Appleby Coke Ovens, Scunthorpe by Manoj Sharma This paper was ...

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BackgroundIn December 1995 continuous obscuration meters were installed in the 2 coke oven battery stacks.These meters give an indication of poor gas combustion and/or oven leakage. Following theinstallation the EA gave AFCO a daily average consent limit of 60% which stayed in place until June2004 when it was reduced to 50%. This new limit made it difficult to stay in consent and a number ofout of consent reports were submitted to the EA. In 2006 following a significant number of out ofconsent reports an action plan was agreed with the EA to arrest the situation. This action planinvolved significant work in the gas alleys on the gas pipe work, waste gas boxes and air distributionsystem. This work was carried out successfully but did not fully solve the problem and it was agreedin a further action plan to start a project to improve obscuration.The main issues since the start of the whole exercise in 2006 have beeni. Gas pipe work blockages.ii. Carbon build up on the air distribution dussenplatters.iii. Water damaged end flues and air ports.iv. Blocked/broken gas nozzles.The problems identified since the start of the improvement work is listed. Some of these problems,specificallya. Sliding joint missing on 3&4 batteriesb. Access to gas cannons on OSC batteriesc. Collecting main to Conducting main restriction on 3&4 Batteries have not beenactioned to date.Project workA DMAIC methodology has been adopted to carry out the project. In this methodology the variousphases e.g. Define, Measure, Analyse, Implement and Control were carried out.In the Define phase, project charter (Figure – 1) has been prepared which talks about the businesscase, problem statement, goal, in scope, out of scope, deliverables etc.Also it has the system for reviewing the progress based on the plan. The expected financial benefits(tangible or intangible) also indicated on it. Further, to understand the process better SIPOC has beencreated, which talks about supplier (Providers of Inputs to the proces), input (Material, resources, ordata required to execute the process), Process (Collection of activities that takes one or more kinds ofinput and creates output that is of value for the customer), output (the products or services that resultfrom the process) and customer (the recipient of the Process output) and establish a relationshipbetween.
Business Case:Obscuration is a very important parameter for coke ovenbatteries from environmental point of view. It effects thesurrounding environment. If obscuration increases,external complaints started increasing. Running below50% level is a prime factor in license to operate.Problem Statement:In past 12 months average obscuration from stack 1&2was frequently above 50%.Goal:To run the stacks at AFCO below 50% by CY08.In Scope :Heating, minor wall repairs etc.Out of Scope:Major regenerator problem, coal quality, gas quality etc.DeliverablesPROJECT CHARTERTeam Members / Potential Team MembersNameRoleMr. M.K.SharmaMemberMr. Tim BartholomewMemberMr. Nigel WeltonMemberMr. Mick ScarfMemberMr. Simon ClowesMemberMr. Martin KeechMemberMr. Stuart BirdMemberProject StatusProcess Impacted: Coke makingClient(s) Impacted: Environment DepartmentBig Y Impacted: Stack ObscurationProject TimelineStart Date: 10/06/2008 Completion Date: 31/12/2008Phase (Expected) Completion DatesDefine: 10/06/2008Measure: 15/06/2008DMAJun’08 Jul’08 Aug’08 Sep’08 Oct’08 Nov’08ICDec’08EPA compliance of Obscuration (
Page 4 and 5: Process capability of stack1 of AFC
Page 6 and 7: NOZZLE CONDITIONSDMAICBatt#1 Nozzle
Page 8 and 9: The conclusions which can be derive
Page 10 and 11: ---> %ge DefectsSurvey Comparison A

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