACED
 TOTAL
 CHARGING
 TIME
PUSHER SIDE
1
HOPPER















1:41
DROP
SLEEVE


L

M










CENTER
2
HOPPER/
STACK
MSP














DROP
SLEEVE

MF
L+FP
LF
F
F









CENTER
3
HOPPER/
STACK















DROP
SLEEVE

MF
LtFP
LF
F
F









COKE SIDE
It
HOPPER















DROP
SLEEVE

L













f - INCREASING ^ DECREASING -» CHANGING TO
S - STACK HP • HOPPER F - FIRE
                                   L - LIGHT FLOW
                                  BL - BLACK
M - MEDIUM FLOW
Y • YELLOW
                                                                          H -  HEAVY FLOW
                                                                          P •  PUFFY
WEATHER .
                                                  MANUAL GAS
REMARKS  It appeared  that all hoppers and stacks puffed  back at the end of the charge.
 MITRE
MCF 2195 12/73
                                            111

-------
                                LARRY CAR OBSERVATION LOG
 COMPANV
   PLANT
 BATTERY
NaMnnal  St-ool
Weirton Steel
Brown's Island
DATE.
 TIME:
OVEN
                                                                          3/28/74
2:54
                                                               A-27
 CHARGE

 IS SEC.

 30 SEC.

 45 SEC

 1MIN.

 1MIN 15 SEC.

 1 MIN. 30 SEC.

 1MIN.45SEC.

 2 MIN.

 2 MIN. IB SEC.

 2 MIN. 30 SEC.

 2 MIN. 45 SEC.

 3 MIN.

 END OF CHARGE

 LID REPLACED
 TOTAL
 CHARGING
 TIME
PUSHER SIDE

HOPPER















1:38
1
DROP
SLEEVE




F










CENTER
2
HOPPER/
STACK
MSP




MS
-








DROP
SLEEVE

Lt
MF
LFP
LF










CENTER
3
HOPPER/
STACK





MS









DROP
SLEEVE

L
LF
LFP
LF










COKE SIDE
4
HOPPER















DROP
SLEEVE















f - INCREASING ^ DECREASING -» CHANGING TO
S - STACK HP - HOPPER F - FIRE
                                   L -  LIGHT FLOW
                                   BL -  BLACK
                                             M - MEDIUM FLOW
                                             V - VELLOW
         H -  HEAVY FLOW
         P -  PUFFY
WEATHER:.
                                                  MANUAL GAS
REMARKS:  Sleeve up to lid at eight  seconds.  Eight to nine seconds to rotate.
 MITRE
MCF 2495 12/73
                                                                       OBSERVER
                                             112

-------
                                TECHNICAL REPORT DATA
                          (Please read Instructions on the reverse before completing)
 1. REPORT NO.
 EPA-650/2-74-062-a
                           2.
                                                       3. RECIPIENT'S ACCESSION-NO.
 4. TITLE AND SUBTITLE Coke Oven Charging Emission
 Control Test Program--Supplemental Observations
               6. REPORT DATE
               September 1974
                                                       6. PERFORMING ORGANIZATION CODE
 7 AUTHOR(S)

 R. W. Bee and R.W. Spewak
                                                       8. PERFORMING ORGANIZATION REPORT NO.
                MTR-6684
9 PERFORMING ORGANIZATION NAME AND ADDRESS
 The Mitre Corporation
 Westgate Research Park
 McLean, Virginia  22101
                10. PROGRAM ELEMENT NO.
                1AB013; ROAP 21AFF-004
                11. CONTRACT/GRANT NO.
                68-02-0650
 12. SPONSORING AGENCY NAME AND ADDRESS
 EPA, Office of Research and Development
 NERC-RTP,  Control Systems Laboratory
 Research Triangle Park, NC 27711
                13. TYPE OF REPORT AND PERIOD COVERED
                Supplemental: 3-4/74	
                14. SPONSORING AGENCY CODE
 IS. SUPPLEMENTARY NOTES
  . ABSTRACT
               rep0rt compares operational information for two coke charging cars
 operating to reduce charging emissions from the Brown's Island battery of National
 Steel's Weirton Steel Division with that for a larry car developed jointly by the
 American Iron and Steel Institute  (AISI) and the U.S. EPA.  A direct comparison is
 made in areas where similarities between the two designs are strong; in areas with
 contrasting features or procedures , their success  is reported relative to design
 intent and EPA objectives.  Both designs have had reasonably good success both in
 automation of oven controls and in improving operator environment.  Both represent
 substantial improvements in emission control: although the AISI/EPA car appears
 to be more capable of sealing emissions during the charge,  it is less consistent than
 the Weirton car in overall emission control. Facts presented by the report origi-
 nated in three areas: a desciption of the Weirton coking system, including oven
 configuration, larry car operation,  and general coke oven charging procedures:
 observation of the two Weirton larry cars during coal charging operation; and
 interviews with coke plant personnel responsible for operating the larry cars.
17
                             KEY WORDS AND DOCUMENT ANALYSIS
                 DESCRIPTORS
                                          b.lDENTIFIERS/OPEN ENDED TERMS
                            c. COSATI Field/Croup
 Air Pollution
 Iron and Steel Industry
 Coke
 Metallurgical Fuels
 Coking
 Charging
   Air Pollution Control
   Stationary Sources
   Emission Observations
   Operability Assessment
   Larry Car
 13B
 11F
 21D

 11H
18 DISTRIBUTION STATEMENT

 Unlimited
   19. SECURITY CLASS (This Report)
   Unclassified
                                                                   21. NO. OF PAGES
119
   20. SECURITY CLASS (Thispage)
   Unclassified
                            22 PRICE
EPA Form 2220-1 (9-73)
113

-------