Izvestiya SPbGTI (TU) No. 34 2016

I. CHEMISTRY AND CHEMICAL TECHNOLOGY Processes and apparatuses

Abroad are actively engaged in briquetting

waste generation, but information about these technologies

try not to distribute and quite strictly protect

nyut. Foreign briquette production, using

not even waste, but high-grade raw materials, highly profitable

white. In developed countries, briquetting is constantly

is given the closest attention. Invest-

sya significant funds in scientific and technological

development, construction of new and improved

nie existing briquette production, especially the use of

using waste or low-grade raw materials. In England,

France, Germany, Czech Republic, Poland, Turkey, USA, Av-

stralia and other countries on various technologies in

large volumes produce briquettes based on coal

noah little things. This is due to the fact that when burning

coal briquettes, compared with the combustion of row-

coal, increases by 25-35% the efficiency of furnace devices,

sulfur dioxide emissions are reduced by 15-20%; more,

than halving solids emissions from smoke

exhaust gases, as well as a 15-20% reduction in underburning of fuel

whose components.

Thus, using waste coke chalk

chi in the process of briquetting, you can significantly eco-

nominate energy and raw materials, reduce costs

pollution environment, as well as create new

efficient jobs and through cost-effective

briquette production bots replenish the budgets of all

levels. All of the above fully applies to

to the process of utilization of pet coke fines.

Production of petroleum coke

and areas of its use

Petroleum cokes (carbon of petroleum origin-

denia) are a porous solid infusible

kuyu and insoluble mass from dark gray to black

colors. They consist of highly condensed, highly

co-aromatic polycyclic hydrocarbons

with a small content of hydrogen, as well as other or-

organic compounds. The elemental composition of crude (not

calcined) petroleum coke (in %): C: 91-99.5; H: 0.035-

four; S: 0.5-8; (N+O): 1.3-3.8; the rest is metals.

The industrial coking process is carried out

is applied to plants of three types: intermittent

coking in coke cubes, delayed coking in

chambers, continuous coking in fluidized

carrier coke layer.

Delayed (semi-continuous) coking

the most widespread both in world practice

ke, so at Russian refineries. After cutting the array finished

product with a jet of water under pressure up to 15 MPa coke

steps into the crusher, where it is crushed into pieces the size of

no more than 150 mm, after which it is fed by an elevator to the

hot, where it is divided into fractions of 150-25, 25-6 and 6-0.5 mm.

Advantages of delayed coking - high yield

low ash coke. From the same amount of sy-

rya by this method can be obtained 1.5-1.6 times more

coke than with continuous coking.

The main indicators of the quality of petroleum coc-

ca are the content of sulfur, ash, moisture, yield of fly-

chemicals, granulometric composition, mechanical

strength.

sulphurous (up to 1%), sulphurous (up to 2%) and high-sulfur

hard (more than 2%). According to the ash content, cokes are divided into

low-ash (up to 0.5%), medium-ash (0.5-0.8%), high-

sokozolnye (more than 0.8%). According to the granulometric

stavu - on lumpy (fraction with a particle size of more than 25

mm), "nut" (6-25 mm), a trifle (less than 6 mm).

Sorting of coke into fractions is carried out only

ko at delayed coking units (DCU).

Lump coke is mainly used

in the metallurgical industry. It is used

to obtain an anode mass in the production of aluminum,

graphite electrodes of arc furnaces in steelmaking

vil production, to obtain sulfidizers in

non-ferrous metallurgy (for converting metal oxides or

metals into sulfides in order to facilitate their subsequent

extraction from ores, in particular in the production of Cu, Ni and Co).

The use of petcoke as a source

raw materials in the production of electrodes for arc electric

furnaces are limited by the sulfur content. Unfortunately,

a significant part of the production is precisely sulfuric

common varieties of petroleum coke, tk. low-sulfur

oil in our country is relatively rare. To delete

sulfur removal, petcoke is subjected to calcination in mine

or rotary kilns at 1000-1400 ºC.

In the chemical industry, petroleum coke is

changes as a reducing agent, for example, in pro-

production of BaS

from barite, upon receipt of CS

carbides

calcium and silicon.

Low-quality sulphurous coke applies -

mainly as a fuel.

Possible areas

use of coke breeze

After delayed coking units at

oil refineries are accumulating

a large amount of finely dispersed coke waste with different

measures of particles from a few microns to 6 mm - the so-called

coke breeze, which so far almost does not find qua-

certified application and requires additional

disposal costs. However, such waste can serve

raw materials for obtaining valuable products and fuel with you

owl trifles, and especially its dusty fractions, remain

etsya in the oil refining industry relevant and in

plan to address the issue of the completeness of the use of the total

coke, and for environmental reasons.

Coke breeze does not find direct use

without additional processing due to finely dispersed

condition and high ash content, difficulty with unloading and

transportation. On the other hand, stocks of traditional

energy carriers are steadily declining, which makes

important development of waste processing industries, in

including coke breeze into marketable products. Pro-

The problem of recycling coke breeze is very promising,

but requires careful development of technology and selection

equipment.

Coke breeze, and especially coke dust,

require special training for recycling

calling. One of the preparation methods is ocusco-

ing. Four methods of dust agglomeration are known:

meration, granulation, briquetting and tableting.

According to many literature data,

optimal for the disposal of coke dust are

briquetting and tableting technologies.

Figure 1 shows the main prospects

tive directions of utilization of coke breeze.

Figure 1. Possible uses for coke breeze.

Introduction

Innovation activity

3 The structure of operating costs of the production and technological system

4 Five vectors of cash flow equivalents

5 Integrated set of criteria

Characterization and analysis of coke production technology in PJSC "SEVERSTAL"

1 Coke production of PJSC Severstal

2 Technological process coke production

3 System of dust and gas collection and utilization of coke dust

4 The main production assets of the coke production of PJSC Severstal

5 Cost structure of coke production

Innovative project for the sale of coke dust in PJSC "SEVERSTAL"

1 Description innovative project

2 Equipment characteristics

3 Cost structure after modernization of the production and technological system

Conclusion

List of sources used

Attachment 1

Introduction

The goals and objectives of the engineering business of metallurgical enterprises, the main field of activity of which is industrial production, are changing with the advent of an innovative economy that has come to replace the industrial market economy in Russian Federation. The main task is to modernize innovative parameters in business management. These parameters serve as an increase in the volume of sales of manufactured products, and a decrease in operational technological costs in production, for the purposes of adaptation. industrial enterprises to the market. Competition is one of the main factors to determine the development of a business in an industry. The basis for the successful functioning of industrial enterprises in the conditions of a large number of enterprises producing the same products, the main requirement is the development of innovative projects that are aimed at increasing the levels of consumer properties, the volume of sales of the manufactured product and reducing operational technological costs. The basis of industrial business, which ensures the release of a product with certain properties of consumption, is the development of innovative projects.

One of the most important properties of nature is economic. Its essence lies in the fact that natural resources used by man have economic properties, economic potential. This fact will be one of the factors of the relevance of writing the work.

With the change in the market situation in the coal mining and processing industry, coke production needs to create a system for the development of production and innovation management. Almost all metallurgical plants, both domestic and foreign, use coke as the basis of blast furnace fuel.

Innovations have always been and are one of the main strategic parameters for the development of an industrial enterprise and its economy as a whole. In accordance with the requirements of the market, technological innovations must bring economic income in the course of the enterprise's activities. To resolve the issue of creating and implementing a particular operation in the technological process, it is necessary to take into account and analyze all the factors and risks of this innovation in comparison with its analogue in terms of technical and economic parameters, and take into account the possible economic results of its application in production.

The main goal of this work is to develop and economic justification an innovative solution in the implementation of one of the wastes, the coke production of PJSC Severstal. In the process of writing a final qualified work, the following were studied:

production and technological process of coal charge coking into blast-furnace coke;

characteristics of coke for blast furnaces of PAO Severstal;

articles and patents on the production and technological process of fuel production by briquetting waste and finely dispersed fractions of the mining industry;

literary sources in the organization of the production process.

The object of study is the area of ​​aspiration and dust collection in the finished coke dispensing system, coke quenching and sorting.

The subject of the study is approaches to the organization of the production and technological process for the production of briquettes from coke dust by the press method.

During the preparation for writing the WRC, the works of the following authors were studied: Belousova V.P., Gryaznov N.I., Ivanov E.B., Leibovich R.E., Papin A.V., Stefanko A.O., Tukkel I. L., Filatova A.B., Shichkov A.N., Shubeko P.Z., Yakovleva E.I.

Separate chapters of the tax legislation of the Russian Federation are studied. Official websites of PAO Severstal and similar industrial enterprises. Electronic resources historical and Russian library.

Innovation activity

1 Innovations, their economic essence and significance

innovation economic coke money

Innovation is the process of development, study, dissemination and use of new ideas that improve the efficiency of the enterprise. With all this, innovation cannot be considered simply an object that is implemented in manufacturing process, but an object that is successfully implemented and makes a profit as a result of scientific research or identified discoveries. It is qualitatively different from previous analogues.

Scientific and technological innovation must be approached as a process of transforming scientific knowledge into scientific and technical ideas, and then into the production of a product to satisfy consumers and users. From the foregoing, two paths to scientific and technological innovation can be identified.

In the first case, mainly product orientations of innovations are reflected. Innovation is defined as a process of upgrading to release a finished product. This direction is widespread in the period, which is positioned by the consumer in relation to the manufacturer rather weak. However, the product itself is not final goal, it is only a tool to meet the use and needs.

Therefore, according to the second case, the processes of scientific and technical innovations are considered as the transfer of scientific and technical knowledge directly to the area of ​​satisfaction of the needs of consumers. At the same time, the products are modernized into the owner of technological processes, and its taking form is determined after linking the technology and the necessary need.

It follows that innovations, firstly, need to have market structure to meet the needs of the consumer. Secondly, any innovation is most often studied as a complex procedure that involves the modernization of both scientific and technical, as well as economic, social and structural orientations. Thirdly, in innovation, the emphasis is on the rapid modernization of innovation into practical use. Fourthly, economic, social, technological or environmental effects must be provided by innovation.

An innovative project is a rationale for the economic feasibility of studying, mastering and implementing innovations. The main priorities in working with innovative projects are to increase production and increase sales, as well as reduce operating costs and increase the company's income while producing products at a constant volume. The task of increasing the volume of production is not a priority for innovative projects.

In addition, as a result of the implementation of an innovative project, it is necessary to organize an increase state budget, local authorities and government agencies, the municipal government's own network should create additional income tax revenue individuals, and owned by the company, and the Federal budget - an additional income tax, as well as value added tax.

Innovation is considered to be the results of the intellectual work of the enterprise, which are in demand by the market and contribute to growth. efficient operation enterprises. According to the theory of Shichkov A.N., innovation is any approach to the development, production activities and marketing of products, as a result of which the enterprise receives a competitive advantage.

In the current conditions of uneven economic activity and unsustainable development, search for new models of economic development, adaptation economic system, and in particular industrial enterprises of a production type, is certainly a characteristic from which their functioning, preservation and modernization are repelled in a changing and competitive activity.

The innovation process is the process of upgrading scientific knowledge into innovation, representing as a sequential chain of events, the result of which innovation flows from an idea to specific products, technologies and services. It extends in practice. The innovation process is aimed at the emergence of the necessary market for products, technological services, and closely interacts with the environment of its activity: its direction, pace of development, goals are tied to the socio-economic environment in which it develops and operates. It should be concluded that only on the innovative approach of modernization it is possible to carry out the growth of the enterprise's economy.

Innovative activity is an activity that is aimed at the work and commercialization of the result of scientific activities and developments in expanding and updating the range and improving the quality of the product, as well as improving the technological processes of their production with subsequent modernization and effective sales work in the domestic and foreign markets.

There are various classifications of innovations, but most researchers distinguish mainly several types:

-product innovations;

-allocation innovations;

-technological innovation.

A product innovation is rightfully considered a new or upgraded product that has high consumer properties or a high market value that generates income for the enterprise.

Technological innovation is the modernization or improvement of production technology, or the study and implementation of a new technological process.

Allocation innovations are aimed at improving the effectiveness of the management of the production and technological system, which affects the competitiveness of the enterprise in the market.

Production and technological system (PTS) - the minimum set of two types of assets tangible and non-tangible. With their help, products with high consumer qualities are produced. The economic equivalent of the consumer qualities of a competitive product is its cost in the market.

Innovation is usually viewed as:

modernization;

result.

Innovation is clearly oriented towards the final calculation of an applied nature, which must always be evaluated as a complex process. It provides a certain effect in the technical and socio-economic sphere of functioning.

Innovation at all its stages of development (life cycle) changes its forms, moving from idea to development. The movement of innovation processes, like any other, is associated with complex interactions of many risks and factors. The involvement in entrepreneurial activity of various options for the forms of organization of innovative processes is determined by the following factors:

affiliation of the external environment (political and economic stop, types of market, nature of competitive confrontation, experience and developments in state-monopoly settlement, etc.);

the influence of the internal environment on this economic system (the presence of the head-entrepreneur with a support team, the resources of the economy with a material foundation, functioning technological schemes, an established organizational structure, an internal system of organization, external links with the neighboring environment, etc.);

feature of the innovation process itself as an object of management.

The innovation process is studied as a process that permeates the majority of scientific, technical, industrial, marketing activities productions. Ultimately, it is focused on meeting the needs of the consumer. The most important factor in the success of innovative functioning is the presence of an innovator-enthusiast who is captured by a new idea and is ready to apply significant amount efforts to bring it to life, as well as the head-entrepreneur who found investments, developed the organization of production, implemented New Product into the sales market, assumed the main risks of responsibility, and also implemented its commercial development.

Innovations form markets for innovations. Investments form the sphere of activity of the enterprise's capital, innovations form the market for development rivalry. The innovation process enhances the assimilation of scientific and technical results, as well as intellectual certainty for the development of a new or improved product (service) and the maximum increase in added value.

2 Innovation Plan development of PJSC Severstal

The metallurgical complex - PJSC "Severstal" serves as the basis of the economic industry of the region. In the ranking largest companies Eastern Europe PJSC "Severstal" - one of the few industrial plants in the production of ferrous metallurgy. PAO Severstal occupies a high position in the rating of industrial enterprises, having risen by 10 lines compared to the activity of 2012.

The enterprise transfers more than 58% of the volume industrial production, 74% comes from exports, 78% of industrial income and about 37% of the region's consolidated budget revenues.

Now the department of technological innovations and development of production sites is being developed in the technical directorate of the plant. The department will participate in the development of innovation policy, the strategy of business development of the society and determine the direction of their qualitative regulation. Development and implementation of a thematic R&D strategy, which is planned to be developed for a period of - 7 years, will function in a directed manner in accordance with the current directions of technological innovation and the successful operation of society. In the future, the thematic order of R&D will be the foundation for the formation of annual R&D strategies.

Among the main effective measures that are involved in the main project is the development of a technology for the restoration of coke oven backfill sites that are subject to strong temperature fluctuations, using the ceramic surfacing method. Planned economical effect will be about a thousand rubles.

The development strategy of the metallurgical plant for 6-9 years is reflected in the formed business plan and regulated qualities:

) increase in production volumes, including products with high added value;

2) an increase in the average sales price;

3) cost optimization;

) increase of the authorized capital of the company;

) boost social significance and responsibility of the plant

From the start of creation joint-stock company the growth of the enterprise is determined by several strategic stages, in the implementation of which all employees of the plant are involved. The work on the strategy is connected with the training of sales and sales employees on the organizational, economic and strategic development plan, which allowed PAO Severstal to modernize approaches to existing areas of activity, directing its movement towards increasing production efficiency and mobilizing most of the internal resources to enter the group of the best steel mills in the world .

Production and marketing of metallurgical products is a priority and highly significant for the business structure. As a result, according to the results of work for 2014, the volume of steel production was determined as 9 million 869 thousand tons, black rolled products - 8 million 710 thousand tons. This is 1.4% and 3.9% higher than in 2014, respectively. According to most analysts in the industry, both domestic and foreign, the growth in the production of rolled metal in the global economy will continue to grow in the same way as consumption. As for medium-term quality, it can be said that according to forecasts, by 2018, metal production in the world will increase to 918.5 million tons, and consumption to 897.7 million tons. In the long term, by 2010 the production of rolled metal in the world will grow to 1,052 million tons, and consumption to 1,020 tons.

In Russia, by 2018, it is planned to increase the production of rolled metal to 50, and by 2021 to 51 million tons.

Thus, based on the current forecast, it can be determined that PJSC Severstal products with marketable properties will be in demand for many years.

The company's management is not going to rest on the results achieved. Currently, the plans of PJSC Severstal provide for the consistent implementation of innovative projects. The main innovations are supposed to be at the beginning of the technological chain: coke production and blast furnace shop.

In addition, two areas are distinguished in the innovative project: a program for saving energy resources and a program for introducing automated system control and accounting of electricity. The main task for the company is to approach the level of consumption of energy resources per ton of liquid steel to the best producers in the world. Reducing costs will be one of the top priorities.

The effect in the activities of improving the quality of rolled metal products and increasing the output of a product with high added value is provided by strategic programs - in the field of production and marketing, technical re-equipment and commercial activities of further modernization of the enterprise

3 The structure of operating costs of the production and technological system

According to Chapter 25 of the Tax Code of the Russian Federation, the cost structure consists of the following items:

)material costs;

)labor costs;

)depreciation deductions;

)other costs.

Figure 1.1 shows a graphical interpretation of the structure of operating costs in the production and technological system.

)Material costs consist of several types of costs:

purchase of raw materials and materials necessary for the production of products;

purchase production equipment, which is not depreciable;

purchase of fuel, energy resources of all kinds necessary for production;

losses during production, storage, and transportation within the limits of natural loss, etc.

) Labor costs include all contributions to employees in cash in kind (C lp ).

) Depreciation (C dc ) - replacement of operational depreciation of fixed assets by transferring their value to the cost of output. The minimum cost of depreciable property is 100 thousand rubles.

) Other costs (C ac ). This group includes travel expenses. Payment of benefits for temporary disability. Amounts of taxes and fees, including social, medical insurance. In addition, this item includes depreciation for intangible assets.

In addition to the cost structure, in the graphical interpretation of the operating cost structure shown in Figure 1.1, there are types of income and taxes (volume of products or services sold, operating profit, net profit, net income).

The volume of product sold is the amount of certain funds that are received from the sale of a product or service. The volume of products sold includes direct costs of production (operating costs) and operating profit.

Operating profit is made up of the difference between the volume of product sold and direct production costs.

The net profit is the balance Money from operating profit in connection with the payment of property tax and income tax.

The structure of operating costs shows the net income of production, according to the following calculation scheme:

.Calculation of operating profit (P) according to formula 1.1:

P = V sv - FROM oc , rub./year, (1.1)

where v sv - volume of output, rub./year;

FROM oc - operating costs, rub./year.

Figure 1.1 - Graphical interpretation of the structure of operating costs in the production and technological system

Calculation of the taxable base for income tax: is the difference between operating profit (P) and property taxes (N fa ).

Income tax (N R

Net profit (P about ) is calculated by formula 1.2:

R about = P - N fa -N R , rub./year. (1.2)

The net income of the enterprise is calculated according to formula 1.3:

D about = P about + C dc + C ia , rub./year, (1.3)

where P about - net profit, rub./year;

FROM dc - depreciation deductions from tangible assets, rub./year;

FROM ia - depreciation deductions from intangible assets, rub./year.

4 Five vectors of cash flow equivalents

According to A. N. Shichkov’s theory, five vectors of cash flow equivalents are rightfully taken as the basis for the conversion processes of production and technological systems. The vectors are implemented by the operating cycle of the production and technological system. The following vectors are considered:

V sv -the volume of products sold;

G 0W 0 - costs of direct technological processes, including operating direct technological costs, wages (operating costs minus depreciation);

D 0 - net income. Includes capital for the restoration and adjustment of fixed assets (deductions for depreciation) and net profit;

U mf - fixed assets, including fixed assets and intangible assets of the enterprise;

Q - production capital, consisting of fixed assets U mf and direct technological costs G 0W 0.

5 Integrated set of criteria

This section describes in detail the process of the integrated set of operating cycle criteria:

1.Operating cycle conversion criterion. In an ideal production and technological system, it is calculated from the ratio of the volume of the product sold, as well as the service cost of production capital. The cost of production capital is the sum of direct technological costs, and fixed assets from intangible assets. The criterion for the conversion of the current operating cycle is no more than 40-45%. This indicator calculated in formula 1.4:

ς = V sv /Q≤ 1. (1.4)

2.The criterion of capitalization of the operating cycle is equal to the ratio of the volume of sold products to services in direct technological costs. The capitalization criterion for the current operating cycle is not more than 1.5, ideally - 2. This criterion is calculated in formula 1.5:

λ = V sv /G 0W 0≤ 2. (1.5)

3.The criterion of investment capital of two types of production is equal to the ratio of net income to the book value of tangible and intangible assets. The calculation is carried out in formula 1.6, which has the following form:

M =D about / U≤ 1. (1.6)

4.The resource criterion for the production capital of an enterprise is the ratio of the cost of production capital to direct technological costs:

r =Q/G 0W 0. (1.7)

5.The characteristic of operating cycles is the ratio of direct technological costs and the amount of fixed assets from intangible assets:

k 0 = G 0W 0/ U. (1.8)

2. Characteristics and analysis of coke production technology in PJSC "SEVERSTAL"

Coke production is one of the main production facilities of PAO Severstal. Its main task is to timely provide five blast furnaces with high-quality coke. The main production assets of coke-chemical production are coke oven batteries, which are used to produce coke from coal charge using a certain technology.

1 Coke production of PJSC Severstal

The coke production of PJSC Severstal was established in 1956. A total of 10 coke batteries were built between 1956 and 1978.

The coke shop of the Cherepovets Metallurgical Plant was designed to provide two blast furnaces with coke. Four coke oven batteries with a capacity of 461 thousand tons of coke per year each, a coal preparation shop, a coal preparation plant with a capacity of 700 tons per hour, a shop for capturing coking chemical products and a biochemical plant for water treatment were built. The first battery with coal preparation and a trapping shop was put into operation on February 13, 1956. The second coke oven battery was also built in 1956, the third - in 1957, coke oven battery No. 4 was put into operation in 1958.

Thus, the 1st stage of development of coke production with a capacity of 1844 thousand tons/year of coke was completed. In 1959, a decision was made to further develop the Cherepovets Metallurgical Plant. Construction of the third blast furnace with a volume of 2000 m 3, the largest in terms of those capabilities. With an increase in the output of pig iron to 2.4 million tons per year, it was planned to build the second stage of the coke production, bringing its capacity to 3.2 million tons per year of coke. In 1963, the fifth, and in 1966, the sixth coke batteries were built with a total capacity of 1380 thousand tons/year of coke (690 thousand tons/year of coke each).

The third stage in the development of coke-chemical production began in 1970, when a decision was made to build a coke oven block of four coke batteries with a capacity of 730 thousand tons / year of coke to provide blast furnace No. 5 with coke. Coke oven batteries No. 7.8 were put into operation in 1972, batteries No. 9,10 - in 1978

In the early 1980s, the coke production of the Cherepovets Metallurgical Plant reached its maximum productivity. Coke production reached 6.3 million tons/year of coke with a design capacity of 6.14 million tons.

Much attention was paid to environmental protection objects. In 1978, a new biochemical plant was built for wastewater treatment, a closed water circulation cycle was completed, and thereby all direct discharges from the territory of the coke production into water bodies were eliminated. More rational schemes for capturing coke dust at coke screens have been developed and implemented, the sludge water removal system has been reconstructed, and a number of other works have been carried out to protect the environment. Emissions of harmful substances into the atmosphere have significantly decreased, pollution of the reservoir of the Rybinsk Reservoir has been excluded.

Gradually, blast-furnace production, carrying out repairs of certain categories in a timely manner, increased the production of pig iron. Difficulties began in the coke production, determined by the aging of batteries. There was a need to stop the batteries for transfer. However, without the construction of a new 11th coke oven battery, this was impossible.

At the same time, several environmental reviews were carried out with the requirement to transfer the coke production to another territory, at a greater distance from the city. A Government Decree was issued, which provided for the shutdown of the first 4 batteries after the launch of the eleventh, which was practically equal in power to the first four batteries. However, the construction of a new battery was not included in the five-year plan for 1985-1990.

The summer and winter of 1989 brought lengthy miners' strikes. Almost all coal reserves were exhausted, technological regimes were forced to change, which led to a deterioration in the state of fixed assets, irreparable destruction of coke oven batteries.

By the beginning of the 2000s, it became necessary to create new coke production capacities, taking into account the renewal of aging fixed assets and the commissioning of blast furnace No. 5. In 1999, the construction of coke oven battery No. 11 with a capacity of 1710 thousand tons/year of coke ( Stage I - 1140 thousand tons / year) its launch was scheduled for 2005.

By 2000, a large amount of work related to the preparation of the construction site had been completed. For two units of the coke oven battery, the lower reinforced concrete slabs and hogs were prepared, the construction of a chimney and a coal tower was started, a coke sorting building was assembled, a greenhouse was received and its installation began, and some refractory products and equipment were purchased. However, due to the difficult financial situation, the construction of the battery had to be suspended. All funds and efforts were focused on the reconstruction of coke batteries No. 5, 6 and the construction of environmental facilities.

In 2006, after replacing the refractory lining and the main equipment, battery No. 5 was put into operation again, in 2007 - battery No. 6. In combination with the reconstruction of coke oven batteries No. 5, 6, chemical recovery shop No. 1 was partially rebuilt and renovated. With the commissioning of batteries No. 5 and 6, in 2006 the first coke oven battery was finally shut down, and in 2007 the second and third ones.

In December 2001, the first stage of the reconstructed biochemical plant was put into operation. Reinforced concrete aerotanks were expanded and closed, the volumes for water purification from oils and phenols were expanded, a new thiocyanate removal complex and a wastewater nitrification plant were built, tanks were built to collect storm water, sludge sedimentation tanks with a pumping station for wastewater treatment.

Figure 2.1 shows a detailed diagram of the feedstock flows for coke production.

Figure 2.1 - Scheme of feedstock flows of the coke production of PJSC Severstal: 1 - coal warehouses, 2 - crushing and processing line, 3 - coal preparation shop, 4 - coke oven batteries, 5 - CDF, 6 - coke sorting, 7 - blast furnace shop, 8 - workshop for capturing and processing chemical products of coal coking

2 Technological process of coke production

Coke is a product of coal sintering, which is a porous black-matte mass. In the process of coal coking pure product 630-750 kg of finished coke is obtained from 1 ton of coal charge. The scope of coke is mainly metallurgy (ferrous, non-ferrous, foundry), in addition, coke is used for gasification, the production of calcium carbide, electrodes, as a reagent and fuel in a number of industries chemical industry.

In metallurgy, coke is presented with high requirements in the field of mechanical strength, since in the operating conditions of a blast furnace, coke is subjected to high pressure of the loaded charge. Thermal characteristics are also of high importance. According to the technological documents for iron smelting at PJSC Severstal, coke should have a calorific value of 31.4 - 33.5 MJ / kg.

Coke is sintered in coke production by means of decomposition of certain types of coal without oxygen access. The main criteria for coke quality are combustibility and reactivity. Combustibility characterizes the rate of ignition and combustion of coke, reactivity indicates the rate of reduction of carbon dioxide by it. These two processes are heterogeneous, and their rate is determined not only by the chemical composition of the coke, but also by the porosity of the product. The contact speed of the interacting phases depends on the porosity of the coke. Not an insignificant factor is given to the content of sulfur, ash, moisture and the release of volatile substances in coke.

The next product of coal sintering can rightfully be considered coke oven gas. Release volumes range from 310 - 340 m 3 per 1 ton of coal charge. The composition and concentration of coke gas mainly depends on the temperature in the coking chamber. The gas directly exits the coking chamber, during coal charge coking, into the gas collection chambers. Coke oven gas contains various gaseous products, including coal tar vapours, crude benzene and water. The next stage of gas production will be its purification. Resins, raw benzene, water and ammonia are removed, then the so-called reverse coke oven gas is obtained, which is used in production as a raw material for chemical synthesis. In addition, coke oven batteries are heated with coke oven gas, and it is also used in other industries of the plant.

Coal tar is a black-brown liquid with a specific odor, which contains more than 250 different substances. chemical origin. The resin mainly consists of resin components, which include: benzene, toluene, xylenes, phenol, cresols, naphthalene, anthracene, phenanthrene, pyridine, carbazole, coumarone, etc. The density of coal tar is 1.7 - 1.20 g/cm 3. Pitch production is from 3 to 5.5% by weight of coking dry coal. The composition of the tar, as well as coke oven gas, mainly depend on the coking temperature, and the tar yield directly depends on the nature of the origin of the coking coals. Depending on the increase in temperature in the coking chamber, the pyrolysis of hydrocarbons deepens, thereby reducing the yield of tar, and the yield of coke oven gas increases. Coal tar contains about 60 chemical products, all of which are used as raw materials for the production of dyes and various pharmaceuticals.

Crude benzene is one of the products of coal tar, mainly composed of carbon disulfide, benzene, toluene, xylenes, coumarone and other chemical substances. The productivity of crude benzene is approximately 1.1% by weight of the coal charge. Its quantity directly depends on the chemical composition and properties of the initial coal. The temperature factor is also of high importance in the production of crude benzene. Crude benzene is the main raw material in the production of individual aromatic hydrocarbons and a mixture of hydrocarbons that serve as raw materials in the chemical industry.

Resin and crude benzene are the main sources of aromatic hydrocarbons for the chemical industry.

Smolny water is a weak aqueous solution consisting of ammonia and ammonium salts with an admixture of phenol, pyridine bases and other chemical products. Top-tar water in the process of its processing releases ammonia, which, together with ammonia from coke oven gas, is used to produce ammonium sulfate and concentrated ammonia water.

Coking as a chemical production is one of the oldest industries. Until the middle of the XIX century. coking found its application mainly for the production of coke in metallurgy. From the second half of XIX in. After the discovery by the domestic chemist N.N. Zinins of aniline from nitrobenzene required products containing benzene, toluene, phonols, cresols, naphthalene, anthracene and other products. A good source of all these products are coal tar and crude benzene.

In modern industry, coal tar and crude benzene have gone from being a waste product to being the main and most important sales product. Almost all combines have installations that capture coal tar and raw benzene. This was the impetus for the creation of unified coking plants. Outside the production of metallurgical plants.

The main raw materials for the production of coke are sintering coals, which give a strong and porous metallurgical coke. AT industrial practice A well-established mixture is made up - a charge consisting of coking coals and coals of other grades. This step made it possible to expand the range of raw materials for the coke industry, to obtain coke High Quality and ensure the high performance of tar, raw benzene and coke oven gas. In the coals used for coke production, the amount of moisture is limited and should be within 5-9%, ash up to 7%, sulfur up to 2%.

The technological process of chemical production, like any other production process, begins with the preparation of raw materials and the preparation of a coal mixture. The coal that arrived at the production is divided according to chemical composition and properties into groups, crushed and mixed, then goes through the stage of enrichment by screening, dedusting, flotation and other technological operations in order to eliminate impurities.

Next, the coal mixture is dried (to optimize moisture content) and finally crushed to a grain size of no more than 3 mm. The prepared charge components are fed into the mixing drums and then into the storage bins of the coal tower.

Prepared coal charge in certain portions fills the bunkers of the coal-loading car, which delivers the charge to the coke battery chamber.

The thermal effect on the coal charge is accompanied by physical and chemical transformations: up to 250 ° C, moisture evaporates, carbon monoxide and dioxide are released; in the range of 300 ° C, resin vapors begin to be released and the so-called pyrogenetic waters are formed; with an increase in temperature above 350 ° C, coal passes into a plastic state; 500-550°C, the plastic mass decomposes with the release of primary coking products (gas and tar) and solidifies, semi-coke is formed. When the temperature rises to 700°C, the semi-coke decomposes, with the release of second-order gaseous products from it; above 700°C, the hardening of the coke occurs predominantly. Volatile products, in contact with hot coke, heated walls and the roof of the chamber in which coking takes place, turn into a complex mixture of vapors (with a predominance of aromatic compounds) and gases containing hydrogen, methane, etc. Most of the sulfur in the initial coals and all mineral substances remain in the coke.

The design and operation of coke ovens depends on indirect heating devices. The heat in them is transferred from the heating gases to the coal charge through the wall. The main factor determining the course of the coking process is the increase in temperature, which is necessary to heat the charge to the dry distillation temperature and carry out endothermic coking reactions. The temperature rise limit is limited by the reduction in resin yield and. crude benzene, changes in the composition of coking products, violation of the strength of refractory materials used for laying furnaces.

A coke oven or battery includes 61-69 parallel chambers, which are both long and narrow channels of rectangular cross section, built of refractory bricks (dinas). Each chamber contains from 17 to 23 tons of coal charge. It has removable doors on both sides, which are tightly closed at the time of loading the chamber, and throughout the entire duration of coal coking, and are removed when the coke is unloaded. There are 3 loading hatches in the roof of the furnace, which open during coal loading and close during the coking period. A loading car moves along the rail track, which are located above the coking chambers. Which, through the loading hatches, loads the charge into the coke chambers. A coke pusher moves along the machine side of the battery along the rail tracks. A machine that, after coking the coke cake, opens the doors of the chamber and pushes out the finished coke. On the opposite side, a quenching car moves along the rail track. He takes the red-hot coke and transports it under the extinguishing tower, and then unloads it into the extinguishing ramp. Heating of coal in the chamber occurs through the walls of the chamber with flue gases passing through the heating walls located between the chambers. Hot flue gases are formed as a result of combustion of blast-furnace, reverse coke oven or, more rarely, generator gases. The heat of the flue gases that come out of the heating pier. They are used as a regenerator for heating the air and gaseous fuel supplied to the heating of coke ovens, as a result of which the thermal efficiency of the oven increases. During operation of the coke chamber, to ensure uniform heating of the coke cake, it is necessary to correctly select the dimensions of the chamber and evenly distribute the coke oven gas in the heating vertical. The optimal chamber width is usually 400-450 mm. The length of the chamber is limited by the static strength of the walls, the difficulty of issuing the finished coke from the chamber and the complexity of the distribution of gases in the heating verticals. The length of the chamber is approximately 14 m. The height of the chamber is determined mainly by the conditions for its uniform heating along its height. Based on this, satisfactory results will be obtained with a chamber height of 5.5-5.7 m.

Uniform distribution of coke oven gases is achieved by dividing the heating walls with vertical partitions along a number of channels, called verticals. The verticals heat the walls with the help of heating gases, which transfer heat to the walls of the chamber and are removed to the regenerators. The temperature difference between the heating gases in the heating channels and the coal charge varies with time. After loading the chamber with a mixture, its value is great. A large amount of heat per unit time enters the cold charge, and coal begins to coke near the walls of the chambers. However, the middle layers of the charge remain cold regardless.

As the coal warms up, the temperature difference gradually decreases. The amount of incoming heat per unit time decreases, however, due to the continuous supply of heat from gases, there is a gradual increase in temperature across the chamber. Therefore, the state of the material in the chamber during coking will be a layer of formed coke near the walls. Further, when the temperature decreases from the walls to the axis of the chamber, a layer of semi-coke is located, then coal, which is in a plastic state, and finally, in the center of the chamber, a constant charge is located. After 12-14 hours, the temperature in the cross section levels off, the layers move towards the axis of the chamber, and gradually the coal load cokes. Thus, at the end of the coking process, the heating of the coking chamber is turned off, the gas risers are discharged. The ejector is brought to the doors of the chamber. Unloads the coke cake into the stew car, moving slowly along the battery. Then the pusher installs the doors of the vacated chamber and goes to the next chamber, and the loading car opens the loading hatches and loads a new batch of charge.

The average processing time of the coking chamber is about 15 minutes. Therefore, for optimal operation of mechanisms and machines, the number of cameras in the battery is adjusted to 70.

The unloaded coke is subjected to quenching, since it ignites when it comes into contact with air.

The output of coke is 65-75% by weight of the mixture. The production capacity of one coconut battery is approximately 1500 tons of coke per day. Depending on the chemical and physical composition, coke is divided into blast-furnace, foundry, power (intended for the production of ferroalloys, calcium carbide, electrodes, for agglomeration of iron ores).

The output of products from 1 t of charge, %, at the coke production site is shown in Figure 2.2.

Figure 2.2 - Exit finished products in the process of coal coking (1 ton)

2.3 Operating system of dust and gas collection and utilization of coke dust

Coke dust at coke-chemical enterprises is obtained in the course of any technological operations related to coke (sorting of bulk coke, dry coke quenching, coke reloading, etc.). Fraction size 0-5 mm. It practically does not find application due to the difficulty with unloading and transportation, it is usually returned to the coking charge in the amount of 3% by weight of the charge (which reduces the useful load of the coal charge).

A significant amount of coke dust is captured in operations:

issuance of coke from the coke oven battery to the wagon for transporting coke;

the process of coke quenching in dry coke quenching units (DSC);

coke sorting operation, into certain fractions (50-250 mm), in coke sorting.

The formation of a dust cloud during the issuance occurs very quickly, and this unorganized emission is usually referred to as bursts. When issuing coke of insufficient readiness, the formation of dense clouds of dense black or black-green smoke is observed. Such phenomena are observed when the coking process is not completed in the center of the coal load or when the furnaces are heated unevenly, leading to the formation of cold zones in the load.

There are several options for dust-free coke dispensing systems: dust suction umbrellas over the coke guide and quenching cars; overlappings over the rail track of the extinguishing car; combined systems of dust-free delivery and coke quenching.

The systems with the device of umbrellas, suction and cleaning of the issuing gases received the greatest recognition. At the same time, suction and dust collection equipment is designed both in mobile and stationary versions. In practice, systems with a mobile umbrella and a stationary dust collection system are most often used. Venturi scrubbers, wet electrostatic precipitators, fabric filters are used as dust collectors. Recently, there has been a trend abroad to switch only to dry dust collectors, as a rule, bag filters.

In 1993, the first dust-free coke dispensing unit (UBVK) with a stationary gas and dust extraction and purification system was launched at the Kommunarsky Coke and Chemical Plant (Figure 2.3). In subsequent years, similar plants were installed in the coke production of Severstal PJSC.

The existing trends are still based on an increase in the volume of exhausted gases up to 150-180 thousand m ³ /h with a corresponding increase in the size and design of the umbrella. The concentration of dust in the gas sucked out from under the umbrella reaches 18-22 g/m³ .

Figure 2.3 - Dust-free coke dispensing system: 1 - umbrella; 2 - coke car; 3 - fan; 4 - hot dust accumulator; 5 - humidification system; 6 - scrubber and screw feeder

By installing groups of cyclones at the first stage of cleaning, they achieve a total degree of purification of 99.1-99.2% with a residual concentration of dust in the exhaust gases of 0.11-0.22 g/m 3. It is easy to see that by increasing the volume of exhausted gases, we obtain an increased dust content, the reduction of which to the required standards requires an increase in the degree of purification.

The simplest option for dry dust collection is a system of conical cyclones. Such systems have been developed and included in projects for most coke production facilities in the Russian Federation.

The main requirement in this case, in addition to high efficiency and acceptable hydraulic resistance, is the prevention of abrasive wear, which is achieved the right choice speeds in the inlet pipe and the cyclone body.

For a stationary installation for dedusting gases, the most effective solution in terms of dust collection is the use of electrostatic precipitators. In this case, the greatest economic effect is obtained by combining the purification of discharge gases and loading gases in them, provided that the trapped mixture of coal, semi-coke and coke dust is utilized. Since the loading gases contain many combustible substances, it becomes necessary to ensure explosion safety, so electrostatic precipitators should be used.

In order to reduce fugitive emissions generated during the issuance of coke from the coking chambers to the quenching car, in 1997, a dust-free coke dispensing unit was built on coke oven batteries No. 5-10 KHP of Severstal PJSC. An umbrella is installed on the door-removing machine, which closes the "basket" of the coke guide and the quenching car.

With the help of telescopic nozzles installed on the umbrella, the umbrella and the gas collector are docked, designed to transport the gas-air mixture for cleaning in two electrostatic precipitators of the EGA type. Then the air, purified from fine dust to a concentration of 50-80 mg/m 3, is released into the atmosphere, and the dust caught by electrostatic precipitators is used as an additive in the charge for coking. The reduction of dust emissions into the atmosphere during the issuance of coke is 200 tons/year.

Of all the dust-free coke dispensing systems currently used abroad (covering over the entire coke side of the battery; suction and cleaning of gases released in a stationary scrubber system; dust-collecting umbrellas above the coke guide and quenching car with gas cleaning equipment on the quenching car or a platform connected to it; dust-collecting umbrellas over the coke guide and the quenching car with a stationary exhaust gas pipeline and a gas cleaning system), the systems of the latter type are recognized as the most effective. At other metallurgical enterprises, almost all coke oven batteries are equipped with such systems.

The width of the dust collecting hood is equal to the width of the coking car, the length varies from 6 to 10 m, depending on the volume of the coking chamber. The power of the smoke exhauster in the system of dust-free delivery at 40°C is 2500-4500 m 3/min depending on the volume of the coking chamber.

There are two sources of organized emissions into the atmosphere in the CDTC: a candle of excess inert gas after a smoke exhauster and a candle through which gases released from coke in the prechamber are emitted.

Significant air pollution by these emissions requires the development of measures to reduce them.

The introduction of dry quenching of coke at domestic coking plants is necessary, primarily because it allows improving the quality of coke in a continuously deteriorating raw material base of coking.

However, one of the environmental benefits of the dry coke quenching process is that the emissions from these plants are organized and can be treated, thereby achieving an overall reduction in specific emissions to the atmosphere during the production of coke.

The temperature of coke after USTK reaches 150-200°C. During transportation, reloading, screening of such coke, intensive dust emission occurs, so the process equipment is equipped with aspiration units. Appointment of aspiration systems - creation favorable conditions work on the content of harmful substances in the air industrial premises by preventing emissions from leaks in process equipment. Aspiration systems are located in accordance with the technological scheme of the CDTC and the sorting of dry quenching coke (Figure 2.4).

The aspiration systems include dry and wet dust collectors. When unloading hot coke from the chambers, a lot of dust is released, so a two-stage cleaning scheme is usually used. As the first degree, groups of cyclones of the TsN-15 type are used, which have a sufficiently high dust collection efficiency (87-97%) with moderate hydraulic resistance (0.35-1.15 kPa). TsS-VTI scrubbers are installed at the second stage of dust collection. The actual degree of dust capture in them is from 60 to 90% and is determined mainly by the flow rate of the irrigating liquid and its quality.

The aspiration systems include dry and wet dust collectors. When unloading hot coke from the chambers, a lot of dust is released, so a two-stage cleaning scheme is usually used. As the first degree, groups of cyclones of the TsN-15 type are used, which have a sufficiently high dust collection efficiency (87-97%) with moderate hydraulic resistance (0.35-1.15 kPa). TsS-VTI scrubbers are installed at the second stage of dust collection. The actual degree of dust capture in them is from 60 to 90% and is determined mainly by the flow rate of the irrigating liquid and the quality of its spraying.

Chamber USTK; 2 - aspiration system of the loading unit USTK (scrubber TS); 3 - aspiration system of the unloading unit USTK (group of cyclones TsN, scrubber TS); 4 - aspiration system of the reloading unit (group of cyclones, scrubber KMP); 5 - blower fan of the dedusting station coke; 6 - aspiration system of a roller screen (VK collector, KMP scrubber); 7 - aspiration system of an inertial screen (VK collector, KMP scrubber); 8 - aspiration system of the unit for loading coke into wagons (group of cyclones TsN, scrubber KMP)

Coke dust, according to the existing classification, can, as a rule, be classified as coarse dust. This simplifies the task of dedusting the suction air by dry methods.

4 The main production assets of the coke production of PJSC Severstal

The main production assets of the enterprise are two types of assets - tangible and intangible. There are no intangible assets in this production and technological system. Tangible assets are fixed assets of the enterprise, which are subject to property tax. The processes of modernization of operational and route technologies of production and technological systems, as well as the development of technological, product and allocation innovations exclude those who are not involved in the production process. production systems and technological machines.

Fixed assets of the enterprise - objects of labor. They are used in the production of a certain type of product for more than a year (12 months), and do not lose their natural shape. Depending on the production operations, fixed assets belonging to the coke production are divided into several points:

-buildings - production shops, warehouses, garages, etc.;

-structures - structures and buildings that determine the necessary conditions for the production process;

-machines and equipment (mechanical, electrical, hydraulic, etc.);

-vehicles.

Fixed assets are mainly divided into two items: active and passive. The active part most often includes all types of equipment, machines and mechanisms and vehicles, almost all assets that are directly involved in all production processes. The passive part is an equally important condition for the production process, but does not accept special participation in production. This group includes all existing buildings and structures. The cost of property of the coke production for 2015 is 280.752 million rubles. This amount will be the basis for depreciation. The cost of fixed assets is presented in more detail in Table 2.1.

Table 2.1 - Fixed assets of the enterprise

Fixed assetsCost, million rubles Buildings18,475Constructions2,9824Machinery and equipment222,901Vehicles24,4864Land plots11,9072Total280,752

The property tax paid by PAO Severstal in respect of the coke production site in 2015 is RUB 5.378 million per year. Land tax - 1.5% of the cadastral value of the land plot - 174626 rubles per year.

5 Cost structure of coke production

According to Chapter 25 of the Tax Code of the Russian Federation, the cost structure consists of four elements: material costs, labor costs, depreciation and other costs.

Figure 2.5 shows a graphical interpretation of the operating cost structure of the coke production for 2015 (million rubles).

A significant share of material costs (C mc ) in the structure - 77.2% - indicates that the production of coke is quite material-intensive. This group includes the following costs:

-costs for the purchase of raw materials and materials used in production;

-the cost of purchasing equipment that is not depreciable (the initial cost of depreciable property is more than 100 thousand rubles);

-costs for fuel, energy of all kinds, water, space heating, etc.;

-costs for the acquisition of works, services of an industrial nature, which are performed by third parties;

-losses during production, storage, and transportation within the limits of natural loss.

Figure 2.5- Graphical interpretation of the structure of coke production operating costs for 2015 (million rubles)

In addition, the cost structure reflects the net income of the enterprise, the calculation algorithm of which is as follows:

.Calculation of operating profit (P) according to the formula (1.3).

.The taxable income tax base is calculated as the difference between operating profit (P) and property tax (N fa ).

.Income tax (N R ) is 20% of the taxable base calculated in the previous paragraph.

.The net income of the enterprise is calculated according to the formula (1.4) as the sum of net profit and depreciation charges from tangible assets.

Having studied the theoretical aspects of the first chapter, five vectors of cash flow equivalents are the basis of the process of transformation of production and technological processes in the enterprise. For coke production, the vectors are shown in numerical values ​​given in Table 2.2.

Table 2.2 - Vectors of cash flow equivalents

Vector nameDesignation Numerical value, million rubles/yearVsv1295.472Direct technological costsG0W01202.689Net incomeD092.783Fixed assetsU280.752Production capitalQ1483.441

The criteria based on the mathematical model of the operating cycle of the enterprise, presented in Chapter 1, for the coke production have the following meanings:

The criterion for the conversion of the operating cycle of the production and technological system is equal to the ratio of the volume of products and services sold to the cost of production capital. For coke production, this criterion is 0.87, which satisfies the condition ς ≤ 1, and calculated by formula (1.4): V = 1295,472 / 1483,441 = 0,87.

The operating cycle capitalization criterion is equal to the ratio of the volume of products and services sold to direct technological costs. For the enterprise under consideration, this criterion is 1.07, which satisfies the condition λ ≤ 2. Calculated by formula (1.5): l = 1295,472 / 1202,689 = 1,07.

The criterion of investment capital of simple and expanded production is equal to the ratio of net income to the book value of fixed assets. For the object of study, this criterion is 0.33, which satisfies the condition M ≤ 1, and is calculated as follows according to formula (1.6): M = 92.783 / 280.752 = 0.33.

The criterion of production capital resources is the ratio of the cost of production capital and direct technological costs and is calculated by formula (1.7): r = 1483,441 / 1202,689 = 1,23.

Characteristic of the operating cycle - the ratio of direct technological costs to the amount of fixed assets and intangible assets and is calculated by the formula (1.8): k 0 = 1202,689 / 280,752 = 4,28.

Since when mastering an innovative project in the production and technological system of coke production, each criterion of the integrated complex changes. In Chapter 3 of this work, all criteria will be recalculated in order to track their change during the development of an innovative project.

3. Innovative project for the sale of coke dust VPJSC "SEVERSTAL"

It follows from the above that the implementation of coke dust in the production and technological process of the coke production of Severstal PJSC consists in mixing it with coal charge in the amount of 3%. This innovative project describes in detail the process of making coke briquettes. The starting material in our case will be coke dust.

Coke dust at coke-chemical enterprises is obtained in the course of any technological operations related to coke (sorting of bulk coke, dry coke quenching, coke reloading, etc.). Fraction size up to 35 mm. The volumes of coke dust formation are very high, on average, about 18-20 thousand tons of coke dust are formed in the coke-chemical production per year. Coke dust practically does not find application because of the finely dispersed state and high ash content, the difficulty with unloading and transportation. The problem of utilization of coke dust is very urgent.

1 Description of innovation

Briquetting is the process of processing material into pieces of a geometrically correct and uniform shape in each case, of almost the same mass briquettes (French briquette).

In the production of briquettes, additional raw materials are formed from small materials (mainly fossil fuels and ores), the use of which is inefficient or difficult, and waste (dust, slag, metal shavings, etc.) is also utilized.

The expediency of briquetting in each case is economically justified.

Depending on the source material, briquetting is carried out with binders (cementing, adhesive) substances at medium pressures (10-50 MN/m 2) and without binders at high pressures (100-200 MN/m 2). To obtain high quality briquettes, the material sent for pressing must meet certain requirements.

In the process of innovation management, the production of coke briquettes from coke dust, it is necessary to take into account a number of specific factors:

the physical properties of the briquettes must be identical to the physical composition of the coke;

fraction of briquettes (70-300mm);

humidity, porosity, calorific value, ash content, etc.

The characteristics of the coke declared by the blast furnace shop at Severstal PJSC are described in Table 3.1.

Table 3.1 - Characteristics of coke

ParametersUnitsValuePorosity%49-53Density /cm 31.80-1.95 Mass kg /3400-500Ash content%9-12Moisture%No more than 0.5StrengthPa6-12Combustion heatMJ/kg 29-30

The solution for pressing a fine fuel fraction was invented at the beginning of the last century. Russian researcher A.P. Veshnyakov. His idea is still used in industry and everyday life. The essence of the idea is to press wood powder into solid elements that can burn and give off heat no worse than coal itself.

Not to mention the detailed manufacturing technology fuel briquettes and without listing their types, it can be noted that they are of two main types:

with the use of binding components;

industrial combustion; without them;

for home use.

The final qualification work describes the technology of making briquettes without the use of binding components. Coke dust is a plastic material, since its surface irregularities are easily deformed. As a result, the contact of the interacting particles is achieved more easily and in a larger area.

The production goes like this:

initially, coke dust and coke breeze are crushed, the largest particle at the outlet should not be more than 6 mm;

the mixture is dried to a moisture content of 25%. For this, steam and gas type dryers are used;

finished products are delivered to the customer (blast furnace).

Scrubbers (dust accumulators), in addition to coke dust, also contain coke breeze. Its fraction is 5-25 mm. In the process of quenching and sorting coke (during reloading, transportation, etc.), as a result of vibration and friction, the edges of the coke pieces break off and coke fines are formed. The ratio of coke breeze to coke dust is 25%.

2 Equipment characteristics

The first step in obtaining a coke briquette will be the grinding and preparation of the starting material, in our case, the coke charge. In the coal mining industry, as well as in a number of production sites of Severstal PJSC, four-roll crushing machines of the DV-400z model have proven themselves well.

In the case of this production and technological process, the volume of large coke fraction is significantly small (25%), respectively, it is optimally suited, for all performance characteristics, two-roll crusher model - "DT-1". Technical characteristics of the equipment are provided in table 3.2

Table 3.2 - Specifications "DT-1"

Crusher "DT-1", as follows from Table 3.2, with its capacity will fully cope with the existing volumes of waste from coke production.

Crushing in roller crushers<#"justify">Having studied and analyzed the offers of suppliers and dealers (domestic and foreign), I settled on the RUF press for briquetting model BP-600 (BP-420A). Enterprise supplier "Association KAMI", Moscow.

Association "KAMI" is an association of leading suppliers industrial equipment, industrial enterprises of Russia, equipment manufacturers, industry universities and research institutes. Since its inception in 1991, KAMI has supplied 150,000 items of equipment to more than 40,000 enterprises. Among domestic clients are Ustyansk Timber Company, Rosatom, Syktyvkar House-Building Plant, March 8 Factory, Toris, Mr. Doors, Avtovaz, Rostvertol, Odintsovo Production Association, Novolipetsk Iron and Steel Works, First Mirror Factory, Naiad, Ormatek, Russian Mattress, KLM, Bear Lakes, "Detinets", "Architect", "Altai-roof", "Wimm-Bill-Dann", "Energotex", TsAGI im. NOT. Zhukovsky, "LG Electronics", theater workshops of the Moscow Art Theater. A.P. Chekhov, State Academic Maly Theater of Russia.

Press BP-600 is designed for the production of fuel briquettes. The resulting brick-shaped briquettes have a size of 150/60/100 mm, which meets all supplier standards. The production of this type of briquettes allows you to effectively dispose of waste and receive economic income. Briquettes are made from dry waste from the timber industry, coal processing and woodworking complex, processing enterprises Agriculture, peat mining and the printing industry without additional input of a binder. In most cases, waste from any type of wood, with a moisture content of up to 15%, and a fraction of the size of dust / sawdust / shavings, can be used as a feedstock.

The pressing technology used in this press is based on a cold hydraulic press with a large force, which makes it possible to obtain a briquette of high quality and good presentation.

The equipment does not require preparation for start-up, the pressing process can start within one minute even after a long stop. The equipment can work 24 hours a day without stopping and does not require constant maintenance. The service life of this press without major repairs is more than 10 years.

The entire process of the press and packing of briquettes is controlled by one operator, which significantly reduces the cost of finished products. The press is supplied complete with a device for packing briquettes. The BP-600 presses were developed and put into mass production more than 10 years ago, the presses work at the largest woodworking enterprises around the world, more than 50 presses have already been launched in Russia.

The resulting briquettes, unlike other forms of briquettes, are convenient for packaging, storage and transportation over long distances, which makes them the most popular in the world today and the demand for such briquettes is constantly growing.

The press is used primarily for medium and large productions with a large amount of dry waste. The fuel material obtained as a result of briquetting is widely used both in industrial heating systems and in individual households. The cost of a set of equipment, including delivery and installation, will be 4,631,000 rubles.

The description of the production and technological process on this equipment is almost identical to all its analogues. First, at a low pressure (25-50 MPa), an external compaction of the material occurs due to the removal of voids between the particles. Then the particles themselves are compacted and deformed. There is a molecular bond between them. In the process of moving from the first to the second press, the workpiece is heated up to 110-130 o C. This operation increases the contact density of coke dust particles. High pressure at the end of pressing (120-150 MPa) leads to the transition of elastic deformations of the particles into plastic ones, as a result of which the structure is strengthened and the desired shape is maintained. The phenols and resins released in this process polymerize on the surface of the particles with the participation of water. Heating the material to a strictly defined temperature (100-110 o C) directly during pressing improves the process. This whole process is controlled by a microprocessor. When cooling and after drying, the briquettes are finally fixed. The next step will be the delivery of briquettes (in parallel with the main products) to the blast furnace. Table 3.3 shows the technical characteristics of the BP-600 press.

Table 3.3 - Characteristics of the BP-600 press

Parameters measurementsValueProductivitytons/hour1-3PowerkW25Pressure of the pressPa20-170Briquette dimensionsMm150/75/50Dimensions of the presscm/cm/cm1800/1800/1900

Table 3.4 describes the characteristics of the manufactured products of the production and technological process for the manufacture of coke briquettes from coke dust.

Table 3.4 - Characteristics of briquettes

ParametersUnits of measurementValuePorosity%15-33Density2.80-2.85MassAsh content%Moisture%StrengthPaCombustion value29-30

Based on the data in Table 3.4 and having studied the technological process of manufacturing coke briquettes, we can draw the following conclusions. Physiochemical properties briquettes are identical to the properties of coke. Due to the increase in the density of the briquette, the calorific value has increased, which will be a positive aspect in iron smelting. At the same time, the ash content decreased, which leads to a decrease in emissions into the environment.

Figure 3.1 - Scheme of raw material flows after the development of an innovative project: 1-coal warehouses, 2-crushing and processing line, 3-coal preparation workshop, 4-coke oven batteries, 5- USTK, 6-coke sorting, 7-blast-furnace workshop, 8-shop capture and processing of chemical products of coal coking.

3 Evaluation of development results technological innovation

Based on the calculations made in the previous chapter, the following changes will occur in the structure of operating costs (Figure 3.2).

Based on Figure 3.2, the following changes will occur in the production and technological system of coke production:

· depreciation charges will increase by 0.1% and amount to 2.8%;

· material costs will decrease by 0.8% as a result of a decrease in specific material costs due to an increase in production volumes and a decrease in the cost of coke dust disposal and will amount to 76.4%;

· operating costs will decrease by 21.006 and will amount to 1214.635 million rubles;

· the volume of sold products will increase by 78.948 million rubles and will amount to 1394.756 million rubles;

· operating profit will increase and amount to 180.121 million rubles;

· income tax will increase by 18.364 and amount to 33.322 million rubles;

· net profit 141.37 million rubles/year;

· net income as the sum of net profit and depreciation charges will amount to 175.379 million rubles. / year, that is, it will grow by 82.596 million rubles;

· labor costs will increase by 0.5% due to an increase in the number of employees and will amount to 176.122 million rubles.

The changed parameters of the operating cycle in coke production at Severstal PJSC during the development and implementation of technological innovation are presented in Table 3.5. There is an increase in the volume of sold products of coke production, net income, the cost of fixed assets and production capital, and a significant drop in direct technological costs.

Figure 3.2 - Structure of costs for the production of coke as a result of the development of an innovative project (million rubles / year)

Table 3.5 - Changing the parameters of the operating cycle

ParametersDesignation Numerical value, million rubles/yearbefore mastering the innovationafter mastering the innovationVsv= G0W0 + D0404.834412.695Direct technological costsG0W0=Cos - Сdc375.840373.651 + U463.575463.76

The payback period of investments is calculated as the ratio of the amount of investment to the fluctuation in the income of the enterprise (formula 3.1). The amount of investments required for the development of an innovative project is 2,374 thousand rubles. Change in net income - 10,049,938 rubles per year. Accordingly, the payback period will be 3 months,

I/ ΔD , years, (3.1)

where I is the amount of investment, rubles/year;

ΔD - increment of net income, rub./year.

The appendix presents in more detail the change in the integrated set of criteria for the operating cycle in coke production. All criteria will change in better side. The conversion criterion increased by 0.02, the capitalization criterion - by 0.03, the criterion of production capital resources of simple and expanded reproduction - by 0.01, the investment capital criterion - by 0.1. The characteristic of the operating cycle received the greatest increase - 0.13.

Conclusion

In the final qualifying work, the goal set and its accompanying tasks were fully achieved. The procedure for the development of an innovative project into the production and technological system of coke production is determined, the methods of the operating cycle and evaluation criteria are studied. Also, in the process of working with the final qualification work, the following questions were considered:

-essence of innovations and their types;

-structure of the innovation process;

-operating cycle criteria in industry.

As a graduation object qualifying work a production site (sintering, issuing, quenching and sorting) of blast-furnace coke was chosen. Public Joint Stock Company "SeverStal".

An innovative project is the modernization of the coke sorting site (organization of an additional production site) in order to obtain coke briquettes using the coke dust and fines press.

The innovative project proposed in this paper will lead to a change in the parameters and criteria of the operating cycle. All criteria are changing for the better. In particular, the conversion criterion increased by 0.02, the capitalization criterion - by 0.03, the criterion of production capital resources of simple and expanded reproduction - by 0.01, the investment capital criterion - by 0.1. The characteristic of the operating cycle received the largest increment - 0.13. Also, the result of the study and implementation of this innovation will be an increase in the annual volume of production and supply of products, high quality and consumer properties of manufactured products, and thereby increasing the competitiveness of products. The main advantage of the innovative project is the complete absence of coke production waste, thereby solving the issues of resource saving and greening of the enterprise's production activities.

It can be stated that innovations in the production and technological systems of industrial enterprises occupy a significantly high position as a tool for the growth of all production indicators. Allocation and product innovations are aimed at increasing the volume of product sales, technological innovations reduce direct technological costs.

Thus, in accordance with the goal set in the WRC, an innovative solution was proposed related to the improvement of one of the production and technological systems of PJSC SeverStal.

The tool for improvement is the development of technological innovation in the production of coke. The proposal was implemented by modernizing the coke sorting section, by installing an additional set of equipment for the production of coke briquettes that meet all the parameters of consumer properties for blast-furnace coke.

List of sources used

1. Great Russian Encyclopedia [Electronic resource].

Belousova, V. P. Formation of factors of ecologization of economic development of an industrial enterprise / V. P. Belousova // Innovations. - 2012. - No. 1. - S. 26-29.

Gryaznov, N.I. Fundamentals of the theory of coking: textbook / N.I. Gryaznov-Moscow: Metallurgy, 2015. - 314 p.

Ivanov, E.B. coke production technology, tutorial/ E.B. Ivanov, D.A. Muchnik. - Moscow: Science, 2014. - 232s

5. History of PJSC "Severstal" [Electronic resource].

6. Leibovich, R.E. Technology of coke production: textbook / R.E. Leibovich, A.B. Filatova, E.I. Yakovlev. - Moscow: Metallurgy, 2013. - 360 p.

Tax Code of the Russian Federation. Part one dated July 31, 1998 No. 146 - FZ (with latest changes and additions) [Electronic resource]: tax code RF. Last valid revision with Commentaries.

National Historical Encyclopedia [Electronic resource].

On science and state scientific and technical policy: Feder. Law of August 23, 1996 No. 127-FZ. - Moscow: Omega-L, 2016. - 78 p.

Papin, A.V. Development of technologies for utilization of coke dust of coke-chemical industries / A.V. Papin // Polzunovskiy Bulletin. - 2014. - No. 4. - S. 159-164.

Production of PJSC "Severstal" [Electronic resource].

Stefanenko, V.T. Purification of dust, gases and air at coke enterprises: textbook / V.T. Stefanenko. - Moscow: Metallurgy, 2012. - 140 p.

Commercial and industrial company "Association KAMI" [Electronic resource].

14. Commercial and industrial company "Termorobot" [Electronic resource]: official. website.

15. Tukkel, I. L. Management of innovative projects: textbook / I. L. Tukkel, A. V. Surina, N. B. Kultin / ed. I. L. Tukkel. - St. Petersburg: BHV-Petersburg, 2011. - 416 p.

Shamina, L. K. Theoretical aspects functioning of innovation processes: textbook / L.K. Shamin. - St. Petersburg: Nauka, 2012. - 85 p.

Shichkov, A. N. Management of innovations and technologies in the production environment: study guide / A. N. Shichkov. - Vologda: 2014. - 109 p.

18. Shichkov, A. N. Organization of innovation management in production and technical systems: monograph / A. N. Shichkov. - Moscow, 2012. - 214 p.

19. Shichkov, A.N. Situational analysis of the market structure in the municipal district (district): monograph / A. N. Shichkov. - Vologda: 2013. - 207 p.

Shubeko, P.Z. Continuous coking process: textbook / P.Z. Shubeko. - Moscow: Metallurgy, 2013. - 200 p.

The values ​​of the criteria parameters before and after the development of innovation

Table 1.1 - Values ​​of criteria parameters before and after reconstruction at the coke production site of PJSC SeverStal

Names of parameters and criteriaValues ​​of parameters and criteriabefore developmentafter developmentSales values, Vsv, million rubles/year1295.4721356.006Direct technological costs, G0W0, million rubles/year1202.6891180.626Balance value, U, million rubles/year280, 752285.712Net income, D0, million rubles/year92.783175.379Production capital, Q=U+G0W0, million rubles/year1483.4411466.338Conversion criterion, ς =Vsv/Q

The owners of the patent RU 2468071:

The invention relates to the technology of briquetting combustible components - coal sludge, small grades of coal, coke dust. The method of briquetting coke dust is to obtain a concentrate. The concentrate is obtained by enrichment of coke dust with a particle size of less than 1 mm with an initial ash content of 10-16.8% wt. and a sulfur content of 0.4-0.5 wt.% by oil agglomeration to an ash content of 5.0-5.5 wt.% and a sulfur content of 0.05 wt.%. The prepared concentrate and the binder heated to 100-133°C are mixed - urea, taken in an amount of 4.0-6.0% by weight of the original concentrate. The mixture is briquetted in steps, for which a load of 5-6 atm is first set, with a holding time of 3-5 minutes and then up to 15 atm with a holding time at a maximum load of 3-5 minutes. EFFECT: obtaining fuel briquettes with low ash content and sulfur content, utilization of coke dust. 6 tab., 3 pr.

The invention relates to a technology for briquetting combustible components, such as coal sludge, fine grades of coal, coke dust, etc. The resulting briquettes can be used as a fuel for combustion in household and industrial furnaces, as well as for coking in the coke-chemical and metallurgical industries.

The volumes of coke dust formation are very high, on average, about 18-20 thousand tons of coke dust are formed per year at one coke-chemical enterprise. Coke dust practically does not find application because of the finely dispersed state and high ash content, the difficulty with unloading and transportation. The problem of utilization of coke dust is very urgent.

The invention contributes to the solution environmental issues associated with the formation and disposal of waste (coke dust).

Known methods for briquetting coal and anthracite, including dehydration and drying of the original coal to a moisture content of 2-3%, mixing it with liquid or solid binders (petroleum bitumen, coal tar pitch, sulfate-alcohol stillage, hard clay, cement), pressing the mixture with a pressure of 20- 50 MPa, and subsequent cooling (see Elishevich A.T. "Technology of briquetting minerals." - M.: Nedra, 1989, p. 86, 92, 98, 101, 106).

These methods have the following disadvantages.

Firstly, the need to use the proposed binder significantly complicates and increases the cost of the process of briquetting coal, because. provides operations for deep dehydration and thermal drying of the initial coal to the minimum moisture content, i.e. up to 2-3%.

Secondly, the existing technologies for briquetting hard coals and anthracites are not intended to be used as feedstock for coke dust (size class 0-1.0 mm) and fine coal sludge (size class 0-1.0 mm) generated during mining and coal processing. Coal sludge and coke dust are dumped into settling tanks and dumps of coal processing enterprises, which worsens the ecological state of the environment in coal-mining regions.

A known method for producing fuel briquettes from brown coal, which consists in mixing brown coal with a particle size of less than 6.0 mm with polyethylene (household waste) pre-crushed to particles smaller than 2 mm in an amount of 4.4÷5.0% (on dry weight of coal ), heating the mixture to a temperature of 120÷140°C with isothermal exposure for 30 min, obtaining briquettes at a briquetting pressure of 78 MPa. The mechanical compressive strength of the resulting briquettes is at least 7.8 MPa (Application for a patent of the Russian Federation No. 2008109775/04, publ. 20.11.2009).

The disadvantages of the known method are as follows: brown coal is used, which has a tendency to oxidize and ignite spontaneously, which makes it difficult to transport briquettes over long distances and store for more than 3 weeks. Another disadvantage is the high pressing pressure of 78 MPa.

Closest to the proposed invention in technical essence (prototype) is a method for producing fuel briquettes, including mixing crushed solid fuel based on coke breeze with a particle size of 0.05-16.0 mm in an amount of 50-80 wt.% with a binder based on modified lignosulfonate in an amount of 8-9% by weight of crushed solid fuel, briquetting the mixture under a pressure of 25 MPa and subsequent heat treatment briquettes (RF Patent No. 2298028, published April 27, 2007).

The known method for producing fuel briquettes has the following disadvantages:

1. High pressing pressure (25 MPa), which is economically and energetically unprofitable and technically difficult to achieve.

2. Sufficiently high binder content - 8-9% by weight of solid fuel.

Briquetting of coke dust is proposed, which is a high-calorie waste of coke-chemical enterprises.

The technical result of the invention is the production of fuel briquettes with low ash and sulfur content, made from coke dust concentrate, which will improve the environmental situation in coal-processing regions.

The technical result is achieved by the fact that in the method of briquetting coke dust, including mixing crushed solid fuel with a binder, briquetting the mixture under pressure, according to the invention, pre-enriched by oil agglomeration to an ash content of 5.0-5.5 wt. % and sulfur content of 0.05 wt.% coke dust with an initial ash content of 10-16.8 wt.%, sulfur content of 0.4-0.5 wt.%, with a particle size of less than 1 mm, carbamide is used as a binder in an amount of 4 0-6.0% by weight of the original concentrate, and the carbamide is heated to 100-133 ° C before being introduced into the original concentrate, and the briquetting of the mixture under pressure is carried out in steps, for which a load of 5-6 atm is first set, with a holding time of 3-5 min and further up to 15 atm with exposure at maximum load 3-5 min.

The inventive method is carried out as follows.

Coke dust is enriched at the plant by the oil agglomeration method to obtain deeply enriched concentrates.

Coke dust is finely dispersed, less than 1 mm in size. According to the amount of ash content, coke dust belongs to medium-ash coal waste, which prevents its return to the coking charge and direct combustion, therefore, the initial stage of its preparation is enrichment.

Since coke dust is finely dispersed (<1 мм), то оптимальный метод ее обогащения - масляная агломерация. К основным достоинствам метода масляной агломерации относят высокую селективность при разделении частиц менее 100 мкм (что и характерно для коксовой пыли), широкий диапазон зольности обогащаемого угля, возможность вести процесс при плотности пульпы до 600 г/л, дополнительное обезвоживание концентрата вытеснением воды маслом при образовании углемасляных гранул.

Technical or drinking water is poured into the container, coke dust is loaded. Before visual mixing for 1-2 minutes, intensive mixing of coke dust and water is carried out using a paddle mixer connected to the engine. Stirring for more than 3 minutes is impractical. In order to avoid the formation of a "funnel", which reduces the intensity of mixing, special barriers are installed in the container. Then the hydrocarbon reagent is added and stirred for another 5-8 minutes. Stirring for less than 5 min does not lead to the formation of oil agglomerates, since the hydrocarbon reagent does not have time to completely wet the surface of dust particles. Increasing the mixing time over 8 minutes is impractical, since additional energy is consumed.

As a result of pulp turbulization (a mixture of water, coke dust and reagent), coke-oil aggregates are selectively formed, which are compacted, structurally transforming into strong spherical granules, while the fuel gets rid of ballast - mineral impurities. The ash content of the obtained concentrates does not exceed 5.5 wt.%, the sulfur content is 0.05 wt.%, which indicates the acceptability of the obtained concentrates for coking technology and energy; the high yield of the product (up to 84% wt.) and the lower ash content and sulfur content of the concentrates are due to the complete separation of the organic and mineral parts of the coke dust during enrichment by the oil agglomeration method.

At the outlet of the installation receive a concentrate with the following characteristics (table 1).

The resulting concentrate and heated to 100-133°C urea in the amount of 4.0-6.0% by weight of the original concentrate are mixed in a mold.

The choice of carbamide as a binder is due to its availability and low cost. Urea is readily available due to its large industrial production and low market value. The consumption of the binder (urea) is determined by the need for the formation of a durable fuel briquette.

The resulting mixture is pressed in a stamp press stepwise: first, a load of 5-6 atm is set, with an exposure of 3-5 minutes, and then up to 15 atm with an exposure at a maximum load of 3-5 minutes. With stepwise pressing, the optimal interaction of the components in the mixture is achieved, with the formation of the structure of the fuel briquette.

At the output, fuel briquettes are obtained with the following technical characteristics (Table 2).

An example of a specific application of the method.

Coke dust is enriched in the pilot plant by oil agglomeration to obtain highly enriched concentrates.

At the outlet of the installation receive a concentrate with the following characteristics (table 3).

Take 100 g of the resulting concentrate and 4 g of carbamide heated to 133°C, mix in a mold and press in a stamp press stepwise: first, a load of 5 atm is set, with an exposure of 3 minutes and then up to 15 atm with an exposure at a maximum load of 5 minutes.

At the output, fuel briquettes are obtained, acceptable for coking and direct combustion, the technical characteristics of which are presented in table 4.

Example 2 Coke dust is enriched in a pilot plant by oil agglomeration to obtain highly enriched concentrates.

Technical or drinking water with a volume of 850 ml is poured into the container, coke dust weighing 200 g is loaded. Coke dust and water are intensively mixed for 1-2 minutes using a paddle mixer connected to the engine. In order to avoid the formation of a "funnel", which reduces the intensity of mixing, special barriers are installed in the container. Then a hydrocarbon reagent (used exhaust oil) is added in an amount of 30 ml and stirred for another 5-8 minutes.

At the outlet of the plant, a concentrate is obtained with the following characteristics (Table 5):

The resulting concentrate weighing 100 g and carbamide heated to 50°C weighing 5 g are mixed in a mold and pressed in a stamp press with a load of 5 atm for 5 min.

1. The temperature of the heated carbamide is not sufficient for its complete melting and, accordingly, its distribution throughout the mass of the coke concentrate is impossible, which leads to a decrease in the strength of the fuel briquette.

2. Reducing the pressure of pressing less than 15 atm leads to a decrease in the strength of the fuel briquette.

Example 3 Coke dust is enriched in a pilot plant by oil agglomeration to obtain highly enriched concentrates.

Technical or drinking water with a volume of 850 ml is poured into the container, coke dust weighing 200 g is loaded. Coke dust and water are intensively mixed for 1-2 minutes using a paddle mixer connected to the engine. In order to avoid the formation of a "funnel", which reduces the intensity of mixing, special barriers are installed in the container. Then a hydrocarbon reagent (used exhaust oil) is added in an amount of 30 ml and stirred for another 5-8 minutes.

At the outlet of the plant receive a concentrate with the following characteristics (table 6).

The resulting concentrate weighing 100 g and carbamide heated to 160°C weighing 15 g are mixed in a mold and pressed in a stamp press with a load of 25 atm for 5 min.

At the output, they do not receive a fuel briquette, because:

1. Heating of carbamide to 150°C leads to its decomposition.

2. According to the mathematical dependence calculated by Dr. A.T. Elishevich, the involvement of more than 10% of the binder in the system is economically and technologically unjustified.

3. The use of a sharp increase in pressure up to 25 atm leads to the production of a fragile fuel briquette due to the inhomogeneous distribution of the binder by weight of the concentrate.

The proposed method for producing fuel briquettes makes it possible to reduce the ash content and sulfur content of fuel briquettes. In addition, the proposed method for producing fuel briquettes uses coke dust, which is a waste product of coke-chemical enterprises, the utilization of which will improve the environmental situation in coal-processing regions.

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Introduction

1. Innovative activity

2.3 Dust and gas collection and coke dust disposal system

2.4 The main production assets of the coke production of PJSC Severstal

2.5 Cost structure of coke production

3. Innovative project for the sale of coke dust in PJSC "SEVERSTAL"

3.1 Description of the innovation project

3.2 Characteristics of the equipment

3.3 Cost structure after modernization of the production and technological system

Conclusion

List of sources used

Attachment 1

Introduction

The goals and objectives of the engineering business of metallurgical enterprises, the main field of activity of which is industrial production, are changing with the advent of an innovative economy that has come to replace the industrial market economy in the Russian Federation. The main task is to modernize innovative parameters in business management. These parameters serve as an increase in the volume of sales of manufactured products, and a decrease in operational technological costs in production, for the purpose of adapting industrial enterprises to the market. Competition is one of the main factors to determine the development of a business in an industry. The basis for the successful functioning of industrial enterprises in the conditions of a large number of enterprises producing the same products, the main requirement is the development of innovative projects that are aimed at increasing the levels of consumer properties, the volume of sales of the manufactured product and reducing operational technological costs. The basis of industrial business, which ensures the release of a product with certain properties of consumption, is the development of innovative projects.

One of the most important properties of nature is economic. Its essence lies in the fact that natural resources used by man have economic properties, economic potential. This fact will be one of the factors of the relevance of writing the work.

With the change in the market situation in the coal mining and processing industry, coke production needs to create a system for the development of production and innovation management. Almost all metallurgical plants, both domestic and foreign, use coke as the basis of blast furnace fuel.

Innovations have always been and are one of the main strategic parameters for the development of an industrial enterprise and its economy as a whole. In accordance with the requirements of the market, technological innovations must bring economic income in the course of the enterprise's activities. To resolve the issue of creating and implementing a particular operation in the technological process, it is necessary to take into account and analyze all the factors and risks of this innovation in comparison with its analogue in terms of technical and economic parameters, and take into account the possible economic results of its application in production.

The main goal of this work is the development and feasibility study of an innovative solution for the implementation of one of the wastes, the coke production of PJSC Severstal. In the process of writing a final qualified work, the following were studied:

- production and technological process of coal charge coking into blast-furnace coke;

- characteristics of coke for blast furnaces of PAO Severstal;

- articles and patents on the production and technological process of fuel production by briquetting waste and finely dispersed fractions of the mining industry;

- literary sources in the field of organization of the production process.

The object of study is the area of ​​aspiration and dust collection in the finished coke dispensing system, coke quenching and sorting.

The subject of the study is approaches to the organization of the production and technological process for the production of briquettes from coke dust by the press method.

During the preparation for writing the WRC, the works of the following authors were studied: Belousova V.P., Gryaznov N.I., Ivanov E.B., Leibovich R.E., Papin A.V., Stefanko A.O., Tukkel I. L., Filatova A.B., Shichkov A.N., Shubeko P.Z., Yakovleva E.I.

Separate chapters of the tax legislation of the Russian Federation are studied. Official websites of PAO Severstal and similar industrial enterprises. Electronic resources of historical and Russian libraries.

1. Innovative activity

1.1 Innovations, their economic essence and significance

innovation economic coke money

Innovation is the process of development, study, dissemination and use of new ideas that improve the efficiency of the enterprise. With all this, innovation cannot be considered simply an object that is introduced into the production process, but an object that is successfully implemented and makes a profit as a result of scientific research or discovered discoveries. It is qualitatively different from previous analogues.

Scientific and technological innovation must be approached as a process of transforming scientific knowledge into scientific and technical ideas, and then into the production of a product to satisfy consumers and users. From the foregoing, two paths to scientific and technological innovation can be identified.

In the first case, mainly product orientations of innovations are reflected. Innovation is defined as a process of upgrading to release a finished product. This direction is widespread in the period, which is positioned by the consumer in relation to the manufacturer rather weak. However, the product itself is not the end goal, it is only a tool to satisfy the use and needs.

Therefore, according to the second case, the processes of scientific and technical innovations are considered as the transfer of scientific and technical knowledge directly to the area of ​​satisfaction of the needs of consumers. At the same time, the products are modernized into the owner of technological processes, and its taking form is determined after linking the technology and the necessary need.

It follows that innovations, firstly, need to have a market structure to meet the needs of the consumer. Secondly, any innovation is most often studied as a complex procedure that involves the modernization of both scientific and technical, as well as economic, social and structural orientations. Thirdly, in innovation, the emphasis is on the rapid modernization of innovation into practical use. Fourthly, economic, social, technological or environmental effects must be provided by innovation.

An innovative project is a rationale for the economic feasibility of studying, mastering and implementing innovations. The main priorities in working with innovative projects are to increase production and increase sales, as well as reduce operating costs and increase the company's income while producing products at a constant volume. The task of increasing the volume of production is not a priority for innovative projects.

In addition, as a result of the implementation of the innovative project, it is necessary to organize an increase in the state budget, local authorities and state bodies, the municipal government's own network should create additional income tax revenues for individuals, and owned by the company, and the Federal budget - an additional income tax, as well as value added tax.

Innovation is rightly considered to be the results of the intellectual work of the enterprise, which are in demand by the market and contribute to the growth of the effective activity of the enterprise. According to the theory of Shichkov A.N., innovation is any approach to the development, production activities and marketing of products, as a result of which the enterprise receives a competitive advantage.

In the current conditions of uneven economic activity and unsustainable development, the search for new models of economic development, the adaptation of the economic system, and in particular industrial enterprises of the production type, is certainly a characteristic from which their functioning, preservation and modernization are repelled in a changing and competitive activity.

The innovation process is the process of upgrading scientific knowledge into innovation, representing as a sequential chain of events, the result of which innovation flows from an idea to specific products, technologies and services. It extends in practice. The innovation process is aimed at the emergence of the necessary market for products, technological services, and closely interacts with the environment of its activity: its direction, pace of development, goals are tied to the socio-economic environment in which it develops and operates. It should be concluded that only on the innovative approach of modernization it is possible to carry out the growth of the enterprise's economy.

Innovative activity is an activity that is aimed at the work and commercialization of the result of scientific activities and developments in expanding and updating the range and improving the quality of the product, as well as improving the technological processes of their production with subsequent modernization and effective sales work in the domestic and foreign markets.

There are various classifications of innovations, but most researchers distinguish mainly several types:

Product innovations;

Allocation innovations;

Technological innovation.

A product innovation is rightfully considered a new or upgraded product that has high consumer properties or a high market value that generates income for the enterprise.

Technological innovation is the modernization or improvement of production technology, or the study and implementation of a new technological process.

Allocation innovations are aimed at improving the effectiveness of the management of the production and technological system, which affects the competitiveness of the enterprise in the market.

Production and technological system (PTS) - the minimum set of two types of assets tangible and non-tangible. With their help, products with high consumer qualities are produced. The economic equivalent of the consumer qualities of a competitive product is its cost in the market.

Innovation is usually viewed as:

Process;

System;

Modernization;

Result.

Innovation is clearly oriented towards the final calculation of an applied nature, which must always be evaluated as a complex process. It provides a certain effect in the technical and socio-economic sphere of functioning.

Innovation at all its stages of development (life cycle) changes its forms, moving from idea to development. The movement of innovation processes, like any other, is associated with complex interactions of many risks and factors. The involvement in entrepreneurial activity of various options for the forms of organization of innovative processes is determined by the following factors:

Belonging to the external environment (political and economic stop, types of market, nature of competitive confrontation, experience and developments in state-monopoly settlement, etc.);

Influence of the internal environment on this economic system (presence of the head-entrepreneur with a support team, resources of the economy with a material foundation, functioning technological schemes, established organizational structure, internal organization system, external relations with the neighboring environment, etc.);

Feature of the innovation process itself as an object of management.

The innovation process is studied as a process that permeates most of the scientific, technical, industrial, marketing activities of industries. Ultimately, it is focused on meeting the needs of the consumer. The most important factor in the success of innovative functioning is the presence of an innovator-enthusiast who is captured by a new idea and is ready to make a significant amount of effort to bring it to life, as well as the head-entrepreneur who has found investments, developed the organization of production, sold a new product to the sales market, accepted for assume the main risks of responsibility, and also implemented its commercial development.

Innovations form markets for innovations. Investments form the sphere of activity of the enterprise's capital, innovations form the market for development rivalry. The innovation process enhances the assimilation of scientific and technical results, as well as intellectual certainty for the development of a new or improved product (service) and the maximum increase in added value.

1.2 Innovative development plan of PAO Severstal

Let's study innovative activity on the example of the enterprise of the city of Cherepovets PJSC "Severstal".

The metallurgical complex - PJSC "Severstal" serves as the basis of the economic industry of the region. In the ranking of the largest companies in Eastern Europe, PJSC Severstal is one of the few industrial plants in the production of ferrous metallurgy. PAO Severstal occupies a high position in the rating of industrial enterprises, having risen by 10 lines compared to the activity of 2012.

The enterprise transfers more than 58% of the volume of industrial production, 74% is exported, 78% of industry income and about 37% of the region's consolidated budget revenues.

Now the department of technological innovations and development of production sites is being developed in the technical directorate of the plant. The department will participate in the development of innovation policy, the strategy of business development of the society and determine the direction of their qualitative regulation. Development and implementation of a thematic R&D strategy, which is planned to be developed for a period of - 7 years, will function in a directed manner in accordance with the current directions of technological innovation and the successful operation of society. In the future, the thematic order of R&D will be the foundation for the formation of annual R&D strategies.

Among the main effective measures that are involved in the main project is the development of a technology for the restoration of coke oven backfill sites that are subject to strong temperature fluctuations, using the ceramic surfacing method. The planned economic effect will be approximately one thousand rubles.

The development strategy of the metallurgical plant for 6-9 years is reflected in the formed business plan and regulated qualities:

1) increase in production volumes, including products with high added value;

2) an increase in the average sales price;

3) cost optimization;

4) increase in the authorized capital of the company;

5) increasing the social significance and responsibility of the plant

From the start of the establishment of the joint-stock company, the growth of the enterprise is determined by several strategic stages, in the implementation of which all the employees of the plant are involved. The work on the strategy is connected with the training of sales and sales employees on the organizational, economic and strategic development plan, which allowed PAO Severstal to modernize approaches to existing areas of activity, directing its movement towards increasing production efficiency and mobilizing most of the internal resources to enter the group of the best steel mills in the world .

Production and marketing of metallurgical products is a priority and highly significant for the business structure. As a result, according to the results of work for 2014, the volume of steel production was determined as 9 million 869 thousand tons, black rolled products - 8 million 710 thousand tons. This is 1.4% and 3.9% higher than in 2014, respectively. According to most analysts in the industry, both domestic and foreign, the growth in the production of rolled metal in the global economy will continue to grow in the same way as consumption. As for medium-term quality, it can be said that according to forecasts, by 2018, metal production in the world will increase to 918.5 million tons, and consumption to 897.7 million tons. In the long term, by 2010 the production of rolled metal in the world will grow to 1,052 million tons, and consumption to 1,020 tons.

In Russia, by 2018, it is planned to increase the production of rolled metal to 50, and by 2021 to 51 million tons.

Thus, based on the current forecast, it can be determined that PJSC Severstal products with marketable properties will be in demand for many years.

The company's management is not going to rest on the results achieved. Currently, the plans of PJSC Severstal provide for the consistent implementation of innovative projects. The main innovations are supposed to be at the beginning of the technological chain: coke production and blast furnace shop.

In addition, two areas are distinguished in the innovative project: a program for saving energy resources and a program for introducing an automated system for monitoring and accounting for electricity. The main task for the company is to match the level of consumption of energy resources per ton of liquid steel with the best producers in the world. Reducing costs will be one of the top priorities.

The effect in the activities of improving the quality of rolled metal products and increasing the output of a product with high added value is provided by strategic programs - in the field of production and marketing, technical re-equipment and commercial activities of further modernization of the enterprise

1.3 The structure of operating costs of the production and technological system

According to Chapter 25 of the Tax Code of the Russian Federation, the cost structure consists of the following items:

1) material costs;

2) labor costs;

3) depreciation charges;

4) other costs.

Figure 1.1 shows a graphical interpretation of the structure of operating costs in the production and technological system.

1) Material costs consist of several types of costs:

Purchase of raw materials and materials necessary for the production of products;

Purchase of production equipment that is not depreciable;

Purchase of fuel, energy resources of all kinds necessary for production;

Losses during production, storage, and transportation within the limits of natural loss, etc.

2) Labor costs include all contributions to employees in cash in kind (C lp).

3) Depreciation (C dc) - replacement of operational depreciation of fixed assets by transferring their value to the cost of production. The minimum cost of depreciable property is 100 thousand rubles.

4) Other costs (С ac). This group includes travel expenses. Payment of benefits for temporary disability. Amounts of taxes and fees, including social, medical insurance. In addition, this item includes depreciation for intangible assets.

In addition to the cost structure, in the graphical interpretation of the operating cost structure shown in Figure 1.1, there are types of income and taxes (volume of products or services sold, operating profit, net profit, net income).

The volume of product sold is the amount of certain funds that are received from the sale of a product or service. The volume of products sold includes direct costs of production (operating costs) and operating profit.

Operating profit is made up of the difference between the volume of product sold and direct production costs.

Net income is the balance of cash from operating income due to the payment of property tax and income tax.

The structure of operating costs shows the net income of production, according to the following calculation scheme:

1. Calculation of operating profit (P) according to formula 1.1:

P \u003d V sv - С about c, rub. / year, (1.1)

where V sv is the volume of output, rub./year;

C o c - operating costs, rub./year.

Figure 1.1 - Graphical interpretation of the structure of operating costs in the production and technological system

Calculation of the taxable base for income tax: is the difference between operating profit (P) and property taxes (N fa).

Income tax (N p) is 20% of the taxable base calculated in the previous paragraph.

Net profit (R o) is calculated according to formula 1.2:

P o \u003d P - N fa - N p, rub. / year. (1.2)

The net income of the enterprise is calculated according to formula 1.3:

D o \u003d P o + C dc + C ia , rubles / year, (1.3)

where R o - net profit, rubles / year;

С dc - depreciation deductions from tangible assets, rub./year;

С ia - depreciation deductions from intangible assets, rub./year.

1.4 Five vectors of cash flow equivalents

According to A. N. Shichkov’s theory, five vectors of cash flow equivalents are rightfully taken as the basis for the conversion processes of production and technological systems. The vectors are implemented by the operating cycle of the production and technological system. The following vectors are considered:

V sv - the volume of products sold;

G 0 W 0 - costs of direct technological processes, including operational direct technological costs, wages (operating costs minus depreciation);

D 0 - net income. Includes capital for the restoration and adjustment of fixed assets (deductions for depreciation) and net profit;

U mf - fixed assets, including fixed assets and intangible assets of the enterprise;

Q - production capital, consisting of fixed assets U mf and direct technological costs G 0 W 0 .

1.5 Integrated set of criteria

This section describes in detail the process of the integrated set of operating cycle criteria:

1. The criterion for the conversion of the operating cycle. In an ideal production and technological system, it is calculated from the ratio of the volume of the product sold, as well as the service cost of production capital. The cost of production capital is the sum of direct technological costs, and fixed assets from intangible assets. The criterion for the conversion of the current operating cycle is no more than 40-45%. This indicator is calculated in formula 1.4:

t \u003d V sv / Q? 1. (1.4)

2. The criterion of capitalization of the operating cycle is equal to the ratio of the volume of sold products to services in direct technological costs. The capitalization criterion for the current operating cycle is not more than 1.5, ideally - 2. This criterion is calculated in formula 1.5:

l \u003d V sv / G 0 W 0? 2. (1.5)

3. The criterion of investment capital of two types of production is equal to the ratio of net income to the book value of tangible and intangible assets. The calculation is carried out in formula 1.6, which has the following form:

M = D o / U? 1. (1.6)

4. The criterion of the resource of the production capital of an enterprise is the ratio of the cost of production capital to direct technological costs:

Q / G 0 W 0 . (1.7)

5. The characteristic of operating cycles is the ratio of direct technological costs and the amount of fixed assets from intangible assets:

k 0 = G 0 W 0 / U. (1.8)

With the development of a larger number of innovations in the production and technological system, almost all the criteria for an integrated complex change.

2. Characteristics and analysis of coke production technology in PJSC "SEVERSTAL"

Coke production is one of the main production facilities of PAO Severstal. Its main task is to timely provide five blast furnaces with high-quality coke. The main production assets of coke-chemical production are coke oven batteries, which are used to produce coke from coal charge using a certain technology.

2.1 Coke production of PJSC Severstal

The coke production of PJSC Severstal was established in 1956. A total of 10 coke batteries were built between 1956 and 1978.

The coke shop of the Cherepovets Metallurgical Plant was designed to provide two blast furnaces with coke. Four coke oven batteries with a capacity of 461 thousand tons of coke per year each, a coal preparation shop, a coal preparation plant with a capacity of 700 tons per hour, a shop for capturing coking chemical products and a biochemical plant for water treatment were built. The first battery with coal preparation and a trapping shop was put into operation on February 13, 1956. The second coke oven battery was also built in 1956, the third - in 1957, coke oven battery No. 4 was put into operation in 1958.

Thus, the 1st stage of development of coke production with a capacity of 1844 thousand tons/year of coke was completed. In 1959, a decision was made to further develop the Cherepovets Metallurgical Plant. Construction of the third blast furnace with a volume of 2000 m 3 , the largest in terms of its capabilities. With an increase in the output of pig iron to 2.4 million tons per year, it was planned to build the second stage of the coke production, bringing its capacity to 3.2 million tons per year of coke. In 1963, the fifth, and in 1966, the sixth coke batteries were built with a total capacity of 1380 thousand tons/year of coke (690 thousand tons/year of coke each).

The third stage in the development of coke-chemical production began in 1970, when a decision was made to build a coke oven block of four coke batteries with a capacity of 730 thousand tons / year of coke to provide blast furnace No. 5 with coke. Coke oven batteries No. 7.8 were put into operation in 1972, batteries No. 9,10 - in 1978

In the early 1980s, the coke production of the Cherepovets Metallurgical Plant reached its maximum productivity. Coke production reached 6.3 million tons/year of coke with a design capacity of 6.14 million tons.

Much attention was paid to environmental protection objects. In 1978, a new biochemical plant was built for wastewater treatment, a closed water circulation cycle was completed, and thereby all direct discharges from the territory of the coke production into water bodies were eliminated. More rational schemes for capturing coke dust at coke screens have been developed and implemented, the sludge water removal system has been reconstructed, and a number of other works have been carried out to protect the environment. Emissions of harmful substances into the atmosphere have significantly decreased, pollution of the reservoir of the Rybinsk Reservoir has been excluded.

Gradually, blast-furnace production, carrying out repairs of certain categories in a timely manner, increased the production of pig iron. Difficulties began in the coke production, determined by the aging of batteries. There was a need to stop the batteries for transfer. However, without the construction of a new 11th coke oven battery, this was impossible.

At the same time, several environmental reviews were carried out with the requirement to transfer the coke production to another territory, at a greater distance from the city. A Government Decree was issued, which provided for the shutdown of the first 4 batteries after the launch of the eleventh, which was practically equal in power to the first four batteries. However, the construction of a new battery was not included in the five-year plan for 1985-1990.

The summer and winter of 1989 brought lengthy miners' strikes. Almost all coal reserves were exhausted, technological regimes were forced to change, which led to a deterioration in the state of fixed assets, irreparable destruction of coke oven batteries.

By the beginning of the 2000s, it became necessary to create new coke production capacities, taking into account the renewal of aging fixed assets and the commissioning of blast furnace No. 5. In 1999, the construction of coke oven battery No. 11 with a capacity of 1710 thousand tons/year of coke ( Stage I - 1140 thousand tons / year) its launch was scheduled for 2005.

By 2000, a large amount of work related to the preparation of the construction site had been completed. For two units of the coke oven battery, the lower reinforced concrete slabs and hogs were prepared, the construction of a chimney and a coal tower was started, a coke sorting building was assembled, a greenhouse was received and its installation began, and some refractory products and equipment were purchased. However, due to the difficult financial situation, the construction of the battery had to be suspended. All funds and efforts were focused on the reconstruction of coke batteries No. 5, 6 and the construction of environmental facilities.

In 2006, after replacing the refractory lining and the main equipment, battery No. 5 was put into operation again, in 2007 - battery No. 6. In combination with the reconstruction of coke oven batteries No. 5, 6, chemical recovery shop No. 1 was partially rebuilt and renovated. With the commissioning of batteries No. 5 and 6, in 2006 the first coke oven battery was finally shut down, and in 2007 the second and third ones.

In December 2001, the first stage of the reconstructed biochemical plant was put into operation. Reinforced concrete aerotanks were expanded and closed, the volumes for water purification from oils and phenols were expanded, a new thiocyanate removal complex and a wastewater nitrification plant were built, tanks were built to collect storm water, sludge sedimentation tanks with a pumping station for wastewater treatment.

Figure 2.1 shows a detailed diagram of the feedstock flows for coke production.

Figure 2.1 - Scheme of feedstock flows of the coke production of PAO Severstal: 1 _ coal storages, 2 _ crushing and processing line, 3 _ coal preparation shop, 4 _ coke oven batteries, 5 _ CDF, 6 _ coke sorting, 7 _ blast furnace shop, 8 _ workshop for capturing and processing chemical products of coal coking

2.2 Technological process of coke production

Coke is a product of coal sintering, which is a porous black-matte mass. In the process of coal coking of a pure product, 630-750 kg of finished coke is obtained from 1 ton of coal charge. The scope of coke is mainly metallurgy (ferrous, non-ferrous, foundry), in addition, coke is used for gasification, the production of calcium carbide, electrodes, as a reagent and fuel in a number of chemical industries.

In metallurgy, high demands are placed on coke in the field of mechanical strength, since in the conditions of operation of a blast furnace, coke is subjected to high pressure of the loaded charge. Thermal characteristics are also of high importance. According to the technological documents for iron smelting at PJSC Severstal, coke should have a calorific value of 31.4 - 33.5 MJ / kg.

Coke is sintered in coke production by means of decomposition of certain types of coal without oxygen access. The main criteria for coke quality are combustibility and reactivity. Combustibility characterizes the rate of ignition and combustion of coke, reactivity indicates the rate of reduction of carbon dioxide by it. These two processes are heterogeneous, and their rate is determined not only by the chemical composition of the coke, but also by the porosity of the product. The contact speed of the interacting phases depends on the porosity of the coke. Not an insignificant factor is given to the content of sulfur, ash, moisture and the release of volatile substances in coke.

The next product of coal sintering can rightfully be considered coke oven gas. The release volumes vary from 310 to 340 m 3 per 1 ton of coal charge. The composition and concentration of coke gas mainly depends on the temperature in the coking chamber. The gas directly exits the coking chamber, during coal charge coking, into the gas collection chambers. Coke oven gas contains various gaseous products, including coal tar vapours, crude benzene and water. The next stage of gas production will be its purification. Resins, raw benzene, water and ammonia are removed, then the so-called reverse coke oven gas is obtained, which is used in production as a raw material for chemical synthesis. In addition, coke oven batteries are heated with coke oven gas, and it is also used in other industries of the plant.

Coal tar is a black-brown liquid with a specific odor, which contains more than 250 different substances of chemical origin. The resin mainly consists of resin components, which include: benzene, toluene, xylenes, phenol, cresols, naphthalene, anthracene, phenanthrene, pyridine, carbazole, coumarone, etc. The density of coal tar is 1.7 - 1.20 g/cm 3 . Pitch production is from 3 to 5.5% by weight of coking dry coal. The composition of the tar, as well as coke oven gas, mainly depend on the coking temperature, and the tar yield directly depends on the nature of the origin of the coking coals. Depending on the increase in temperature in the coking chamber, the pyrolysis of hydrocarbons deepens, thereby reducing the yield of tar, and the yield of coke oven gas increases. Coal tar contains about 60 chemical products, all of which are used as raw materials for the production of dyes and various pharmaceuticals.

Crude benzene is one of the products of coal tar, mainly composed of carbon disulfide, benzene, toluene, xylenes, coumarone and other chemical substances. The productivity of crude benzene is approximately 1.1% by weight of the coal charge. Its quantity directly depends on the chemical composition and properties of the initial coal. The temperature factor is also of high importance in the production of crude benzene. Crude benzene is the main raw material in the production of individual aromatic hydrocarbons and a mixture of hydrocarbons that serve as raw materials in the chemical industry.

Resin and crude benzene are the main sources of aromatic hydrocarbons for the chemical industry.

Smolny water is a weak aqueous solution consisting of ammonia and ammonium salts with an admixture of phenol, pyridine bases and other chemical products. Top-tar water in the process of its processing releases ammonia, which, together with ammonia from coke oven gas, is used to produce ammonium sulfate and concentrated ammonia water.

Coking as a chemical production is one of the oldest industries. Until the middle of the XIX century. coking found its application mainly for the production of coke in metallurgy. From the second half of the XIX century. After the discovery by the domestic chemist N.N. Zinins of aniline from nitrobenzene required products containing benzene, toluene, phonols, cresols, naphthalene, anthracene and other products. A good source of all these products are coal tar and crude benzene.

In modern industry, coal tar and crude benzene have gone from being a waste product to being the main and most important sales product. Almost all combines have installations that capture coal tar and raw benzene. This was the impetus for the creation of unified coking plants. Outside the production of metallurgical plants.

The main raw materials for the production of coke are sintering coals, which give a strong and porous metallurgical coke. In industrial practice, a mixture has proven itself well - a charge consisting of coking coals and coals of other grades. This step made it possible to expand the range of raw materials for the coking industry, obtain high quality coke and ensure high productivity of tar, raw benzene and coke oven gas. In the coals used for coke production, the amount of moisture is limited and should be within 5-9%, ash up to 7%, sulfur up to 2%.

The technological process of chemical production, like any other production process, begins with the preparation of raw materials and the preparation of a coal mixture. The coal that arrived at the production is divided into groups according to its chemical composition and properties, crushed and mixed, then it goes through the stage of enrichment by screening, dedusting, flotation and other technological operations in order to eliminate impurities.

Next, the coal mixture is dried (to optimize moisture content) and finally crushed to a grain size of no more than 3 mm. The prepared charge components are fed into the mixing drums and then into the storage bins of the coal tower.

Prepared coal charge in certain portions fills the bunkers of the coal-loading car, which delivers the charge to the coke battery chamber.

The thermal effect on the coal charge is accompanied by physical and chemical transformations: up to 250 ° C, moisture evaporates, carbon monoxide and dioxide are released; in the range of 300 ° C, resin vapors begin to be released and the so-called pyrogenetic waters are formed; with an increase in temperature above 350 ° C, coal passes into a plastic state; 500-550°C, the plastic mass decomposes with the release of primary coking products (gas and tar) and solidifies, semi-coke is formed. When the temperature rises to 700°C, the semi-coke decomposes, with the release of second-order gaseous products from it; above 700°C, the hardening of the coke occurs predominantly. Volatile products, in contact with hot coke, heated walls and the roof of the chamber in which coking takes place, turn into a complex mixture of vapors (with a predominance of aromatic compounds) and gases containing hydrogen, methane, etc. Most of the sulfur in the initial coals and all mineral substances remain in the coke.

The design and operation of coke ovens depends on indirect heating devices. The heat in them is transferred from the heating gases to the coal charge through the wall. The main factor determining the course of the coking process is the increase in temperature, which is necessary to heat the charge to the dry distillation temperature and carry out endothermic coking reactions. The temperature rise limit is limited by the reduction in resin yield and. crude benzene, changes in the composition of coking products, violation of the strength of refractory materials used for laying furnaces.

A coke oven or battery includes 61-69 parallel chambers, which are both long and narrow channels of rectangular cross section, built of refractory bricks (dinas). Each chamber contains from 17 to 23 tons of coal charge. It has removable doors on both sides, which are tightly closed at the time of loading the chamber, and throughout the entire duration of coal coking, and are removed when the coke is unloaded. There are 3 loading hatches in the roof of the furnace, which open during coal loading and close during the coking period. A loading car moves along the rail track, which are located above the coking chambers. Which, through the loading hatches, loads the charge into the coke chambers. A coke pusher moves along the machine side of the battery along the rail tracks. A machine that, after coking the coke cake, opens the doors of the chamber and pushes out the finished coke. On the opposite side, a quenching car moves along the rail track. He takes the red-hot coke and transports it under the extinguishing tower, and then unloads it into the extinguishing ramp. Heating of coal in the chamber occurs through the walls of the chamber with flue gases passing through the heating walls located between the chambers. Hot flue gases are formed as a result of combustion of blast-furnace, reverse coke oven or, more rarely, generator gases. The heat of the flue gases that come out of the heating pier. They are used as a regenerator for heating the air and gaseous fuel supplied to the heating of coke ovens, as a result of which the thermal efficiency of the oven increases. During operation of the coke chamber, to ensure uniform heating of the coke cake, it is necessary to correctly select the dimensions of the chamber and evenly distribute the coke oven gas in the heating vertical. The optimal chamber width is usually 400-450 mm. The length of the chamber is limited by the static strength of the walls, the difficulty of issuing the finished coke from the chamber and the complexity of the distribution of gases in the heating verticals. The length of the chamber is approximately 14 m. The height of the chamber is determined mainly by the conditions for its uniform heating along its height. Based on this, satisfactory results will be obtained with a chamber height of 5.5-5.7 m.

Uniform distribution of coke oven gases is achieved by dividing the heating walls with vertical partitions along a number of channels, called verticals. The verticals heat the walls with the help of heating gases, which transfer heat to the walls of the chamber and are removed to the regenerators. The temperature difference between the heating gases in the heating channels and the coal charge varies with time. After loading the chamber with a mixture, its value is great. A large amount of heat per unit time enters the cold charge, and coal begins to coke near the walls of the chambers. However, the middle layers of the charge remain cold regardless.

As the coal warms up, the temperature difference gradually decreases. The amount of incoming heat per unit time decreases, however, due to the continuous supply of heat from gases, there is a gradual increase in temperature across the chamber. Therefore, the state of the material in the chamber during coking will be a layer of formed coke near the walls. Further, when the temperature decreases from the walls to the axis of the chamber, a layer of semi-coke is located, then coal, which is in a plastic state, and finally, in the center of the chamber, a constant charge is located. After 12-14 hours, the temperature in the cross section levels off, the layers move towards the axis of the chamber, and gradually the coal load cokes. Thus, at the end of the coking process, the heating of the coking chamber is turned off, the gas risers are discharged. The ejector is brought to the doors of the chamber. Unloads the coke cake into the stew car, moving slowly along the battery. Then the pusher installs the doors of the vacated chamber and goes to the next chamber, and the loading car opens the loading hatches and loads a new batch of charge.

The average processing time of the coking chamber is about 15 minutes. Therefore, for optimal operation of mechanisms and machines, the number of cameras in the battery is adjusted to 70.

The unloaded coke is subjected to quenching, since it ignites when it comes into contact with air.

The output of coke is 65-75% by weight of the mixture. The production capacity of one coconut battery is approximately 1500 tons of coke per day. Depending on the chemical and physical composition, coke is divided into blast-furnace, foundry, power (intended for the production of ferroalloys, calcium carbide, electrodes, for agglomeration of iron ores).

The output of products from 1 t of charge, %, at the coke production site is shown in Figure 2.2.

Figure 2.2 - Output of finished products in the process of coal coking (1 ton)

2.3 Operating system of dust and gas collection and utilization of coke dust

Coke dust at coke-chemical enterprises is obtained in the course of any technological operations related to coke (sorting of bulk coke, dry coke quenching, coke reloading, etc.). Fraction size 0-5 mm. It practically does not find application due to the difficulty with unloading and transportation, it is usually returned to the coking charge in the amount of 3% by weight of the charge (which reduces the useful load of the coal charge).

A significant amount of coke dust is captured in operations:

Issuance of coke from the coke oven battery to the car for transporting coke;

The process of coke quenching in dry coke quenching units (DSC);

The operation of sorting coke, into certain fractions (50-250mm), in coke sorting.

The formation of a dust cloud during the issuance occurs very quickly, and this unorganized emission is usually referred to as bursts. When issuing coke of insufficient readiness, the formation of dense clouds of dense black or black-green smoke is observed. Such phenomena are observed when the coking process is not completed in the center of the coal load or when the furnaces are heated unevenly, leading to the formation of cold zones in the load.

There are several options for dust-free coke dispensing systems: dust suction umbrellas over the coke guide and quenching cars; overlappings over the rail track of the extinguishing car; combined systems of dust-free delivery and coke quenching.

The systems with the device of umbrellas, suction and cleaning of the issuing gases received the greatest recognition. At the same time, suction and dust collection equipment is designed both in mobile and stationary versions. In practice, systems with a mobile umbrella and a stationary dust collection system are most often used. Venturi scrubbers, wet electrostatic precipitators, fabric filters are used as dust collectors. Recently, there has been a trend abroad to switch only to dry dust collectors, as a rule, bag filters.

In 1993, the first dust-free coke dispensing unit (UBVK) with a stationary gas and dust extraction and purification system was launched at the Kommunarsky Coke and Chemical Plant (Figure 2.3). In subsequent years, similar plants were installed in the coke production of Severstal PJSC.

The existing trends are still based on increasing the volume of exhaust gases up to 150-180 thousand m³/h with a corresponding increase in the size and design of the umbrella. The concentration of dust in the gas sucked out from under the umbrella reaches 18-22 g/m3.

Figure 2.3 - Dust-free coke dispensing system: 1 - umbrella; 2 - coke car; 3 _ fan; 4 _ hot dust collector; 5 _ humidification system; 6 _ scrubber and screw feeder

By installing groups of cyclones at the first stage of purification, a total degree of purification of 99.1-99.2% is achieved with a residual concentration of dust in the exhaust gases of 0.11-0.22 g/m 3 . It is easy to see that by increasing the volume of exhausted gases, we obtain an increased dust content, the reduction of which to the required standards requires an increase in the degree of purification.

The simplest option for dry dust collection is a system of conical cyclones. Such systems have been developed and included in projects for most coke production facilities in the Russian Federation.

The main requirement in this case, in addition to high efficiency and acceptable hydraulic resistance, is the prevention of abrasive wear, which is achieved by the correct choice of speeds in the inlet pipe and cyclone body.

For a stationary installation for dedusting exhaust gases, the most effective solution in terms of dust collection is the use of electrostatic precipitators. In this case, the greatest economic effect is obtained by combining the purification of discharge gases and loading gases in them, provided that the trapped mixture of coal, semi-coke and coke dust is utilized. Since the loading gases contain many combustible substances, it becomes necessary to ensure explosion safety, so electrostatic precipitators should be used.

In order to reduce fugitive emissions generated during the issuance of coke from the coking chambers to the quenching car, in 1997, a dust-free coke dispensing unit was built on coke oven batteries No. 5-10 KHP of Severstal PJSC. An umbrella is installed on the door-removing machine, which closes the "basket" of the coke guide and the quenching car.

With the help of telescopic nozzles installed on the umbrella, the umbrella and the gas collector are docked, designed to transport the gas-air mixture for cleaning in two electrostatic precipitators of the EGA type. Then the air, purified from fine dust to a concentration of 50-80 mg/m 3 , is released into the atmosphere, and the dust caught by electrostatic precipitators is used as an additive to the charge for coking. The reduction of dust emissions into the atmosphere during the issuance of coke is 200 tons/year.

Of all the dust-free coke dispensing systems currently used abroad (covering over the entire coke side of the battery; suction and cleaning of gases released in a stationary scrubber system; dust-collecting umbrellas above the coke guide and quenching car with gas cleaning equipment on the quenching car or a platform connected to it; dust-collecting umbrellas over the coke guide and the quenching car with a stationary exhaust gas pipeline and a gas cleaning system), the systems of the latter type are recognized as the most effective. At other metallurgical enterprises, almost all coke oven batteries are equipped with such systems.

The width of the dust collecting hood is equal to the width of the coking car, the length varies from 6 to 10 m, depending on the volume of the coking chamber. The power of the smoke exhauster in the system of dust-free delivery at 40°C is 2500-4500 m 3 /min, depending on the volume of the coking chamber.

There are two sources of organized emissions into the atmosphere in the CDTC: a candle of excess inert gas after a smoke exhauster and a candle through which gases released from coke in the prechamber are emitted.

Significant air pollution by these emissions requires the development of measures to reduce them.

The introduction of dry quenching of coke at domestic coking plants is necessary, primarily because it allows improving the quality of coke in a continuously deteriorating raw material base of coking.

However, one of the environmental benefits of the dry coke quenching process is that the emissions from these plants are organized and can be treated, thereby achieving an overall reduction in specific emissions to the atmosphere during the production of coke.

The temperature of coke after USTK reaches 150-200°C. During transportation, reloading, screening of such coke, intensive dust emission occurs, so the process equipment is equipped with aspiration units. The purpose of aspiration systems is to create favorable working conditions for the content of harmful substances in the air of industrial premises by preventing emissions from leaks in process equipment. Aspiration systems are located in accordance with the technological scheme of the CDTC and the sorting of dry quenching coke (Figure 2.4).

The aspiration systems include dry and wet dust collectors. When unloading hot coke from the chambers, a lot of dust is released, so a two-stage cleaning scheme is usually used. As the first degree, groups of cyclones of the TsN-15 type are used, which have a sufficiently high dust collection efficiency (87-97%) with moderate hydraulic resistance (0.35-1.15 kPa). TsS-VTI scrubbers are installed at the second stage of dust collection. The actual degree of dust capture in them is from 60 to 90% and is determined mainly by the flow rate of the irrigating liquid and its quality.

The aspiration systems include dry and wet dust collectors. When unloading hot coke from the chambers, a lot of dust is released, so a two-stage cleaning scheme is usually used. As the first degree, groups of cyclones of the TsN-15 type are used, which have a sufficiently high dust collection efficiency (87-97%) with moderate hydraulic resistance (0.35-1.15 kPa). TsS-VTI scrubbers are installed at the second stage of dust collection. The actual degree of dust capture in them is from 60 to 90% and is determined mainly by the flow rate of the irrigating liquid and the quality of its spraying.

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