Coke Gas Technology

Have Questions about Process Data Management? We have all the answers!

What is PDM?

Process data management is not a software program. It is the compilation of your operating data, in-depth technical analysis of the data, and a monthly report.

We already compile our data, so how is this different?

While most coke plant gas cleaning operations compile their own data, they have neither the time nor the staff to fully analyze the extensive data that is generated on a daily basis.

When we have operating problems or issues, we review our data to help us resolve the problem. Is this not what you are suggesting?

Analysis of the data during an operating problem is certainly a practiced procedure. However, the real value of PDM is not just assisting in present operating problems, but more importantly in forecasting operating issues. PDM does not wait for a problem, it looks for a developing problem.

I review some key operating data every day and I can see possible problems. I do not wait for one month. With PDM are you not suggesting that a problem can be developing but that it would take up to one month to uncover it?

Certainly there are some key data points that can highlight an existing or developing problem. However, these are generally cases where the problems are either about to or already have had a significant affect on the process. So, a regular review of these key data points would still be necessary and valuable to the daily operational performance. A gas cleaning operation contains many different processes that affect each other. Consequently, a small change in one process can create a small change in other processes. PDM is designed to see the “small” changes that are not easily seen through a regular review of some key operating parameters. When all these “small” changes are added together, the impact on performance can be very significant.

I already create and review trend charts of key operating parameters. Therefore, I can see problems beginning to develop. What advantage does PDM provide?

While the monthly report from PDM will contain some trend charts, it also incorporates SPC analysis of the data. In this way, minor changes can be seen before they become evident on a trend chart.

What data does PDM require?

PDM requires all the available data. There is no limit. The more data that is available the more detailed the review and the more predictive the summary.
Some examples of the data include;

This seems like a very extensive list of data. I do not think I would have the time to review the monthly summary.

The monthly report from PDM is developed based on your needs. It also incorporates an executive summary designed to highlight the vital few from the trivial many. This allows for a quick review. Also, the report is setup to allow easy access to each individual process, should you wish to focus on a specific area.

You mentioned that the cooling tower and cooling water performance would also be monitored. Does this not require a specific and unique capability?

Cooling is a vital part of a gas cleaning operation. There are always two sides to an exchanger. Water-side performance can have a profound affect on the operating performance. PDM has the experience and supports this part of the process.

We operate a DCS, so we have many data points that are logged frequently. How does this affect the quantity of data that we would provide?

PDM is designed to accept up to 12 readings per day for each data point.

We have some very sensitive data that we may not wish to share. How would this impact PDM?

All data received is confidential and shared only as specifically direct by the customer. However, it is also understandable that you may not wish to share some data. Depending on which data you wish to restrict access, it can have a very significant and detrimental affect to the value of PDM. It may also preclude the use of PDM.

I have many years of experience in my operation and a support staff that is also very knowledgeable. While we have some operations that can be considered similar to what one might see, we also have some unique operations and conditions. Also, I have contacts within the industry to share knowledge and experience. Without this knowledge, how can PDM see the “whole” picture?

As you said, there are similar operations but also unique processes and operating conditions. With PDM, you have access to an experienced global knowledge database. A combination of your knowledge and that of PDM provides a synergy of the similarities and the differences.

Can you give me some practical examples of what PDM could tell me?

1) Many operations experience periodic high cyanides in their waste liquor. While some of these can be readily explained, there are occurrences that are short in duration without any obvious explanation. With PDM, a cause and effect can be developed to identify the operating condition(s) when high cyanides are encountered. Then changes in operating procedures may be developed to minimize this impact. If changes are not possible, then response procedures can be developed to minimize the impact on environmental compliance.

2) Fouling of the ammonia still is common in the industry. The frequency of mechanical cleaning usually varies from plant to plant and also within the same plant. The industry recognizes most of the reasons for this fouling. However, since the frequency varies, there is a set of operating conditions that contribute to increased fouling periods. With PDM, a cause and effect can be developed to identify these operating condition(s). Then, operational changes can be made to the contributing factors upstream and at the ammonia still to minimize the impact.

3) The flushing liquor decanter is a very important part of the operation. It is also subjected to many changing operating conditions and therefore experiences a high variability in its performance. Poor performance affects many other operations downstream. Through intensive monitoring of the performance data, many of the changes in the operating condition can be eliminated or minimized. The result is a more reliable and stable liquor quality.

Who develops these cause and effect scenarios?

A combination of your knowledge in your operation and the knowledge and experience of PDM’s technical support are used to develop these cause and effect assessments.

What does a service like this cost?

There are a number of factors, such as the form in which the data is supplied, capacity of the plant and the number of gas cleaning steps that contribute to the cost. Based on a capacity of 1,000,000 tons/year of coke, the cost is much less than the cost of a single operating individual. The objective of PDM is to reduce the operating costs and improve environmental compliance. If it fails to do this, then any cost is too high.

Can I just focus on part of the operation?

Every unit operation in a gas cleaning plant can be affected by external conditions, both upstream and downstream. By focusing on only a part of the total operation would significantly reduce the value of PDM in problem prevention/identification and may preclude it’s use.

Since PDM seems to depend on historical data, how long does it take to begin realizing a measurable benefit in my operation?

Generally, it would take about 3-4 months of data to establish the initial analysis to begin the problem prevention/identification feature. Where available, existing historical data can be supplied so that this value can be almost immediately achieved. Also, beginning immediately, you would benefit from the technical knowledge/experience that could identify some initial improvements.

What kind of support does PDM provide when operating problems are encountered that have not been foreseen?

PDM will provide technical support as required. Increased data analysis specific to the problem would be provided, based on the data that you supply. There is no additional cost to this service.

Does PDM provide engineering support?

There are many capable companies that can provide engineering support. PDM limits its engineering support to reviewing existing engineering proposals and offer comments based on experience. PDM will also support conceptual ideas, again based on experience.

What happens to all of our data?

All of the supplied data and the monthly report are kept confidential. The supplied data can be returned in the form it was received either at the conclusion of the contract or in a time interval that you request.

Would I not have sufficient analysis after about 1 year that would make the continued need for PDM not be worth the investment?

Gas cleaning plants generally do not receive the same investment or equipment updating that is common in other parts of the steelmaking operation. This results in a loss of efficiency, which increases the operating costs. Also, environmental compliance limits are continually changing. These two conditions put added pressure on the daily operation. This means that the value of PDM actually increases every year.