EPA-650/2-74-Q76
September 1974
Environmental Protection Technology Series
m
-------
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
-------
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
-------
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
-------
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
-------
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
-------
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
-------
TABLES
TABLE NO. DESCRIPTION PAGE NO.
I UTILITY REQUIREMENTS 55
II REQUIRED MAINTENANCE 57
vii
-------
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
-------
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.
-------
-------
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-
-------
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-
-------
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.)
-------
-------
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
-------
-------
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
-------
10
-------
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
-------
12
-------
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
-------
lit
-------
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
-------
16
-------
-
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
-------
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
-------
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
-------
20
-------
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
-------
22
-------
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
-------
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
-------
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
-------
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
-------
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<
-------
28
-------
-------
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
-------
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
-------
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
-------
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
-------
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
-------
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
-------
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-
-------
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.
-------
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.
-------
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.
-------
-------
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
-------
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
-------
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
-------
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.
-------
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
-------
52
-------
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
-------
-------
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
-------
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
-------
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
-------
58
-------
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
-------
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
-------
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
-------
62
-------
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
-------
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*
------- |