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US20030057083A1 - Clean production of coke - Google Patents

Clean production of coke Download PDF

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Publication number
US20030057083A1
US20030057083A1 US09/954,603 US95460301A US2003057083A1 US 20030057083 A1 US20030057083 A1 US 20030057083A1 US 95460301 A US95460301 A US 95460301A US 2003057083 A1 US2003057083 A1 US 2003057083A1
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Prior art keywords
coke
tar
fines
mixture
pyrolyzer
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US09/954,603
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English (en)
Inventor
Craig Eatough
Jon Heaton
Steven Eatough
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Combustion Holdings LLC
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Individual
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Priority to US09/954,603 priority Critical patent/US20030057083A1/en
Assigned to COMBUSTION RESOURCES, LLC reassignment COMBUSTION RESOURCES, LLC ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: EATOUGH, CRAIG N., EATOUGH, STEVEN R., HEATON, JON S.
Priority to PCT/US2002/002839 priority patent/WO2003025093A1/fr
Publication of US20030057083A1 publication Critical patent/US20030057083A1/en
Priority to US10/666,419 priority patent/US20040055864A1/en
Priority to US10/691,339 priority patent/US20040079628A1/en
Priority to US11/999,160 priority patent/US7785447B2/en
Assigned to COMBUSTION HOLDINGS, LLC reassignment COMBUSTION HOLDINGS, LLC CHANGE OF NAME (SEE DOCUMENT FOR DETAILS). Assignors: COMBUSTION RESOURCES, L.L.C.
Abandoned legal-status Critical Current

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    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10B—DESTRUCTIVE DISTILLATION OF CARBONACEOUS MATERIALS FOR PRODUCTION OF GAS, COKE, TAR, OR SIMILAR MATERIALS
    • C10B57/00—Other carbonising or coking processes; Features of destructive distillation processes in general
    • C10B57/04—Other carbonising or coking processes; Features of destructive distillation processes in general using charges of special composition
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10B—DESTRUCTIVE DISTILLATION OF CARBONACEOUS MATERIALS FOR PRODUCTION OF GAS, COKE, TAR, OR SIMILAR MATERIALS
    • C10B53/00—Destructive distillation, specially adapted for particular solid raw materials or solid raw materials in special form
    • C10B53/08—Destructive distillation, specially adapted for particular solid raw materials or solid raw materials in special form in the form of briquettes, lumps and the like
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10L—FUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G OR C10K; LIQUIFIED PETROLEUM GAS; USE OF ADDITIVES TO FUELS OR FIRES; FIRE-LIGHTERS
    • C10L5/00—Solid fuels
    • C10L5/02—Solid fuels such as briquettes consisting mainly of carbonaceous materials of mineral or non-mineral origin
    • C10L5/06—Methods of shaping, e.g. pelletizing or briquetting
    • C10L5/10—Methods of shaping, e.g. pelletizing or briquetting with the aid of binders, e.g. pretreated binders
    • C10L5/14—Methods of shaping, e.g. pelletizing or briquetting with the aid of binders, e.g. pretreated binders with organic binders
    • C10L5/16—Methods of shaping, e.g. pelletizing or briquetting with the aid of binders, e.g. pretreated binders with organic binders with bituminous binders, e.g. tar, pitch
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10L—FUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G OR C10K; LIQUIFIED PETROLEUM GAS; USE OF ADDITIVES TO FUELS OR FIRES; FIRE-LIGHTERS
    • C10L5/00—Solid fuels
    • C10L5/02—Solid fuels such as briquettes consisting mainly of carbonaceous materials of mineral or non-mineral origin
    • C10L5/26—After-treatment of the shaped fuels, e.g. briquettes
    • C10L5/28—Heating the shaped fuels, e.g. briquettes; Coking the binders

Definitions

  • the present invention relates generally to clean production of coke and more particularly to the use of two types of carbon, one of which comprises low quality coal fines, such as waste coal fines, and/or waste coke or char fines which, after mixing, may be fired without formation into objects or formed into objects and fired to produce solid pyrolyzed objects or pieces, with by-products from pyrolyzation being recycled for use within the coke-producing closed system.
  • low quality coal fines such as waste coal fines, and/or waste coke or char fines which, after mixing, may be fired without formation into objects or formed into objects and fired to produce solid pyrolyzed objects or pieces, with by-products from pyrolyzation being recycled for use within the coke-producing closed system.
  • Coke heretofore has conventionally been produced from high quality sources of carbon, such as high quality coking coals.
  • Prior processes and apparatus for conventionally producing coke typically are open or partly open systems, which generate by-products released to pollute the atmosphere.
  • the present invention overcomes or substantially alleviates problems associated with prior ways of conventionally producing coke.
  • the present invention may be summarized as comprising closed system apparatus and processes by which carbon feedstock, comprised of a mixture of non-coking coal and/or another carbonaceous material, such as waste coke fines, are mixed together and pyrolyzed into coke either as solid pieces or not.
  • carbon feedstock comprised of a mixture of non-coking coal and/or another carbonaceous material, such as waste coke fines
  • solid pieces or objects of the mixture are formed, they are fired through pyrolyzation into solid pieces of coke, with solid and/or liquid and gaseous by-products of pyrolyzation being recycled for use within the closed coke-producing system, thereby eliminating release of undesirable substances to the atmosphere.
  • Feedback tars with or without a char-forming binder, is added to the carbon mixture prior to pyrolyzation.
  • Another paramount object of the present invention is to produce a novel form of coke and to do so using novel apparatus and unique processes.
  • a further dominant object is to produce coke from a mixture comprising low quality or non-coking coal fines, which mixture is pyrolyzed into high quality coke.
  • Another important object is to produce coke from a mixture comprising waste coke fines, which mixture is pyrolyzed into high quality coke.
  • An additional object of importance is to produce coke so as to avoid contaminating the environment by recycling or recirculating solid and/or liquid and gaseous by-products within the closed coke-producing system.
  • FIG. 1 is a flow diagram of one process by which low quality coal and another carbonaceous material, such as waste coke fines, are transformed into metallurgical and other grades of coke; and
  • FIG. 2 is a flow diagram of another similar process by which low quality coal and other carbonaceous material is transformed into metallurgical and other grades of coke.
  • the present invention addresses these problems and provides processes by which waste coke fines (including coke breeze generated from conventional coking processes or petroleum coke) with coal fines are blended to produce a high quality coke product.
  • Non-coking coal fines and coke fines may be blended together in such proportions that production of pyrolysis by-products is limited to the amount required for binding and for process heat.
  • Feedback tar may be combined with additional synthetic or natural binder to produce prime quality solid coke pieces or objects, such as briquettes or blocks.
  • the process 1) uses feedstock material more efficiently than other form coke processes by eliminating discharge of secondary, low value by-products, and 2) uses undesirable materials and industrial wastes not heretofore used to produce coke (i.e., low quality coal and/or coke or char fines) as a feedstock which represent a current serious environmental problem.
  • Energy savings for a steel plant can be exemplified by assuming a typical coke fines waste rate of 10% of the total coke production. Energy savings are noted in the increased utilization of raw materials, including extraction, transportation, and differences in processing requirements. Based on a steel mill capacity of about 6,000 tons of hot metal (THM)/day this represents an energy savings of about 4.5 ⁇ 10 11 kJ/year over current technology.
  • TBM hot metal
  • coke is a universal fuel used in the iron and steel industry.
  • Metallurgical coke is commonly required for operation of iron ore reduction facilities, such as blast furnaces.
  • Foundry coke is required for scrap melting in cupolas and in casting operations.
  • Coke is also an important fuel for other applications, such as the phosphate industry.
  • Coke ovens have for some time been of serious environmental concern due to the release of particulate and sulfur gases, as well as emissions of carcinogenic and mutagenic polycyclic aromatic hydrocarbons (PAHs) and benzene-toluene-xylenes (BTX). Consequently, the coke-manufacturing industry is being subjected to increasingly stringent environmental regulations. Advances in coke oven design, such as non-recovery ovens and jumbo coking reactors, show some environmental advantages but still require expensive coking coals to operate and represent a very large capital investment. As environmental regulations become more stringent, existing coking facilities will continue to be closed and capacity reduced.
  • Form coke is a term which generally describes carbonized, briquetted or otherwise formed fuel, made from pyrolyzed coal chars.
  • FMC pyrolyzed coal chars.
  • the coal is crushed and then charred at temperatures between 600 and 800° C., then mixed with a binder, briquetted, and finally carbonized at 900-1000° C.
  • the initial partial devoatilization is designed to prevent swelling or sticking of the briquettes during the high temperature treatment.
  • the binders needed for this briquetting are usually obtained from the combined by-products and tars generated during the low and high temperature charring and carbonizing steps.
  • Most form coke processes can utilize non-coking coals for a portion of the feedstock, combined with expensive coking coals.
  • the FMC process requires multiple, staged, fluid-bed heaters to char and carbonize the coal.
  • the tars are captured and used as a binder to form the char into briquettes which are calcined in a shaft furnace.
  • the process incurs high capital costs.
  • the now discontinued CTC process used gasification to char the feed coal.
  • the char was then crushed, hot-briquetted and finally calcined.
  • By-products had to be refined into salable liquid fuels in order for the CTC process to be economically feasible.
  • the CTC process utilized high grade coking coals for a portion of its feedstock.
  • a supplemental binder system may include combining a natural or synthetic binder with a carbonaceous binder such as tar, including but not limited to feedback tar from within the system.
  • a carbonaceous binder such as tar
  • Extensive development and testing of the waste coke fines briquettes has been performed. Indications are that waste coke fines briquettes formed using the present invention, compare favorably with other successful form cokes, such as those obtained from the FMC and CTC processes. See TABLE 1, below: TABLE 1 Comparison of briquettes from proposed process with other successful form cokes.
  • Apparent Abrasion Form Coke Type Specific gravity Resistance CSR CRI FMC 1 0.8 69 47 75 CTC 2 1.2 54 30 15 New Process 3 1.4 80 50-70 15-30
  • the economics of the present coke fines process is improved by: (1) use of feedback tar, resulting in the elimination of the need to import the tar portion of the binder and/or (2) elimination of the requirement to process and sell excess low-value tars.
  • the present invention contemplates blending coke fines (e.g. coke breeze generated from conventional coking processes or petroleum coke) with waste non-coking coal fines.
  • coke breeze and/or petroleum coke fines and low grade coal fines are blended with a binder.
  • the blend may be fed directly into the pyrolyzer or pressed into briquettes or other solid forms and subsequently cured.
  • the relative mixture of coke fines with coal fines can be varied depending on the devolatilization products of the coal to obtain a process with closed material-loops where all of the products of devolatilization are used within the process.
  • the temperature of the formed feedstock is elevated at a rate approximately within the range of 1500-2000° C./hr to a maximum temperature within the range of 800-1100° C.
  • the devolatilization behavior of the feedstock varies during heat-up, depending on the feedstock mixture, but gases and tar evolve, leaving a carbon matrix behind.
  • Devolatilization behavior depends on many factors such as peak temperature, heating rate, particle size and coal type. General trends are that occluded carbon dioxide and methane are driven off at about 200° C. Above this temperature, internal condensation occurs among the macromolecular structures with the evolution of carbon dioxide and water.
  • the evolution of hydrogen begins at 400-500° C. with a critical point at about 700° C. characterized by a rapid evolution of hydrogen and carbon monoxide.
  • Tar formation begins at around 300-400° C., with a maximum yield occurring at approximately 500-550° C., depending on heating rate and particle size.
  • the character and composition of the tars will vary with temperature.
  • Low-temperature tar usually consists mainly of olefin, paraffin hydrocarbons, and cyclic hydroaromatic structures.
  • the aromatic nature of tar increases with increasing temperature until high-temperature tars are composed mostly of aromatic hydrocarbons.
  • the present processes take advantage of the fact that coke is very low in volatile matter (1-2%) and therefore produces nearly no pyrolytic products.
  • This process comprises blending coke fines with coal fines in the proper amount to create just enough pyrolytic products required to perpetuate the process.
  • the mixture of coal/coke fines are cleaned and blended with tar or other fixed-carbon producing binders.
  • the mix may then be formed into appropriate solid shapes. These shapes are then fed to a pyrolyzer, where the temperature is raised to 800-1100° C. to devolatilize the solid objects driving off tars and gases and leaving a strong, high carbon-content coke.
  • the gases and tars are cooled to approximately 300° C., condensing the tars, allowing them to be separated from the fuel-rich gas and collected.
  • the tars are then recycled to be used within the process as a binder while the gases are oxidized to provide heat to the pyrolyzer.
  • the resulting products are 77% fixed carbon (coke product), 15% tars (used as a binder on a recycle basis), and 8% gas (used to fuel the pyrolyzer).
  • This gas consists of about 25% water and carbon dioxide, leaving about 6% of the total feed as a combustible gas.
  • the heating value of this gas is typical of coke oven gas (about 21,600 kJ/kg).
  • About 1300 kJ of energy in the form of fuel rich gas is produced per kilogram of uncoked briquettes. The amount of energy required to raise the temperature of the briquettes from ambient to 900° C.
  • the attending amount of evolved combustible gas is sufficient to operate a pyrolysis unit at 84% thermal efficiency.
  • the feedstock mix can be adjusted according to pyrolysis product requirements.
  • the original briquettes typically will lose only about 20-25% of their weight as opposed to 35-50% in prior form coke processes.
  • briquettes or other solid objects obtained from the present invention have a higher product yield.
  • the proposed process 1) utilizes low-value carbon fines to produce a high-value coke product; and 2) operates with closed material loops so that the sale of low-value, secondary products is not required to enhance its economic viability, a characteristic of prior form coke processes.
  • a typical form coking practice requires that the process be divided into three steps; 1) coal pyrolysis to form a dense char, 2) briquetting of the char with a binder, and 3) curing the resulting briquettes. Simply binding coal fines together and curing the resulting briquettes is not acceptable. The resulting briquettes exhibit considerable mass loss (35-50%), are small, laden with stress cracks, structurally weak, and likely too reactive. Excess by-products, such as coal tars, must be collected and sold to make the process economically feasible. Due to the high cost of processing these by-products and their aromatic nature they must often be sold as low quality feedstock materials to refiners at a low price.
  • the processes of the present invention allow the coal pyrolysis and briquette curing processes to be combined. It does not require coking coals nor does it necessarily produce a surplus of pyrolytic products. Coal fines and coke fines are blended together in such proportions that just the amount of pyrolysis products are produced needed for perpetuating the binding and heating phases.
  • the tar portion of the binder may be supplemented with a synthetic or natural binder, as appropriately determined by those skilled in the art, which produces a prime quality coke briquette or block. Since dense, low reactivity discarded or waste coke fines from conventional coke ovens or petroleum refining operations are used as a portion of the feedstock, product mass loss is significantly reduced, resulting in a strong product, where reactivity is lowered.
  • Tremendous energy resources are normally associated with coal and coke-intensive industries such as mining, iron and steel production, metal castings, and other manufacturing processes. During normal materials handling, significant amounts of fines are generated which, in the best case, can be sold as a low quality product, but typically are landfilled. This loss of raw material is about 5-15% of the total coal or coke production and represents a significant energy loss.
  • the present processes allow the steel and mining industries to minimize disposal by utilizing heretofore unused, potentially valuable wastes, thus reducing material costs, land-fill charges and other expenses. Energy savings occur as the consumption of raw materials and the generation of land-filled waste is reduced.
  • This innovative technology significantly reduces wastes generated from coking and mining operations and represents a high end use for petroleum coke fines. Like all effective process-specific recycles, the amount of raw materials input for a given output is reduced.
  • Energy savings are noted in the increased utilization of raw materials, including extraction, transportation, and differences in processing requirements. Energy savings for a steel plant producing 6,000 THM per day can be exemplified by reasonably assuming a typical coke fines generation rate of 10% of the total coke production. Use of the briquettes represents a more than 1 to 1 savings in raw materials, since the briquette replaces both the raw material of appropriate size and the feedstocks that would have been discarded since they were too fine. To produce the additional coke required to compensate for the generation of fines that are too small to use, for the plant size described, requires approximately 1.1 ⁇ 10 12 kJ/year.
  • the cost associated with form coke plants can vary according to the process requirements.
  • Capital costs for the 1 million ton/year FMC plant was estimated at $350 million in 1992.
  • Operating costs were very sensitive to raw material costs and were most favorable for western coals priced at $10/ton, where 60% of the coal weight is lost in the process, as by-products.
  • Total costs associated with coke production were stated to be about $63/ton using western coals, $90/ton with Midwestern coals, and $107/ton with eastern coking coals.
  • the costs for western and Midwestern coals assume a credit for sale of by-products.
  • An FMC formed coke plan uses multiple fluidized beds for char production and a curing oven and calciner for coke production.
  • the processing and capital costs associated with commercial use of the present technology are expected to be much lower than for prior form coke processes, since the char production step is eliminated.
  • Total costs for coke production from the present process are likely to be in the range of $50-60/ton, without requiring the sale of by-products.
  • Current metallurgical coke prices are in the range of $100-120/ton and foundry coke is $140-160/ton.
  • Metallurgical coke used in blast furnaces must be (1) a fuel to provide heat to meet the endothermic requirements of chemical reactions and melting of the slag and metal, (2) a producer and regenerator of reducing gases for the reduction of iron oxides, and (3) an agent to provide permeability for gas flow and support for furnace burden. Because of the many requirements placed on metallurgical coke, it must meet stringent standards of strength, size and composition. As a fuel and producer of reducing gases, the carbon content should be maximized. As a regenerator of reducing gas, it should have an adequate reactivity to carbon dioxide and water vapor. To provide permeability and burden support, it should be charged in a narrow size range and experience minimal breakdown as it progresses through the blast furnace.
  • the ‘solution loss’ reaction produces carbon monoxide from carbon dioxide reacting with coke above 900° C. It is highly endothermic or energy consuming.
  • iron and carbon monoxide are produced by carbon reacting endothermically with iron oxide by the direct reduction reaction.
  • the joint CSR/CRI test heats a bed of coke in a nitrogen atmosphere to 1100° C. in 30 minutes, reacts the coke sample in a flow of CO 2 for 120 minutes with the bed temperature constant at 1100° C., cools the sample to 100° C., transfers the sample to a tumbler, and tumbles the sample for 600 revolutions in 30 minutes.
  • the sample is then sieved in a 3 ⁇ 8 inch sieve.
  • the CSR is calculated as the remaining portion in the sieve compared to the amount removed from the furnace.
  • the purpose of the CRI test is to give insight into the ability of CO 2 to react with the carbon in the coke, a necessary reaction in the blast furnace but which must be controlled to prevent carbon from being consumed prematurely.
  • the CSR test provides information about two different issues; 1) the strength of the briquettes after reacting with CO 2 , and 2) the amount of dust produced by CO 2 attack and bed agitation. Fine dust can be detrimental in the blast furnace since it can decrease the permeability of the bed requiring increased blast pressure to force the air up through the bed.
  • FMC and CTC Processes described above have demonstrated that they are able to produce form coke capable of blast furnace use.
  • the FMC process utilizes subbituminous coals and lignites, and yields small (11 ⁇ 4 ⁇ 11 ⁇ 8 ⁇ 3 ⁇ 4 in, or 7 ⁇ 8 ⁇ 3 ⁇ 4 ⁇ 1 ⁇ 2 in) coke briquettes, that have performed well in experimental blast furnace trials.
  • a comparison of FMC formed coke and a standard metallurgical coke is shown in TABLE 3 (Berkowitz, 1979) and some data from tests of FMC coke in a US Steel Corporation experimental blast furnace are summarized in TABLE 4(Berkowitz, 1979).
  • the ability to utilize the present new coke product can be determined by comparing its properties with cokes that have been proven to be effective blast furnace fuels.
  • TABLE 5 compares some of the advantages of coke fines briquettes produced according to the present invention with other cokes previously or currently used as blast furnace fuels and also lists what is accepted as a standard metallurgical coke (Berkowitz, 1979). While the coke fines/coal fines briquettes may vary somewhat from those produced with coke fines only, the properties will be similar. Testing of briquettes made with coal/coke blends show crush strength values of around 1400 psi.
  • Coals charged to standard coke ovens comprise a blend of coals with differing properties. Typically 3-5 coals are blended together in such proportions that the properties of the blend will produce a high quality coke product. If a weakly coking coal of low fusibility is used in the blend then the strongly coking coal component must be more fusible and higher in volatile matter to compensate. Therefore, even though mildly and weakly coking coals may be used in a particular blend, the blend would be formulated such that its properties would reflect the parameters outlined below in TABLE 6. TABLE 6 lists referenced characteristics for high quality coking coals or blends (Van Krevelen, 1993.) Coal blends not meeting these characteristics would produce inferior coke.
  • low quality coking coals are any coals, individually and collectively, that fall appreciably outside one or more of the parameters listed in TABLE 6. Although such coals may be included in a blend for standard coke oven use, they do not meet the requirements by themselves. Such coal or coals could be used as the sole source of coal within the new process.
  • FIGS. 1 and 2 are flow diagrams of processes by which fine or particulate carbonaceous material, normally considered waste, is transformed into metallurgical and other grades of coke.
  • FIGS. 1 and 2 are identical flow diagrams, except that char-forming binder is not added to the mix in the mixer 16 . Accordingly, with this exception, the following description of FIG. 1 applies also to FIG. 2.
  • Two sources of feedstock are provided, i.e. low grade coal 10 and discarded or waste coke 12 .
  • Any suitable carbonaceous material such as petroleum coke fines, coke breeze char, or carbon black, may comprise material 12
  • coal, or waste coal fines may comprise material 10 . If unsatisfactorily large in size, the materials 10 and 12 can be crushed to a fine particle size. Material 10 and material 12 , if not sufficiently particulate, are, therefore, crushed by a commercially available crusher 14 , to obtain suitably sized fine particles.
  • Any suitable crusher may be used provided, however, in most applications, the crusher must be able to reduce oversized material to about 1 ⁇ 4′′ or 1 ⁇ 8′′ and below.
  • the percentages of the various materials being fed to the crusher 14 depend largely on the type of materials being fed. Typically, coal, petroleum coke, and in some cases, metallurgical coke breeze may be fed to the crusher. Coal may account for 20-40% of the mix, petroleum coke may be 40-70%, and metallurgical coke breeze 5-10% of the total mix.
  • the mixer 16 must be able to adequately combine the carbon fines and the fedback tars and pitches as well as integrate liquid synthetic and/or natural binders, if used.
  • the fines comprising materials 10 and 12 crushed or not crushed as the case may be, are blended in mixer 16 with feedback tars including pitches, obtained during the process (FIG. 2) or feedback tars obtained during the process are mixed with a suitable natural and/or synthetic binder (FIG. 1).
  • Suitable char-forming binders comprises tars, pitches, CAT bottoms and thermosetting resins.
  • the effluent from the mixer 16 may be displaced into a solid object former 18 , which may be a briquette machine when solid coke objects or pieces are desired.
  • the former 18 compresses the mixture into a desired shape e.g. briquettes, blocks, etc. Formation of solid objects or pieces, such as briquettes, is optional, since coke is usable in a variety of forms.
  • the mixture can be discharged from the mixer 16 straight into the pyrolyzer 20 , without formation into solid objects. Any suitable type of former may be used depending on the size and shape desired for the final product, as specified by the end user.
  • the solid objects, such as briquettes, from the former 18 are or material from the mixer 16 is introduced into a pyrolyzer 20 , where the same is coked and prepared for final use.
  • the pyrolyzer furnace 20 must be able to heat the feedstock to around 800-1100° C. at a rate of 1500-2000° C./hr and be able to capture the resulting off-gases and tars.
  • the Pyrolyzer 20 normally lowers the coke volatility below 2%. This typically requires temperatures of greater than 800° C., usually within the range of 800-1100° C. Heat-up rate is important to prevent cracking of final product and should be no greater than about 1500° C. per hour.
  • Coke, as solid objects or otherwise, is discharged from the pyrolyzer 20 at site 22 .
  • gases and tars evolve as by-products in the pyrolyzer 20 . As they evolve they exit the pyrolyzer at site 24 and become the influent to a separator 28 at site 26 .
  • the separator 28 separates the by-product tars from the gases.
  • the tars are discharged at site 30 and fed back as a binder into the mixer 16 at site 34 , either with or without the addition of an additional char-forming synthetic and/or natural binder.
  • the gases are discharged at site 32 and fed back as fuel for the pyrolyzer 20 .
  • the separator 28 must be able to collect the off-gases and cool, condense and collect the condensed tars.
  • the present technology's primary objective is to produce fuel for the steel industry's iron production blast furnaces.
  • the finished product can also be used in cupolas in the foundry industry as smokeless fuel, or a general carbon fuel source.
  • the technology provides a less expensive, high-performance product with few if any by-product contamination or environmental problems.

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US09/954,603 2001-09-17 2001-09-17 Clean production of coke Abandoned US20030057083A1 (en)

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Application Number Priority Date Filing Date Title
US09/954,603 US20030057083A1 (en) 2001-09-17 2001-09-17 Clean production of coke
PCT/US2002/002839 WO2003025093A1 (fr) 2001-09-17 2002-02-01 Production de coke non polluante
US10/666,419 US20040055864A1 (en) 2001-09-17 2003-09-19 Clean production of coke
US10/691,339 US20040079628A1 (en) 2001-09-17 2003-10-22 Clean production of coke
US11/999,160 US7785447B2 (en) 2001-09-17 2007-12-03 Clean production of coke

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US10/666,419 Continuation-In-Part US20040055864A1 (en) 2001-09-17 2003-09-19 Clean production of coke
US10/691,339 Continuation US20040079628A1 (en) 2001-09-17 2003-10-22 Clean production of coke
US11/999,160 Continuation US7785447B2 (en) 2001-09-17 2007-12-03 Clean production of coke

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US10/691,339 Abandoned US20040079628A1 (en) 2001-09-17 2003-10-22 Clean production of coke
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US11/999,160 Expired - Lifetime US7785447B2 (en) 2001-09-17 2007-12-03 Clean production of coke

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US20040055864A1 (en) 2004-03-25
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US7785447B2 (en) 2010-08-31

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