In an industrial coke processing plant, the resulting coke oven gas had to be discharged in a controlled manner in the event of malfunctions and burned as completely as possible. At the same time, the plant’s strong tendency to contamination placed high demands on the valve technology used. A robust, process-reliable solution was required for gas routing and condensate drainage under demanding operating conditions.
At a glance
- Industry: Heavy industry / process industry
- Application: Coke oven gas treatment in a coking plant
- Medium / Process: Coke oven gas, steam, condensate
- Challenge: High susceptibility to contamination, emission reduction, safe media handling
- STASTO solution: Combination of a slide gate valve for steam injection and an angle seat valve for condensate drainage
- Result: Reduced emissions, lower plant contamination, stable process operation
The challenge
In coke production, coke is used as a reducing agent for blast furnace processes. During production, coke oven gas is generated, which is discharged via flare systems in the event of a malfunction. These operating conditions lead to increased emissions and heavy contamination of plant components.
The process conditions were characterized by gaseous media with varying operating states as well as by the integration of steam for post-combustion. In addition, condensate resulting from the steam injection was produced, which had to be discharged in a controlled manner.
Standard valves were not sufficiently suitable for this combination of gas conveying, steam injection and condensate drainage under conditions with heavy contamination. What was required was a technically precisely matched solution with high operational reliability and dependable function, even in continuous operation.
The STASTO solution
To achieve an almost complete combustion of the coke oven gas, steam was specifically mixed into the gas flow via a slide gate valve. This design is particularly suitable for demanding media and enables robust, process-stable control of the steam dosing.
The condensate produced during steam injection was safely discharged via an angle seat valve. This valve design is characterized by high flow capacity, good controllability, and reliable sealing – even in thermally stressed applications.
The combination of both valve types enabled a functionally separated but systemically integrated solution:
- Precise steam injection for emission reduction
- Safe discharge of condensate to prevent deposits and operational disturbances
The integration was carried out in close coordination with the plant manufacturer. The installation situation, media routing, maintenance accessibility and long-term stability were the main focus of the technical design.
The result
Targeted steam injection enabled the coke oven gas produced to be almost completely combusted.
The contamination of the system was significantly reduced, thereby decreasing maintenance effort and downtime risks. At the same time, emission levels during malfunction operation were significantly reduced.
The valve combination used proved to be operationally reliable and consistently dependable – even under the demanding conditions of a coke processing plant.
Added value for machine builders
- Technically coordinated combination of different valve types
- High process reliability with gaseous and condensing media
- Robust design for contamination-intensive applications
- Good integration capability into existing process plants
- Maintenance-friendly design
This solution is particularly suitable for
- Coke and coking plants
- Process plants with flare operation
- Gas treatment plants
- Applications with steam injection
- Systems with a high tendency to contamination
Contact
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