AFT Fathom to Increase Efficiency at Steel Plant: Coke Oven Gas Cooling Temperature Improvement Project
AFT Fathom™ Case Study
ArcelorMittal Dofasco | Coke Oven Gas Cooling System | Mining & Metals
“Improved COG cooling temperatures will increase the
amounts of condensable material, such as tar and naphthalene,
dropping out of the gas during the initial stage of the cooling/cleaning
process.”
– Justin Clappison, Piping Specialist
PROBLEM
- $6M capital project to improve temperatures in Coke Oven Gas cooling system
- Chance to improve efficiency, improve by-product quality, and extend equipment life
ANALYSIS
- Improvements and additions to existing system were tested via an AFT Fathom model
- New operational requirements were validated
SOLUTION
- Model-informed pipe layout, flow rates, valve sizing, and pump/motor requirements to purchase with confidence
- New equipment achieved desired output temperature
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Problem Explained
ArcelorMittal Dofasco (AMD) is in the construction phase of a $6M capital project to improve their coke oven gas (COG) cooling system temperatures at the #2 By-Products plant in Hamilton, Ontario. Operational benefits of lower gas temperatures are increased efficiency of the COG cleaning/cooling process, improved by-product quality and reduced buildup that will extend equipment life and reduce maintenance time.
Tools & Analysis
Justin Clappison, piping specialist at AMD, used AFT Fathom to design improvements and additions to the existing COG cleaning system. The model was used to validate new operational requirements of the system.
COG is generated in a series of coke ovens during the coal carbonization process. The large volume of COG produced is continuously withdrawn from the coke ovens and delivered to primary coolers (PC’s) by a centrifugal blower. The COG undergoes the first stage of the cooling/cleaning process within the PC’s. Flushing liquor is introduced to the PC’s through a spray header arrangement. Cooling is achieved as the gas travels vertically upward through the PC’s, counter to the downward fall of flushing liquor. The ideal exit temperature of the COG is about 25 degrees Celsius (77 F). New flushing liquor pumps and piping are being installed as well as the PC’s internals modified to help achieve this temperature.
Solutions & Benefits
When asked about the benefits of AFT Fathom, Clappison said, “We were able to validate our piping layout, flow rates, control valve sizes, and pump/motor power requirements. Useful outputs were used in discussion with team members and vendors throughout the project. Proper equipment and valves have been purchased with confidence using the results of the software.”
AFT Fathom Model: Cooling system at #2 By-Products Plant in Hamilton, Ontario
Blue show pipe buildup downstream of primary cooler