On the production management of coke ovens

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Hope everyone can make use of it! (Please paste it directly here) Thoughts on Coke Oven Production Management, Tianjin No. 2 Gas Factory: Liu Hongguang Abstract: From the perspective of production practice, this article offers practical insights on how to address the key issues in coke oven production management. Focusing on the four core aspects that are interrelated in coke oven production management – safety, environmental protection, energy consumption requirements, and operational control – it discusses ways to optimize these aspects and improve performance, thereby achieving the best balance among safety, environmental protection, and economic efficiency. Keywords: safety, environmental protection, energy consumption indicators, operation, control, management. Coke production is a task that requires high standards in terms of safety, environmental protection, energy consumption, as well as operation, control, and management; these aspects are interrelated and influence one another. With the adjustments in the market economy and social development, new challenges and requirements have emerged regarding green and environmentally friendly production, control targets for energy consumption, safety standards for production that put people first, as well as high levels of efficiency in modern production operations. For over a decade, Tianjin No. 2 Gas Factory has focused on the management of coke oven production as its key priority, starting with safe production management in order to safeguard the survival of the enterprise ； Starting from environmentally friendly practices, upholding modern green and sustainable production concepts ； Starting from the rational optimization of internal energy, upholding the concept of maximizing the efficiency of modern energy ； Starting from strict operational control management, ensure a high standard of modern production operational control management ； Maximizing economic benefits has achieved good results. I. Safety Management Safety management is undoubtedly the lifeline of coke oven production, as dictated by the nature and characteristics of coke production. “The “safety” issue requires employees to develop a sense of their own safety and self-protection, to eliminate any unsafe practices, and to enhance the standardization of operations in accordance with the established procedures for their respective positions. We note that most of the problems related to \"safe\" production accidents are caused by \"unsafe operations\"; such \"unsafe operation practices\" represent the human factors that lead to accidents. To this end, a safety management system is established. 1. Strengthen the supervision of daily safety education for employees, and enhance their awareness of the importance of following operating procedures as specified for their roles. 2. Establish a long-term mechanism for safety management, as well as systems for safety management and operational supervision and assessment. 3. Establish and improve various safety management systems in accordance with ISO management system requirements, and ensure their effective implementation. 4. Strengthen the regular safety inspections and patrols of various equipment and facilities, as well as the supervision at key points, critical pathways, and essential surfaces in each manufacturing process. 5. Standardize various safety management plans for emergency repairs, maintenance, and inspections. 6. Strengthen, standardize, and optimize the maintenance, replacement, and renovation of various necessary equipment and facilities. 7. Establish an internal “safety tree” in the enterprise to strengthen safety supervision. II. Environmental Protection: With the advancement of the construction of \"environmentally friendly cities,\" modern industrial enterprises are required to adopt greener and more sustainable production methods to meet higher standards. Therefore, under the current circumstances, the characteristics of the coking industry mean that environmental management has undoubtedly become an essential focus within production management. Generally speaking, the environmental pollution issues that may arise during the coke oven production process are mainly coal smoke, waste gas, and soot. Controlling and managing these aspects is mainly approached from two directions: one is to strictly regulate all aspects of coke oven production ； Second, make the necessary investments and renovations in a timely manner. 1. Identify the weak points, determine the areas and stages where pollution occurs in the coke ovens, and ensure that all positions and work sites work together to create a cohesive effort aimed at preventing any operations that are not environmentally friendly. 2. Enhance the awareness of adhering to standard operating procedures for each position. The key is to ensure proper operation and to enhance environmental awareness. 3. Strengthen the intensity of regular inspections and maintenance, such as periodic inspections of the furnace walls, checks on the combustion condition, as well as timely spraying and repair of the furnace walls. 4. Strengthen the internal environmental protection inspection and assessment system. III. Energy consumption requirements: The amount of heat consumed by coke ovens is an important indicator for assessing the quality of thermal management in these ovens, and it also serves as an economic indicator for evaluating the efficiency of coke oven management. Therefore, efforts must be intensified in managing the factors that affect the heat consumption of coke ovens. 1. Strengthen the regular measurement and adjustment of the core temperature and standard temperature of the coke cake; establishing a reasonable thermal regime is the fundamental measure. 2. Controlling the temperature in the furnace top area at an appropriate level is crucial; this involves ensuring that the carbonization chamber is filled with coal during operation, reducing the residence time of waste gas in the furnace top, and lowering the temperature in the upper part of the coke cake while maintaining uniform heating throughout its thickness. 3. Configure an appropriate air excess factor to achieve proper combustion. 4. Reduce the exhaust gas temperature and strictly control it between 200----300°C, as shown in Table 1. 5. Strictly control the moisture content of the coal used in blending, and reduce the moisture content of the coal fed into the system ； Reducing the heat carried away by water vapor is an effective way to lower heat consumption, as shown in Table 2. 6. Ensure the tightness and thermal insulation of the furnace body and equipment, and strengthen the sealing and spray repair work on the furnace roof, furnace door, and partition walls around the small burners. Table 1: Coke Oven Heating Schedule
Month | Oven No. | Top Space Temperature (°C) | Flue Gas Temperature (°C) | Standard Hearth Temperature (°C) | Air Excess Factor | Heat Consumption (7%) KJ/KG – Machine Side | Heat Consumption (7%) KJ/KG – Coke Side
2006, February | 1# | 827 | 240 | 270 | 1235 | 1272 | 1.21 | 1.23 | 2379 | 2# | 833 | 280 | 280 | 1235 | 1272 | 1.19 | 1.21 | 2368 | 3# | 833 | 252 | 248 | 1234 | 1270 | 1.12 | 1.08 | 2653
2006, March | 1# | 828 | 240 | 271 | 1232 | 1269 | 1.19 | 1.21 | 2365 | 2# | 833 | 273 | 283 | 1232 | 1269 | 1.2 | 1.21 | 2387 | 3# | 833 | 232 | 225 | 1228 | 1268 | 1.15 | 1.18 | 2259
2006, April | 1# | 832 | 230 | 250 | 1222 | 1258 | 1.2 | 1.22 | 2376 | 2# | 832 | 270 | 260 | 1221 | 1258 | 1.21 | 1.19 | 2363 | 3# | 831 | 227 | 215 | 1223 | 1257 | 1.2 | 1.18 | 2281

Table 2: Coaling Coal Specifications
Month | Moisture (%) | Ash Content (%) | Volatile Matter (%) | Sulfur Content (%) | X (mm) | Y (mm) | G – Fineness (%)
06/02 | 9.3 | 9.85 | 28.19 | 0.8 | 36 | 15 | 76 | 75.3
06/03 | 9.2 | 9.94 | 28.46 | 0.76 | 37 | 15 | 71 | 75.4
06/04 | 9.3 | 9.88 | 29.43 | 0.73 | 32 | 31 | 73 | 75.0

IV. Operational Control and Management
Adjusting the production pace in response to market demands for coke, the conditions of raw coal, and the availability of gas from external sources is essential. It is necessary to adjust the coking time appropriately, as well as to modify the proportion of coaling coal in a timely and reasonable manner to meet the demand for gas and coke production. Optimizing production processes and strengthening management in all aspects are key to maximizing production efficiency, which is the main focus of daily operations in coal gas plants. By firmly focusing on the core aspect of production process management, it successfully integrated coal blending, coking time, and coke oven production management in a cohesive manner, and adopted a series of scientific and effective technical measures ； Optimize the existing coal sources to reduce the cost of coal fed into the furnace as much as possible while ensuring the quality of coke, and focus on maximizing the efficiency per furnace. At the same time, pay attention to the parameters of blended coal such as ash content, sulfur content, gel layer, cohesion, and fineness; significant efforts are made in the rational optimization of coal blending, resulting in good economic benefits. Strengthen the standardized operation management of coke ovens; only by standardizing daily operations can the normal operation of these ovens be ensured. Strengthen the daily maintenance of the furnace body; the quality of furnace maintenance is an important aspect of coke oven management and also reflects economic efficiency ； Therefore, standardizing the operational management in all aspects of daily activities is the key to ensuring this ； To address this, daily and regular inspections of the furnace walls have been intensified, along with timely and planned shot blasting repairs; this is also an aspect that ensures environmentally sustainable operation of the coke ovens. Strengthen the management of daily operations related to coal loading, leveling the coal layer, and coke pushing. These three aspects represent the spatial and temporal aspects of the daily operation of coke ovens, and they are closely related to aspects such as the stability of the heating system in the coke oven and the maintenance of the oven itself. Establish a reasonable heating regime under the specified coking time. Great effort is put into the operations that affect coke quality, focusing on key details in daily operations. Coal must be loaded completely, evenly, tightly, and uniformly; loading should minimize smoke generation, sparks, and coal spillage in order to reduce environmental pollution ； During leveling the coal, it is necessary to ensure complete leveling in order to reduce the formation of coke on the top, as shown in Table 3. Table 3: Coke quality – Monthly values in Mt%, Ad%, Vda%, St,ad%, M40%, M10%
06/02: 13.9, 12.86, 1.2, 0.71, 84.1, 8.3
06/03: 12.9, 12.69, 1.11, 0.72, 84.7, 8.2
06/04: 12.7, 12.80, 1.25, 0.71, 84.7, 8.3

V. Conclusion: As the **system continues to improve, economic development progresses, and awareness of safety, environmental protection, and energy consumption grows ； In the management of coke oven production, only by integrating safety, environmental protection, energy consumption, and operational control in a cohesive manner and making concerted efforts can we ensure the long-term smooth operation of coke production. This is the key to transforming effective management into tangible benefits, as well as the ultimate philosophy behind coke production. This post was last edited by liuze78 on 2007-12-5 08:30]