The coke oven by-product plant is an integral part of the by-product coke making process. In the process of converting coal into coke, the volatile matter in the coal is vaporized and this volatile matter results in a liquid condensate stream and a gas stream. The functions of the by-product plant is to recover by-product coal chemicals and to condition the gas so that it can be used as fuel.

Technology span

• Gas processing & Primary coal chemicals recovery plants.
• Secondary coal chemical processing, other chemicals, petrochemicals based on process licensor’s know how.
• Up scaling of pilot plant to commercial scale plant based on study conducted by clients.

Areas of activities

MECON had engineered and commissioned different projects for Coke Oven By-Product Plant with capacity to process coke oven gas from 20,000 Nm3/hr to 60,000 Nm3/hr per stream.

We undertake complete engineering & consultancy services for following By-Products & Coal Chemicals Plant.

• Coke Oven Gas Cleaning Plant consist of PGC, ETP, Exhauster, Decanter & Flushing Liquor Pump.
• Ammonium Sulphate Plant.
• Ammonia Destruction.
• Combined ammonia and H₂S treatment process.
• Benzol Recovery and rectification of Benzol to pure products.
• Tar Distillation Plant.
• Solar oil Regeneration Plant.
• Naphthalene recovery from Coke Oven Gas.
• Mechanised Naphthalene Crystallization Plant (MNCP)
• Revamping and retrofitting of By-Product Plant units of Coke Oven Battery

Comprehensive range of services

Study report of plant units

• Adequacy of existing plant units
• Study the present yield, quality & environment aspect.
• Design norms vis-à-vis actual operating records

Plant survey and condition study

• Study of operating parameters
• Survey of individual equipment, gas mains including mechanical, electrical, instrumentation
• Visual & appliance based survey covering ultrasonic & thermo-vision testing
• Asset evaluation
• EIA/ EMP reports

Reports

• Analysis of survey results
• Identify areas of defects & malfunctioning
• Specify modification, augmentation and replacement
• Recommend updating of technologies
• Recommend changes in operating and maintenance practices
• Recommend modus operandi of execution of work
• Cost estimation
• Techno-economic indices for updated technologies
• Market survey, site selection for green-field projects

Replacement /Retrofitting services

• Specify improved material of construction
• Modification scheme, technological up-gradation of plant & equipment
• Improve environment in existing plant premises meeting new pollution norm
• Increased operational and maintenance flexibility
• Incorporate additional safety requirement
• Dovetailing of computer compatible instrumentation
• Improved cost indices

Engineering

• Preparation of tendering specification
• Basic & detailed engineering for retrofitting in the working plants

Execution services - From concept to commissioning including

• Site selection.
• Process evaluation and recommending most viable process.
• Freezing of concept.
• Detailed Project Report.
• Basic Engineering.
• Scaling up from bench to commercial scale.
• Consultancy and detailed engineering.
• Design of equipment & piping system.
• Project planning, scheduling & monitoring.
• Procurement services.
• Inspection of Plant & Equipment.
• Supervision of construction & erection.
• Trial runs & commissioning.
• Guarantee tests.

Major projects executed

• Detailed engineering for complete By-Product Plant for Bokaro Steel Limited & Bhilai Steel Plant 4.0 Mt Expansion covering Tar Distillation Plant, Benzol Recovery & Distillation Plant.
• Basic & Detailed Engineering for Benzol Refining & Rectification Plant at Bokaro Steel Limited (Capacity 180 t/day).
• Turnkey execution of Benzol Recovery & Distillation Plant at Visakhapatnam Steel Plant based on in house technology.
• Turnkey execution of Benzol Refining & Rectification unit with Hydro refining & Extractive Distillation Technology at Visakhapatnam Steel Plant (capacity 180 t/day) based on know-how from M/s Krupp-Koppers.
• Basic & Detailed Engineering for By-Product Plant at Neelachal Ispat Nigam Ltd.
• DCDA Sulphuric Acid Plant at Bokaro Steel Limited - Turnkey Execution.
• Detailed Engineering for Electrolytic Manganese Dioxide Plant at MOIL, Nagpur.
• Revamping of By-Product units of SAIL Plants after condition study.

Major projects under execution

1.   I.S.P. Battery No. 10 Complex, Burnpur
2.   I.S.P. Battery No. 11 Complex, Burnpur
3.   Revival of 3rd Stream Benzol Plant, Bokaro Steel Plant
4.   Up gradation of CO & CCD, Rourkela Steel Plant
5.   By-product facility of CO Batt. 4, Visakhapatnam Steel Plant
6.   By-Product facility of Battery 4. Rourkela Steel Plant
7.   By-Product facility of Battery 1 & 2 , Bhilai Steel Plant
8.   By-Product facility of Battery 5, Bhilai Steel Plant
9.   By-Product facility of Battery 1 & 2, Bhilai Steel Plant
10. By-Product facility of Battery 6, Rourkela Steel Plant
11. 7 Mt Expansion (By-Product for Battery 11 Complex), Bhilai Steel Plant
12. 7 Mt Expansion(Sulphuric Acid Plant), Bhilai Steel Plant
13. Hydro Refining & Extractive Distillation Plant, Bhilai Steel Plant