EPA-650/2-74-Q76
September 1974
Environmental Protection  Technology  Series





                                                                 m



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                                    EPA-650/2-74-076
             COKE  OVEN
SMOKELESS  PUSHING  SYSTEM
         DESIGN  MANUAL
                    by

               R. O. McClelland

             Koppers Company, Inc.
              1420 Koppers Building
          Pittsburgh, Pennsylvania 15219

                    and

              Ford Motor Company
                 Steel Division
                P.O. Box 1631
            Dearborn, Michigan 48121
             Contract No. 68-02-0630
              ROAP No. 21AFF-010
           Program Element No. 1AB013
         EPA Project Officer: D. A. Kemnitz

            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 docs mention of trade names or commercial products constitute
endorsement or recommendation for use.
                                  ii

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                         ABSTRACT



In 1970 the Ford Motor Company contracted with Koppers Company to


design and construct a system to eliminate the emissions to the atmosphere


during the pushing of coke from the 45-oven "A" battery located at the


Rouge Plant in Wayne County, Dearborn, Michigan.  In June, 1972 the


system was placed in operation and after a one month de-bugging period


was accepted by Ford as an integral part of the regularly operating


battery equipment.



                                                            A
The ten year old "A" battery at Ford consists of 45 - 13 ft.  high ovens


that each produce 12 tons of blast furnace coke at a gross coking time


of 18 hours with a "push" scheduled every 15 minutes.




The method selected to eliminate the pushing emissions was the "Coke


Guide Fume Hood" where the entire coke guide is enclosed with a hood


that extends out over the quench car.   Prior to the push the hood is


connected to a stationary fume main that is under suction and the


hot coke emissions that are generated during the push are conveyed


to a high energy wet-type gas scrubber where the gas stream is cleaned


before being emitted to the atmosphere.




"A list of factors for converting from non-metric to metric units is


provided in Section IX.



                            iii

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Clearances between the hood and quench car are held to a minimum to



provide sufficient indraft velocities to overcome normal lateral wind



effects.  These effects have been evident in similar installations in



Japan and Germany where wide clearances have been required to permit



the quenching car locomotive to pass under the hood.  In the Koppers'



concept at Ford, the profile of the existing quench car has been built-up



to that of the locomotive to enable the reduction of clearances with the



coke guide hood.  Also the utilization of a fan with a capacity of over



110,000 acfm ensures that the indraft velocities will be maintained at



a high level.








This report is submitted in partial fulfillment of Contract No. 68-02-0630



by Koppers Company, Inc. for Ford Motor Company under the sponsorship



of the Environmental Protection Agency and will describe in detail



the design and operation of the "Coke Oven Smokeless Pushing System"



at Ford Motor Company.
                            iv

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                             CONTENTS






                                                                 PAGE NO.






List of Figures                                                   vi




List of Tables                                                    vi i




Acknowledgments                                                   viii






Sections




I     Conclusions                                                  1



II   Introduction                                                 3




III  Process Description                                          11




IV   Process Design                                               21




V    Environmental Posture                                        k$




VI   Capital Cost Estimates                                       49



VII  Operating Costs, Utility Requirements,  and Maintenance       53




VIII Post Start-Up Modifications                                  59




IX   Units of Measure - Conversions                               63

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                              FIGURES


FIG.  NO.                     DESCRIPTION                           PAGE NO.


  1           SYSTEM GENERAL ARRANGEMENT                             7

  2           SYSTEM GENERAL ARRANGEMENT WITH LEGEND                 9

  3           SYSTEM FLOW DIAGRAM                                    13

  I*           WATER FLOW DIAGRAM                                     15

  5           INSTRUMENT FLOW DIAGRAM                                17

  6           COKE GUIDE HOOD GENERAL ARRANGEMENT                    19

  7           COKE GUIDE HOOD PLAN                                   23

  8           QUENCH CAR AND LOCOMOTIVE ALTERATIONS                  27

  9           QUENCH CAR TO PUSHER RAM SYNCHRONIZATION               29

 10           FUME COLLECTING MAIN GENERAL ARRANGEMENT               33
             AND SECTION

 II           SEQUENTIAL OPERATION OF FAN LOUVERS AND                35
             BUTTERFLY VALVE

 12           GAS SCRUBBER SYSTEM GENERAL ARRANGEMENT                37

 13           GAS SCRUBBER SYSTEM ELEVATION                          39
                                VI

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                              TABLES






TABLE NO.                   DESCRIPTION                           PAGE NO.




  I                     UTILITY REQUIREMENTS                         55




  II                   REQUIRED MAINTENANCE                         57
                                vii

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                           ACKNOWLEDGMENTS


The following personnel and organizations are recognized with appreciation

for their contribution and assistance in preparation of this Design Manual:
    Mr. R. Chaiken



    Mr. E. C. Neff



    Mr. J. L. Robbins



    Mr. F. C. Voelker,  Jr.


    Mr. R. 0. McClelland


    Mr. D. A. Kemnitz
- Project Director
  Steel Division
  Ford Motor Company

- Assistant Project Director
  Steel Division
  Ford Motor Company

- Assistant Project Director
  Steel Division
  Ford Motor Company

- Manager Pollution Control  Projects
  Koppers Company

- Project Director
  Koppers Company

- Project Officer
  Control Systems Laboratory
  Environmental  Protection Agency
                                 viii

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                            SECTION I






                           CONCLUSIONS








The overall goal in preparation of this report is to demonstrate a system




designed for coke oven pushing emission control capability, operability,




reliability, and maintainabi1ity.








Although the system can be used on new installations, it was designed




primarily to serve existing coke plants and, at this writing, has been  in




operation for two years with minimal downtime.








Tests conducted by Koppers Company during October and November of 1972




indicate a scrubber efficiency of 99% and an outlet stack loading of 0.02




grains/scf  (dry).








These results, coupled with reliability and automatic operation, make the




"Coke Guide Fume Hood" an effective answer to pushing emission control.








Ford Motor Company's satisfaction with the system is indicated by the fact




that in early 1974 Koppers was awarded the contract to extend the fume main



to serve Battery "AX" and engineering is complete for installation on the




remaining batteries, "B", "C", and "DX", in the Rouge coke plant.

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                            SECTION II






                           INTRODUCTION








The "A" battery In the Rouge coke plant Is located at the south end of the



six battery (205 operating ovens) complex that includes "A", "AX", "B",



"C", "D", and "DX."  Battery "D" is out of service, and "AX" and "DX"



are comprised of 13 and 25 ovens, respectively.








Ford Engineering requested that the gas cleaning system be sized to



allow extending the fume main to include Batteries "AX" and "B" in



the future.








In designing the system for an existing battery, consideration had to be



given to construction downtime and interference with the constant day to



day operation of the coke plant.  As a result of these considerations the



system becomes an "add-on" device whereby no major alterations to the



battery or present method of quenching are required.  Also being a fully



automatic installation, no additional  personnel are required for its opera-



tion.








The system is designed for capturing only the emissions generated during



the pushing of coke into a standard open-type quench car.  These emissions



vary with every push; ovens having "green" ends due to insufficient carboni-

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zation time or condition of the oven doors generate the most participate



matter, and properly coked-out ovens create relatively little emissions.








During a moderately "green" push there is an acceleration of fume com-



bustion under the hood which tends to clean-up the coke by the time the



quench car leaves the hood.








During an emergency situation when the gas scrubber is not functioning due



to maintenance on the fan or motor, the door machine operator need only



to place the selector switch on "manual", then rack the coke guide in as



done normally and no other emission  control system functions will occur.



The telescoping section of the hood that connects to the fume main will not



extend, and when the push is made in the conventional  manner, the hot coke



emissions will go out the top of the hood to the atmosphere resulting in no



downtime of the door machine or coke guide.








Operators of existing coke plants who may be contemplating the installation



of this system in their plants might consider the following items that were



considered in designing the installation at Ford:






1)    Sufficient real estate near the battery on which to place the gas



      scrubber components.






2)    Sufficient clearance on the coke side of the battery to run the fume



      main and locate the towers that support the fume main truss.  Some



      of the common obstructions in this area are material handling equip-

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      merit, conveyors, screening stations, coke wharfs, stacks, cross-




      over mains, and piping.








3)    Sufficient bench length to park out the door machine and coke guide due




      to the additional length of the fume hood seal  plates.








In addition to the above items, it is also noted that the wheel loads of the coke



guide hood do not exceed those of the door machine, thus eliminating the need




to strengthen the bench supports.








With respect to the efficiency of the gas cleaning system, an analysis of the gas




stream before scrubbing indicates that it contains l.?6 Ibs.  of particulate




matter per ton of coke, which means that over 21 Ibs. of particulate matter are




generated during each push.  The Wayne County, Michigan, air  emission code




states that emissions of Ringelmann #2 or greater are to exist for not more than




k minutes out of any 30-minute period, and the outlet particulate loading is to




be less than 0.05 grains per standard cubic foot.  These requirements were



designed for and met with ease.








Figure 1 - System General  Arrangement (Dwg. 319-A626) -- illustrates the




various components incorporated into this new system, their interaction with




each other, and with the coke oven battery proper.  (The components are



identified in Figure 2.)

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2
O
m
                                                                                                                              KOPPERS-FORD

                                                                                                                       COKE OVEN SMOKE EMISSION ABATEMENT

                                                                                                                          FORD MOTOR CO.  DEARBORN. MICH.

                                                                                                                          SYSTEM GENERAL ARRANGEMENT
                                                                                                                   DRAWN3Y|« "-CLiLL>uiipflTE|  i is ?4 [SCALE,
J3I9-A626

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COKE GUIDE FUME HOOD
DOOM MACHINE
QUENCH CAR
QUENCH LOCOMOTIVE
FUME COLLECTING MAIN
BUTTERFLY VALVE
VENTURI SCRUBBER
FLOODED ELBOW
CYCLONE SEPARATOR
FAN
FAN MOTOR
STACK
WATER RECWCULATING TANK
             WATER PUMPS
   K OFFERS-FORD
SYSTEM GENERAL ARRANGEMENT

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10

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                            SECTION III








                        PROCESS DESCRIPTION






Figures 3,*t, and 5 (Drawings 319-A627, 319-A628, and 319-A629) describe




the conditions of the fume hood, fume main and gas scrubber during the coke




"push."








Figure 3 (Drawing 319~A627) is a system flow diagram showing the various




components and their relative function in making up the complete system.








Figure fr (Drawing 319~A628) indicates the general application and use of water




in the gas scrubber system.  Mill cooling water is the source of make-up to




the recirculating water system to replace the 50 gpm of dirty water that is




drained off to the quenching sump.  City water is used at the fan for the cool-




ing of bearings and cleaning of fan blades with the drains from each sub-




sequently going to the quenching sump.








Figure 5 (Drawing 319~A629) is an instrument flow diagram with complete




information on the monitoring and control of the process as conceived for this




design.  The gas flow definition as presented in Figure 3 represents the fume




flow quantities at the maximum levels.  The fume system discharge indicated




on Figure 3 represents the Wayne County, Michigan, requirements, with the




actual discharge as measured by Koppers Company being considerably less.
                              11

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12

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                                               ELECTRIC  CYLINDER FOR
                                               OPENING DOORS
                                               230 V.D.C.
 FLOW IN MAIN
 DURING PUSH
• 210.000 ACFM §> 650'F
                           SEAL PLATE,.

/


1- . - J




\



\
\
=OP
1 7 s; 	 ,
i i /
ir- BAFFLE --J
PLATES |
u L L
£ i

                                                                             -2" SAP
                                                                              20 MPH
                                                                              INFILTRATION
                                                                              VELOCITY
                                                                              ^QUENCH TRACK
                                                                                                     -ELECTRIC CYLINDER
                                                                                                      FOR BUTTERFLY VALVE
                                                                                                      440 VAC

"A'L^ ^r^X
ELECTRIC CYLINDERS /
FOR RAISING ( LOWERING /
SEAL PLATES \ /
230 WC. ^\ I
PT


{ \ /-y- (AUXJTRACTION DRIVE
1 J^A MOTOR 10 HP

~ I — COKE GUIDE
L_ FUME HOOD

VENTURI -_
SCRUBBER,
         -OCOMOTIVE
                                              QUENCH CAR
                                                                                           WAYNE COUNTY CODE Of:
                                                                                         CD RINGELMANN"2 OR GREATER
                                                                                           FOR NOT MORE THAN 4 MINUTES
                                                                                           IN ANY 30
                                                                                         (2) OUTLET LOADING OF
                                                                                           <\05 GRAINS /SCF
                                                                                                ELBOW
3]

P
OJ
                        (-OR SYNCHRONIZATION
                        SEE DWG 319 A 6M
                  WATER RECIRCULATING
                  PUMPS 50 HP MOTORS
                  1000 G.RM. EACH
                  ONE OPERATING AND
                  ON£  STANDBY
                                                                                                                                      CYCLONE
                                                                                                                                      SEPARATOR
                                                                 FAN LOUVERS
                                                                                                                              -J	
                                                                                                                                      FAN LOUVER-	^J>
                                                                                                                                      DRIVE MOTOR
                                                                                                                                  SUMP
                                                                                                                                                                                     SILENCcS
                                                                                                                                                                                     STACK
RECIRCULATIN6
WATER TANK
5000 GAL
                                           112,000 ACFM
                                           -60' W.C
                                                                                                                                                                       Ii2' F
2
O
rn
OJ
                                                                                      KOPPERS-FORD
                                                                               "CKE OVEN SMOKE EMISSION ABATEMENT
                                                                                      FORD MOTOR COMPANY
                                                                                SYSTEM PLOW  DIAGRAM

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lit

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WATER BtORCUlATING
PUMPS 50 HP MOTOBS
1000 GPM. EACH
ONE OPE PAT ING AND
ONE
                                                                                                                             KOPPEf?S-FORD
                                                                                                                      COKE OVEN SMOKE EM1SSKX ABATEMENT
                                                                                                                            FORD MOTOR COMPANY
                                                                                                                         WATER  FLOW  DIAGRAM
                                                                                                                   AWN B»1»«tCLEU-A»l|3

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16

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                                                                                                                                                                                -
                                                                                                                                             HJ -INTERLOCKED
                                                                                                 -ELECTRIC CYLINDER
                                                                                                  FOB BUTTERFLY VALVE
                    FUME MAIN    DOORS
       L	1 I	IL
                                                          r.Lir.U-U.Lr-L-
                                             r~~~!l—V~~!T
                                             i    •!   11    M    ;:       ;]    ji
                                             L—JL.J.._JLJi	iL.JL.JL.


/




JXOMOTIVE


\





~!|~ n / >j 	 .
! |K
: ii 3
QUENCH CAR
         v j	vy_
                                                                                                                                                                             STACK
0
Ol

?
o
                                                                                                         RECIRCULATX6
                                                                                                         WATER TANK
   NAMEPLATE EN6KAVING
Nl- FAN MOTOR LOAD CONTROL
Hi-WASTL OS TEMPERATUHES.
                                 N4-»»TER FLOV TD KINBKT
                                 N6- FAI4 INLET TEMPEBATU*
         ANNUNCIATOR
SCO-I - FAULT -FAN MOTOR -TOIPFtD Off.
   2 - ABNORMAL- TEMP vie- FAN.
   3- HI&H TEMP- FAN INLET.
   4- LC* FLOr-vaTEi> TO scRueeen.
   5- FLA5K.R
   fe-  POXEN LOSS- FAN MOTOR-TEMP MOm TOO.
   7-  LQX PttSS,- FAN B^mNSS.
   B -  LOX 5UCTIQN-COUJCTIK8 »MN.
                                                                     ,
                                                             -S«»RECNO ENG>»AVINQ.
                                                                                                                       KOPPERS-FORD
                                                                                                                 COKE CVEN 5MOH£ EM6SION ABATEMENT
                                                                                                                       FOTO MOTOO CO»*NY
                                                                                                              INSTRUMENT  FLOW  DIAGRAM

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The diagrams also provide information on design parameters used in the



processing of the gas stream through the gas scrubber.








The fan and recirculating water system operate continuously with a push



scheduled every 15 minutes and each push lasting 40 seconds.  The sequence



of conditions that exist between pushes comes about by the fan louvers, fume



main butterfly valve, and fume main doors.  This sequence is described on



Figure 6 (Drawing 319"A630) and in essence consists of:








1)    Closing the fan louvers between pushes, thereby placing the fan on



      idle and reducing power consumption.








2)    Opening the fume main butterfly valve temporarily to reduce



      the suction in the main, requiring less effort to open and



      close the fume main doors.








3)    Closing the two fume main doors used in the previous push and



      moving the coke guide fume hood to the next oven on the



      schedule, then opening the corresponding two doors which



      completes the connection between the hood and gas scrubber.
                               18

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                                                                              GRATING £ HANDRAIL
(  EXISTN6
1  COKE SIDE
  COLLECTINE
    MAIN
                                                                           EXISTING GAMMA RAY
                                                                              INTERLOCK
                                                      EXISTING GUEN CAB
                                                      W/RWTITCN PLATES
                                                      EXISTIN6 QLEN.LOCO
                                                                                              exisriNG COKE ooee -

                                                                                       QUENCH CAR TRAVEL
                              ELEVATION
             EST. Wll«MTt
STAHOARD COKE 6UIOC  SOgOOO LB
           FUM1HOOO  4«jPOOLf
               TOTAL
TO QUENCH STATION

     IfVATlQN
          KOPFERS-FORD
   COKE OVEN SMOKE EMISSON ABOTEMEKT
          FORD MOTOR CCWWY
COKE GUIDE PIKE HOOO - GEN.ARRGT

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20

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                            SECTION IV






                          PROCESS DESIGN






This section provides definition of the various major components that are




new or have been altered to make up the "Coke Oven Smokeless Pushing




System" as defined in Figure 2 (Drawing 319-A&26).








A. Coke Guide Fume Hood (Figures 6 and 7 - Drawings 319"A631-632)




   The coke guide fume hood captures the pushing emissions normally generated



   while the coke is in the guide and while the coke is falling into the quench




   car.  This has been accomplished by taking the existing coke guide and




   enclosing it with steel plate.  A spring loaded angle frame was added that




   forms a vertical  seal against the buckstays when the coke guide is racked in.




   The top section was sealed by welding a canopy plate between the buckstays




   at each oven.








   Over the entire coke guide and extending out over the quench car is the fume




   hood.   The hood is supported by a set of wheels that have been added on




   the outboard sides of the existing coke guide.  These wheels ride on the



   bench rails and each supports a pivot bearing onto which the oven side of




   the fume hood rests; the remainder of the hood extends out over the quench




   track and is supported by means of an elevated third rail that runs the full



   length of the battery.
                                21

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22

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                                                                               OVEN SIDE
                                                                                                                                    BtCK. OF BUOCSTAYS
-n
o
m

ro
OJ
     I A-A

CWG3I9-A63I
      KOPPERS - FORD

COCF CVEN SMOtCE EKISSCN ABATEMENT

   .   FORD MOTOR COMFWNY

     GUIDE FUME HOOD - PLAN
                                                                   15-7-1 l

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Differences in elevation between the third rail and the bench rails that



come about naturally through construction tolerances, thermal growth,



age, etc., account for the pivot bearings, that support the oven side



of the fume hood, allowing the outboard side to move freely up and



down.  Any lateral variations between the bench rails and the third



rail are compensated for by utilizing extra wide flanged wheels that



ride the third rai1.








The coke guide is coupled to the door machine which has a traction drive



sufficient to move both machines.  To compensate for the additional weight



of the fume hood and to avoid skewing, an auxiliary traction drive was



placed on the fume hood and located on the elevated third rail.  This



drive has a 10 h.p. motor that is synchronized with the door machine



drive.








The fume hood is constructed of steel plate and lined with Cera-felt



insulation and stainless steel plates that are loosely bolted in place to



allow for thermal cycling caused by each push.  The fume hood is fitted



with movable seal plates that are 10 ft. in length and fit down over the



contour of the quench car.  Each seal plate is raised and lowered with an



electric cylinder, and it is normally in the raised position to allow



approximately 7  in. clearance for the quench car and locomotive to pass



by.  Prior to the push and after the quench car is in position, the seal

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plates are lowered to within approximately 2 in. of the quench car thus




cutting down on the infiltrated air and increasing the indraft velocity




during the push.








The main body of the hood is approximately 10 ft. long and, with a 10 ft.




seal plate on each side, the hood covers 30 ft. of the 40 ft. quench




car.  Air infiltration through the quench car is kept to a minimum by




adding baffles  in the car.  This will be described later under "Quench




Car and Locomotive Alterations".








The captured emissions are directed upward toward the fume collecting




main through a snorkle shaped section in the hood.  The snorkle section




is coupled to the fume collecting main prior to a push by means of an




electric cylinder that extends and moves a telescoping section of the




snorkle against a flat surface of the main.  The fume main is equipped with




a series of doors having levers that protrude upward.  As the cylinder moves




the telescoping section against the main,  a bar attached to the cylinder




engages the levers and opens two doors that swing into the snorkle section




of the fume hood.  This completes the coupling of the hood to the fume




main.   When the push is complete, the cylinder retracts and the doors




close under their own weight.
                                25

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B. Door Machine Alterations



   Alterations to the existing door machine included the addition of an electric



   relay cabinet and an operator's control  panel.








C. Quench Car and Locomotive Alterations (Figure 8 - Drawing 319~A636)



   The fume hood can only extend downward to a distance sufficient to allow



   the quench car and quench locomotive to pass beneath.  The quench loco-



   motive is approximately 4 ft. higher than the quench car.  This



   necessitated building the sides of the quench car up to equal  the height



   of the quench locomotive.  This was done with steel  plate as shown on



   Figure 8 (Drawing 319-A636).








   The quench car moves approximately 30 ft. during the push and  would



   require a hood length of approximately 70 ft. if the ends of the quench car



   were to act as seals during the entire push.  By adding three  partition



   baffles in the car as shown on Figure 8 (Drawing 3'9~A636) a hood length



   of 30 feet was used with the partition plates sealing the ends during the



   entire push.








   Due to building up the sides of the quench car and covering the coke guide



   with a fume hood, the quench locomotive operator can no longer see the



   push and move his car slowly to distribute the coke evenly over the entire



   length of the quench car.  For this reason the "Pusher Ram to  Quench Car



   Synchronization" system, Figure 9 (Drawing 319~A&37)i was required.
                                 26

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                                                                                                                              fttRTITION
                                                                                                                              BAFFLES C3)~
          RECEIVER £ MASTER  \  LOCO.CAB.EXT. TO HOUSE
          CONTROL CABINET   /  SYNCRO ELEC (Xtf
                            EM3 PLATES
                          ^BOTHENDS


                         /
                                                                           40'-OV INSCe END OF PLATES
L   J4.J	C
                          OUNCH CAR WHtEL ASSY Fr*
                          JYNCRO TO PIBHER »AM TRAVEL
                          SEE CMS 319 A«7
ELEVATION
             KOPPERS-TORD
       COKE CVEN 3KLXE EKSSCN
             FOKD NOfCR OMfWY
QUENCH G^ 6 IDCO ALTERATIONS ARRG'T
DRAWN BY|wS.WHITC|»Tt-|3- ft-
                                                                                                                                                            i' Ol3l9-A£3<

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28

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The synchronization system is an electro-mechanical  device that indicates



via a set of pointer dials the relative position of the pusher ram and the



quench car.  The indicator cabinet is located in the locomotive cab to



be observed by the operator.








A roto-pulsar unit has been attached to the pusher ram drive and emits an



electrical pulse for every 3 in. of ram travel.   This pulse is sent via a



signal transmitter through the pusher machine collector rails which are



in turn coupled to the quench locomotive collector rails by a signal coupler.



A signal receiver on the quench locomotive receives the pulse signals from the



pusher ram drive and by a series of relays energizes a stepping motor that



moves the pointer dial in the indicator cabinet.  The pointer dial starts to



move from left to right when the ram head enters the oven and continues



until the ram is fully extended.







The pointer dial that indicates the quench car travel is located  in the



indicator cabinet below the ram position pointer dial,(but not directly in



line) with the quench car pointer being approximately 7 in. to the right



of the ram pointer.  This 7 in. is equal to approximately 16 ft. 3 in. of



ram travel and is called the "Pre-Push" distance or the distance the



ram travels after it enters the oven, makes contact with the coke, com-



presses the coke, and pushes enough coke into the front of the quench car



requiring the car to be moved.
                                  30

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The quench car pointer dial is also moved by a stepping motor that




receives its pulses from a set of vane operated limit switches located




on the rear outside wheel of the quench car.  When the quench car begins




to move, a vane wheel attached to the axle of the car passes through the




limit switches momentarily closing a circuit that sends an electrical




pulse to the stepping motor for every 3 in. of quench car travel.








A series of gears between the stepping motors and the pointer dials




compensates for the difference in overall movement between the ram and



the quench car and also allows for changes in the "Pre-Push" distance,




if desired.








In operation the locomotive operator spots the quench car under the hood,




turns the synchro system "on", then indicates he is ready to catch.  He




watches the ram position indicator, and when the ram head enters the oven,




the pointer dial starts to move from left to right slowly.  When the ram




position indicator moves approximately 7 in., it will be directly in line with




the quench car pointer, and he will move the car slowly keeping the pointers in




line.  When the ram is fully extended, the ram pointer will  be at the extreme




right of the indicator cabinet and the quench car will have moved so that its




pointer will also be in line at the extreme right indicating that the push is




complete.  The operator then pushes the reset button, and while the pointer




dials return to their original position the operator proceeds to the quench



station.
                                31

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D. Changes to the Locomotive include extending the cab to house the



   synchronization indicator cabinet and also adding the synchronization



   master control cabinet to the outside of the cab.








E. Fume Collecting Main (Figure 10 - Drawing 319-A635)



   The fume collecting main runs the full length of the battery.   It is a



   66 in. I.D., with 1/2 in. wall, tubular steel section having one flat



   side facing the oven on which are mounted 52 doors.  Each door is



   approximately *t ft. 5 in. high by 2 ft. 8 in. wide and is hinged



   at the top having a lever that protrudes upward.  Forty-six doors are



   required to service the k$ ovens, and there are 6 spare doors on the



   south end of the main for testing purposes.  The flat surface of the fume



   main is slanted 5° off vertical to allow the weight of the door to assist



   in sealing the adjustable knife edges that run the perimeter of each door.








   The fume main has a walkway its full  length with a service platform on



   either end; the main is supported approximately 33 ft. above the quench



   track by a steel box truss that spans approximately 106 ft. between towers.



   In addition to the fume main, the truss also supports the elevated third



   rail for the fume hood.  There are sampling ports for test purposes along



   the entire length of the main.
                                 32

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P
6

I
m
01
OJ
                                                                        3-llj-
                                              OVEN
                                              SIDE
                                             FUME MAIN DOOR
                       SOUTH END OVEN*
                          BATTEHY'A'
                   t DOOR
                   OPENINi
2^, _
                                                              ENLARGED   SECTION-AA   THRU  MAIN
                                                      45 OVENS-44SPACES« 3'-9J'- 167-9" FOR BATTERY'A'
                                                                               4 NORTH END OVEN*49
                                                                                 BATTERY'A"
                                                       S2-OOOR OPENINGS-5ISPACES» 3'-9V-l94'-5V
    OUt NCHINC
     STATION

    I
                                                                                                               END  VIEW
                              ELEVATION
                            (LOOKING WEST)
            KOPPERS ~ FORD
      COKE CVEN SMOKE EMISSION
            FORD MOTOR CCMR6W
FUME CaLECI MAJN-GENL
                                                                                                                                                           1 3I9-AJ3S

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F. Fume Main Butterfly Valve (Figure 11 - Drawing 319-A630)



   The purpose of the butterfly valve at the south end of the fume main



   is to relieve the suction in the main momentarily, thus requiring



   minimum effort to open the fume main doors.  The valve is 30 in. in



   diameter and is opened and closed with an electric cylinder.  The



   cylinder is activated by a Femco signal received from the coke guide



   when it is racked into the oven and prior to the fume main doors being



   opened.  After the doors are opened a Femco signal is sent to the



   butterfly valve to close.








G. Venturi Scrubber (Figures 12 and 13 - Drawings 319-A633-63*t)



   The gas scrubber system is located at the south end of the battery.



   As the collected, hot gases are conveyed down the fume main under



   suction pressure, they first meet with the venturi scrubber which is



   a high energy wet-type scrubber equipped with a variable throat slide



   block damper and designed to operate at a pressure differential of 60 in. w.c.



   Plant service water injected through water sprays located ahead of the



   throat of the venturi provides a sheet of water for complete coverage



   of the throat area.  The high velocity gases when passing through the throat



   area will atomize the water which results in the dust particles being en-



   trained in the water droplets.  The venturi scrubber is made of COR-TEN steel,



   with stainless steel water deflection plates in the tapered throat area.  The



   spray nozzles are equipped with manual reamers.
                                    3*.

-------
            BATTERY
              CASENQ1
                         I. NOT PUSmN64FAN PL I NO
                                     TRAVELS TDtVEN
O
o
m
w
ui
                                     TIKCR TO Of.TRACT IS
                                     STAHTEDBf COW
                                     QUO, unvfutf, not*.
CASE NO. 5
                                                             CASENQ2
                                                                                      Fun* MAIN BUTTERFLY
                                                                                      VALVE AUTOMATICALLY
                                                                                      CL09CS Af TER PRESET
                                                                                      TK
                                                                                                                                              Y VALVE
                                                                                                              BATTERY
                                                                                                             CASENQ3
                                                                                                                                 (»CO ELECTRIC
                                                                                                                                       ALTIOMATCM1J
                                                                                                                                 EXTOOWONW
                                                                                                                                 2 DOORS
                                                                                                                  I. RACO CYLINDER TIMES OUT
                                                                                                                  2. CYLINDER EXTENOS
-------
36

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         16 -8
                                33-11
                                                                                   <£ FUME MAM

                                                                                     SBWCE PLATFORM
                                                                                                                                 COKE SIDE BENCH
QUENCHING TRACK (. QUENCHING STATION
                                                                                                                  KOFPERS - FORD
                                                                                                            COKE OVEN SMOKE EMISSION ABATEMENT
                                                                                                                  FORD MOTOR COMPANY
                                                                                                        GAS 9CRIJBBER SYSTEM - GEN. ARRGT,
                                                                                                    DRA^VN By|WlWHITElCKTEl3-l5-74

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38

-------
12-fc
                                                                                       FUkC MAN ELBOW
                                                                                                BUTTERFLY CAMPER
                                                                                               W*PER SERVICE R.ATFCRM
                                                                                                 MOOD SERVICE PLATFORM
                                                KINBCTOR SUPPORT
                                                { SERvce PLATFOSH
                                                                                                       KOPPERS - FORD
                                                                                                COKE O/ENSMOKE EMISSION ARATEMtNT
                                                                                                       PfRD MDTOR COUWNY
                                                                                           GAS SCRUBBER SYSTEM - ELFV  ARRGT.
                                                                                              Bv|w.awHiTE|r/:r!3-i5-

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H. Flooded Elbow (Figures 12 and 13 - Drawings 319-A633-63**)



   After leaving the venturi scrubber the descending gases,  spray water



   and wetted dust particles will enter the flooded elbow which will  change



   the direction of the flow ninety degrees (90°)  and direct  it into  the cyclone



   separator.  The change in direction of the gases in the elbow will



   result in the heavier dust and entrained water particles  dropping



   out of the gas steam and into the water pool  on the bottom of the



   flooded elbow.  The water pool will also protect the elbow from dust



   abrasion.  The flooded elbow is made of 3/8 in. COR-TEN steel, with a



   clean-out door and a water drain connection.








J. Cyclone Separator (Figures 12 and 13 - Drawings 319"A633~63*0



   From the flooded elbow, the scrubbed gases enter tangentially into the



   lower level of the cyclone separator where centrifugal forces, due to



   the cyclonic action of the gas flow, cause the water droplets to separate



   out of the gas stream.  The droplets collect  on the outer wall of  the



   separator and flow down to a drain at the bottom.  The gases, free of



   entrained water, exit at the top of the separator and are directed down-



   ward through a 76 in. diameter duct to the exhaust fan at yard level.



   The 3/8 in. thick, COR-TEN steel separator is 15 ft. 8 in. in diameter by



   31 ft. 0 in. high and is designed to operate  at a pressure of minus 65 in.



   w.c. at the outlet connection.

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K.  Induced Draft Fan (Figures 12 and 13 - Drawings 319-A633"63fO




   The fan is designed for the following normal  operating conditions:




        Gas flow                          112,000 acfm




        Gas temperature                   132°F




        Gas density at fan inlet          0.0525 Ib./cu.  ft.




        Static pressure                   Minus  60 in.  w.c.




        WR2 (rotor)                       12,800 Ib.  -  ft.2




   The fan is a direct driven type,  arrangement  3, with motor operated




   variable inlet  dampers  that place the fan on  idle  between  pushes.




   The operation of these  inlet dampers is explained  in Figure 11




   (Drawing 319-A630).   The fan has  a 3/8 in.  COR-TEN steel  housing and




   1A in. thick blade liners.  The  bearings are ring oiled,  self-aligning and




   water cooled.  The fan  is supported on a  fabricated  steel  sub-base with




   pedestals and pedestal  caps under each bearing. The fan  blades are  water




   sprayed to insure against particle build-up by two (2) nozzles  located in




   the fan housing.  Each  nozzle delivers 3  gpm  of city water and  there are




   three (3) drains in the fan housing that  carry the water  to the drain sump.








   The fan is driven by a  2000 h.p., 1785 rpm, ^160 v.a.c.,  2^*0 amp, weather




   protected, NEMA Class II  induction motor  direct connected  through a  k-\/2  in.




   Fast's flexible coupling.   The motor is mounted on a sole  plate and  the




   bearings are oil cooled.

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   NOTE:   The induced draft fan, the 2000 h.p.  motor and the starting



   switchgear, transformers and resistance rack that supply the required



   4160 v.a.c. were supplied by Ford Motor Company.








M. Exhaust Stack (Figures 12 and 13 - Drawings  319-A633-63*0



   From the induced draft fan the gases are directed through an evase



   section into the exhaust stack that, in turn, directs the gases vertically



   above yard level before emitting them to the atmosphere.








   The 60 ft. high stack is 10 ft. in diameter  at the base with a 7 ft. 6 in.



   diameter top section and is made of 3/8 in.  thick COR-TEN steel.  A



   ladder extends the full height, and a manhole inspection cover is



   located approximately 3 ft. above yard level.








   To attenuate the noise emanating from the stack an Aeroacoustic model



   SSA-5 silencer of the stack-stuffer type Is  used.







N. Water Recirculating Tank (Figures 12 and 13  - Drawings 319-A633-632*)



   Dirty water from the flooded elbow and cyclone separator drains by



   gravity into a 5,000 gal. water reelrculating tank located beneath the



   flooded elbow at yard level.








   The 8-1/2 ft. diameter by 13 ft. high tank has two compartments that are



   separated by a weir.  The dirty water enters one side of the tank, and



   during the residence time before it flows over the weir, the solid

-------
   particles settle to the bottom where they are drained off to the quenching




   sump at approximately 50 gpm.  Make-up water to the tank is mill service




   water regulated by a level control valve.








P. Water Recirculating Pumps (Figures 12 and 13 " Drawings 319"A633-63*Q




   From the clean side of the water recirculating tank, water is pumped to




   the venturi  scrubber spray nozzles by two (2) water recirculating pumps,




   one operating and one standby.  Each pump is of the horizontal centrifugal




   type designed to deliver 1,000 gpm at 100 ft. tdh.  Pressure switches




   provide for automatic start-up of the non-operating pump on loss of



   water pressure in the system.  Each pump is driven by a 50 h.p. motor.








Q. Electrical and Instrument Control Panels (Figure 5 " Drawing 319-A629)




   Cabinets to house the electrical equipment and instruments to control the




   fan, fan motor, annunciators, and related components were placed in the




   existing control  room at the south end of "A" battery and in the reversing



   room between "AX" and "B" batteries.

-------

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                          SECTION V






                    ENVIRONMENTAL POSTURE






The design concepts introduced with this new system were developed for the




express purpose of eliminating the air pollution created from the pushing




of incandescent coke from the ovens into a shallow-bed car for transport




to a batch type station for quenching.








Potentially, substantial emissions of smoke and particulate are discharged into




the atmosphere during the period when the coke passes through the guide,




when the coke breaks up leaving the guide, and during the distribution of



coke into the quench car.  The quantity of the emissions encountered during




this operation is affected by the completeness or efficiency of the coking




process within that particular oven.  If the push contains coke that is not




completely carbonized, the combustion of the volatile matter will cause




considerably more emissions than a push that contains only coke that has




been properly carbonized.








The method of pushing and the type of machinery (i.e. coke guide, door




machine, locomotive, and quench car) used at Ford Motor Company are of the




conventional design used in all but a few coke plants throughout the world.








By placing a hood over the coke guide and quench car the objectives of the




system are to capture all of the gases and particulate matter, which are




generated from the coke push, as well  as the up-drafted air.  With the

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incandescent coke, the combustible gases, and the indrafted air, the gases



are burned to C02 and h^O.  In addition, the particulate matter is scrubbed out



of the gas stream, ultimately discharging only cooled gas, consisting mostly



of air, to the atmosphere.








For particulate matter to be collected and removed from a hood that covers



the emission source, sufficient capture velocities must be maintained to



keep the matter airborne until it reaches the cleaning device.  The hood at



Ford is designed with a clearance of 2 in. between the hood and quench car



when the seal plates are down and the car is in position.  This clearance



would give an indraft velocity of 30 ft./sec. and be more than ample



to negate the effects of external air movements, such as wind.  Due to the



settling and movement of the quench tracks,  the actual clearance after con-



struction was found to be considerably greater than 2 in. in some locations,



and the indraft velocities were measured at  12 ft./sec. which was still



sufficient to capture the emissions in all but the highest of wind conditions.



This greater clearance allows more air to be drawn into the gas stream and



results in lower gas temperatures and greater gas density.  The average gas



temperature  in the fume main just downstream of the oven being pushed was



found to be  approximately 400°F instead of the design temperature of 650°F



as indicated on Figure 3 (Drawing 319-A627).  This decreased temperature was



due mainly to the larger clearances and the  fact that the operator did not always

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 lower  the seal plates before each push.  Air leakage into the system from




 sources such as the perimeter of doors, expansion joints In the fume main, and




 the butterfly valve seat was found to be 5% as determined by Orsat




 analysis taken at both ends of the fume main.








 An analysis of the gas before scrubbing indicated that it contained 1.76




 Ibs. of particulate matter per ton of coke pushed.  The Ford ovens contain



 12 tons of coke which means that over 21 Ibs. of matter are generated from



 each push.  The Wayne County, Michigan, air emission code requires that




 the outlet loading from the stack must be less than 0.05 grains/scf which would



 require a scrubber efficiency of 97-5%.








 From tests made by Koppers the outlet stack loading was found to be 0.02




 grains/scf indicating that the gas cleaning system, when used as designed,




 has an efficiency of 99%-








 The water requirements of the system are mostly for the sprays in the




 venturi scrubber which require approximately 890 gpm of recirculated




water.  The solids are removed from the water by a settling chamber in the



 reelrculating water tank.  The chamber has  a continuous blowdown of




50 gpm to the quenching sump where the solids are clam-shelled out in the




normal manner along with the coke breeze from the quenching tower.  Make-




up water to the system is mill  cooling water.   Chemical analysis of the blow-




down water compared to the make-up water showed only slight Increases in




cyanide, phenols,  and thiocyanates,  with no increase of ammonia.  The remainder

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of the water required is city water for the cooling of fan bearings and fan



blade sprays, with the drains from each also going to the quenching sump.








To attenuate the noise created at the gas scrubber area, the fan housing



was sprayed with a 3/8 in. thick coat of sound deadening material and the



stack was equipped with a silencer of the stack-stuffer type.








When the system was first started in June 1972, the noise at the stack base



was excessive and the cause was found to be that the evase section at the



fan exit formed a ninety degree (90°) angle with the stack, and the air blast



against the outer wall of the stack created excessive  vibration.  By placing



brick in the stack base forming a radius to turn the air blast ninety degrees



(90°), the noise and vibration were reduced considerably.  Noise level at the



stack base after the brick was installed was 101 DbA dropping off to 81 DbA



at a distance of 60 ft.  from the stack at yard level.

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                         SECTION VI






                   CAPITAL COST ESTIMATES






The following cost estimates represent the installed cost of facilities




including overhead, engineering, material, and labor.  They are considered




representative of project cost prevailing to June 1972.






1.   Coke Guide Fume Hood including:




     (a)  Modifications to existing coke guide, door machine, quench car,



          and locomotive.




     (b)  Pusher machine to quench car synchronization unit. 	 $ 460,000






2.   Fume Collecting Main including:




     (a)  Main and truss




     (b)  Support towers, foundations, and piling




     (c)  Elevated third rail  	 $ 523,000






3-   Gas Scrubber including:




     (a)  Venturi  scrubber




     (b)  Cyclone separator with flooded  elbow



     (c)  Fan and fan motor




     (d)  Stack




     (e)  Recirculating water  tank  and pumps

-------
   (f)  Foundations and structural steel



   (g)  Instruments and controls



   (h)  Piping and electrical 	    $ 817,000
                                                  Total           $1300,000






The distribution of the total cost is estimated as follows:



Engineering, overhead and administrative expense 	    $  620,000



Material 	       600,000



Labor							-       580.000



                                                 Total            $1,800,000





The above price reflects the cost of the "Coke Oven Smokeless Pushing System"



as installed at Ford Motor Co.  Some items that could affect the cost of future



installations are:



1. The oven height, determining the size of the hood.



2. The number of ovens, determining the length of the fume main.



3. The number of support towers for the fume main and the distance between



   each tower.



l». The location of the Gas Cleaning System relative to the quenching sump.



5. Obstructions on the coke side of the battery requiring special design of



   the fume main, truss, and support towers.
                                 50

-------
6. The materials that the Gas Cleaning System components and Coke Guide Fume Hood




   are made from.




7- The number and size of the pilings required due to soil analysis.
                                   51

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52

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                            SECTION VII






      OPERATING COSTS. UTILITY REQUIREMENTS, AND MAINTENANCE






An evaluation of utility costs to operate the Smokeless Pushing System is




shown on Table 1.








The control panel  for the system operation is located on the door machine




and all functions  are initiated at that point by the door machine operator




requiring no additional  personnel over the conventional method of pushing.








For the most part  the major expense in the operation of the system is the




electrical utility requirements for the fan motor and water recirculating pump




motor.








During an average  1 hour operation, there are approximately four pushes.




When the guide is  racked into the oven in the normal manner (approximately 1




to 2 minutes before the push), the system is automatically placed on full




suction.  The push lasts for kQ seconds which means that the fan is on full




power for approximately 2-1/2 minutes at each push or 10 minutes of each  hour.




For the remaining  50 minutes the fan is at idle consuming half of its rated




power or 1000 h.p.








The water recirculating pump runs constantly at 50 h.p.
                                53

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                               TABLE I


                       UTILITY REQUIREMENTS


                            ELECTRICAL


QUANTITY          DESCRIPTION                                          KW

   1             Fan Motor	     850

           1/6 Time at 2000 h.p. (full  load)

           5/6 Time at 1000 h.p. (idle)

   2       VENTURI SCRUBBER WATER PUMPS  	      41

           1  operating and 1  spare

           50 h.p.
   k       ELECTRIC CYLINDERS
   1        FAN DAMPER CONTROL MOTOR
 Intermittent
Operation
                                    0.38
                                     TOTAL KW/HOUR 	          891-38


           KWH per year = 2k hrs. x 365 days x 891.38 = 7,808,488


                               WATER


50 gpm mill  water make-up to recirculating water tank

50 gpm x 60 min.  x 2*4 hr. x 365 days = 26,280,000 gal./yr.
                               55

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The four electric cylinders that operate the fume hood shroud, seal plates,



and butterfly valve along with the motor that controls the fan louvers are



intermittent in operation and the power consumption is negligible as shown



on Table I.








The 50 gpm mill water make-up to the water recirculating system at Ford is



drawn from the Rouge River Canal at a cost of pumping, only.








Maintenance requirements are listed on Table II with required preventive



maintenance being the only type that can be projected.  Maintenance due to



incorrect operation, malfunction, or accidental damage are considered to be



no more than any piece of operating machinery of similar magnitude.
                                56

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                             TABLE  I I


                       REQUIRED MAINTENANCE


 1. Check  lubrication to fan and motor bearings 	    weekly

 2. Ream venturi sprays 	    twice/week

 3. Open blow-down valve on dirty side of recirculating
   water  tank  to max. position for  10 minutes then
   return  to 50 GPM setting	    once/shift

 4. Check oil level of water pumps	    weekly

 5. Switch operating water pumps	    weekly

 6. Check  fan inlet louvers for travel	    daily

 7. Check  to see that fume hood shroud extends fully and
   seals against fume main	    daily

 8. Check all indicating lights to be sure limit switches
   are operating and bulbs are not  burned out	    daily

 9. Observe the following instruments to be sure system
   is operating properly 	    daily

   a)   Venturi scrubber differential pressure gauge

   b)   Fan bearing temperature gauges

   c)   Motor bearing temperature gauges

   d)   Fan ampere recorder

   e)   Gas temperature recorder

   f)   Water flow recorder

   g)   Water pressure gauge

   h)   Annunciators for fault alarms


The above maintenance should require an average of 1  hour and 30 minutes

per day.
                                57

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58

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                           SECTION VIII






                    POST START-UP MODIFICATIONS






The "Coke Oven Smokeless Pushing System" was placed into operation




in June 1972.  It was soon noticed that the noise and vibration emanating




from the base of the stack was excessive.  This was corrected by add-




ing brick in the stack base to form a turning radius for the air blast from




the fan outlet.








The synchronization system initially utilized a set of gears and a roto-




pulsar unit mounted on the quench car wheel.  The critical alignment and




the presence of water and coke breeze accounted for the rapid deterioration




of these components, and a set of vane operated limit switches was then




introduced to eliminate any physical contact in this environment.  Other




minor problems have plagued the synchronization system since start-up,




resulting in Ford's removing the baffle plates from the quench car, as well




as cutting back the end plates so the quench car operator can visually make




the catch.  When the synchronization system is reliably operating again,




the baffles and end plates are to be replaced to restore the system to its




designed capabilities.
                               59

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After several months operation, it was noticed that the operator did not



always lower the seal plates prior to each push, which results in even



larger areas where ambient air can infiltrate the hood.  After one



year the plates were never lowered, so it was decided to remove the



electric cylinders and fix the seal plates in a position with sufficient



clearance to allow the quench car and locomotive to pass by.








In spite of the seal plates remaining in the up position, the baffle plates



being removed from the quench car, and the end plates of the quench



car being cut back, the hood continues to do a satisfactory job of



collecting the pushing emissions in all  but extreme conditions, such



as severely "green" ovens and high winds.








Due to the uncertainty of the suction created in the main or the effectiveness



of the seal that runs the perimeter of each door, the fume main butterfly



valve was added to relieve the suction and assure that the electric cylinder



could open the doors.  In late 1973, a test was made keeping the butterfly



valve closed, then placing the main on full suction and opening the doors.



Several  days of  operation in this manner proved that the butterfly valve



was not required, so it was welded shut.








During the first winter, heat tracing was added to the water system to



prevent freezing and an enclosure with a space heater was built over the
                               60

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recirculating pumps by Ford.








The above mentioned modifications, through the combined efforts of



Ford and Koppers, bring the operating system up to date as of this



writing, with numerous design criteria being established for future



applications.
                                61

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62

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                            SECTION  IX






                  UNITS OF MEASURE - CONVERSIONS






Environmental Protection Agency policy  is to express all measurements




in Agency documents  In metric units.  When  implementing this practice




will result  in undue cost or lack of clarity, conversion factors are




provided for the non-metric units used  in a report.  Generally, this




report uses  British units of measure.   For conversion  to the metric




system, use  the following conversions:








To convert from                  To                  Multiply by




cfm                            m3/sec                  0.000^719




°F                                °C                   5/9 (°F-32)




ft.                               m                    0.301*8




gal.                              1                     3.785




gpm                            I/sec                   0.0631




gr/scf                         mg/Nm3               2288.136




hp                                W                  7^5.7



in.                               m                    0.025**



in. we                         N/m2                  2^8.84




Ib                               kg                    0.45*4




tons (short)Xhr                kg/hr                 907.185
                              63

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                                 TECHNICAL REPORT DATA
                          (Please read Instructions on the reverse before completing)
 1. REPORT NO.
   EPA-650/2-74-076
                                                       3. RECIPIENT'S ACCESSION-NO.
4. TITLE AND SUBTITLE
                                                       6. REPORT DATE
 Coke Oven Smokeless Pushing System Design Manual
               September 1974
                                                       6. PERFORMING ORGANIZATION CODE
7-AUTHOR(S)R.O. McClelland, Koppers Co. , Inc.
1420 Koppers Bldg. ,  Pittsburgh, PA  15219
                                                       8. PERFORMING ORGANIZATION REPORT NO.
9. PERFORMING ORGANIZATION NAME AND ADDRESS

Ford Motor Co. ,  Steel Division
P.O. Box 1631, Dearborn, Michigan 48121
                                                       10. PROGRAM ELEMENT NO.
               1AB013; ROAP 21AFF-010
              11. CONTRACT/GRANT NO.
                                                        68-02-0630
 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
               Final; 1970-June 1972	
              14. SPONSORING AGENCY CODE
16. SUPPLEMENTARY NOTES
 16. ABSTRACT
              rep0r£ describes the design (by Koppers Co. ) and operation of a system
 to eliminate atmospheric emissions during the pushing of coke from the 45-oven
 A-battery at Ford Motor Co. 's Rouge Plant in Dearborn, Michigan. The system was
 placed in operation in June 1972 and, after a 1-month debugging, was accepted as an
 integral part of the regularly operating battery equipment. The 10-year-old A-battery
 consists of 45 13-ft high ovens , each producing 12 tons of blast furnace coke at a gross
 coking time of 18 hours with a "push" scheduled each 15 minutes. The Coke Guide Fume
 Hood, where the entire coke guide is enclosed with a hood that extends out over the
 quench car, was used to eliminate the  pushing emissions. Prior to the push,  the hood
 is connected to  a stationary fume main that is under a partial vacuum; the hot coke
 emissions generated during the push are conveyed to a high-energy wet-type gas
 scrubber where the  gas stream is cleaned before being emitted to the atmosphere.
 Clearances between the hood and  quench car are held to a minimum to provide suffic-
 ient indraft velocities to overcome normal lateral wind effects. These effects have
 been evident in  similar installations  in Japan and Germany where wide clearances have
 been required to permit the quenching  car locomotive to pass under the hood. In the
 A-battery the quench car profile is built up and a 110,000-acfm fan ensures sufficient
 inrirnft
 7.
                              KEY WORDS AND DOCUMENT ANALYSIS
                 DESCRIPTORS
                                           b.lDENTIFIERS/OPEN ENDED TERMS
                          c.  COSATI Field/Group
Air Pollution
Coking
Iron and Steel
   Industry
Metallurgical Fuels
Coke
Has Scrubbing	
8. DISTRIBUTION STATEMENT

Unlimited
  Air Pollution Control
  Stationary Sources
  Coke Pushing
  Coke Guide Fume Hood
  Quench Car
13B
13H

11F, 05C
21D

07A
  19. SECURITY CLASS (This Report)
   Unclassified	
21. NO. OF PAGES

     72
  20. SECURITY CLASS (This page)
   Unclassified
                           22. PRICE
EPA Form 222O-1 (9-73)
61*

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