CROSS REFERENCE
This Application is an application for grant of a Patent of Addition to Patent
Application No. 1114/KOL/2011 filed in the name of Tata Steel Limited.
FIELD OF THE DISCLOSURE
The present disclosure relates to an arrangement for addition/use of Molasses
(Khandsarisira) in stamp charged coke making for producing the improved
quality of coke i.e. coke strength after reaction (CSR) and coke production
with the lesser use of coal blend moisture. More particularly, the present
invention relates to an arrangement (100) for sprinkling molasses over coal
conveyor for producing improved quality of coke.
BACKGROUND OF THE DISCLOSURE
In stamp charge coke making technology making stable coal cake is a
challenge. The factors controlling coal cake stability are coal grain
distribution, stamping energy and the water content as the binder. Water has
the detrimental effect on hot silica refractory. Moreover, occasional coal cake
breakage is common.
During laboratory scale trial it was found that molasses is acting as a good
binder for providing good stability of coal cake. Therefore, replacement of
part water improved the coke quality and fuel efficiency of the coke plant.
To find the alternative thought of binder other than water lead to this unique
solution of adding molasses in coal for the first time in coke making history. There
are many instances of using various type of chemical binders, but molasses, a by-
product of the sugar industry and very cheap found to be the best solution techno-
economically in coke making. Molasses addition not only improved coal cake stability
and reduced coal moisture as envisaged, but it also improves coal throughput, CO2
footprint as known from Indian Patent application no. 1114/KOL/2011.

SUMMARY OF THE DISCLOSURE
The present disclosure relates to developed an arrangement for a low-cost
safe binder for increasing the throughput, improving the coke quality
especially coke CSR in recovery stamp charge coke making process.
The present disclosure provides an arrangement for developing a low-cost
safe binder for increasing the throughput, improving the coke quality
(especially coke CSR) in recovery stamp charge coke making process. More it
also relates to a method for improving metallurgical coke strength at high
temperature by carbonization different type of coal blend in stamp charging
condition adaptable to smooth operation of the blast furnace and producing
low-cost hot metal. In stamp charge coke making, the stability of coal cake
has become a subject matter of considerable importance as it not only
ensures trouble free stamping but also prolonging the coke oven battery life
and improved the productivity.
In this disclosure, plant scale trial had shown a reduction in coal blend
moisture by ≥1.0%. One percent reduction in moisture means reducing
10200kcal/t heat and reduces 10000t CO2 emission on coke oven batteries
number 8 & 9. This reduction of moisture improved the oven throughput and
increased the coke production by 0.75%. The disclosure also showed that
improvement in coke quality especially coke CSR by 1.0-2.0 point (1 point
improvement in coke CSR reduces 2kg coke rate for producing 1 ton hot
metal) and hence it contributes the stability of the hot metal and it also
contribute towards the reducing coke rate. This indicates an improvement in
thermal efficiency and which may reflect in specific heat consumption or
higher coal throughput on full-scale implementation. These improvements are
over and above the improved coal cake stability which will lead to better coal
throughput and improved battery life.

Experiment
The coal blend used in the study was characterized through physical,
chemical and petrographic analysis at Coal and Coke Testing Laboratory. The
typical analysis of coal blend is shown in Table 1.
Carbonization test in Coke oven Batteries
The trial was taken in 4.5 meter tall commercial recovery stamp charged coke
oven batteries at Tata Steel Limited Jamshedpur. These batteries consist of
series of ovens (70 numbers of ovens in each battery) separated by heating
chambers. These ovens and heating chambers are arranged in an array to
form a coke oven battery. Each oven also has an ascension pipe, which is
connected to a common pipe called Hydraulic main, which in turn is
connected to Gas collecting main. Through this pipe, the gas generated
during carbonization is taken to by-product plant. In the ovens of these
batteries, the coal is charged in the form of coal cake (bulk density of
charged coal cake is ~1150kg/m3), which is prepared by stamping of the coal
with the help of stamping-cum-charging and pushing (SCP) machine, and
hence these batteries are called stamp charge batteries. The all other
operating parameters like coal charge, granulometery, cross-battery
temperature, coke end temperature, and coking time were maintained
identical during the present disclosure.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
The disclosure, its functioning and the development to carry out the method
according to the disclosure will become more clearly understood from the
following detailed description of the embodiments and with reference to the
accompanying drawings in which:
Fig. 1 – show an overall process flow sheet of molasses storage, mixing and
dosing scheme

Table 1 depicts the important properties of coal blend.
Table 2 depicts the important properties of molasses.
DETAILED DESCRIPTION OF THE DISCLOSURE
Table 1 presents the typical properties of charged coal blend like ash
(13.27%), volatile matter (23.46%), free swelling index (6.5), maximum
fluidity (240 ddpm), maximum expansion (13%) and maximum contraction
(23%) during the plant trails in stamp charged coke oven batteries.
Table 2 present the important properties of Molasses like appearance (dark
brown syrupy liquid), physical state (liquid), solubility (soluble), order
(sweet), specific gravity (1.4-1.5), TRS (40-45 g/100 g), brix (85-95%) and
sucrose (18-25g/100g).
The present inventors have conducted extensive research to develop to use a
low cost and safe binder to obtain stable coal cake with lower coal cake
moisture in stamp charge coke making technology to producing coke of
desired coke quality for the blast furnace.
Since molasses (Khandsarisira) is a viscous material, therefore, it is difficult
for homogeneous mixing in running coke plant. Therefore, it was felt
necessary to make a mixing, spraying and dosing/addition arrangement in
coal blend in commercial stamp charge coke oven batteries. To overcome the
issue, a novel process of homogeneous mixing and dosing of molasses in a
predefined ratio in coal blend have been developed for smooth operation of
the coal handling plant. The arrangement is very flexible to dose desired
quantity of molasses in a better manner without any hindrance of the coke
plant operation. This idea is a novel and is first in kind idea.

Process Flow Sheet
An arrangement (100) is shown in Figure 1. The arrangement (100) used
molasses storage tank (108), mixing and dosing tank (112), overflow tank
(124) and molasses spraying sprinkler (120) with nozzle assembly.
The molasses is unloaded from the tanker through pump-2 to molasses
storage tank. A manual valve is provided at suction and discharge of pump-2
to have a better control while unloading. Two manual valves are provided
after the pump-2 and before the molasses storage tank for loading the
material.
Molasses storage tanker can have a capacity of 10000 liters with an agitator
for mixing and delivery of uniformly mix material. The tank is fitted with a
level sensor for measuring the material level inside the tank to avoid the
material overflow from the tank. A sampling valve is provided at the bottom
of the tank for sample collection and analysis.
The discharge line of storage tanker is mixing and dosing tank (112) which is
used for preparing a required assay of the molasses solution. The overflow
lines from the storage tank and mixing and dosing tank are connected to
overflow tank.
The schematic diagram of the mixing and dosing tank is showed in Figure 1.
Dosing tank has a capacity of 12000 liters. One water line is connected to top
dish of the tank for dilution of the molasses. The required quantity of water
and molasses are transferred in mixing and dosing tank with the help of flow
meter. This tank is fitted with an agitator (116) for and delivery of the
homogeneous mixed material. The tank is fitted with level sensor for
measuring the material level inside the tank to avoid the material overflow
from the tank. This tank is also fitted with the sampling valve at the bottom
of the tank for sample collection and analysis.

The overflow line of molasses storage tank and mixing & dosing tank is
connected to overflow tank. One water line has been connected with overflow
tank for dilution of the molasses. A compressed air line is connected to the
overflow thank for uniform mixing of the molasses with water. The connected
airline also helps for spraying the molasses assay on a coal conveyor belt
(104) with the help of spraying nozzle. A line is provided at the bottom of the
tank for discharging the residual material from the overflow tank. A pressure
relief valve is provided at the top of the overflow tank for releasing the extra
pressure (>1.5 kg/cm2) generated by compressed air during the mixing of the
molasses with water.
The flow rates of water and molasses are monitored by flow meters. This
tank has one overflow line at top and molasses assay discharge line at the
bottom. The agitator assembly provides the uniform mixing to prepare the
required molasses assay. The discharge lines connect with a pump which
transfers the molasses assay to spraying system. The flow rate of molasses
assay at main discharge line is monitored by flow transmitter/meter, and
necessary changes are made by regulating the manual valve after the flow
meter. Bypass line also provided in main discharge line for maintenance
purpose. This tank has a sampling line at the bottom for collecting the sample
for analysis purpose. The tank molasses assay level is monitored by radar
type level transmitter which is fixed at the top dish end.
The spray arrangement of molasses assay at coal conveyor is showed in
Figure 1. Two headers are placed at the top of the conveyor belt, and each
header has three nozzles for spraying the molasses assay on crushed coal at
the coal conveyor belt. The flow rate of molasses assay at spraying nozzles is
set according to the incoming moisture of crushed coal. The molasses assay
sprayed in such a way in coal conveyor belt so that the assay is uniformly
distributed over crushed coal.

1. The present disclosure is relates on the addition of the molasses
(Khandsarisira) at 0.1 -0.5% in coal blend which will provide better
results.
2. The present disclosure is based on reduction in coal blend moisture
ranges from 1.0-1.5% from the current level of moisture
3. The present disclosure is relates on improvement in coke strength after
reaction (Coke CSR) in the rage of 1.0-2.0 points.
4. The present disclosure is relates to the reduction of specific energy
consumption and CO2 reduction.
5. The present disclosure is relates to molasses or khandasarisira which is a
by-product of Sugar Industry.
The main advantages of the present disclosure are
1. Dosing system has been installed with semi-auto operation of mixing of
water and molasses in a predefined ratio to dilute molasses because
molasses is a viscous material and hence it is not mixed properly.
2. Designing of spraying nozzle at coal conveyor belt.
The property of coal blend to be used in the arrangement is shown in Table 1.
Table 1: Typical properties of coal blend


Similarly, the property of Molasses to be used in the arrangement is shown in
Table 2.

LIST OF ABBREVIATIONS:
BD : Bulk Density
CSR : Coke strength after reaction
FSI : Free swelling index
IM : Inherent Moisture
Ro (avg.) : Average reflectance of vitrinite
VM : Volatile Matter

WE CLAIM:
1. An arrangement (100) for sprinkling molasses over coal conveyor
(104), the arrangement (100) comprising:
a molasses storage tank (108) being configured to accept molasses
from molasses source by means of pipe line, the molasses storage
tank (108) being further configured to pump molasses to a dosing tank
(112);
the dosing tank (112) being further configured to accept water;
the dosing tank (112) comprising an agitator (116) to agitate mixture
of water and molasses, the dosing tank (112) being coupled to a
sprinkler (120) by means of pipe line to convey mixture of water and
molasses to the said sprinkler (120), the sprinkler (120) being
positioned over running coal conveyor (104); and
the dosing tank (112) and the molasses storage tank (108) being
coupled between an overflow tank (124) and line pipe between the
dosing tank (112) and coal conveyor (104) to accommodate overflows
from.
2. The arrangement (100) as claimed in claim 1, wherein the sprinkler
(120) being double head or triple head sprinkler.
3. The arrangement (100) as claimed in claim 1, wherein the the
molasses storage tank (108) comprises level sensor to sense the level
of molasses.

4. The arrangement (100) as claimed in claim 1, wherein the the dosing
tank (112) comprises level sensor to sense the level of mixture of
water and molasses.
5. The arrangement (100) as claimed in claim 1, wherein the the lines
between the molasses storage tank (108) and the dosing tank (112),
source and the molasses storage tank (108), the dosing tank (112)
and the coal conveyor (104) comprises flow transmitter to display and
regulate flow.
6. The arrangement (100) as claimed in claim 1, wherein the molasses
storage tank (108) comprises an agitator.