Control of Coke Oven Emissions by Use of A Closed Pipeline Charging System

The body of information presented in this paper is directed to those individuals concerned with the control of air pollution emissions which occur as a result of the operation of by-product coke plants. It describes a new process which represents a major change in the charging operation wherein preheated coal can be charged to coke ovens via a closed pipeline system thus replacing the conventional larry charging car and thereby eliminating air pollution estimated to be as much as 70% of the total emissions from coke oven operations. Coal is dried and preheated in a continuous fluidized bed process utilizing products of combustion of coke oven gas. The coal is recovered in conventional cyclone collectors and conveyed to the ovens via a new and novel pneumatic conveying system where the gas used is superheated steam. Jet energy repeatedly thrusts the coal upward and forward through the pipe, obtaining a high efficiency of transport of solids ten times that of conventional systems. Major advantages of the process demonstrated to date include (1) elimination of emissions from charging, (2) reduction of emission from pushing, (3) improved battery top working conditions, (4) increased oven productivity as much as 45%.     

An Epidemiological Study of Exposure to Coal Tar Pitch Volatiles Among Coke Oven Workers

Recent studies of mortality among coke plant workers indicate that there is an excess of respiratory cancer among men employed at the coke ovens and that the mortality is related to work areas and length of exposure to coal tar effluents, the body of information presented in this paper is directed to categorization of coke oven jobs into different work areas in terms of exposure to coal tar pitch volatiles developing an index of cumulative exposure to investigate the dose-response relationship between exposure and mortality. The exposure data have been taken from a study conducted by the Pennsylvania Department of Health, State Division of Occupational Health, and mortality data are based on a long-term study of steelworkers, conducted by the Department of Biostatistics, University of Pittsburgh. A summary index calculated for each worker combining the level of exposure and length of time exposed indicates that, as expected, both these factors are related to the development of cancer, particularly cancers of the respiratory system.

Conclusions of note are: Measured levels of coal tar pitch volatiles are 2-3 times higher for men who work at the top of coke ovens as compared to men employed at the side of the ovens. Even though the specific carcinogenic element or elements in the coke oven environment are not known at the present time, in-. creasing levels of exposure to coal tar pitch volatiles are related to art increased risk of dying from malignant neoplasms. Further coal tar pitch volatile measurements need to be made and analyses designed which will specify the dose-response relationship more precisely. This will provide information necessary to evaluate the recommended Threshold Limit Value.     

A Microscopic Classification of Settled Particulates in the Vicinity of a Found Coke-Making Operation

The purpose of this study was the specific identification of the components of settleable particulate samples collected near a coke-making operation. The identification technique employed is a new application of reflected-light microscopic examination of polished sections of the material. The inherent optical characteristics of the individual particles are utilized to classify them as coal (high?, medium?, and low-volatile), coke (coke balls, pyrolytic carbon, slot-oven coke, and char), fly ash or mineral matter. The application of this method of analysis is unique in that classification of particles is based on these inherent optical properties and not on shape, color, or other subjective criteria. This microscopic classification technique is based on accepted methods and should be generally applicable by petrographers on the basis of the photomicrographs and the detailed procedures which are included. On the basis of the data obtained during a six-month study near a coke-making operation it is concluded that material handling and stockpiling operations are major contributors to settled particulate deposition, while coke oven charging was not a major source. This study has shown that a broad program of engineering control will be required to significantly reduce settled particulate deposition in the immediate vicinity of a coke-making operation.     

dry coke quenching,air pollution and energy: a status report

Dry quenching of incandescent coke after it has been pushed from the coking ovens is a proved, reliable process that is presently being used in several industrialized countries. Foremost among dry quenching’s advantages are: (1) virtual elimination of air pollutants emitted during quenching; (2) elimination of potential water pollution associated with wet quenching; (3) improvements in the working environment; (4) saving substantial amounts of energy in usable forms; (5) producing more usable coke that is superior to wet-quenched coke. By continuously circulating inert gases through a cooling chamber that contains hot coke, dry quenching recovers waste-heat energy that can be used to produce steam, to produce electricity, to preheat combustion air, to preheat coal, to dry coal, and to preheat feed water supplied to fuel-fired boilers. The pay-out period on the capital investment (approximately $7,100,000) for an installation capable of processing 5500 tons of coke/day is less than four years.     

AISI-EPA-Battelle Coke Oven Door Sealing Program

The problem of coke oven door leakage is generally recognized as one for which no proven solution exists. In 1974 the United States Environmental Protection Agency and the American Iron and Steel Institute entered into a jointly funded research project with Battelle Columbus Laboratories. The initial project was to define the problem by literature search, operator interviews and profile measurements of jambs and doors.

Numerous concepts of seal designs were developed and then rated by industry and Battelle reviews. It was determined that a metal-to-metal seal offered the greatest probability of success. It was felt that jamb warpage was the most serious problem to be solved.

In the fall of 1976 another contract was signed by EPA and AISI assigning Battelle the task of developing to the point of fabrication a system to eliminate or significantly reduce leakage from coke oven end closures. This program included mathematical modeling, physical modeling, field data collecting, analysis, and full scale unit design.

A retrofittable door seal design has been developed and preparations are underway for operating evaluation at eight steel plants. The design is retrofittable to the two principal coke oven doors in service and should accommodate the worst jamb warpage usually found.     

Fabric Filter Applications on Coke Oven Pushing Operations

Coke oven pushing emissions containing quantities of tars and dust require new approaches to adapt fabric filter collectors. This paper deals with the Wheelabrator/Taisei precoat filter systems being used on coke oven pushing operations. The Taisei test program and the filter installation at Tokyo Gas are discussed. The variables to be evaluated in the design of a fabric filter emission control system are examined.     

Fugitive coke oven gas emission profile by continuous line averaged open-path Fourier transform infrared monitoring

Although most coke oven research is focused on the emission of polycyclic aromatic hydrocarbons, well-known carcinogens, little has been done on the emission of volatile organic compounds, some of which are also thought to be hazardous to workers and the environment. To profile coke oven gas (COG) emissions, we set up an open-path Fourier transform infrared (OP-FTIR) system on top of a battery of coke ovens at a steel mill located in Southern Taiwan and monitored average emissions in a coke processing area for 16.5 hr. Nine COGs were identified, including ammonia, CO, methane, ethane, ethylene, acetylene, propylene, cyclohexane, and O-xylene. Time series plots indicated that the type of pollutants differed over time, suggesting that different emission sources (e.g., coke pushing, quench tower, etc.) were involved at different times over the study period. This observation was confirmed by the low cross-correlation coefficients of the COGs. It was also found that, with the help of meteorological analysis, the data collected by the OP-FTIR system could be analyzed effectively to characterize differences in the location of sources. Although the traditional single-point samplings of emissions involves sampling various sources in a coke processing area at several different times and is a credible profiling of emissions, our findings strongly suggest that they are not nearly as efficient or as cost-effective as the continuous line average method used in this study. This method would make it easier and cheaper for engineers and health risk assessors to identify and to control fugitive volatile organic compound emissions and to improve environmental health.     

Environmental Progress and Problems: A Chemical Industry Perspective

From 1995 to 2004, in Genoa, Italy, daily concentrations of twelve polycyclic aromatic hydrocarbons (PAHs) were measured in particulate phase (PM10), around a coke oven plant in operation from the 1950s and closed in 2002. The study permitted to identify the coke oven as the main PAH source in Genoa, causing constant exceeding of benzo(a)pyrene (BaP) air quality target (1.0 ng/m3) in the urban area till 1,900 meters distance downwind the plant. For this reason the plant was closed. Distance and daily hours downwind the coke plant were the main sources of variability of toxic BaP equivalent (BaPeq) concentrations and equations that best fitted these variables were experimentally obtained. During full plant activity, annual average BaPeq concentrations, measured in the three sampling sites aligned downwind to the summer prevalent winds, were: 85 ng/m3 at 40 m (site 2, industrial area), 13.2 ng/m3 at 300 m (site 3, residential area) and 5.6 ng/m3 at 575 m (site 4, residential area).

Soon after the coke oven's closure (February 2002) BaPeq concentrations (annual average) measured in residential area, decreased drastically: 0.2 ng/m3 at site 3, 0.4 ng/m3 at site 4. Comparing 1998 and 2003 data, BaPeq concentrations decreased 97.6% in site 3 and 92.8% in site 4.

Samples collected at site 3, during the longest downwind conditions, provided a reliable PAH profile of fugitive coke oven emissions. This profile was significantly different from the PAH profile, contemporary found at site 5, near the traffic flow.

This study demonstrates that risk assessment based only on distance of residences from a coke plant can be heavily inaccurate and confirmed that seasonal variability of BaPeq concentrations and high variability of fugitive emissions of PAHs during coke oven activities require at least one year of frequent and constant monitoring (10-15 samples each month).

Implications: Around a coking plant, polycyclic aromatic hydrocarbons (PAHs), concentrations depend mainly on downwind hours and distance. Equations that best fit these variables were experimentally calculated. Fugitive emissions of an old coke oven did not comply with the threshold BAP air concentration proposed by the World Health Organization (WHO), up to 1,900 m distance. The study identified the PAH profile of fugitive emissions of a coke oven, statistically different from the profile of traffic emissions. During its activity, in the Genoa residential area, 575 m away from the plant, 92.8% of found PAHs was due to coke oven emission only.     

Economics of Coke Oven Charging Controls

This study was undertaken to determine which of several alternative air pollution abatement systems affords the most economical solution to the control of atmospheric emissions during the charging of coal into by-product coke ovens. The study was limited to the consideration of existing by-product batteries, and the assumption was made that no coking plant has the alternative to do nothing nor will the plant choose to delay abatement through legal procedures. The data indicate that a jumper pipe installation with a new larry car provides the most economical control.     

Determination of PAH sources in dated sediments from Green Bay, Wisconsin, by a chemical mass balance model

Six sediment cores were collected from Green Bay, Wisconsin, in order to identify possible sources of polycyclic aromatic hydrocarbons (PAHs) by a chemical mass balance (CMB) model. The cores which were obtained in 1995 had total PAH concentrations between 8.04 and 0.460 ppm. 210Pb and 137Cs dating was used to determine historical trends of PAH inputs, and elemental carbon particle analysis was done to characterize particles from combustion of coal, wood and petroleum. The results show that coke burning, highway dust, and wood burning are likely sources of PAHs to Green Bay. The contribution of coke oven emissions (CB) for the Green Bay cores is in the range of 5 to 90%. The overall highway dust (HWY) contribution is between 5 and 70%. There is a maximum (approximately 67%) contribution of HWY around 1988 which is in agreement with the historical US petroleum consumption. The wood burning (WB) contribution is between 1 to 30%, except in core GB-A where a maximum (approximately 50%) is found around 1994. The average relative errors of measurement for x2 equal to the number of degrees of freedom, are 52.5, 56.2, 36.2, 52.3, and 42.8 (df = 3) for the Green Bay cores A, B, C, E, and F, respectively. The sums of the contribution factors are less than one, indicating gain of inert biological or other bulk material between source and receptor. The results of carbon particles for Green Bay core D show that coal, oil, and wood burning are consistent with the CMB modeling results.     

Source apportionment of polycyclic aromatic hydrocarbons in surface soil in Tianjin, China

Principal component analysis and multiple linear regression were applied to apportion sources of polycyclic aromatic hydrocarbons (PAHs) in surface soils of Tianjin, China based on the measured PAH concentrations of 188 surface soil samples. Four principal components were identified representing coal combustion, petroleum, coke oven plus biomass burning, and chemical industry discharge, respectively. The contributions of major sources were quantified as 41% from coal, 20% from petroleum, and 39% from coking and biomass, which are compatible with PAH emissions estimated based on fuel consumption and emission factors. When the study area was divided into three zones with distinctive differences in soil PAH concentration and profile, different source features were unveiled. For the industrialized Tanggu-Hangu zone, the major contributors were cooking (43%), coal (37%) and vehicle exhaust (20%). In rural area, however, in addition to the three main sources, biomass burning was also important (13%). In urban-suburban zone, incineration accounted for one fourth of the total.     

焦炉装煤烟尘治理方案的探讨

焦炉装煤烟尘含有害物质，污染环境，危害人体健康。袋式除尘器的使用，消除了烟尘的污染，但因投资大、运行费用高、操作复杂，难以得到快速、广泛的推广。根据实验结果和已有应用情况，本文推荐了三相流化床除尘装置和颗粒层除尘器，它们可用于焦炉装煤烟尘治理，其投资和运行费用会大大降低。     

焦炉装煤烟尘治理方案的探讨

焦炉装煤烟尘含有害物质,污染环境,危害人体健康。袋式除尘器的使用,消除了烟尘的污染,但因投资大、运行费用高、操作复杂,难以得到快速、广泛的推广。根据实验结果和已有应用情况,本文推荐了三相流化床除尘装置和颗粒层除尘器,它们可用于焦炉装煤烟尘治理,其投资和运行费用会大大降低。     

Lysimeter Test of Coke Plant Effluent Disposal to Land in India

ABSTRACT

From the Indian national point of view, the importance of coal carbonizing industries is great and growing. These industries produce huge quantities of highly polluted effluents and discharge them into rivers without proper treatment. A large coke plant of Bharat Coking Coal Ltd. has been surveyed, and the impact of its effluent on surface water quality is discussed. Approximately 175-200 m³ of effluents are discharged from the plant every day. Land application has been considered as a low-cost means of disposal of coke oven effluents. Column lysimeters were prepared by collecting soil from a nearby agricultural field, putting it layerwise into a column, and compacting it carefully to simulate the original in situ conditions. Raw effluents, diluted effluent, and water (as a blank) were applied to the three lysimeters twice a week with a 5 cm flooding. Upon application of diluted effluent (1:1) into lysimeter No. 2, the leachate collected at 190 cm depth was within the tolerance limit of drinking water standard (IS 10,500). The impact of raw and diluted effluent on groundwater quality and soil are discussed. The renovation efficiency of living filter (lysimeter No. 2) was 99.37% for oil and grease, 86.92% for COD, and 53.22% for TDS, and it is estimated that 2.73 hectares of land can be irrigated with the effluents of the coke plant without deteriorating groundwater and soil quality.     

Performance and Problems of Claus Plant Operation on Coke Oven Acid Gases

The application of Claus Plant sulfur recovery units to the coke oven gas (COG) acid gases at three Bethlehem Steel Corporation plants is discussed. While many of the problems encountered are not unique to coke oven gas-derived acid gases, it was found that special consideration must be given to the effect of components not normally encountered in the typical Claus plant application to petroleum derived gases. It is perhaps fortunate that the feed composition to the three units was sufficiently different to expedite recognition of the source of some of these difficulties. One substance of concern is the hydrogen cyanide normally found in COG acid gases. In the absence of some means of removing or decomposing this material before it enters the Claus Plant extensive corrosion within the unit is observed after a short period of time. This is due to the fact that, contrary to expectation, a substantial quantity of this material survives the burner flame. The various alternatives in its elimination are discussed. A second major contaminant in COG acid gases is particulate iron sulfide and iron cyanide. While the exact source of these materials is in doubt, there is little doubt that in the absence of their removal, inorganic blockages within the Claus Plant will occur. By properly accounting for the special properties of coke oven gas-derived acid gas we have recently achieved short term sulfur recovery efficiencies of 95% and higher.     

Aerial Detection of Vegetation Damage Utilizing a Simple 35-mm Camera System

The body of information presented in this paper is directed to environmental scientists interested in the detection of vegetation damage from air pollution. A dual 35-mm camera bank, manually operated from a small aircraft, was tested as a sensor system for detecting vegetation damage caused by air pollution. The cameras were filled with color and color infrared film and attached to a frame so that simultaneous exposure was possible. This gave a matched pair of photographs for each scene.

A test site was selected that contained three very large coal-fired power plants and a complex of beehive coke ovens. The power plants burn medium-sulfur coal (2 to 3%) which, after coal preparation, results in stack emissions of between 1500 and 2000 ppm sulfur dioxide (S0₂). The coke ovens are relatively old and have effectively no pollution controls. The ovens emit hydrogen sulfide, sulfur dioxide, a variety of benzene-based organics, and heavily dust-laden smoke. The areas near the power plants and coke ovens were monitored by photographic overflights on a regular basis. A variety of aerial photographs were made to test for optimum light conditions, exposure times, and altitudes. Field trips were carried out to examine photographed areas at the ground level.

Two areas were found to have vegetation damage on a scale that made aerial photographs useful. One area was damaged from effluent from the coke ovens; another area exhibited symptoms characteristic of oxidant-type damage where low sulfur dioxide concentrations may have been a contributing factor. In each case the 35-mm camera system was a success in terms of detecting and recording the stress. The chief advantages of such a technique are ease of operation, flexibility, and economy. Compared with conventional aerial photography, the savings are considerable. The disadvantages are small area coverage per photograph and difficulty in obtaining vertical photographs that would have a uniform scale. However, for this particular project, these were not serious drawbacks.     

小型焦炉废气和废水处理方法

焦炉装煤和推焦烟气合用 1套收集系统。除尘废水经吸附后用于熄焦 ,熄焦水经吸附后用于湿式除尘 ,实现循环零排放。煤气洗涤水循环为废水中氨氮的处理提供了可行的方法     

Coke Oven Pushing Emission Control System

This report deals with the entrapment, pickup, and transfer of hot gases during a typical coke oven push. Background information that led to the development of the Great Lakes Coke Oven Pushing Emission Control System is presented along with the problems that were encountered and solved during the design, construction, installation, and start-up of a pilot plant entrapment structure on a battery of 40 Simon Carves coke ovens. This unique entrapment structure has operated successfully since April 1972, and has been visited by representatives from almost all coke manufacturers in the U.S., as well as interested groups from several foreign countries. In addition to these operation groups, we have been visited by various state and federal pollution authorities, such as the Environmental Protection Agency, Battelle Institute, and National Institute of Occupational Safety and Health. At the present time we are erecting a similar entrapment structure on the north side of our plant, comprising 18 Koppers and 35 Wilputte ovens.     

Waste burning and heat recovery characteristics of a mass burn incineration system

An experimental investigation on waste combustion characteristics of a mass burn incinerator is conducted in this study. Three different charging modes, including operator manipulation, periodic feeding, and temperature control, are taken into consideration. The results indicate that the burning characteristics in the combustion chambers are closely related to the operating modes. For the operator manipulation where the wastes are sent into the incinerator in two short periods, the entire temperature distribution of the primary combustion chamber can be partitioned into two parts, thereby yielding waste group combustion. Temperature oscillations in both the primary and secondary combustion chambers are characterized for the periodic feeding. However, because of the shorter charging period and smaller amount of waste, the burning interaction between the two chambers is initially weak and becomes notable in the final stage. When temperature control is performed, the burning oscillation of the primary combustion chamber is further amplified so the combustion interaction is drastic. These exhibitions are mainly caused by the competition between endothermic and exothermic reactions. The instantaneous heat exchange efficiency of the cyclone heat recovery system (CHRS) installed in the incineration system is also evaluated to obtain details of energy recovery behaviors. As a result, the efficiency tends to decrease linearly with increasing temperature of hot flue gas. This arises from the fact that heat loss from the gas to the environment is increased when the temperature of the former is higher, even though the temperature gradient across the cyclone is enlarged.     

Characterisation of volatile organic compounds and polycyclic aromatic hydrocarbons in the ambient air of steelworks

Investigations have been undertaken at two integrated steelworks in the UK to characterise airborne organic micro-pollutants and to assess the contribution of iron ore sintering and coke making operations on the air quality. Concentrations of volatile organic compounds (VOCs), namely benzene, toluene and p-xylene, were measured continuously within the boundary of a coking plant using for the first time differential optical absorption spectrometry (DOAS) between 2004 and 2006. Concentrations were obtained along two monitoring paths surrounding the coke plant and the average benzene concentration measured along both paths over the campaign was 28 μg m^?3. Highest benzene concentrations were associated with winds downwind of the coke oven batteries. Concentrations of polycyclic aromatic hydrocarbons (PAHs) in ambient air were measured during 27 consecutive days in 2005 at three different locations on an integrated steelworks. PAH profiles were determined for each sampling point and compared to coke oven and sinter plant emission profiles showing an impact from the steelworks. The mean benzo [a] pyrene concentration determined in the immediate vicinity of the coke ovens downwind from the battery was 19 ng m^?3, whereas for the two other sites average benzo [a] pyrene concentrations were much lower (around 1 ng m^?3). Data were analysed using principal components analysis (PCA) and results showed that coke making and iron ore sintering were responsible for most of the variation in the PAH concentrations in the vicinity of the investigated plant.