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Water environment protection

For protection of water bodies against pollution by waste waters GIPROKOKS provides the following: Division of sewerage systems by sources of their formation (rainwater, sludge, utility, phenolic). Unit for sludge waters treatment for system of wet dust cleaning and hydraulic cleaning. Unit for mechanical and biochemical treatment of industrial phenolic waste waters with utilization of treated waste waters on the territory of coke oven and by-product enterprises.

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Processing of carbon-containing feed

Alternative technologies for using feedstock containing carbon Contemporary economic challenges: Insufficient production of oil and gas condensate. Necessity to ensure rational and effective usage of natural resources. Unstable prices for oil and motor fuel. Insufficient quality of domestically produced motor fuel.  Environmental problems of the conventional usage of hard coal fuel. Depleting potential of conventional technologies for the production of motor fuel.

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3D plan development
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Coal handling

GIPROKOKS performs complex design and engineering activities for conventional sequence of coal blend handling for carbonization: receipt, de-freezing, preliminary crushing, stocking, proportioning of coals, supply of coke oven and by product production wastes to coal blend, finishing grinding, mixing and transportation of coal blend to coal tower

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Architecture and construction

All technologies and concepts for subsequent construction work are specified taking into account the current rules and regulations: local, construction, climatic, functional, engineering, technological, fire-fighting, sanitary-hygienic, ecological, and also economic requirements of the Customer.

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Electrical engineering

GIPROKOKS elaborates electrical engineering part of design documentation for major construction, reconstruction and major repair of technological facilities and power supply facilities of coke oven and by-product enterprises.

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General layout and transport

This is an engineering document which solves a set of issues related to management of territory for construction: leveling; building; reconstruction; lanscaping.

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Coke production

GIPROKOKS executes complex designing of coke oven plant facilities: coke oven batteries for production of blast furnace and foundry coke; ovens for production of special kinds of coke; pushing emission control systems; coke dry cooling plants; coke wet quenching complexes; coke transportation, handling, screening, uploading and storage facilities; coal towers; garages for repair of coke oven machines; hangars for erection of coke oven batteries brickwork; refractories, materials and equipment storage.

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Coke dry cooling plant

GIPROKOKS is the founder of state-of-the-art technology of coke dry cooling. The widespread tightening of environmental standards and the need to introduce energy-saving technologies of high quality coke production alongside the deterioration of coking coal feedstock base predetermine the priority of coke dry cooling for the near future.

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Coke oven batteries for carbonization of stamped coal blend

GIPROKOKS has successfully implemented the technology of preliminary stamping (coal blend stamping) which is increasingly used to produce coke from coal blends with an increased content of lean-caking  coals up to 65% (conventional technology provides up to 35%). The essence of the process is the compaction of coal grains during stamping. This assists to improve coking of coal during carbonization and to produce coke of high mechanical strength.

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By-product recovery plants

Main design facilities: By-product recovery plant. The plants of hydrogen sulfide recovery from coke oven gas to produce sulfuric acid or sulfur. Crude benzene processing plants. Tar processing plants. Various binders preparation units. Tank batteries for liquid products. Storages for bulk products storing, packaging and loading. Coke oven gas fine purification units for long-distance gas transportation. Central plant laboratories. Liquid waste products utilization unit. Systems of by-product plants' equipment sealing. Fuel production units, including motor fuel, from coal and other raw materials. Technical projects of individually manufactured equipment.

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Heat-and-power engineering

Production of steam with various parameters and highly efficient generation of electric energy due to using secondary energy resources from iron & steel making plants, coke oven and by-product recovery plants as well as fossil fuels: Selection of optimal system for co-generation of steam and electric power on the basis of common heat and gas balance of production plant. Ensuring low prime cost of the generated steam and electric power due to using secondary energy resources. Using up-to-date equipment from the leading manufacturers (boilers and steam turbines of individual manufacture, gas turbines, gas reciprocating engines, etc.).

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Automated control systems

Following the policy of the uniformity between technology and automation of processes GIPROKOKS performs projects for creation and modernization of systems for automated control and management of technological processes using up-to-date equipment and software, accumulated experience of their implementation and continuous operation: Coke oven batteries. Coke dry cooling plants. By-product recovery plants. Associated facilities of coke oven and by-product plants.

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Atmospheric air protection

GIPROKOKS offers the following main technical solutions:

Elaboration and improvement of technological processes that allow to minimize negative impact upon environment.

Systems of dry coke cooling and complexes of wet coke quenching with improved design that reduce emissions of harmful substances into atmosphere.

Aspiration systems with single and two-stage cleaning of aspiration air with implementation of BAT-technologies.

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Coke production

Coke production
Coke dry cooling plant
Coke oven batteries

In modern design of coke oven batteries GIPROKOKS adopted heating system PVR (twin vertical flues with recirculation of waste gases)

Despite development of new technologies of direct reduction of iron, coke oven and blast furnace process remains the supreme technology in industrial production of ferrous metals.

Coke production

GIPROKOKS executes complex designing of coke oven plant facilities:
  • Coke oven batteries for production of blast furnace and foundry coke.
  • Ovens for production of special kinds of coke:
  • Pushing emission control systems.
  • Coke dry cooling plants.
  • Coke wet quenching complexes.
  • Coke transportation, handling, screening, uploading and storage facilities.
  • Coal towers.
  • Garages for repair of coke oven machines.
  • Hangars for erection of coke oven batteries brickwork.
  • Refractories, materials and equipment storage.
Design of ovens and units for production of special kinds of coke:
  • Continuous operation vertical type coke ovens for production of blast furnace and foundry coke,
    carbon reducing agents.
  • Circular coke ovens for production of blast furnace and foundry coke, carbon reducing agents,
    carburizing compounds.
  • Non-recovery coke ovens, horizontal or vertical ones, with production of coke, heat and/or
    electrical power.
Options of coke oven batteries design:
  • Capacity: from 200 thousand tones up to 1500 thousand tones of coke with 6% moisture per year.
  • Volume of carbonization chambers: from 20 up to 70.5 m.
  • Geometrical dimensions of carbonization chambers: height up to 7.4 m, width from 0.41 up to 0.56 m, length up to 20 m.
  • Heating gas supply: gun-flue, under-jet.
  • Type of heating: compound, mixed, coke oven gas.
  • Withdrawal of foul coke oven gas: by single, two gas collecting mains.
  • Method of charging: by gravity (coal charging car), stamped (using stamping) coal cake.
  • Air supply: single-stage conventional, multi-stage.

Coke ovens of GIPROKOKS design

Dimension range of coke ovens

HEIGHT, ММ LENGTH, ММ WIDTH, ММ VOLUME, М3
3800 13170 460 20,0*
4300 13980 410 21,6
4300 13120 500 24,6
5000 15040 410 27,3
5000 14940 450 29,8
5000 15900 500 35,8*
5500 14940 410 30,1
5500 15900 410 32,3
5500 15900 450 35,2
5500 14940 480 35,5
6000 13980 410 30,7
6200 13120 450 32,7
6250 16820 500 47,4*
6650 15860 450 42,9
7000 15860 410 41,3
7000 16000 410 41,6
7000 16820 480 51,0
7400 18740 500 63,4
7600 19680 520 70,5

 

Coke ovens of GIPROKOKS design ensure:
  • Production of coke of specified quality, uniform in degree of readiness and grain size.
  • Low heat consumption for heating of ovens and, accordingly, high thermal efficiency.
  • Low resistance of heating system.
  • Uniformity of heating lengthwise and heightwise the coking chamber.
  • Tightness and improved strength of brickwork and long service life of ovens (not less than 25-30 years).
  • Easy and optimal adjustment of ovens heating.
  • Comprehensive control of the technological process.
  • Favorable working conditions of the service personnel.
  • Emission standards.
Associated facilities of coke oven block:
  • In order to eliminate emissions of solid particles into atmosphere the coke oven batteries are
    equipped with pushing emission control (PEC) systems along with dry cleaning of dust –laden air.
  • Coke quenching may be carried out both in coke dry quenching plant and by coke wet quenching
    method.
Giprokoks has developed and is applying new coke handling process concepts:
  • Single-stage screening pattern with the use of new high performance vibrating screens.
  • Crushing of coke (before its screening) with the use of a roller-toothed crusher (both for the
    entire coke stream and with the separation and subsequent crushing only of coarse coke +80
    mm).
  • Separation of coke grade +80 mm at high-performance vibrating screens.
  • For maintenance of coke oven equipment and coke oven machines at coke oven batteries the provision is made for garages with a set of devices and a repair station.