US3619376A - Method of making metallurgical coke briquettes from coal, raw petroleum coke, inert material and a binder - Google Patents

Method of making metallurgical coke briquettes from coal, raw petroleum coke, inert material and a binder Download PDF

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US3619376A
US3619376A US630373A US3619376DA US3619376A US 3619376 A US3619376 A US 3619376A US 630373 A US630373 A US 630373A US 3619376D A US3619376D A US 3619376DA US 3619376 A US3619376 A US 3619376A
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particles
coal
coke
process according
plasticizing agent
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Joseph J Patel
Frederick L Shea Jr
Richard L Stec
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GREAT LAKES CARBON CORP
Daewoo Engineering and Construction Co Ltd
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    • CCHEMISTRY; METALLURGY
    • C10PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10BDESTRUCTIVE DISTILLATION OF CARBONACEOUS MATERIALS FOR PRODUCTION OF GAS, COKE, TAR, OR SIMILAR MATERIALS
    • C10B53/00Destructive distillation, specially adapted for particular solid raw materials or solid raw materials in special form
    • C10B53/08Destructive distillation, specially adapted for particular solid raw materials or solid raw materials in special form in the form of briquettes, lumps and the like

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  • Anorneya ace eyer m [54] METHOD OF MAKING METALLURGICAL COKE BRIQUETTES FROM COAL, RAW PETROLEUM ABSTRACT: The process comprises: mrxmg selected car- COKE, INERT MATERIAL AND A BINDER bonaceous particles wlth a plastlcrzer; heating the particles 30 Claims 3 Drawing Figs. and the P13916126! to a suitable temperature; compressing the plastlclzed particles while they are hot Into green bodies of [52] US. Cl 201/6, desired shape and ifi d maximum porosity and minimum 2on8 201/22' 201mg 264/29 density; and carbonizing the formed green bodies, employing [511 int.
  • Cl ClOb 55/02 a controlled carbonization process Cal-e it taken to avoid any [50] Field of Search 201/5, 6, 7, Substantial] amount f oxidation f the panicles and/or f the 8, 21-24, 34, 42; 264/29; 44/ 23 formed green bodies during most of the aforesaid heating, pressing and carbonizing steps, particularly while the particles [56] References Cited or bodies are at substantially elevated temperatures. Other UNITED STATES PATENTS elements of the process will become a arent from a detailed PP 2,336,151 12/1943 Kruppa 201/6 X reading ofthis specification.
  • Such cokes are well suited for use in the phosphorus and calcium carbide industries as a reductant, and as a carbonaceous aggregate in the production of Soderberg anodes or prebaked anodes for the aluminum industry.
  • the process in a preferred embodiment, comprises producing metallurgical coke from two main active particulate carbonaceous ingredients, viz coal and a raw uncalcined coke made by coking a heavy liquefiable hydrocarbon to a volatile matter content exclusive of water of about 8 percent to about 20 percent e.g. raw petroleum coke, and a plasticizing agent for one or both of these materials.
  • inert essentially nonfusible during the coking process
  • inert materials such as anthracite, or coke breeze, or calcined petroleum coke, or poorly fusing or oxidized raw petroleum coke, or ores to be reduced in subsequent use of the coke
  • the final coke may sometimes also be prepared from raw uncalcined coke as the sole active particulate starting material plus a plasticizing agent for same; or from raw or partially devolatilized bituminous coal as the sole active particulute starting material plus a plasticizing agent for it.
  • inert essentially nonfusible during the coking process
  • the final coke may sometimes also be prepared from raw uncalcined coke as the sole active particulate starting material plus a plasticizing agent for same; or from raw or partially devolatilized bituminous coal as the sole active particulute starting material plus a plasticizing agent for it.
  • plasticizing agent for it.
  • the invention will be carried out using as the active particulate starting material a blend of coal and raw uncalcined coke, 100 parts of blend in proportions of to 15 parts of the raw uncalcined coke and 15 to 85 parts of the coal.
  • plasticizing agent(s) which agent(s) serve many functions, but primarily to soften the particulate starting materials and to lower the temperature(s) at which the main active particulate ingredient(s) may be press-formed or briquetted to produce formed green bodies having strengths satisfactory for further processing and subsequent ultimate use after being carbonized.
  • the starting raw uncalcined coke is preferably of the delayed coker" type made by coking a heavy, liquefiable petroleum hydrocarbon to a volatile matter (VM) content exclusive of water of from about 8 percent to about 20 percent, and more typically from about 1 1 percent to about 16 percent; it is preferred, also, that it be able to fonn a button," as this property is defined hereinafter in connection with the volatile matter content test, and that it have a VM content of at least about 10 percent, particularly if the raw uncalcined coke is employed as the only active particulate starting material. lts VM content may be as low as 8 percent when used in admixture with coal.
  • the coal has a volatile matter content of from about 15 percent to about 45 percent and may cover the low, medium and high-volatile coal range; if the coal has a VM content exceeding about 20 percent and is used as the sole or major active particulate starting material, it is necessary to subject the starting coal to an initial or preliminary partial devolatilization step before it is used in the process and this is discussed in more detail hereinafter.
  • the starting particulate material(s) typically are stored in separate hoppers l, 2 and 3 and blended in a desired proportion by means of controlled feeders.
  • the materials in these hoppers may be dewatered or partially dried if necessary. If not sufficiently dry, the starting material(s) or mixture is fed to a rotary dryer 4 prior to entering a pulverizer system.
  • the starting material(s) or mixture is crushed, milled or ground (additionally mixed) to a typical particle size of substantially percent minus ls-inch if the particles are not already this size; however, they may be coarser or finer than this.
  • a screen 6 may be used to restrict or control the size of the particles used in the subsequent steps of the process.
  • particle sizing exceedingly fine for example 100 percent minus 325 mesh, (or even as fme as 50 percent minus 200 mesh) is generally avoided because unnecessary for optimum results and unduly expensive; that is, it accomplishes nothing extra, adds to the processing costs, and can result in formed bodies which are undesirably dusty.
  • the main or major portion of the heating of the particles to the desired temperature may be carried out by entrainment heating in an inert gas stream such as in conveying pipe 8, after the particles pass through surge bin 7, and weight feeder 7a and seal valve 7b.
  • the heat for the entrainment heating system is provided by the combustion of gas in chamber 9 of the air-gas mixture from mixer 10. The heated particles are then separated from the hot gases in cyclone-collector or cyclone-separator it.
  • the particles may also be heated in the mill 5, either entirely or partially or in many other ways provided an inert atmosphere or an inert gas system is maintained to prevent excessive oxidation, which is generally detrimental to fusibility of the particles and strength of the finished product.
  • Cyclone-wparator 111 will typically have a high-separation efliciency such as in excess of about 95 percent.
  • the separated solids are then conveyed to mixer 17, where they are then mixed with the plasticizer, while the flue gases and residually entrained fines from the cyclone-separator 11 are directed elsewhere. They may be cycled back into the process such as through a second cyclone-separator 12, which typically will be about 50 percent efflcient in separating the residual fines from the flue gases.
  • Part of the residual fines, then, from separator 12 are cycled to mixer 17 while part also are cycled back to combustion chamber 9 together with return flue gases.
  • a portion of the gases from cyclone-separator 12 are recycled to combustion chamber 9 to provide temperature control of the heating gases while excess gas from 12 is vented to the atmosphere. Any fines in the exhaust gases vented to the atmosphere may be disposed of by combustion or recovered, after cooling, in a baghouse.
  • the heated particles from cyclone-separator 11 and some also from separator 12 are, as aforesaid, typically conveyed to a continuous mixer 17, such as a pug mill or continuous mix muller. It should be apparent from FIG. 1 that the particles entering mixer 17 are in a heated condition.
  • the particles are mixed in mixer I7 with a heated plasticizer from plasticizer tank 13, the temperature of the plasticizer in the tank being sufficiently high to substantially lower its viscosity but not so high as to boil or decompose it.
  • This tank and/or the plasticizer within same may be heated, such as by means'of electric heater 14, or by other suitable means such as hot oil or steam.
  • a metering pump 15 may be used to control the amount or proportion of plasticizer (typically from about I to about 8 percent and more preferably from about 2 to about 6 percent by weight of the particulate materials entering mixer 17 which is fed to mixer 17 to be mixed with the heated particles. This proportion of plasticizer may also be expressed as parts per hundred (p.p.h.) parts of particulate materials.
  • Auxiliary heating means 16 typically are used in the plasticizer feed lines to the mixer to rapidly raise its temperature to the approximate level of the particles. The heated plasticizer may conveniently be sprayed onto the particles in mixer 17.
  • Mixer l7 typically will also be heated, such as by the burning of natural gas in air in chamber 18 and passing the heated gas to heater jacket 19, so as to keep the particles-plasticizer mix at the desired elevated temperature for molding or briquetting.
  • This elevated temperature is at least as high as about 300 F. but is also below the fusion temperature of the base solid carbonaceous material(s) before these material(s) are mixed with the plasticizer.
  • the plasticizer and particles are typically rapidly mixed in a short period of time, such as in from about 0.5 to about l minutes while they are still at an elevated temperature above about 300 F. during which time the mix fuses or becomes plasticlike.
  • the mix is then molded or briquetted, such as by a briquet press 20, before it is rendered nonplastic due to overheating (either timewise or temperature wise).
  • the retention time that the mixture of particles and plasticizer is maintained at maximum temperature prior to pressing is generally limited to no more than about minutes. (Typically the material flows continuously through the mixer and a proportion of the total retention time is required to complete mechanical mixing; the remainder is necessary to allow for interaction or alloying between the plasticizer and raw coke and/or raw coal, which interaction takes place in mixer 17 and also in hopper-feeder 20a both of which are maintained under substantially inert or nonoxidizing conditions.)
  • the pressure employed is variable depending on the temperature of the particles being formed, the formulation being processed, the type of press or forming operation used, etc.
  • the formed green bodies produced typically have an apparent density (A.D.) between about 0.85 and about 1.25 grams per cubic centimeter (g./cc.) and a porosity between about 8 percent and about 37 percent.
  • A.D. apparent density
  • g./cc. grams per cubic centimeter
  • porosity between about 8 percent and about 37 percent.
  • the hot formed green bodies are transferred, such as by conveyor 21 (which typically will also be housed in a substantially inert or nonoxidizing atmosphere) to a carbonizer 22 where they are gradually but rapidly heated (preferably 8 hours or less) in a substantially inert atmosphere to the degree (e.g. typically l,000 F. to 2,000 F.) that their volatile matter content is substantially reduced from the green state.
  • the foregoing described technique for carrying out the process is that which is preferred, and is also that which is illustrated in the block drawing of FIG. 2. It should be apparent, however, that there are process techniques or variations which are somewhat different from the foregoing procedure but which are also within the scope of the invention.
  • the block drawing of FIG. 3 illustrates such an alternative technique.
  • the starting particulate materials are first mixed with the plasticizer before being heated, rather than being separately heated before being mixed with the plasticizer.
  • the entire mixture is then relatively rapidly heated during which heating step the plasticizer alloys with the particulate starting materials.
  • This heating step can conveniently be carried out while simultaneously mixing all of the materials and also while conveying the materials to the fonning apparatus.
  • the mixture is heated to a temperature at least as high as about 300 F.
  • the retention time that the mixture of particles and plasticizer is maintained at maximum temperature prior to pressing is generally limited to no more than 5 minutes. It will be noted that in this process variation the retention time at maximum temperature is sub stantially the same as in the process variation of FIG. 2. It will be appreciated, however, that, because no elevated temperature conditioning step(s) are carried out, more time is generally required or employed in the heating step to get the plasticized mixture up to maximum temperature than in the heating step of the plasticized mixture of FIG. 2.
  • the briquetting and carbonizing steps are then carried out in the same manner as for the process of FIG. 2. It is important that the temperature of the plasticized particles reach at least about 300 F. for any of the blends of this invention. Otherwise a poor briquetting operation follows and the strength of the carbonized briquettes is poor.
  • the maximum temperature(s) and retention time(s) at maximum temperature which may be employed will vary and must be adjusted for each type of formulation to be briquetted; but for any given formulation there must be close control of the time and temperature conditions. Otherwise the mixture employed will not be softened enough for satisfactory briquetting or will be overheated or heated too long and rendered nonplastic and unsatisfactory for briquetting.
  • plasticizers described herein are used mainly as processing aids in enabling the use of lower-pressures and temperatures in forming than would otherwise be necessary to produce strong green bodies. That they function as such is apparent from the fact that the plasticizer plus an inert such as anthracite, when heated to forming temperature, and pressed, does not yield a cohesive briquet; the active particulate material(s) alone when processed in this same manner, e.g. heated and pressfonned, also do not become cohesive or yield a cohesive body. But the active particulate material(s) plus plasticizer when heated and processed in an identical manner do form cohesive bodies.
  • the plasticizers act as such, viz as plasticizers before the forming operation, rather than as a binder. This is not to say, however, that the plasticizers cannot be converted partially or largely to carbon (and thus function also as a binder) during the carbonization step.
  • process variations which are possible and which should be obvious are to heat the particulate starting material(s) (either the active and/or the inert) separately from the plasticizer by techniques other than entrainment heating, such as by batch techniques or in a mill or in a mixer or in a fluidized bed, etc.; and then mix the plasticizer with the heated particles.
  • the particulate starting materials may also initially be heated separately and to different temperatures before they are blended with each other and with the plasticizer. If so, the inert material may typically be heated to a higher temperature than the active material.
  • the plasticizer may be separately heated or may receive part or all of its heat from the preheated particles.
  • Other possible process variations will be obvious to those skilled in the art.
  • EXAMPLE 1 Fifty parts of bituminous coal having a VM content of 26.1 percent and 50 parts of raw petroleum coke having a VM content of 13.5 percent stored in separate hoppers l and 2 as illustrated in FIG. 1 were blended in these proportions by means of controlled feeders.
  • the blended materials contained about 5 percent moisture and were dried in rotary dryer 4 by subjecting them to a temperature of about 250 F. for about I minutes.
  • the dried mixture was then fed to a pulverizer system such as used in powdered coal burners.
  • the mixture was milled or ground (and additionally mixed) to a particle size such that substantially 100 percent of the mixture could pass through a mesh screen (Tyler) (or roughly minus zit-inch).
  • a screen 6 was used to restrict or prevent larger sized particles from entering the subsequent steps of the process.
  • the main or major portion of the heating of the particles to the desired temperature was carried out by entrainment heating in an inert gas stream in conveying pipe 8, after the dried, milled and mixed particles passed through surge bin 7, weight feeder 7a and seal valve 7b.
  • Weight feeder 7a was used to closely control the quantity of material entering the conveying pipe 8.
  • feeder 7a was set to admit 4,640 pounds (:3 percent) of particulate material per hour to conveying pipe 8. (Although illustrated as horizontal in FIG. I, it should be understood that conveying pipe 8 may be at any desired slope including vertical, with the particles moving in a downward direction.)
  • Conveying pipe 8 was 2 feet in diameter and 2l feet long.
  • the heat for the entrainment heating system was provided by the burning of natural gas in combustion chamber 9 of the air-gas mixture from mixer 10.
  • the combustion chamber 9 was designed to provide 2.54 million B.t.u./hour heat release; 1.73 million Btu/hour of this being provided by the burning of 29 s.c.f.m. (standard cubic feet per minute) of natural gas in 290 s.c.f.m. of air from the air-gas mixer 10; and 0.81 million B.t.u./hour of this being provided by the return and/or combustion of hot flue gases and fines from the "Fines" cyclone-separator 12.
  • the nonoxidizing gas leaving combustion chamber 9 has an output temperature of 800 F. and a rate of 7,950 cubic feet per minute (c.f.m.
  • This rate of flow corresponds to a linear velocity of the gases in the pipe 8 of about 50 feet per second.
  • the particles are conveyed in this gas stream and have an average retention time in the pipe of less than a second while they are heated to such a temperature that after separation from the gases in the cycloneseparator ll they have a temperature of about 400 F.
  • rapid heating rates are preferred for maxlmum production, as much time as is convenient, rapidly or slowly, as desired, or as best suited to process rates or the equipment available, may be taken to heat the particulate starting materials to the desired elevated, nonfusing temperature before they are mixed with the plasticizer.
  • entrainment type heating is not essential and the particles may be heated in the mill 5, either entirely or partially or in many other ways, such as in a fluid bed.
  • the typical cyclone-separator 11 used is so designed as to have a high-separation efliciency, such as in excess of about percent, or about 97 percent, for the size particles being processed.
  • the separated solids are then passed to mixer 17, (97 percent of 4,640 or about 4,500 pounds/hour) where they are then mixed with the plasticizer, while the flue gases and residually entrained fines (about I40 pounds/hour) from the cyclone-separator 11 are directed elsewhere.
  • mixer 17, 97 percent of 4,640 or about 4,500 pounds/hour
  • the flue gases and residually entrained fines about I40 pounds/hour
  • a second cycloneseparator 12 typically will be about 50 percent efficient in separating the residual lines from the flue gases.
  • About half of the residual fines, then, (about 70 pounds/hour) from separator 12 are cycled to mixer 17; while part also (about 58 pounds/hour) are cycled back to combustion chamber 9 together with return flue gases.
  • Another minor part (about 12 pounds/hour) are disposed of by combustion or recovered, after cooling, in a baghouse.
  • a damper 12b is typically used to restrict the proportion of fines which are so processed and to favorably proportion the percentage cycled back to combustion chamber 9.
  • Seal valves 1 1a and 12a from cyclones II and 12 permit the flow of solids and eliminate gas flow into the mixer, the feed rate into the mixer being effectively controlled by weight feeder 7a.
  • the heated particles from cyclone-separator 11 and a minor proportion also from cyclone-separator 12 are, as aforesaid, conveyed to a mixer 17.
  • the heated particles were mixed in mixer 17 with a heated plasticizer from plasticizer tank 13. the temperature of the plasticizer in the tank being sufiiciently high to substantially lower its viscosity but not so high as to boil or decompose it.
  • This tank and/or the plasticizer within same was heated by means of heater 14.
  • the plasticizer used was thermal tar having the following properties:
  • the viscosity of the thermal tar in Saybolt Universal Seconds at 210 F. was 95.
  • a metering pump 15 was used to control the amount or proportion of plasticizer cycled into mixer 17 to be mixed with the heated particles. Preferably, as aforesaid, this will vary from 2 to about 6 parts by weight per hundred parts of the particulate materiaKs) entering mixer 17 or will be from about I I to about 33 gallons per hour. In the present example 5 parts or percent thermal tar by weight was used.
  • Auxiliary heating means 16 were used in the plasticizer feed lines to the mixer in order to rapidly raise the temperature of the plasticizer from 300 F. to the approximate level (400 F.) of the particles and also the temperature desired for briquetting.
  • auxiliary heating means are used because it is preferred not to heat the plasticizer to this temperature level for too long a period of time prior to mixing it with the heated particles.
  • the heated plasticizer of lowered viscosity may conveniently be sprayed onto the particles in mixer 17.
  • Mixer 17 is typically also heated by hot gases, such as from the burning of natural gas in chamber 18 (e.g. 0.8 s.c.f.m. of natural gas in 8.8 s.c.f.m. ofair to provide 51,170 B.t.u./hour), in heater jacket 19, so as to keep the particles-plasticizer mix at the desired elevated temperature for pressure-forming or briquetting; the products of combustion from the heater jacket being vented to stack.
  • the plasticizer and particles were then rapidly mixed in mixer 17, which typically has a maximum retension time of about minutes and more typically about 10 minutes, and were then pressure formed in double roll briquet press at a pressure of 28,000 p.s.i., while at about the 400 F. temperature and before the alloy formed was rendered nonplastic, after which the hot formed green bodies (about 4,500 pounds/hour were passed, by conveyor 21, to a carbonizer 22 where they were gradually heated in 6 hours in an inert atmosphere to a maximum temperature of 1,800 F.
  • the briquets produced were pillow shaped and were 3 inches long, 2 inches wide and possessed a maximum thickness of 1% inches; it should, however, be appreciated that the green bodies of this invention can have other shapes such as semlcylindrical, or tubular, or doughnut-shaped, etc; depending in large part upon the necessity or desirability of producing porosity in the packed bed of the furnace in which they are used. Such alternative shapes may also readily be resorted to in order to facilitate rapid evolution of volatiles in the carbonizing step (and hence a rapid carbonizlng step) and, at the same time, the minimization of flaws, or cracks or spalling, etc, during the carbonization step. Generally, however, the formed green bodies of the invention will be so shaped that at least one of its dimensions does not exceed about 2 inches.
  • the active material(s) used will be a blend of coal and raw coke and this blend will comprise from 15 to 85 percent of a coking coal, and correspondingly from 85 to 15 percent of raw coke (preferably raw petroleum coke). As indicated in FIGS. 2 and 3, to these active base materials may be added minor amounts ofinert.
  • the invention may be carried out by using the raw uncalcined coke as the sole active particulate starting material, said coke, when used alone, having a volatile TABLE I Modified Weight percent Plastinizer p.p.h. Mix, tumbler test,
  • the raw coke referred to may be obtained as a fusible residue by the thermal cracking or coking of petroleum hydrocarbon oils, cracked asphalts, straight run asphalts, coal tar pitch, wood tar pitch, and the like.
  • an especially useful and preferred raw coke is raw petroleum coke produced in a delayed coker.
  • the invention may be carried out by using raw coal or partially devolatilized coal as the sole active particulate starting material, so long as its VM content does not exceed about 20 percent.
  • the use of raw coke alone or of coal alone (having a proper VM content) are illustrated in the examples of table I. As is apparent from the tumbler tests, however, mixtures of coal and raw coke result in higher values and are, therefore, preferred in the processes of the present invention.
  • the raw coke as obtained When the raw coke as obtained has a volatile matter content above about 20 percent it can be heated under controlled conditions, which should avoid localized overheating, to reduce the volatile matter content to come within the ranges specified. This can be done at relatively low-temperatures of about 500-l,000 F. Care should be taken that oxidation does not occur and that the volatile matter content is not reduced to a point below that of the ranges set forth.
  • the plasticizer should be neither substantially vaporizable (at atmospheric pressure) nor substantially thermally decomposable below about 490 F., which temperature is well above the temperature at which the alloying effect of the plasticizer with the raw coke and/or coal generally occurs.
  • Suitable substances for plasticizers include coal tar, coal tar fractions, coal tar pitches, certain high-boiling hydrocarbon oils and residues produced in catalytic cracking of petroleum distillates such as thermal tar, petroleum pitch, wood tar pitch, anthracene oil, heavy wood tar oils and pitches, heavy lignite tar oils and pitches, phenanthrene, and the like. Heavy petroleum hydrocarbon residues and asphalts, whether cracked or straight run, may also be used as plasticizers.
  • a plasticizing agent (which may also be referred to as a plasticizer or alloying agent) depends upon a number of factors such as the material(s) with which it is alloyed, its cost, etc. Any plasticizer which will partially alloy with the raw coke and/or coal used can be used. Not all are exactly equivalent.
  • Aromatic hydrocarbons are preferred. The oxygen or nitrogen derivatives of aromatic hydrocarbons are also useful, but are less desirable than the hydrocarbons.
  • the plasticizer should not contain substantial amounts of substances which decompose to give strongly oxidizing decomposition products. Cycloparaffinic hydrocarbons or their derivatives may be used, for example, the furfural extract of heavy lubricating oils. Mixtures of the hydrocarbons and their derivatives may be used to advantage in many instances.
  • the plasticizer should not vaporize or decompose substantially below about 490 F.
  • the most desirable plasticizers are those which are converted to a large extent into coke. Excessive production of vapors and gases tend to unduly increase the porosity of the coke bodies.
  • High-sulfur content materials are generally undesirable because metallurgical coke having a high-sulfur content is frequently objectionable to the user of the coke.
  • the comminuted coal and/or raw coke and the plasticizer can be preliminarily mixed at room temperature where this is convenient, particularly if the plasticizer is in finely divided solid condition.
  • those plasticizers which are normally liquid can be mixed cold with the coal and/or coke.
  • the mixing can be carried out at elevated temperatures such as by heating the coal or coke, or a fairly uniform mixture of coal and/or raw coke and plasticizer, to a temperature above about 300 F. and typically in the range of about 320500 F. and more typically 340-450 F and the mixing step carried out in any suitable type of equipment, so that mixing and plasticizing or alloying take place simultaneously.
  • the proper time-temperature for this alloying treatment is quite critical and will vary depending upon the volatile matter content of the coal and/or raw coke and the particular plasticizer employed and its viscosity.
  • the plasticized particles should not be heated for too long a period of time and/or to too high a temperature before they are pressure-formed since it is possible that such treatment will render the plasticized particles nonplastic and result in difficulties in fonning the green bodies, or in green bodies of poor strength.
  • time-temperature conditions, or holding times at maximum temperature can readily be established for any given mixture described herein and using the guidelines discussed herein, using the briquettability of the plasticized particles and the properties of the baked briquets as criteria.
  • the alloying treatment should preferably be carried out in a nonoxidizing atmosphere, particularly when or after the plasticized particles approach or reach their maximum temperature.
  • the mixing can be carried out with the raw materials warmed, e.g. to l0O-200 F., but at a temperature below that at which the alloying effect is initiated or complete and this followed by further processing at a higher temperature.
  • the alloying treatment is controlled so that it does not proceed too far. This usually can be controlled by the temperature used, although time has a substantial effect. If a mixture of a plasticizer and coal and/or raw coke is heated while mixing at a temperature above the range given, or above the maximum desirable temperature for that particular mixture, it goes through first a pasty form and then the mixture changes in character and becomes too dry to extrude and difficult to mold such as by a continuous roll briquetting operation. In other words, the plasticized coal and/or raw coke should furnish its own lubrication effect on the dies. With certain plasticizers, this over treatment may occur in the temperature range given if the time is extended too long, for example, beyond 5 minutes or even less.
  • the criticality of the time and temperature relationship in the alloying step varies with the amount and kind of plasticizer employed. It also varies, with the volatile matter content and particle size of the coal and/or raw coke. In general, however, the small or line coal and/or raw coke particles which are typically employed in the present invention alloy rapidly because of the large surface area and small diameter of the particles.
  • Bituminous coal llasticizer (parts per hundred parts of coke and coal) VM VM (percent) Parts (percent) Asphalt. Anthracene oil. Thermal tar. Petroleum pitch. Thermal tar.
  • Thermal tar The thermal tar. Coal tar pitch. Coal tar. Thermal tar. Coal tar.
  • Coal tar pitch The Thermal tar. Coal tar. Thermal tar.
  • the bituminous coal was partially devolatillzed prior to blending (in order that the VM content of the coal-petroleum coke mixtures would not exceed about 20%) before it was blended with the petroleum coke and processed in accordance with the steps of this invention.
  • the particles will be heated long enough (within the time ranges previously set forth) and/or to a sufliciently high temperature (also within the previously discussed temperature ranges) to bring about the desired softening and alloying efiect, but not so long and/or to such high temperatures that the alloy formed is rendered non-plastic.
  • Plasticized coals or raw cokes that may be employed in this process must, after being pressure-formed or briquetted, be of a character in which there is little plastic and no liquid flow during any stage of the carbonizing operation. If the coals or coke have too high a volatile matter content or if the plasticized mixtures tend to melt and flow before decomposition of the decomposable components of the formed green bodies has occurred, the minute channels from the interior of the bodies to the exterior by which the decomposition vapors escape will tend to seal off, resulting in processing problems in the carbonizing step and the production of large pores and carbonized bodies of poor strength. However, when prepared with the materials having the properties previously described and according to the methods outlined, such flow does not occur and the vapor escape channels remain small and uniformly dispersed throughout the bodies being carbonized, so that the gases can escape rapidly and without the production of large pores or channels.
  • coal having a volatile matter content of from about 20 percent upwards to about 45 percent in the present process in an amount such that the resultant blend (coal plus raw petroleum coke) would have a volatile matter content higher than about 20 percent by weight, then it is necessary to partially devolatilize such coals by any suitable means known to those skilled in the art, so that the volatile matter content of the resultant blend is no higher than about 20 percent. If this partial devolatilization of the coal operation results in excessive agglomeration of the coal, it may be preliminarily crushed to reduce it to a reasonable size, after which it can then be used as a raw material in the present process.
  • All of the materials in the blend to be briquetted or pressure formed are generally heated to approximately the same temperature, In the process of doing this, however, the various ingredient(s) will be affected differently. For example, if a substantially inert material such as anthracite is used, it will typically merely be heated up to operating temperatures; on the other hand the coal and/or raw petroleum coke blended with the plasticizer undergo an alloying effect. The time and/or temperature the particles are kept in or heated to in this heating step also depend upon a number of factors in addition to those already discussed.
  • the forming apparatus 20 or rolls of the briquetting machine may be at any desired temperature, such as at approximately the same temperature as the particles or higher, or at room temperature, or at a temperature intermediate of these, etc.
  • the briquetting rolls may be water cooled, or oil cooled, etc.
  • the heated solids prior to briquetting must be protected from undue atmospheric oxidation which is detrimental to the strength of the finished product. it is also apparent that in the presence of excess air there is danger of ignition and combustion. An inert gas atmosphere may be provided.
  • the pressure employed in the forming step is variable depending on the temperature of the plasticized particles being fonned, the formulation being processed, the type of press or forming operation used, etc.
  • a piston press it will be between about 500 and about 15,000 p.s.i., employing lower pressures with higher temperatures and vice versa.
  • blend temperatures 300-350 F. and pressures of 1,000 to 2,000 p.s.i.
  • a roll-press is most preferred for volume production and when such a forming apparatus is employed the "pressing time" (the time when the alloyed particles being shaped are actually under pressure or when pressure is actually applied) is usually less than 2 seconds and typically less than one.
  • Other fonning apparatus can be employed, such as previously discussed.
  • a minimum porosity of at least 8 percent should be maintained in the formed green body in order that a minimum of problems arising in the forming and carbonizing steps and in order that the carbonizing step may be carried out in a rapid operation. if the porosity of the formed bodies is too low and attempts are made to rapidly carbonize such bodies, then the escaping remaining volatiles tend to rupture the articles and produce coke of unsuitable size or strength for metallurgical purposes.
  • the maximum porosity of the formed green bodies is 37 percent. lf higher than this, then they are too weak or have too low an apparent density (after being carbonized) for their contemplated uses.
  • the apparent density of the carbonized product is generally between about 1.0 and 1.5 g./cc. With regard to the apparent density of the formed green bodies, this should be between about 0.85 and 1.25 g./cc.; of course the lower density bodies have the higher porosity and the higher density green bodies have the lower porosity.
  • the formed green bodies preferably are also substantially immediately carbonized, without substantial cooling. This is because if the temperature of the formed material is permitted to drop very much between the forming and carbonizing steps, undesirable cracks or flaws are much more likely to develop in the formed articles than if they are carbonized immediately without any substantial cooling.
  • the overall cycle is such that the operation typically requires no more than about minutes in heating the particles to a temperature between 300 and 500 F., mixing them with the plasticizer, press-forming the alloyed particles while they are still at an elevated temperature between about 300 F. and about 500 F. (viz little or no colling being permitted before the forming operation) and getting the formed articles into the carbonizer.
  • no substantial surges are permitted in the cycle.
  • the carbonaceous particles being heated or the formed carbonaceous masses being processed are kept moving very uniformly or regularly, with no substantial buildup being permitted.
  • any preceding preheating bringing the particles up to a given relatively low temperature such as about 200 F.
  • a given relatively low temperature such as about 200 F.
  • the subsequent carbonizing step without adverse, or as much adverse, effect upon the quality of the product produced, or the freedom from troubles of the process.
  • the press-formed bodies may be rapidly (e.g. much faster than the 18-24 hours typically required by the prior art byproduct coking oven methods) carbonized, such as to a temperature of between about l,000 and about 2,000 F. (or to a product VM content of 5 percent or less) within a period of 8 hours maximum, without impairment of the qualities of the product. Carbonizing periods of from 3 to 6 hours are typical. Of course a longer period than 8 hours may also be employed, but it will usually be disadvantageous to do so.
  • the formed green bodies generally do not resoften and stick to each other, or deform upon being processed in the hot carbonizer 22 because of their having been alloyed" and pressure-formed into separate and distinct shapes, during which a strong cohesive bond within the formed green bodies has been effected. Therefore, the bonds between the particles in the individual formed bodies are very good and the carbonized bodies produced are typically of superior strength. With certain formulations and under certain conditions, however, there may be a tendency for the briquets to adhere to each other. if there is a tendency for the briquets to stick to each other during carbonization, they may be subjected to a brief or limited surface oxidation to set and prevent resoftening of their surfaces during carbonization.
  • the formed green bodies may be carbonizing in any suitable carbonizing apparatus capable of providing a substantially inert or nonoxidizing atmosphere.
  • the carbonizing apparatus 22 is so constructed, or so regulated, that the formed green bodies can be raised to the desired final carbonizing temperature in a well regulated manner.
  • the desired final temperature is l,472 F. (800 C.) and the formed green bodies are at a temperature of 400 F. when they leave the forming apparatus 20 and enter the carbonizer 22, they preferably will be heated from the 400 F. (or about 204 C.) temperature to the 800 C. (1,472 F.) temperature at a very closely controlled upheat rate or upheat rates, such as at a rate not exceeding 400 C.
  • Controlled temperature gradients which are more gentle than the foregoing such as not exceeding 300 C. for any given hour increment of time, or 8 C. for any given minute increment of time, (for example, a baking rate of 3 C. per minute) are more typical or representative of those generally used in the carbonizing step.
  • the particular upheat rate within the foregoing described ranges which will be chosen and employed will also be dependent upon the density, porosity, size, shape and VM content of the formed green bodies being processed.
  • Rotary kilns, shaft kilns and moving grates, with gradually increasing temperature zones as the formed bodies proceed through the carbonizer, and capable of providing a substantially inert atmosphere, are very suitable for accomplishing the foregoing type of heating.
  • the formed bodies After the formed bodies are heated to the desired temperature, they typically are then gradually cooled in an inert atmosphere until they reach a temperature of about 220 F. or lower.
  • a single piece of apparatus, with heating zones and cooling zones, may be employed for both carbonizing and cooling, or cooling may be accomplished in a separate piece of equipment.
  • the cooled formed coke (which may be stored in a product bin or immediately shipped, or immediately used in a cupola or blast furnace, etc.
  • temperatures at least as high as about l,000 F. are required and temperatures higher than this such as at l,472-l ,760 F. are preferred for optimum properties.
  • Temperatures higher than l,760 F. such as up to about 2,000 E, may also be employed but will generally not be required in order to make a satisfactory commercial product.
  • the volatile matter (VM) content of the raw cokes and coals of this invention are determined in accordance with the A.S.T.M. Procedure No. D271-48 as modified for peat and lignite, and being exclusive of water.
  • a relatively small sample of the raw coke or coal is 'heated at 950 C for a period of time between about to minutes. The difference in weight of the sample prior to and after heating constitutes the volatile content" of the material tested.
  • the raw cokes employed in the invention not only have the specified VM content of between about 8 and about 20 percent and more typically between about i l and about 16 percent when used with coal, or of at least about 10 percent when used alone, but that they also form a hard, coke agglomerate or button" while being heated in accordance with the previously mentioned A.S.T.M. procedure, except that a 5 gram sample instead of a 1 gram sample is used. This latter property is essential when the raw coke is employed as the sole active particulate ingredient.
  • a process for making shaped metallurgical coke bodies which comprises:
  • A forming a mixture from (a) a blend of active carbonaceous materials consisting of from to 85 parts by weight of fusible coal particles having a volatile matter content of at least about 15 percent and from 85 to 15 parts by weight of particles of raw, uncalcined coke made by coking a heavy liquefiable, hydrocarbon to a volatile matter content exclusive of water of about 8percent to about percent, the sum of the parts of coal and the parts of raw coke equaling 100; and (b) from about 1 to about 8 parts of a plasticizing agent by weight of the coal and raw coke particles, said plasticizing agent being neither substantially vaporizable nor substantially thermally decomposable below about 490 F., the average volatile matter content of the coal and raw coke particles taken together not exceeding about 20 percent, and said coal and raw coke each being agglomerative when heated and alloyed according to step B following:
  • step B the maximum temperature to which the mixture is heated in step B is between about 320 F. and about 500 F. and wherein the time that the mixture is maintained at maximum temperature prior to being compressed in step C is no more than about 5 minutes.
  • a process for making shaped metallurgical coke bodies which comprises:
  • A forming a mixture comprised of 100 parts of fusible coal particles having a volatile matter content of at least about 15 percent and no higher than about 20 percent, and from about i to about 8 parts of a plasticizing agent by weight of the coal, said plasticizing agent being neither substantially vaporizable nor substantially thermally decomposable below about 490 F., and said coal being agglomerative when heated and alloyed according to step B following;
  • a process according to claim 11 wherein said plasticizing agent is thermal tar.
  • step B the maximum temperature to which the mixture is heated in step B is between about 320 F. and about 500 F. and wherein the time that the mixture is maintained at maximum temperature prior to being compressed in step C is no more than about minutes.
  • a process for making shaped metallurgical coke bodies which comprises:
  • A forming a mixture comprised of 100 parts of raw, uncalcined coke particles made by coking a heavy liquefiable, hydrocarbon to a volatile matter content exclusive of water of about percent to about 20 percent, and from about 1 to about 8 parts of a plasticizing agent by weight of the raw coke particles, said plasticizing agent being neither substantially vaporizable nor substantially thermally decomposable below about 490 F., and said coke being agglomerative when heated and alloyed according to step B following;
  • step B A process according to claim 21 wherein the maximum temperature to which the mixture is heated in step B is between about 320 F. and about 500 F. and wherein the time that the mixture is maintained at maximum temperature prior to being compressed in step C is no more than about 5 minutes.
  • a process according to claim 29 wherein said raw coke particles are heated by entrainment heating of the particles in an inert gas stream and wherein the heated particles are separated from the inert gas before being mixed with the plasticizing agent.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Oil, Petroleum & Natural Gas (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Coke Industry (AREA)
  • Working-Up Tar And Pitch (AREA)
US630373A 1967-04-12 1967-04-12 Method of making metallurgical coke briquettes from coal, raw petroleum coke, inert material and a binder Expired - Lifetime US3619376A (en)

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Cited By (15)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3888958A (en) * 1970-03-21 1975-06-10 Bergwerksverband Gmbh Process for making shaped pieces from low temperature coke of low bulk weight
US3907648A (en) * 1972-02-29 1975-09-23 Sumitomo Metal Ind Method of manufacturing formed coke for blast furnaces without causing the fusion of the coke
US4178215A (en) * 1976-06-30 1979-12-11 Sumitomo Metal Industries Limited Method of manufacturing blast furnace coke
US4185055A (en) * 1971-09-24 1980-01-22 Aluminum Pechiney Process for heat-treating carbon blocks
US4234387A (en) * 1978-04-28 1980-11-18 Her Majesty The Queen In Right Of Canada, As Represented By The Minister Of Energy, Mines And Resources Coking poor coking coals and hydrocracked tar sand bitumen binder
US4452670A (en) * 1978-07-20 1984-06-05 Koppers Company, Inc. Method and apparatus for recovering preheater coal fines
US5928495A (en) * 1995-12-05 1999-07-27 Legkow; Alexander Emulsion for heavy oil dilution and method of using same
US20070023549A1 (en) * 2005-04-29 2007-02-01 French Robert R Method to transform bulk material
US20070187222A1 (en) * 2003-09-11 2007-08-16 Kenji Kato Method for pretreating and improving coking coal quality for blast furnace coke
US20080222947A1 (en) * 2007-03-13 2008-09-18 French Robert R Method To Improve The Efficiency Of Removal Of Liquid Water From Solid Bulk Fuel Materials
WO2009018550A1 (en) * 2007-08-01 2009-02-05 Gtl Energy Ltd Method of producing water-resistant solid fuels
US20100133086A1 (en) * 2007-04-27 2010-06-03 Yoshimasa Kawami Apparatus and process for producing biocoke
US20100162618A1 (en) * 2007-04-27 2010-07-01 Yoshimasa Kawami Biocoke producing apparatus and process therefor
AU2011202676B2 (en) * 2007-08-01 2012-06-28 Gtl Energy Ltd Method of producing water-resistant solid fuels
CN112877086A (zh) * 2021-01-25 2021-06-01 焦作钧菲津材科技有限公司 一种石油焦煅烧控制方法

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE2640787C3 (de) * 1976-09-10 1980-09-25 Fa. Carl Still Gmbh & Co Kg, 4350 Recklinghausen Verfahren und Vorrichtung zur Herstellung von Hochofenkoks
FR2464294A1 (fr) * 1979-08-29 1981-03-06 Savoie Electrodes Refract Grains carbones synthetiques a hautes caracteristiques mecaniques, procede de preparation, application a la realisation de blocs carbones, electrodes et pates carbonees

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US2808370A (en) * 1953-10-12 1957-10-01 Great Lakes Carbon Corp Metallurgical coke
US3010882A (en) * 1952-07-14 1961-11-28 American Cyanamid Co Process of extruding anthracite coal to form a metallurgical coke-like material
US3018226A (en) * 1960-10-07 1962-01-23 Consolidation Coal Co Method for preparing coked briquets from caking coals
US3018227A (en) * 1957-01-22 1962-01-23 Consolidation Coal Co Preparation of formcoke
US3316155A (en) * 1963-01-25 1967-04-25 Inland Steel Co Coking process

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US2336151A (en) * 1940-07-02 1943-12-07 American Cyanamid Co Pressure treatment of coking coals
US3010882A (en) * 1952-07-14 1961-11-28 American Cyanamid Co Process of extruding anthracite coal to form a metallurgical coke-like material
US2808370A (en) * 1953-10-12 1957-10-01 Great Lakes Carbon Corp Metallurgical coke
US3018227A (en) * 1957-01-22 1962-01-23 Consolidation Coal Co Preparation of formcoke
US3018226A (en) * 1960-10-07 1962-01-23 Consolidation Coal Co Method for preparing coked briquets from caking coals
US3316155A (en) * 1963-01-25 1967-04-25 Inland Steel Co Coking process

Cited By (25)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3888958A (en) * 1970-03-21 1975-06-10 Bergwerksverband Gmbh Process for making shaped pieces from low temperature coke of low bulk weight
US4185055A (en) * 1971-09-24 1980-01-22 Aluminum Pechiney Process for heat-treating carbon blocks
US3907648A (en) * 1972-02-29 1975-09-23 Sumitomo Metal Ind Method of manufacturing formed coke for blast furnaces without causing the fusion of the coke
US4178215A (en) * 1976-06-30 1979-12-11 Sumitomo Metal Industries Limited Method of manufacturing blast furnace coke
US4234387A (en) * 1978-04-28 1980-11-18 Her Majesty The Queen In Right Of Canada, As Represented By The Minister Of Energy, Mines And Resources Coking poor coking coals and hydrocracked tar sand bitumen binder
US4452670A (en) * 1978-07-20 1984-06-05 Koppers Company, Inc. Method and apparatus for recovering preheater coal fines
US5928495A (en) * 1995-12-05 1999-07-27 Legkow; Alexander Emulsion for heavy oil dilution and method of using same
US7645362B2 (en) * 2003-09-11 2010-01-12 The Japan Iron And Steel Federation Method for pretreating and improving coking coal quality for blast furnace coke
US20070187222A1 (en) * 2003-09-11 2007-08-16 Kenji Kato Method for pretreating and improving coking coal quality for blast furnace coke
US8453953B2 (en) 2005-04-29 2013-06-04 Gtl Energy Holdings Pty Limited Method to transform bulk material
US20110167715A1 (en) * 2005-04-29 2011-07-14 Gtl Energy, Ltd Method to transform bulk material
US20070023549A1 (en) * 2005-04-29 2007-02-01 French Robert R Method to transform bulk material
US7913939B2 (en) 2005-04-29 2011-03-29 GTL Energy, Ltd. Method to transform bulk material
US20080222947A1 (en) * 2007-03-13 2008-09-18 French Robert R Method To Improve The Efficiency Of Removal Of Liquid Water From Solid Bulk Fuel Materials
US8454801B2 (en) * 2007-04-27 2013-06-04 Naniwa Roki Co., Ltd. Apparatus and process for producing biocoke
US20100162618A1 (en) * 2007-04-27 2010-07-01 Yoshimasa Kawami Biocoke producing apparatus and process therefor
US20100133086A1 (en) * 2007-04-27 2010-06-03 Yoshimasa Kawami Apparatus and process for producing biocoke
US8460515B2 (en) * 2007-04-27 2013-06-11 Naniwa Roki Co., Ltd. Biocoke producing apparatus and process therefor
WO2009018550A1 (en) * 2007-08-01 2009-02-05 Gtl Energy Ltd Method of producing water-resistant solid fuels
AU2011202676B2 (en) * 2007-08-01 2012-06-28 Gtl Energy Ltd Method of producing water-resistant solid fuels
AU2008255240B2 (en) * 2007-08-01 2011-04-14 Gtl Energy Ltd Method of producing water-resistant solid fuels
US20090158645A1 (en) * 2007-08-01 2009-06-25 French Robert R Methods of Producing Water-Resistant Solid Fuels
US8673030B2 (en) * 2007-08-01 2014-03-18 Gtl Energy Holdings Pty Limited Methods of producing water-resistant solid fuels
US9499756B2 (en) 2007-08-01 2016-11-22 Gtl Energy Holdings Pty Limited Roll press
CN112877086A (zh) * 2021-01-25 2021-06-01 焦作钧菲津材科技有限公司 一种石油焦煅烧控制方法

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ES352683A1 (es) 1969-07-16
JPS5427001B1 (en:Method) 1979-09-07
GB1194962A (en) 1970-06-17
LU55886A1 (en:Method) 1968-11-27
DE1771160A1 (de) 1972-01-13
FR1587053A (en:Method) 1970-03-13
BE713700A (en:Method) 1968-08-16

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