Reduction of emissions and energy utilisation of coke oven underfiring heating systems through advanced diagnostics and control (Ecocarb) : final report

The project aims are to reduce emissions and maximise the energy efficiency of coke oven heating using intelligent diagnostics and individual wall heating control. A new understanding of the combustion characteristics under abnormal conditions caused by through-wall leakage, combustion inefficiency and regenerator malfunctioning has been obtained using plant trials, physical modelling and analysis. The information and data from these investigations have enabled a data-driven real-time diagnostic system to be developed for detecting and identifying heating faults at early stages of occurrence. Waste gas analysis, plant data and process knowledge have helped in the identification of the main parameters for detection and location of heating faults (Tata Steel), required for the development of a diagnostic system. This system was further extended into a real-time advisory system (UNEW), which was implemented on-line at DLCO to provide feedback on heating faults to plant personnel. A regenerator inspection robot was developed and applied under real coke oven conditions as part of a complete evaluation of combustion efficiency, with guidelines to identify combustion problems (AMMR/CPM).An experimental heating flue was constructed to investigate the effects of through-wall leakage and nozzle blockage (BFI), and along with CFD modelling, it was shown that flue gas dust, CO, H2 and O2 contents can be used as indicators of heating faults. An individual wall heating control system was designed and implemented to counteract the effects from heating faults (Uhde), with no detrimental effect on NOX emissions or heat distribution.