Clairton Improvement project
U.S. Steel
|
United States
|
2008–2014
960,000 tpa increase in capacity.
2 million labor-hours with 0 LTIs.
2 months ahead of schedule.
Clairton produces most coke in the US.
Challenges
- U.S. Steel needed engineering (battery limits), procurement, and construction management services for their coke oven project, including a cogeneration facility that will use the coke-oven by-product gases to produce and supply electricity to all three Pittsburgh-area Mon Valley Works facilities.
- The project involved installing a new state-of-the-art, high-efficiency coke battery to replace the lost metallurgical coke capacity of three existing batteries.
- It also required the addition of a fully assembled screening station, tied-into and commissioned while existing equipment remains in operation.
Solutions
- The new C Battery has 84 ovens that replace ones from the 1950s, producing the same amount of coke with better emission control.
- Added a new foul-gas collection technology known as the "PRO-ven" system was added. This was its first application in the USA on a coke battery, dramatically improving oven process control and reducing oven emissions.
- Automation systems were fully assembled and shop tested.
- Implemented a fully assembled screening station and brought it into operation without the need to shut down existing equipment.
Highlights
- Best Energy/Industrial Project, Engineering News-Record, Mid-Atlantic Region and ESWP Project of the Year.
- Completed two months ahead of schedule, under budget, and with more than 2 million labor-hours with 0 LTIs.
- New C Battery with 84 ovens, eliminating ones from the 1950s, producing the same amount of coke and reducing emissions.
- Implemented a new foul-gas collection technology known as the 'PRO-ven' system. Employed for the first time in the USA on a coke battery, it dramatically improves oven process control and reduces oven emissions.
"USS was very pleased to have the facility two months early, which provided not only additional product availability but also Federal Tax Relief."
Project numbers
$500 million70 new permanent positions
850 tradesmen during construction
84 ovens eliminated existing ovens from 1950s