ON

COAL CHEMICAL PLANT(OBJECTIVES)To clean Coke Oven Gas for using it as fuel for heating Coke Oven Batteries and for other consumers.

COAL CHEMICAL PLANT(CLEANING PROCESS)Co-gas coming out of Batteries has Tar, Ammonia,Crude Benzol and gas rich in Hydrogen and methane. The Tar ,Ammonia and Crude Benzol is removed from Co-gas before it is used as fuel in batteries.

COAL CHEMICAL PLANT(CLEANING PROCESS- WHERE & HOW)The Tar, ammonia and crude benzol is removed in Gas Cleaning Plant (RECOVERY PLANT).

Tar is removed and sent to tar plant for the distillation to get tar products.

Ammonia liquor is separated from tar and pumped back to gas collecting mains.

Excess ammonical liquor is pumped to ammonia columns for further treatment. After treatment it is sent to MBC.

COAL CHEMICAL PLANT(CLEANING PROCESS- WHERE & HOW)Ammonia is removed in gas cleaning unit (Ammonium Sulphate plant). The gas passed through the 4-5% Sulphuric Acid Bath. Ammonia in Co-gas Reacts with acid and forms ammonium Sulphate.

Crude Benzol is removed in Benzol Recovery unit of gas Cleaning Plant.

COAL CHEMICAL PLANT(SUB-SECTIONS) RECOVERY

BENZOL PLANT

TAR DISTILLATION PLANT

RECOVERYGAS CONDENSATION PLANT(GCP)

AMMONIUM SULPHATE PLANT

BENZOL RECOVERY PLANT

MBC PLANT

RECOVERYBat-1Bat-2Bat-3PGCESPEXHFGCSc-2Sc-1CentrifugeDrierAmm-liquirSLUDGESaturatorAmo- SlurryTo consumersCo gasBO OILDBO OIL FROM BDPBaggingTarFogTarTAROILCO-GASseperator

GAS CONDENSATION PLANT(OBJECTIVES)Exhaust Co-gas from Batteries.Maintaining Constant Suction.Condensation of TAR& Amm. liquor.Continuous pumping of F.L to Batteries.Separation of Tar, F.L & Sludge.

GAS CONDENATION PLANT(EQUIPMENT)PGCs -10 no -20,000 cum/hr.ESPs -06 nos -40,000 cum/hr.Exhausters-5 nos-76,000 cum/hr.F.L Pumps -6 nos- 1,500 cum/hr.Decanters 8nos- 380 cum.

AMMONIUM SULPHATE PLANT(OBJECTIVES)To purify Co-gas To recover Ammonia.

CAPACITY OF ASP unit :-41,700 Ton / year

AMMONIUM SULPHATE PLANT(EQUIPMENT)Saturators -5nos.Centrifuges-5nos-3.2 Ton/hr.Drier-2nos-8.0Ton/hr.Bagging Machine-2nos-10bags/min

BENZOL RECOVERY PLANT(OBJECTIVES)Recovery of slip Naphthalene from Co-gas. Enriching Tar with Naphthalene.Recovery of Crude Benzol from Co-gas.

BENZOL RECOVERY PLANTTwo Streams of Co-gas flow.Each stream consists of One Final Gas Cooler.Two Benzol Scrubbers.

MBC PLANT(OBJECTIVES)Effluent Water treatment.

BENZOL PLANT(OBJECTIVES)To recover Crude Benzol from Benzolised Oil.To remove Impurities from Crude Benzol.To produce Pure Products from C.B.

BENZOL PLANT(SUB-SECTIONS)Benzol Distillation Section.Hydro Refining Unit.Extractive Distillation Unit.Crude & Finished Products Storage.

BENZOL DISTILLATION SECTION(OBJECTIVES)To separate Crude Benzol from Benzolised Oil.To separate HCB from Crude Benzol.

BENZOL DISTILLATION SECTION(EQUIPMENT)Two streams.Each Stream consisting of- Stripping column-1No.- Steam pre-heater-2Nos.-DBO Coolers-6Nos.- Oil-Oil Heat Exchangers-3Nos.- Oil Dephlegmators-2Nos.- Water Dephlegmators-1No.- Decanter-1No.Common for both streams--CB-1 Condensers-2Nos.-CB-1 Column-1No.-CB-2 Column-1No.

BENZOL DISTILLATION UNITCRUDE BENZOLDBO TO SCRUBBERSLIVE STEAMSTRIPPING

COLUMNCBONECOLUMN

CB-ICOOLERSTO CFPSCBTWOCOLUMN

CB-ISTEAMSTEAMCB-IIB.O

HYDROREFINING UNIT(OBJECTIVES)To remove Sulphour Compounds from Crude Benzol.To produce BTXS Raffinate for processing in Extrative Distillation Unit.

HYDROREFINING UNIT(FLOE SCHEME)De-Fronting agent(For removal of CS2)CB-1STAGE EVAPORATORHeating by tharmal oil.Recycle gas mixingEvaporation in stage.PER-REACTORNi-Mo CatalystStyrene Ethyl Benzene

H2MAIN-REACTORCo-mo CatalystThiophene Butane+H2SCondensation &seperation of RC gas

H2STRIPPER COLUMNTHERMAL TREATMENTREMOVAL OF H2SBTXS REFINATE

EXTRACTIVE DISTILLATION UNIT(OBJECTIVES)To separate non aromatics from benzene & tolune.To produce pure benzene, pure tolune, Light solvent oil &still bottom oil from BTXS Raffinate.

EXTRACTIVE DISTILLATION UNIT(FLOW SCHEME)BTXSP.D COLUMNXS Fr.Batch Distillation for LSN / SBO products.B/T Fr.E.D COLUMNN- Formyl Morphiline solvent used for removal of CH, MCH, from Aromatic Benzene, toluene.NFM dissolves H.C.N . A leaves as Vapours from top of column.NFM with dissolved H.C.STRIPPING COLUMN(VACUUM)HC(B/T)NFM Recycled to ED column.HC(B/T)BT SEPARATION COLUMNBENZENETOLUENE

CRUDE &FINISHED PRODUCT STORAGE UNIT(OBJECTIVES)To store crude benzol HCB and pure products.

To despatch HCB and pure products to customers by road tankers.

CRUDE &FINISHED PRODUCT STORAGE UNIT(EQUIPMENT)Total Storage capacityCB Tanks-4Nos-2800kl.PB Tanks -4Nos-2000kl.PT Tanks-2Nos- 400kl.LSO Tanks-5 Nos- 250kl.NA Tanks-2Nos- 100kl.HCB Tanks -2Nos - 200kl.

TAR DISTILLATION PLANT(SUB-SECTIONS)Tar Distillation Section.Pitch Cooling & Loading Area.Naphthalene & Anthracene Fraction Crystallization section (NAFC). Tar & Oil Storage.

Tar & oil storageDecanter 1 noReciprocating pump 2 noFurnace Fist stage1st EvaporatorWaterReciprocating pump 2 no

Furnace 2nd stage

2 nd EvaporatorSoft pitchReactorMH PitchCollecting TankPitch BaysFor coolingCutting & BaggingLight OilPhenolNaphthaleneWash OilAnthracene I OIlAnthracene II OIl

Distillation columnTo NAFC TAR DISTILLATION PLANT

TAR DISTILLATION SECTION

Tar received from FGC unit to TOS unit.From TOS tar is pumped to Decanter in TDS unit.After removal of water from decanter moisture content in tar reduces to 5-6%.Tar is heated in the first stage of furnace to a temp.of120-150 deg C and sent to first stage evaporator.In first stage evaporator complete de-moisturisation is done.

TAR DISTILLATION SECTION

Tar after first stage evaporator is again heated in II stage of furnace to a temp. of 330-350deg C.In the second stage evaporator oil fraction is separated from top of second stage evaporator(35-40%) and soft pitch from bottom.The oil fraction is sent to the distillation column, where individual oil products are tapped , cooled collected in storage tanks.

TAR DISTILLATION SECTIONTHE PRODUCTS FROM DISTILLATION COLUMN ARE AS FOLLOWS:-Light oilPhenol Fraction.Naphthalene fraction.Wash oil.Anthracene oil-I & II.

PITCH COOLING AND LOADING AREAThe soft pitch from second stage evaporator is sent to reactors, where it is subjected to areation to increase the softening point to get the Alluminium grade pitch.Al. grade Pitch is cooled in dumping yards. It cut, bagged and dispatched to customers.Part of the soft pitch is used to make PCM by mixing it with Anthracene & Wash Oil mixture

NAFC

Naphthalene fraction is further processed in NAFC unit to make Hot Pressed Napthalene(35-40Kg Cakes). The cakes are crushed, bagged and dispatched to customers.Drained Naphthalene oil is also produced in NAFC unit. It will have around 35-40% Naphthalene.

TAR & OIL STORAGE(OBJECTIVES)To store crude Coal tar and Oil products.

To despatch Tar, PCM and Oil products to customers by road / rail tankers

PERFORMANCE -CCP

Chart1

8.97

10.56

12.64

7.67

9.32

10.99

7.99

8.35

10.43

Sheet1

PERFORMANCE REVIEW OF COAL CHEMICAL PLANT

S.NoPARAMETERSUNITJAN'05FEB'05MAR'05APRIL'05MAY'05JUNE'05JULY'05AUG'05SEPT'052004-05

1Ammonium Sulphate YieldKg/Tdc13.1013.2013.5013.7013.0012.7012.8012.6013.0013.20

2Crude Benzol YieldKg/Tdc6.756.706.756.506.506.403.503.005.506.00

3Crude Tar YieldKg/Tdc32.0032.0032.0031.5031.6031.7032.0031.8032.1031.80

4NH3 Content in Raw Gasg/Nm39.2409.1469.2479.1289.2589.1508.8609.4759.090-----

5NH3 Content in Clean Gasgm/Nm30.0040.0360.0370.0390.0340.0310.0220.0350.034-----

6Benzol Content in Raw Gasgm/Nm329.08029.83027.64027.19028.83028.96028.35023.18029.810-----

7Benzol Content in Clean Gasgm/Nm310.1909.9409.7409.19011.3609.77011.36018.94011.040-----

8Tar fog in Clean Gasgm/Nm3-----------------------------------------------------------

9Naph.Content in Clean Gasgm/Nm30.3380.3350.3220.3180.3720.3800.1500.0290.220-----

10Q I of Tar2.1652.2852.3842.3942.3042.4732.2002.3202.620-----

PERFORMANCE REVIEW OF COAL CHEMICAL PLANT

S.NoPRODUCTIONSUNITJAN'05FEB'05MAR'05APRIL'05MAY'05JUNE'05JULY'05AUG'05SEPT'052004-05

1Ammonium SulphateTon32993000341434343345317832873257315037578

2Crude TarTon80337257806178908162795181868197776390379

3Crude BenzolTon155313581518142214811400785705112514750

4C G BenzeneTon6808005907006605104105006007433

5N G ToluneTon2102602162452802002002002402220

6Light Solvent OilTon65133105130145120901101251066

7SOL-110(N.A)Ton1301751651452101851501641581465

7Heavy Crude BenzolTon142163182206195200100702002319

8Still Bottom OilTon201512151015101518247

9H P NapthaleneTon2701902601861702051571671082543

10Coal Tar Fuel(PCM)Ton31803610245033003570280029302740254039390

11M H PitchTon228069028201700122021851345162564020430

1TAR DISTELLEDTon66304700705058005200630049105200335070590

2CRUDE BENZOL PROCESSEDTon1263158012751400148511709801120121513698

SALES-PERFORMANCE REVIEW OF COAL CHEMICAL PLANT

S.NoPRODUCTSUNITJAN'05FEB'05MAR'05APRIL'05MAY'05JUNE'05JULY'05AUG'05SEPT'052004-05

1Ammonium SulphateTon31042865217042263606311233233532318736309

2Crude TarTon1957151827979561641247624203438409719774

3H P NapthaleneTon252174245200513031452011272502

4M H PitchTon10301161270045157228657661550017561

5Coal Tar Fuel(PCM)Ton000012777184200

6WASH OILTon149011952525368749283

7D.N.OTon991541399911385981671091241

8Phenol FractionTon12489148109105116107120571312

10Heavy Crude BenzolTon140153127186132171142811521887

11C G BenzeneTon5878695903416189283211647018228

12N G ToluneTon1612402392283082182051822462449

13Light Solvent OilTon6411510122912161181351071159

14SOL-110(N.A)Ton128154181148183212137841191491

15Still Bottom OilTon10192091020609126

##SALES REVENUECrore8.9710.5612.647.679.3210.997.998.3510.43117.58

Q.I OF TAR FOR THE YEAR'05-MONTHWISE

MONTH

MONTH

SALES REVENUE FOR THE YEAR 2005-MONTH WISE(IN CRURES)

:

Sheet1

Sheet2

Sheet3

OUR SALEABLE CHEMICALSAmmonium Sulphate (PUSHKALA)Crude Coal TarHard PitchHP NaphthaleneDrained Naphthalene Oil (DNO)Phenol Fraction

CG BenzeneNG TolueneLight Solvent NaphthaSOL 110Coal Tar Wash OilAnthracene OilCoal Tar Fuel / PCM

AMMONIUM SULPHATE(PUSHKALA)Nitrogen by Wt. 20.60 % (min.)Moisture by Wt. 1.00 % (max.)Free Acidity by Wt. 0.04 % (max.)Packing 50 Kg Bag

CRUDE COAL TAR

Grade - 1Grade - 2Specific Gravity at 200C1.16 1.201.16 1.20Moisture % (max)4.004.00Viscosity ( E deg.) at 93 0 C1.70 2.501.70 2.50Residue on Distillation (above 360 0 C) % min. 5353Benzene Insoluble % max.1415Quinoline Insoluble % max.88

HP NAPHTHALENE

ColourWhite or Light BrownCrystallization Point78.500 CAsh by Wt.0.20 % (max)Moisture by Wt.0.50 % (max.)Sulphur by Wt.0.40 % (max.)Benzene Insoluble0.20 % (max.)

DRAINED NAPHTHALENE OIL (DNO)Specific Gravity1.02 (max.)Moisture 4.00 % (max.)Naphthalene30 - 50 %

PHENOL FRACTION

Specific Gravity0.99 1.00( at 20 deg C)Distillation(0-2100C)95.0 %Phenol (%)18 30Naphthalene30 % (max.)Moisture4% (max)

SOL 110 (NON AROMATICS) Specific Gravity0.84 (min) (at 15 deg C)Distillation Range 55 - 1100C ( 1 95 %)

COAL TAR WASH OILSpecific Gravity at 380C1.04-1.08Moisture % (max)4.00Distillation-------Up to 2300C % (max)10.002300C- 3000C % (max)85.00Above 3000C % (max)5.00Naphthalene % (max)15.00

TOLUENE (Nitration Grade)

Distillation Range0.6 (Including 110.60C)(1 - 96%)Specific Gravity at 15/150C0.870 - 0.874Residue on Evaporation5 mg/100 ml (max)H2S & MercaptanesNegativePurity (by GLC method)99.2 % (min)

TOLUENE (Industrial Grade)Distillation RangeUp to 1050C5 mlUp to 1200C90 mlSpecific Gravity at 15/150C0.860 - 0.875Residue on Evaporation10 mg/100 ml (max)H2S & MercaptanesNegativePurity (by GLC method)92.0 % (min)

CG BENZENEDistillation Range 0.6 (Including 80.10C)(1 - 96%)Specific Gravity at 0.879 - 0.886 15.6/15.60CResidue on Evaporation 5 mg/100 ml (max)H2S & MercaptanesNegativeTotal Sulphur (ppm max.)2.0Non Aromatics (ppm max)500Crystallization point (min) 5.30CPurity by GLC method99.92% min

HARD PITCH BALCO GRADESoftening Point (R&B)90 95 0 CCoking Value (conradson)53 (min)Benzene Insoluble 30% (min)Quinolene Insoluble10% (max)Ash 0.3% (max)

HARD PITCHINDAL GRADESoftening Point (R&B)86 - 105 0 CCoking Value (conradson)52 (min)Benzene Insoluble 27% (min)Quinolene Insoluble10% (max)Ash0.2% (max)

HARD PITCHNALCO GRADESoftening Point (R&B)105-112 0 CCoking Value (conradson)52 (min)Quinolene Insoluble 5-12% (max)Ash 0.5% (max)

HARD PITCHHINDALCO GRADESoftening Point (R&B)107-114 0 CCoking Value (conradson)54 - 56Benzene Insoluble 30 37 %Quinolene Insoluble7 - 12% Ash 0.5% (max)

HARD PITCHGRADE # 1Softening Point (R&B) 90 105 0 CCoking Value (conradson) 48 (min)Benzene Insoluble 25% (min)Quinolene Insoluble 12% (max)Ash 0.5% (max)

HARD PITCHGRADE # 2Softening Point (R&B)101-115 0 CCoking Value (conradson)51 (min)Benzene Insoluble 28% (min)Quinolene Insoluble12% (max)Ash 0.5% (max)

ANTHARACENE OILSpecific Gravity1.12at 200C (max)Moisture % (max)3.00Distillation % (max)20.00up to 3000C

COAL TAR FUEL (Pitch Creosote Mixture)Moisture % (max)4.00Viscosity ( E0)2 8 at 930 C

IN ADDITION TO ABOVE, MEDIUM HARD PITCH CAN ALSO BE MADE AS PER THE CUSTOMERS SPECIFICATION.

TOLUENE SolventsArtificial SweeteningPaint IndustriesRubber IndustriesRubber ChemicalsPrinting Ink.Benzoic AcidSodium BenzoatesSynthetic FibersAdhesivesBenzyl ChlorideThinners & Varnishes

HP NAPHTHALENEDye intermediatesInsecticidesDispersing AgentsTanning AgentsBeta NaphtholRefined Naphthalene

BENZENERaw material for various Drugs, Dye-stuff, Synthetic Rubber, Styrene.PesticidesMonochlorobenzeneCaprolactumPhenolDDTLAB

Nitro BenzeneAnilineMaletic AnhydrideCumeneCyclo-HexavonNylon-6Resin IntermediatesNylon IntermediatesStyrene

HARD PITCHHard Pitch is used in Industries requiring Pitch Carbon for Electrodes and it is used by Aluminium Industries.It is also used for manufacturing graphite and in blast furnaces ladle repair.

AMMONIUM SULPHATEMainly used as Fertilizer due to its nitrogen content.Presently also used as a Nitrogen bearing material in mixed Fertilizer in Fertilizer manufacturing plant.

LIGHT SOLVENT NAPHTHASolventsStarting material for Dyes.Printing InkThinner

COAL TAR WASH OILPreservation of Wooden SleepersCarbon Black Feed Stocks.Disinfectant

ANTHRACENE OILAnthracene Oil is an excellent material as a feed stock for Carbon Black and gives better yields and quality of the finished product.

DRAINED NAPHTHALENE OILNaphthalene bearing feed stocks.Naphthalene and Coal Tar Oils are separated and used for their specific end uses.