Coal blends, foundry coke products, and related systems, apparatus, and methods

Abstract

Disclosed herein are methods and systems for coking a coal blend to produce a foundry coke product. The method for producing the coke product may include charging a coal blend to a coke oven and heating the charged coal blend so that a crown temperature of the coke oven is above a lower coking temperature limit. A pyrolysis duration begins when the oven crown is above the lower coking temperature limit and ends when the oven crown temperature is below the lower coking temperature limit.

Description

[Technical Field]

[0001] The present disclosure relates to coal blends, foundry coke products, and related systems, apparatus, and methods. [Background technology]

[0002] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims priority to U.S. Provisional Patent Application No. 63 / 382,446, filed November 4, 2022, the disclosure of which is incorporated herein by reference in its entirety.

[0003] Background technology Coke can be classified into various subcategories. Foundry coke is of very high quality, including larger size, relatively fewer impurities, and relatively higher carbon content, strength, and stability than blast furnace coke. Foundry coke is used to melt iron in foundry cupolas to produce cast iron and ductile iron products. However, foundry coke has high production costs, including manufacturing, transportation, and environmental costs. Therefore, there is a need in the art for improved production processes that can provide high-quality foundry coke at higher yields or lower costs.

[0004] Coke is a solid carbon fuel and a carbon source produced from coal used in steel production. Coal can be obtained from a combination of different coal sources and often has widely different qualities and compositions. These resources can be used as fuel or feedstock for a variety of applications, such as steel production, cement production, and power generation. Furthermore, various regulatory environments or economic incentives can create additional requirements for the coal types that a particular foundry, factory, or plant is permitted to use.

[0005] The features, aspects, and advantages of the techniques of the present disclosure may be better understood with reference to the following drawings. [Brief explanation of the drawings]

[0006] [Figure 1] 1 illustrates an exemplary schematic system for obtaining coal parameters for multiple coal types and determining a coal blend composition, in accordance with one or more embodiments of the present technique. [Figure 2] FIG. 1 illustrates an isometric partial cross-sectional view of a portion of a horizontal heat recovery coke plant in accordance with one or more embodiments of the present technique. [Figure 3] 1 is a table illustrating the volatile matter (VM) fractions of various coal types that can be used in coal blends, in accordance with one or more embodiments of the present technology; [Figure 4] 1 is a table illustrating properties associated with various coal types used in a coal blend, in accordance with one or more embodiments of the present technology; [Figure 5] 1 is a table illustrating compositions associated with various coal types used in coal blends in accordance with one or more embodiments of the present technology; [Figure 6] 10 is a table showing additional measurements associated with various coal types used in a coal blend, in accordance with one or more embodiments of the present technology; [Figure 7] 1 is a flowchart of a process for determining a composition of a coal blend in accordance with one or more embodiments of the present technique. [Figure 8] 1 is a flowchart of a process for producing a coke product using a coke oven in accordance with one or more embodiments of the present technique. [Figure 9] 1 is a chart showing the combustion profile for a blast furnace coke product operation. [Figure 10] 1 is a chart illustrating a combustion profile for a foundry coke production operation in accordance with one or more embodiments of the present technique; [Figure 11] 1 illustrates coke particles configured to be heated in a casting cupola in accordance with one or more embodiments of the present technique. [Figure 12] 1 shows a table of exemplary foundry coke products and foundry coke properties in accordance with one or more embodiments of the present technique; [Figure 13]1 is a chart illustrating foundry coke product yield in accordance with one or more embodiments of the present technique; [Figure 14] 1 is a chart illustrating particle size in accordance with one or more embodiments of the present technology. [Figure 15] 10 is a chart illustrating 4 inch drop shutter characteristics in accordance with one or more embodiments of the present technology. [Figure 16] 10 is a chart illustrating 6 inch drop shutter characteristics in accordance with one or more embodiments of the present technology. [Figure 17] 10 is a chart showing ash mass fraction in accordance with one or more embodiments of the present technology; [Figure 18] 10 is a chart showing moisture mass fraction in accordance with one or more embodiments of the present technology; [Figure 19] 1 is a chart showing sulfur mass fraction in accordance with one or more embodiments of the present technology. [Figure 20] 1 is a chart showing the mass fraction of SiO2 versus the mass fraction of Al2O3 in the ash of a foundry coke product, in accordance with one or more embodiments of the present technique; [Figure 21] 1 is a chart showing the mass fraction of Fe2O3 versus the mass fraction of CaO in the ash of a foundry coke product, in accordance with one or more embodiments of the present technique; [Figure 22] 1 is a chart illustrating ash softening temperature versus model ash melting temperature for different batches of foundry coke product, in accordance with one or more embodiments of the present technique; [Figure 23] 1 is a chart illustrating ash softening temperature versus ash mass fraction for different batches of foundry coke product, in accordance with one or more embodiments of the present technique; [Figure 24] 1 is a chart illustrating observed ash fusion temperatures versus modeled ash fusion temperatures for different batches of foundry coke products, in accordance with one or more embodiments of the present technique; DETAILED DESCRIPTION OF THE INVENTION

[0007] Those skilled in the relevant art will appreciate that the features shown in the drawings are for illustrative purposes and that variations are possible, including different or additional features and arrangements thereof.

[0008] I. Overview Foundry coke is a relatively large-sized coke of very high quality, including very few impurities and very high fixed carbon content, strength, and stability. Foundry coke is used as a carbon source to melt iron and recycled steel in cupola furnaces and produce cast iron and ductile iron products. However, foundry coke production costs, including manufacturing, transportation, and environmental costs, are high. Therefore, there is a need in the art for an improved production process that can provide high-quality foundry coke with a higher yield or at a lower cost. Conventionally produced coke typically has an ash fusion temperature (AFT) above 2650 degrees Fahrenheit (°F). This high temperature causes the ash to melt deeper in the cupola, thereby reducing the available surface area of ​​the coke exposed to the molten metal. As a result, carbon transfer to the iron is reduced.

[0009] The coke products disclosed herein for the present technology have an AFT below 2600°F and therefore melt higher in the cupola, thereby increasing the amount of carbon surface exposed to the molten metal. Additionally, from a viscosity standpoint, the low AFT allows the molten ash to move through the carbon layer more quickly, improving phase separation in the well section of the cupola and allowing more carbon to come into contact with the molten metal. As used herein, the term "molten metal" refers to molten iron, molten steel, or the final molten mixture of molten iron and molten steel.

[0010] AFT can be obtained in various ways and can be divided into different types of AFT. In some embodiments, AFT can be measured from a sample of ash created by the complete combustion of coal, coal blends, or coke products. Elemental analysis of ash can be performed element by element, where, for example, individual silicon atoms generate a signal in an analytical instrument. To obtain mass percentage values ​​used in model ash fusion calculations, some embodiments of the present technology can treat all elements as fully oxidized and determine mass percentages based on the oxidation form. For example, some embodiments of the present technology can determine the mass of SiO but not the mass of Si. In some embodiments, mass percentages of SiO, AlO, FeO, CaO, other compounds, etc., can be normalized to add up to 100%.

[0011] Alternatively or additionally, AFT may be measured by an AFT test, such as standard American Society for Testing and Materials (ASTM) method D1857. For example, some embodiments of the present technology may determine the initial deformation temperature (IDT), softening temperature (ST), hemispherical temperature (HT), and flow temperature (FT). These measured temperatures may have different values ​​relative to one another and may be used to characterize a particular coal, coal blend, or coke product. Furthermore, as discussed elsewhere, the composition of the ash remaining from the combustion of a coal or coal blend is considered to be the same as the ash remaining after the combustion of a coke product produced from that coal or coal blend. Some embodiments may characterize the ash composition of a coal blend as a weighted average of the ash compositions of the coal components, weighted by their respective mass fractions in the coal blend.

[0012] Additionally, conventional operations can also add CaCO3-containing rock to the charge to be used as a flux to remove ash. The CaCO3 either penetrates the ash and reduces the AFT, or the ash itself dissolves in the CaCO3-containing rock. This is an inefficient method of introducing fluxing agents, given the very low surface area-to-volume ratio for fluxing to occur. Based on the unexpected discovery of the impact of low AFT on desired carbon transport disclosed herein, the coke can be "pre-fluxed" by selecting a coal or coal blend with a relatively high ash content of low-melting oxides, such as CaO, MgO, Fe2O3, Na2O, and KO, relative to the high-melting oxides, Al2O3 and SiO2.

[0013] In casting cupolas, coke is used as a fuel and carbon source to produce cast iron. Coke serves four functions in the cupola: (1) providing heat from combustion to melt the iron or steel, (2) supplying carbon to the iron, (3) providing structural support to the iron or steel charge, and (4) creating a gas-permeable layer that allows gases to migrate upward and spread, providing good contact with the iron or steel.

[0014] Some embodiments may perform the operations described herein to produce a coke product that allows for a higher rate of carbon transfer to the iron or steel during the casting operation, which may improve cupola performance. Some embodiments may use one of various types of furnaces to produce the coke product, such as a heat recovery furnace, a non-recovery furnace, a Thompson furnace, another type of horizontal furnace, a vertical by-product furnace, etc.

[0015] II. Coal Blends for Producing Foundry Coke Products and Related Systems and Methods Some embodiments of the present technology may perform operations to increase the efficiency of coke product production operations in ways that can reduce energy consumption and increase yields. These operations may include determining the composition of a coal blend used to produce the coke product, which may include coals from different coal sources. Some embodiments may select specific coals for their VM content, where VM content and distribution may determine the impact on coke product yield, coke product properties, etc. Some embodiments may also perform specific processes in producing the coke product in the coke oven, which may include opening and closing coke oven valves to maintain certain temperature relationships within sections of the coke oven. These processes may result in a coked product that is unique compared to other coked products in terms of reactivity, size, or other properties.

[0016] FIG. 1 illustrates an exemplary system 100 for obtaining coal parameters for multiple coal types 112, 113, 114, and 116 (collectively referred to as “coals 110”) and for determining the composition of a coal blend 140, according to one or more embodiments. Various facilities and equipment may be used to blend the coals 110 from various sources to form the coal blend 140. In some embodiments, not all of the coal types illustrated in FIG. 1 are used to form the coal blend 140 (e.g., only coal type A 112 and coal type B 113 are used). Each of the coals 110 may be tested using a coal parameter measurement system 120 to determine coal parameters, such as VM mass fraction, measured ash composition, measured sulfur composition, inert matter composition, etc. Some embodiments may also use other coal properties, such as the fluidity of tar in the coal, and the AFT, vitrinite reflectance, etc., of the coal, when selecting the coal types or amounts to use in the coal blend. Alternatively or additionally, some embodiments of the present technology may obtain coal parameters from a third-party data source (e.g., a database application program interface (API), or manual user input on an input device such as a keyboard or touch screen).

[0017] In some embodiments, the coal parameters may take into account measurements of reactive components or subtypes of reactive components, such as vitrinite, liptinite, and reactive semifugenite. The coal parameters may also include measurements of, or select amounts of, inert materials to include in the coal blend, such as breeze, inert semifugenite, fugenite, macrinite, and mineral matter. In some embodiments, the inert material content of the coal blend may be 32.0% or greater, or may be limited to a specific range, such as 28.0%-40.0%, or 33.0%-35.0%. Some embodiments may determine the types and amounts of coal, breeze, and other components of the coal blend to meet target coal blend parameters or a corresponding set of target coke blend parameters, such as target coal blend parameters indicative of a high-strength homogeneous coke. For example, some embodiments of the present technology may select the type of vitrinite present in the coal blend, which may include one or more of V9, V10, V11, V12, V13, V14, V15, V16, V17, V18, and V19.

[0018] After obtaining the coal parameters for the coal 110, some embodiments of the present technology may determine a combination of coal types for the coal 110. For example, a first combination of coal types may include 20% coal type A 112, 30% coal type B 113, 40% coal type C 114, and 10% coal type D 115. Some embodiments may represent each combination of coal types as a vector in an n-dimensional blending space, where "n" may represent an integer equal to or less than the number of available coal types that can be used to create the coal blend. For example, some embodiments of the present technology may represent the first combination as a vector [0.2, 0.3, 0.4, 0.1] to represent a blending point, where the blending point may indicate the amount of each coal corresponding to the amount of each coal in the coal blend. Additionally, some embodiments of the present technology may add additives to the coal blend. Such additives may include calcium oxide, limestone, calcium-containing materials, trona, soda ash, caustic soda, slag (e.g., low-ash melting slag, basic oxygen furnace (BOF) slag, cupola slag, etc.), iron, nickel, potassium, magnesium, sodium, calcium sulfate, rock wool, biochar, or biomass (e.g., low-AFT biomass). Alternatively or in addition, some embodiments of the present technology may add mineral additives such as dolomite, various other calcium-, iron-, magnesium-, or sodium-containing minerals. Some embodiments may use metal oxides such as Al2O3, SiO2, Fe2O3, MgO, Na2O, or TiO, transition metal oxides, or calcined minerals as additives to the coal blend. Some embodiments may add metal halide additives such as CaCl2, MgCl2, or NaCl. Some embodiments may add metal sulfate additives such as CaSO4 to the coal blend. Some embodiments may add aluminum or silicon mineral additives, such as quartz, muscovite, or feldspar, to the coal blend.Some embodiments may add additives derived from industrial waste or recycled streams, such as blast furnace slag, foundry cupola slag, metal fines, wallboard waste, flue gas desulfurization plant gas by-products (e.g., fly ash), coal-fired plant fly ash, heat recovery steam generator wash mud, or unwashed coal.

[0019] After the additive is added, the coal blend may have a calcium mass fraction, lime mass fraction, trona mass fraction, soda ash mass fraction, caustic soda mass fraction, low ash fusion slag mass fraction, BOF slag mass fraction, cupola slag mass fraction, iron mass fraction, nickel mass fraction, potassium mass fraction, magnesium mass fraction, sodium mass fraction, calcium sulfate mass fraction, rock wool mass fraction, biochar mass fraction, biomass mass fraction, or mass fraction of another additive that is greater than 0% but less than a predetermined threshold. The threshold may vary based on the particular embodiment and may be configured such that the mass fraction of the additive is less than 10.0%, less than 5.0%, less than 3.0%, less than 1.0%, etc. By using small amounts of additive, some embodiments of the present technology may significantly reduce ash fusion values ​​or other properties and increase the efficiency of the coke product. Alternatively or additionally, some embodiments of the present technology may include a greater amount of additive, in which case the coal blend may include more than 10.0% additive. For example, some embodiments of the present technology may use an additive with a calcium oxide mass fraction of more than 70.0%, in which case the inclusion of the additive may increase the calcium oxide mass fraction of the coal blend to more than 10.0%. Unless otherwise specified, the mass fraction of an element may refer to the element itself, a compound containing the element, or both. For example, the calcium mass fraction may refer to the mass fraction of calcium alone in a material, the mass fraction of calcium oxide, or the mass fraction of another calcium-containing compound, or the total mass fraction of any combination thereof, etc.

[0020] The VM of coal often contains vitrinite, which can be classified based on its reflectance or other physical properties. Some systems can classify vitrinite by vitrinite types V8 to V18, and different coals can contain different distributions of vitrinite types. As used in this disclosure, high-volatile coal can be characterized as having a VM mass fraction greater than a VM mass fraction threshold, in which case different systems can use different thresholds to define high-volatile coal. For example, some embodiments of the present technology can characterize high-volatile coal as coal having a VM mass fraction that is 28.0% or greater. Some embodiments can use other VM mass fraction thresholds to characterize high-volatile VM, such as 25.0%, 27.0%, 30.0%, 31.0%, or some other threshold greater than or equal to 25.0%.

[0021] As used herein, low-volatile coal can be characterized as having a VM mass fraction below a VM mass fraction threshold, where different thresholds can be used to define low-volatile coal depending on the system. For example, some embodiments of the present technology can characterize low-volatile coal as coal with a VM mass fraction of 20.0% or less, although different values ​​other than 20%, such as 14.0%, 15.0%, 17.0%, 21.0%, etc., can be used. Some embodiments of the present technology can use other VM mass fraction thresholds to characterize high-volatile VM as VM above the mass fraction threshold. The mass fraction threshold can be equivalent to values ​​such as 14.0%, 15.0%, 21.0%, 22.0%, 23.0%, or some other threshold equal to or less than 25.0%.

[0022] Some embodiments of the present technology may characterize or partially characterize low-volatile coal relative to high-volatile coal by using a predetermined difference, where the predetermined difference may be a value greater than 1.0%, such as 2.0%, 3.0%, 4.0%, 8.0%, or some other value. For example, some embodiments of the present technology may set the difference between a first threshold used as the high-volatile coal threshold and a second threshold used as the low-volatile coal threshold as equal to 4.0%, where selecting 30% as the first threshold may cause the system to automatically select 26% as the second threshold. Alternatively, some embodiments of the present technology may determine or enable an alternative value to be the second threshold, such as 21%. By setting the thresholds used to define high-volatile and low-volatile coals or defining the difference between the two thresholds, some embodiments of the present technology may also automatically define medium-volatile coal as coal that is neither high-volatile nor low-volatile coal.

[0023] This disclosure refers to the AFT of a coal blend or coke product. The AFT of a coke product may be determined in various ways, such as by experimental observation (observed AFT) or by using an empirical model (model AFT). Unless otherwise specified, the term "ash fusion" can refer to either an empirical model of ash fusion or observed ash fusion. As discussed elsewhere, the AFT may be 2600°F or less, 2450°F or less, 2400°F or less, 2350°F or less, 2300°F or less, 2250°F or less, 2200°F or less, 2150°F or less, 2100°F or less, 2050°F or less, 2000°F or less, 1950°F or less, 1900°F or less, 1850°F or less, or 1800°F or less.

[0024] In some embodiments, empirical models of AFT can be determined from residual compounds in the ash generated from the combustion of a coke product. When the value of AFT is constrained to a range, these empirical models can help form compositional boundaries in a multidimensional compositional parameter space. The compositional parameters in the parameter space can represent the amounts of elements or compounds within a material or group of materials, and the amounts can include mass fractions, volume fractions, etc. of the corresponding compounds. By using different empirical models or different ranges for AFT, some embodiments constrain the ash content of a coke product to different regions of the compositional parameter space, which can then constrain the composition of the coke product itself. For example, the empirical model of ash fusion can be defined by Equations 1-3 below: where "AFT" can be the model ash fusion temperature in degrees Celsius (°C), "SiO2_mass_fraction" can be the mass fraction of SiO2 in the ash of the coke product ("coke product ash content"), "Al2O3_mass_fraction" is the mass fraction of Al2O3 in the coke product ash, "Fe2O3_mass_fraction" is the mass fraction of Fe2O3 in the coke product ash, "CaO_mass_fraction" is the mass fraction of CaO in the coke product ash, "MgO_mass_fraction" is the mass fraction of MgO in the coke product ash, and "K2O_mass_fraction" is the mass fraction of K2O in the coke product ash:

[0025]

number

[0026] Some embodiments may apply different models based on different compositions. For example, based on determining that the mass fraction of Al2O3 and SiO2 in the ash composition of a coal blend is 65% to 80%, some embodiments of the present technology may calculate the model AFT using Equation 3, while in other cases, they may calculate the model AFT using Equation 2. Some embodiments may use different models for different optimization operations. For example, some embodiments of the present technology may use Equation 3 to optimize a coal blend selected for coke production to have a lower content of Al2O3 and SiO2 and a higher content of Fe2O3 and CaO. Furthermore, some embodiments of the present technology may use a known model AFT, while some embodiments of the present technology may use a new model AFT equation. For example, some embodiments of the present technology may determine the AFT using Equation 1, which can be found in Chapter 8 of the Cupola Handbook, 6th ed., (c) 1999, American Foundrymen's Society, Inc., incorporated herein by reference. Some embodiments of the present technology may use other AFT models, such as those described by Equation 2 or Equation 3. Various other limits may be placed on the mass fractions of the components of the coal blend. For example, some embodiments of the present technology may produce coal blends in which the alumina Al2O3 content of the ash of the coal blend is less than 10.0%, less than 7.0%, less than 6.0%, less than 5.0%, etc.

[0027] By constraining the AFT to specific boundaries, some embodiments of the present technology can limit the composition of the ash. In some embodiments, the specific boundaries can encompass temperature ranges, such as 982°C (1800°F) to 1204°C (2200°F), 1204°C (2200°F) to 1426°C (2600°F), or 982°C to 1426°C. If the ash is an ash product produced by combustion of a coke product, the limitations on the composition of the ash impose constraints on the coke product itself. For example, some embodiments of the present technology can produce a coke product with certain amounts of Al, Si, Ti, Ca, Mg, Fe, Na, or K such that combustion of the coke product results in an ash having a composition that satisfies Equation 2. Various compositional boundaries for the ash content of the coke product can be used. For example, some embodiments of the present technology can produce a coke product such that the model AFT of the coke product, as determined by Equation 3, is within the AFT boundaries. For example, the AFT boundary can be a temperature range of 1260° C. (2300° F.) to 1427° C. (2600° F.), 1260° C. to 1371° C. (2500° F.), 1260° C. to 1316° C. (2400° F.), or 1260° C. to 1427° C. In some embodiments, the lower temperature limit can be a different value, such as 982° C. (1800° F.) or a value less than 1288° C., such as 816° C. (1500° F.), 649° C. (1200° F.), or some other value less than 1288° C.

[0028] Additionally, some embodiments of the present technology may constrain the AFT to be approximately a target value, where a parameter is approximately a target value if the parameter is within 10% of the absolute value of the target value. For example, some embodiments of the present technology may constrain the AFT to approximately 982°C (1800°F), 1204°C (2200°F), 1260°C (2300°F), 1288°C (2350°F), 1316°C (2400°F), 1343°C (2450°F), 1371°C (2500°F), 1399°C (2550°F), or 1427°C (2600°F).

[0029] In some embodiments, the composition of the coal blend may include idiosyncrasies such as an ash fusion value of 2400°F or less, which corresponds to less than 1316°C. Some embodiments may recommend or produce coal blends that include low VM and high VM mass fraction coals, without necessarily including any mid-VM mass fraction coals. For example, a coal blend may have a bimodal profile of high VM and low VM coals within the coal blend. In such a bimodal profile, the coals of the coal blend may include only first and second sets of coals, where the first set of coals of the coal blend may include only high VM coals with a VM mass fraction greater than 30.0%, and the second set of coals of the coal blend may include only low VM coals with a VM mass fraction less than 22.0%.

[0030] Some embodiments may map the blending point to a corresponding coal parameter point ("coal parameter point") in a coal parameter space, where each dimension in the coal parameter space may represent a coal parameter. In some embodiments, the dimension of a coal parameter point may be determined as a linear combination of coal 110 weighted by the value of the corresponding blending point. For example, a coal blend may include a two-coal blend including 50% coal type A 112 and 50% coal type B 113. If coal type A 112 has a VM mass percentage equal to 15% and coal type B has a VM mass percentage equal to 25%, then the VM mass percentage of the coal blend may correspond to the average of these two VM mass percentages, i.e., 20%.

[0031] Some embodiments may obtain a set of target coal parameters, where the target coal parameters may be provided as default values, provided by manual data entry, obtained from a third-party data store, provided via an electronic message, etc. For example, the target coal parameters may include a coke reactivity index (CRI) or coke strength after reaction (CSR) value. In some embodiments, the CRI or CSR may be manually entered by a user, obtained from a database, received via an API, etc. Some embodiments may use a model based on the set of coal parameters to determine a corresponding set of coke parameters. The model may include a statistical model, a semi-empirical analytical model, a neural network model, a physical simulation model, etc. As described elsewhere in this disclosure, some embodiments of the present technology may use a model that accounts for nonlinear relationships between coal parameters and coke parameters. For example, some embodiments of the present technology may use a neural network, e.g., a feedforward neural network, to predict the set of coke parameters.

[0032] In some embodiments, the neural network can be trained with historical data. For example, some embodiments of the present technology can train a neural network based on past blends and the results of those blends, which may include coke properties such as CSR, weight loss percentage, CRI, or another coke parameter that is nonlinear with respect to the associated coal parameters. Alternatively, or in addition, some embodiments of the present technology can predict coke parameters using analytical physics-based models or semi-analytical models. The use of neural networks, or other nonlinear methods, to predict coke parameters based on coal parameters can be advantageous due to the nonlinear effects associated between coal and coke parameters. Additionally, some embodiments of the present technology can provide additional inputs to the neural network model, such as breeze parameters, the amount of breeze used, etc.

[0033] Some embodiments can adapt to changes in the availability of different coal types. For example, a source mine for coal type A 112 may close, a transportation line carrying coal type A 112 may experience significant delays, a regulatory environment may make the use of a particular coal impractical, etc. In response to determining that a coal type used in a coal blend is unavailable or expected to become unavailable, some embodiments of the present technology can generate an alternative coal blend formulation located at a location in the coal parameter space that is within a distance threshold of a first point in the coal parameter space. For example, some embodiments of the present technology can initially use a first coal blend that is 20% by weight of coal type A, which is located at a first point in the coal parameter space that includes a VM ratio of 25% by weight, a sulfur ratio of 0.4% by weight, and an ash ratio of 6% by weight, etc. After receiving a message indicating that coal type A is limited to 5% (e.g., as a result of inventory reduction), some embodiments of the present technology can perform a series of operations to determine one or more additional combinations that satisfy the coal type usage restriction and the coal parameter space. If the first coal parameter point is not achievable, constrained by coal type availability, some embodiments of the present technology may determine an alternative coal blend formulation located at a coal parameter point within a threshold coal parameter spatial distance of the first coal parameter point.

[0034] Some embodiments may use the blending point to determine the blend and process of additional coals for the coal blend 140. For example, some embodiments of the present technology may use operations described herein to determine a blending point that indicates a coal blend including 20% ​​coal type A 112, 30% coal type B 113, 40% coal type C 114, and 10% coal type D 115, and integrate these respective proportions of coal into the coal blend 140. Some embodiments may then feed the blended coals to a coke oven 150, where some embodiments of the present technology may add coke breeze 111 to the coke oven 150 to create a coke product with similar or the same coke properties as a target set of coke properties.

[0035] 2 illustrates an isometric, partial cross-sectional view of a portion of a horizontal heat recovery coke plant in accordance with one or more embodiments of the present technology. A furnace 200 of the coke plant may include various ducts, chambers, valves, sensors, or other components. For example, the furnace 200 may include an open cavity defined by a hearth 202, a pusher-side furnace door 204, a coke-side furnace door 206 opposite the pusher-side furnace door 204, opposing sidewalls 208 extending upward from the hearth 202 and between the pusher-side furnace door 204 and the coke-side furnace door 206, and a furnace crown 210 forming an upper surface of the open cavity of a furnace chamber 212. Additionally, the furnace 200 may include a set of crown inlets 214 that admit primary combustion air into the furnace chamber 212. In some embodiments, the set of crown inlets 214 may penetrate the furnace crown 210 and allow open fluid communication between the furnace chamber 212 and an environment outside the furnace 200. In some embodiments, airflow through an air inlet or air duct (e.g., intake duct) can be controlled by a damper that is configured in one of several states between fully open and fully closed to vary the airflow. For example, the crown air inlet 214 can include a damper, such as a similarly operating crown inlet air damper 216, that can be configured in different states to admit airflow into the furnace crown 210. While embodiments of the present technology can use only the crown air inlet 214 to supply primary combustion air into the furnace chamber 212, certain embodiments can use other types of air inlets, such as door air inlets, without departing from aspects of the present technology.

[0036] As mentioned above, control of ventilation within furnace 200 or other operations within furnace 200 may be performed by a control system. Such operations may include operating a coking cycle, which may include loading a coal blend into furnace 200, controlling intake damper 236 to be configured in any one of several states between fully open and fully closed, etc. Upon completion of the coking cycle, some embodiments of the present technology may coke the coal blend to produce a coke product useful in producing steel in a cupola furnace. In some embodiments, the foundry coke product may be used in a cupola furnace using the operations described in U.S. Application No. 18 / 052,739, entitled "FOUNDRY COKE PRODUCTS AND ASSOCIATED SYSTEMS AND PROCESSING METHODS VIA CUPOLAS," the disclosure of which is incorporated herein by reference as Appendix A. In some embodiments, the coke product may be removed from the furnace 200 through a coke side furnace door 206 by a pusher ram or another mechanical extraction system. In some embodiments, the coke may be quenched (e.g., wet or dry quenched) and sectioned before being delivered to a user.

[0037] FIG. 3 is a table illustrating the volatile matter (VM) fractions of various coal types that can be used in coal blends, according to one or more embodiments of the present technology. The vitrinite content for various coal types and their corresponding classifications are shown in table 300. The coals listed in row 301 include coal types "T1," "T2," "T3," "T4," "T5," "T6," "T7," and "T8." As shown by table 300, some coals can be considered low-volatile coals, where the low-volatile coal contains primarily vitrinite with low volatility, e.g., vitrinite V14, V15, V16, V17, or V18. As shown by table 300, some coals can be considered high-volatile coals, where the high-volatile coal contains primarily vitrinite with high volatility, e.g., vitrinite V8, V9, or V10. Some coals can be considered medium-volatile coals, where the medium-volatile coals primarily contain vitrinites having volatilities that are not considered high or low volatile, e.g., vitrinite V11, V12, or V13.

[0038] As described elsewhere in this disclosure, some embodiments of the present technology may select a coal blend that includes primarily high-volatile or low-volatile coals. For example, some embodiments of the present technology may determine, recommend, or select the coals shown in Table 300 for inclusion in a coal blend, where the selected coals include low-volatile coals T1 and T2 and high-volatile coals T8 and T9. The low-volatile coals shown in columns 311-312 may be characterized by relatively high amounts of low-volatile vitrinite, e.g., V15 vitrinite and V16 vitrinite, compared to high-volatile vitrinite, e.g., V13 vitrinite. Similarly, the high-volatile coals shown in column 313 may be characterized by relatively high amounts of V8, V9, and V10 vitrinite compared to the vitrinite of the other coals.

[0039] As described elsewhere in this disclosure, some embodiments of the present technology may produce unique coal blends by excluding medium-volatile coals from the coal blend to increase the yield of coke products produced using the coal blend. Such coal blends may be unique in that they lack medium-volatile coals, despite conventional methods of producing and using coal blends that include medium-volatile coals due to conventional assumptions regarding the need for medium-volatile coals to balance vitrinite during the pyrolysis reactions that produce coke. For example, a coal blend may include high-volatile and low-volatile coals. The high-volatile coal may have a high-volatile vitrinite fraction such that a majority of the vitrinite fraction is composed of high-volatile vitrinite, with the sum of the V8, V9, V10, and V11 vitrinite fractions exceeding 50%. The low-volatile coal may have a low-volatile vitrinite fraction such that a majority of the vitrinite fraction is made up of low-volatile vitrinite, with the sum of the V14, V15, V16, V17, and V18 vitrinite fractions being greater than 50%. As used in this disclosure, the V16 vitrinite fraction (which may include having a volume fraction greater than 50%, a mass fraction greater than 50%, etc.), where the vitrinite fraction can be relative to the total maceral content of the coal or the total mass of the coal.

[0040] In some embodiments, the coals in the coal blend may have different ash fusion values, as shown in table 400. As shown elsewhere in this disclosure, the ash fusion of the product may be lower in the coal blend compared to one or more of the constituent coals of the coal blend. For example, as described elsewhere herein, a coal blend including coal types T1, T2, and T9 may have an ash fusion value different from any of these values. As discussed elsewhere in this disclosure, some embodiments of the present technology may consider various coal parameters when determining the mixture of coals for a coal blend. For example, some embodiments of the present technology may obtain coal parameters for a set of coal types T1-T9, as shown in table 400. Some embodiments may then determine the amount of coal, breeze, or other additives for the coal blend. For example, some embodiments of the present technology may obtain a set of sulfur values ​​shown in row 413 of table 400 and a set of ash fusion values ​​shown in row 420. Some embodiments may then obtain target ash fusion values ​​as target coal blend parameters and determine a coal blend composition from coals T1-T9.

[0041] As described elsewhere in this disclosure, some embodiments of the present technology may constrain or otherwise limit the coals used to low-volatile or high-volatile coals, without using medium-volatile coals. For example, if coal type T1 is a low-volatile coal, coal type T5 is a medium-volatile coal, and coal type T9 is a high-volatile coal, some embodiments of the present technology may limit the use of coal type T5 when determining which coals to use in a coal blend. Furthermore, some embodiments of the present technology may limit or require the use of coal of a specific coal type. For example, some embodiments of the present technology may receive instructions requiring the use of coals having a VM mass fraction between 0% and 20%, thereby restricting the coal blend to include at least one coal from coal type T1 or coal type T2. Furthermore, some embodiments of the present technology may obtain multiple target coal blending parameters, or a range or ranges of target coal blending parameters. Some embodiments may provide a corresponding number of possible coal combinations of different coal types that meet these target coal blending parameters or a set of ranges of coal blending parameters.

[0042] FIG. 4 is a table illustrating properties associated with various coal types used in a coal blend, according to one or more embodiments of the present technology. As shown in table 400, coals of different coal types can have different properties, in which case some embodiments of the present technology can use the properties as coal parameters for use in meeting target parameters. For example, some embodiments of the present technology can receive program instructions to meet target parameters representing a required VM for a coal blend. In response, some embodiments of the present technology can determine a range of VM values, represented by row 411 of table 400, that meets the required VM or range of required VM values ​​for the coal blend. Some embodiments of the present technology can perform similar operations for each of the coal properties listed in rows 411-428.

[0043] FIG. 5 is a table illustrating compositions associated with various coal types used in a coal blend, according to one or more embodiments of the present technology. As shown in table 500, coal from different coal types may have different compositions. Some embodiments may use material composition as a coal parameter for use in meeting target coal parameters. For example, some embodiments of the present technology may receive program instructions to meet target coal parameters that represent a required calcium oxide value or range of calcium oxide values. In response, some embodiments of the present technology may determine a range of coal compositions for coal types T1-T9 that meet the required calcium oxide value or range of calcium oxide values.

[0044] 6 is a table showing additional measurements associated with various coal types used in a coal blend, in accordance with one or more embodiments of the present technology. As shown in table 600, a coal blend may contain a variety of compounds. Due to heterogeneity and sources of variation within the coal source, a coal blend with the same proportions of the same coal types may result in different sample values ​​for each coal blend sample tested.

[0045] FIG. 7 is a flowchart of a process for determining a coal blend formulation according to one or more embodiments of the present technology. Some embodiments may obtain a set of coal parameters for a set of available coals, as indicated by block 704. As described elsewhere, coal parameters may include various properties or compositions associated with a particular coal type. For example, a coal blend may include relative or absolute measures of VM, ash, sulfur, total inerts, mineral matter, model AFT, AFT ST value, AFT HT value, solidification temperature, expansion, the amount of a particular type of volatile matter (e.g., the amount of V8 vitrinite, V9 vitrinite, etc.), or other coal parameters. Some embodiments may obtain the coal parameters from user input, from a historical record of values ​​stored in a database, from an application program interface (API), etc.

[0046] Some embodiments of the present technology may derive a set of target coal blending parameters, as indicated by block 708. For example, some embodiments of the present technology may derive the target coal blending parameters based on input provided by a user via a graphical user interface (GUI). Alternatively, or in addition, some embodiments of the present technology may derive the target coal blending parameters from a saved configuration file, a record of historical values, or an API. Some embodiments may estimate, predict, or otherwise determine the target coal blending parameters from the target coke parameters. For example, some embodiments of the present technology may derive target reactivity and sulfur mass fraction as target coke parameters. Some embodiments may then provide the target coke parameters to a machine learning predictive model to determine the set of target coal blending parameters.

[0047] Some embodiments of the present technology may determine a coal blend formulation based on a set of coal parameters and a set of target coal blend parameters, as indicated by block 712. Some embodiments may determine a percentage or other type of ratio indicating the amount of coal types to use in the coal blend by manipulating the coal types and amounts of coal to use to conform to a set of target coal parameters. For example, some embodiments of the present technology may receive program instructions or parameters in a configuration file indicating target coal parameters for a target VM content. Some embodiments may then perform a set of operations to calculate a blending point representing a mixture of different coals corresponding to different coal types. For example, some embodiments of the present technology may perform an optimization operation to determine regions in the coal parameter space that can be filled by selecting different coals from a set of available coals.

[0048] Some embodiments of the present technology may limit the determination of coal blends to include medium-volatile coals, such as coals having a VM mass fraction where V11, V12, or V13 vitrinite is the major component of the VM mass fraction or maceral content of the coal blend. For example, some embodiments of the present technology may first receive target coal parameters indicating a target VM mass fraction of 0.25, or some other value, such as 10%, 20%, 25%, or more. Some embodiments may then explore the coal parameter space formed by possible mixtures of different coal types to meet this target VM mass fraction, which may include low-volatile or high-volatile coal types while excluding medium-volatile coal types. Some embodiments may determine a coal blend formulation such that the mass fraction of low-volatile coal in the coal blend is equal to or greater than a first mass fraction threshold and the mass fraction of high-volatile coal in the coal blend is equal to or greater than a second mass fraction threshold, which may be equal to or greater than 50% and which may be equal to or less than 50%. For example, some embodiments of the present technology may determine the composition of a coal blend such that the mass fraction of low-volatile coal in the coal blend is 60% or greater and the mass fraction of high-volatile coal in the coal blend is 15% or greater. Alternatively, or in addition, some embodiments of the present disclosure may determine the composition of a coal blend such that the mass fraction of high-volatile coal in the coal blend is greater than or equal to a first mass fraction threshold and the mass fraction of low-volatile coal in the coal blend is greater than or equal to a second mass fraction threshold, where the first mass fraction threshold may be greater than or equal to 50% and the second mass fraction threshold may be less than or equal to 50%. For example, some embodiments of the present technology may determine the composition of a coal blend such that the mass fraction of high-volatile coal in the coal blend is 60% or greater and the mass fraction of low-volatile coal in the coal blend is 15% or greater.

[0049] As described elsewhere in this disclosure, a low-volatility coal type can have a corresponding volatility equal to or less than a first volatility threshold, and a high-volatility coal type can have a corresponding volatility equal to or greater than a second volatility threshold, which can be less than the second volatility threshold. Referring to Figure 3, some embodiments of the present technology can produce a coal blend formulation, showing a coal blend including Breeze, coal type T1, coal type T2, and coal type T9. However, despite this unusual coal blend mixture, some embodiments of the present technology can produce a resultant coke product with an ash fusion value within useful parameter ranges, e.g., an ash fusion value equivalent to 2526°F, or an improved CRI, e.g., a CRI of 30% or greater, 35% or greater, or 40% or greater.

[0050] As described elsewhere in this disclosure, some embodiments of the present technology may recommend a coal blend containing coke breeze. Some embodiments may select coke breeze or the amount of coke breeze to include based on breeze parameters related to the coke breeze. For example, some embodiments of the present technology may obtain the VM mass fraction of the breeze, the ash mass fraction of the breeze, or the sulfur mass fraction of the breeze. Some embodiments may then determine the amount of coke breeze to include in the coal blend based on the obtained set of breeze parameters. In some embodiments, the amount of coke breeze to include in the coal blend may range from 1% to 20% coke breeze, although other ranges are possible. For example, some embodiments of the present technology may recommend a coal blend containing 10% coke breeze based on a determination that this amount of coke breeze, in combination with other coals, satisfies a set of target coal blend parameters.

[0051] Some embodiments of the present technology may determine a coal blend having a relatively high ash mass fraction. While some embodiments of the present technology may use a low ash mass fraction (e.g., less than 10.0%) in the coal blend, some embodiments of the present technology may recommend formulating a coal blend having an ash mass fraction of 10.0% or more, where an ash mass fraction greater than 10.0% may be considered a high ash content for the coal blend. For example, some embodiments of the present technology may determine a coal blend having an ash mass fraction of 10.0%, 11.0%, 15.0%, or 20% or more. By increasing the use of ash in the coal blend, some embodiments of the present technology may increase the effective strength of the coke product produced from the coal blend. Furthermore, recycling the ash by-product from the coking operation improves the resource efficiency of operations for producing coke products from coal blends by reducing reliance on additional additives for the coal blend.

[0052] Some embodiments of the present technology may recommend blending coal blends containing coke breezes limited to a particular size or size range. For example, some embodiments of the present technology may recommend blending a first coal blend containing coke breezes limited to 10 mesh coke breezes or larger, or blending a second coal blend containing coke breezes limited to 20 mesh coke breezes or larger. In some embodiments, blending of different coal blends may be recommended, where size restrictions may be negatively correlated with the amount of coke breezes recommended to be included in the coal blend blend. For example, some embodiments of the present technology may limit a coal blend to use coke breezes characterized by 10 mesh coke breezes or larger, such that less than 5.0% of the coke breezes used are characterized by 10 mesh coke breezes or larger. Alternatively, or in addition, some embodiments of the present technology may use a coke breeze characterized as having a 20 mesh coke breeze or larger, such that less than 10.0% of the coke breeze used is characterized as a 20 mesh coke breeze or larger. Alternatively, or in addition, some embodiments of the present technology may use a coke breeze characterized as having a 90 mesh coke breeze or smaller, such that less than 10.0%, less than 15.0%, or less than 25.0% of the coke breeze used is characterized as a 90 mesh coke breeze or smaller.

[0053] As described elsewhere, some embodiments of the present technology may determine a coal blend formulation including multiple coal types, e.g., first, second, and third coal types. Some embodiments may select the coal types to use using an optimization operation that satisfies one or more target coal blend parameters, where these optimization operations may compensate for limitations in coal availability, coal amounts, or coal variations between different coal batches. For example, some embodiments of the present technology may recommend a coal blend having a first amount of a first coal and a second amount of a second coal. The first coal may be a low-volatile coal such that the mass fraction of V16 vitrinite is greater than 25% of the total VM mass fraction of the first coal, and the second coal may be a high-volatile coal such that the sum of the more volatile vitrinite fractions, e.g., the sum of the fractions of V8 vitrinite, V9 vitrinite, and V10 vitrinite, is greater than 40% of the total VM mass of the second coal. Some embodiments of the present technology may use 40% as the threshold, although other values ​​are possible, such as 50%, 60%, 70%, or some other percentage above 40%.

[0054] While VM content is a major consideration for coal blend formulation, other properties, such as ash fusion value, sulfur mass fraction, calcium mass fraction, or ash mass fraction, may also be considered for the coal blend. For example, some embodiments of the present technology may provide a coal blend formulation in which the coal blend exhibits a sulfur oxide mass fraction greater than 5.0% or a calcium oxide mass fraction greater than 5.0%. As discussed elsewhere in this disclosure, some embodiments of the present technology may benefit from using a coal blend with higher reactivity or larger dimensions to offset elevated calcium or sulfur values. By increasing the values ​​of components such as sulfur or calcium during coal blend formulation, some embodiments of the present technology may provide additional robustness that was not feasible in previous coal blending operations because the coal blends produced from those operations had calcium or sulfur contents that may have been too high for casting operations. Furthermore, while some target properties may be compositional, some properties may be based on other physical phenomena. For example, some embodiments of the present technology may produce coal blends having a fluidity between 100 divisions per minute (ddpm) and 1200 ddpm, or some other fluidity range, such as between 200 ddpm and 1200 ddpm. Other fluidity ranges for the coal blends are also possible. For example, the fluidity of the coal blend may be 100 ddpm or greater.

[0055] As described elsewhere, some embodiments of the present technology may use a coke oven to produce a coke product or a group of coke products from a coal blend. As used in this disclosure, the ash fusion of a coal blend may be equal to the ash fusion of a coke product produced from the coal blend, and these two terms may be used interchangeably. Some embodiments may recommend a coal blend having an AFT within a range. For example, some embodiments of the present technology may recommend a coal blend having an AFT equal to 2326°F, or another temperature that is less than 2500°F, or another AFT threshold. In some embodiments, the AFT threshold may vary based on other target coke product parameters. In many cases, a coal blend may be used to produce a coke product with a relatively low ash fusion. In this case, low ash fusion may provide benefits downstream of the casting operation, requiring fewer casting resources or less coke product to produce steel or other cast products.

[0056] Various types of optimization algorithms can be used to determine blending points for coal blends of various components to meet target coal blend parameters when limited within a parameter space of coal parameters. Some embodiments can use a linear solver to determine a vector representing a blending point in the parameter space. For example, the set of coke parameters can include a first subset of coke parameters and a second subset of coke parameters, where the first subset of coke parameters is nonlinear with respect to any parameter in the coal parameter space and the second subset of coke parameters is linear with respect to at least one coal parameter. Some embodiments can determine the blending point using lower-upper (LU) decomposition of a matrix representing the coal parameters to solve for a vector representing the second subset of coke parameters, where the solution vector can represent a first blending point. Some embodiments can then predict coke parameters, such as CSR, based on the first blending point. Upon determining that the predicted nonlinear coke parameters do not meet criteria based on the target nonlinear coke parameters (e.g., not equal to the target parameter, greater than or less than the target parameter by an amount greater than an acceptable threshold, etc.), some embodiments may select additional blending points. Some embodiments may then determine a set of coal parameters corresponding to each additional blending point and mimic or otherwise predict additional coke parameters based on the set of coal parameters. Some embodiments may then select one or more of the additional blending points for use as a composition for the coal blend based on the predicted additional coke parameters.

[0057] Some embodiments of the present technology may determine the composition of a coal blend so that the resulting total VM mass fraction of the coal blend meets a target VM mass fraction or a range of target values. In some embodiments, a target range of target VM mass fraction values ​​may be determined in advance. For example, some embodiments of the present technology may receive program instructions that recommend a coal blend composition such that the total VM mass fraction is between 17.0% and 25.0%. Some embodiments may then recommend a coal blend composition that meets that range. For example, with reference to FIGS. 3 and 5, some embodiments of the present technology may recommend a coal blend composition that includes 12% coke breeze, 48% T1 coal, 20% T2 coal, and 20% T9 coal. While the above describes a VM range of 17.0% to 25.0%, other thresholds are possible. For example, some embodiments of the present technology may limit the VM mass fraction of a coal blend to less than 27.0%, 30.0%, or some other value.

[0058] Some embodiments of the present technology can control a blending system to produce a coal blend based on the coal blend recommendation. Some embodiments can implement a control system to collect, process, and mix different coal types to produce a coal blend according to the ratios and ingredients indicated by the coal blend composition. For example, some embodiments of the present technology can determine a coal blend composition that includes 12% Coke Breeze, 48% T1 coal, 20% T2 coal, and 20% T9 coal. Some embodiments can then operate a set of control mechanisms to mix 12 tons of Coke Breeze, 48 tons of T1 coal, 20 tons of T2 coal, and 20 tons of T9 coal in a mixing chamber to produce the coal blend.

[0059] III. COKING OF COAL BLENDS TO PRODUCE FUND COKE PRODUCTS AND RELATED SYSTEMS AND METHODS FIG. 8 is a flowchart for a process for producing coke products using a coke oven according to one or more embodiments of the present technology. Some embodiments may increase the moisture content of the coal blend, as indicated by block 812. Referring to FIG. 2, the coal blend being loaded into the oven chamber 212 may be initially exposed to water to increase the moisture content of the coal blend. For example, some embodiments of the present technology may activate a pump or valve to spray water or another fluid onto the coal blend to increase the moisture content of the coal blend as it is transported along the conveyor belt. It should be understood that a fluid containing water may be described as water in this disclosure.

[0060] In some embodiments, pumps, valves, or other mechanisms may be controlled to spray or otherwise expose the coal blend to a fluid to increase the moisture mass fraction of the coal blend to a value between 1.0% and 20.0%. Some embodiments may allow for some latitude in increasing the moisture mass fraction of the coal blend. For example, some embodiments of the present technology may increase the moisture mass fraction of the coal blend from 8.0% to 13%. Some embodiments may use a tighter latitude, for example, exposing the coal blend to an amount of water such that the moisture mass fraction of the coal blend is set to be between 10% and 12%. Some embodiments may determine the amount of water to spray based on the VM mass fraction of the coal blend. Some embodiments may add water such that a 1% decrease in moisture mass fraction from a baseline moisture content results in a 1% decrease in VM from the baseline value. For example, some embodiments of the present technology may add water to the coal blend so that the moisture mass fraction of the coal blend is equal to the VM mass fraction of the coal blend minus a predetermined value, for example, 10%. Additionally, although some embodiments use 10% as a default value, other values ​​are possible, such as 15%, 14%, 10%, 8%, 5%, or some other threshold less than 50%.

[0061] Some embodiments of the present technology may include a sensor for determining the moisture content of the coal blend and further increasing or changing the moisture mass fraction of the coal blend based on the measured moisture. For example, some embodiments of the present technology may determine that the measured moisture content of the coal blend is less than a first moisture threshold and, in response, add additional fluid to the coal blend. Alternatively, some embodiments of the present technology may determine that the measured moisture content is greater than a second moisture content and, in response, add additional dry coal blend to the wet coal blend. In some embodiments, the first moisture threshold may be a value equal to or greater than 1.0%, e.g., 5.0%, 10.0%, 12.0%, etc., and the second moisture threshold may be a value equal to or less than 15.0%, e.g., 15.0%, 13.0%, etc.

[0062] Some embodiments of the present technology may open the dampers of a coke oven, as indicated by block 824. Some embodiments may keep the dampers of the coke oven open during the initial heat-up period of the coke oven. For example, some embodiments of the present technology may use a set of controllers to send commands to damper actuators to open a set of soleflue dampers. After being set to an open state, the set of soleflue dampers may allow fluid communication between the open atmosphere and the soleflue of the coke oven before and while a coal blend is being placed in the coke oven. Furthermore, as described elsewhere in this disclosure, some embodiments of the present technology may change the state of the dampers to a partially closed or fully closed state using a set of commands sent by a controller to the same or a different actuator.

[0063] Some embodiments of the present technology may load the coal blend into the coke oven, as represented by block 828. As described elsewhere in this disclosure, some embodiments of the present technology may use a coke oven to produce coke products from the coal blend. Some embodiments may load the coal blend by using a pusher charger machine and operations associated with the pusher charger machine.

[0064] Some embodiments of the present technology may utilize a heat recovery coke oven to reduce fuel or power consumption of the coke oven. For example, some embodiments of the present technology may verify that a minimum temperature associated with the coke oven has been reached by measuring the temperature of the coke oven. The minimum temperature may vary based on the specific implementation or coke oven and may be a temperature greater than 500°F, e.g., 1000°F, 1500°F, or some other temperature greater than 500°F. In response to determining that the measured temperature of the coke oven has reached a minimum temperature, some embodiments of the present technology may initiate a heat recovery operation, e.g., a steam recovery operation, and reduce fuel consumption of the coke oven.

[0065] Some embodiments of the present technology may perform damper operations to maintain the coking temperature of the crown and sole flue of the coke oven during the pyrolysis duration of the coking cycle, as indicated by block 832. Some embodiments may perform opening and closing operations of sets of dampers during the cycle. For example, some embodiments of the present technology may initially heat the coke oven during the coking cycle while a set of intake dampers is in a fully open configuration. Some embodiments may then initiate a closing operation that switches the set of intake dampers to a second configuration, which may be a partially open configuration or a fully closed configuration. In some embodiments, the pyrolysis duration (sometimes referred to as the coking duration) may be considered to have begun after a lower coking temperature limit is reached, which may be a value that characterizes a foundry coking temperature, which may be a temperature greater than a by-product temperature of 1800°F or a blast furnace temperature of 2500°F. For example, the lower coking temperature limit can be a value within a range, and the range can be 1200-2300°F, 1800-2300°F, or 2000-2400°F. For example, the lower coking temperature limit can be 1990°F. In some embodiments, the pyrolysis duration can be considered to end after the coking reaction has ended, and a coal or coal blend that has reached the end of the coking reaction can be referred to as "coked." Some embodiments of the present technology can detect the end of the coking reaction in a furnace based on a temperature decrease in crown temperature or sole flue temperature. In some embodiments, the duration of a coking cycle can be determined as the sum of the pyrolysis duration and the soak time, where the soak time represents the time the coke product remains in the furnace from the end of the pyrolysis duration until the coke product is removed from the furnace.

[0066] Some embodiments can use sensor measurements to determine whether to open or close a valve. For example, some embodiments of the present technology can read a set of crown temperature measurements from a crown temperature sensor. Some embodiments can then determine whether the set of crown temperature measurements meets a set of crown temperature criteria by determining whether a crown temperature threshold is met by one or more temperature measurements. Alternatively, or in addition, some embodiments of the present technology can determine whether the set of crown temperature measurements meets a set of crown temperature criteria by determining whether a temperature change rate threshold is met by a change in a series of crown temperature measurements. For example, some embodiments of the present technology can determine whether the temperature change rate of the crown temperature has increased to above a temperature change rate threshold of 50°F per hour, or some other value below 50°F per hour (e.g., a temperature change rate threshold of 35°F per hour). In response to determining that the temperature change rate is equal to or greater than the temperature change rate threshold, thereby meeting the temperature change rate threshold, some embodiments of the present technology can use a controller to activate a damper to close or partially close, thereby reducing the amount of air entering the coke oven.

[0067] Some embodiments can maintain a temperature imbalance between the crown temperature of the coke oven and the sole flue temperature of the coke oven during the pyrolysis duration. For example, some embodiments of the present technology can maintain the crown temperature in a range of 2000-2400°F during the pyrolysis duration, with the crown temperature varying within a predetermined range. Additionally, narrower crown temperature ranges are possible. For example, the crown temperature can vary between 1149°C (2100°F) and 1316°C (2300°F). Furthermore, the target temperature can be varied depending on the coking operation. For example, some embodiments of the present technology can maintain a temperature range within 100°F of a first target temperature equal to 2000°F, such that the crown temperature or another coking temperature in the coke oven does not vary by more than 100°F from 2000°F during the pyrolysis duration or a predetermined subduration of the pyrolysis duration. Additionally, other temperature differentials or target temperatures are possible for approximately isothermal pyrolysis durations or sub-durations, and the temperature differential can be less than 200° F., and the target temperature can be a temperature between 1300° F. and 2600° F. For example, the temperature differential can be less than 25° F., 50° F., 100° F., 150° F., or 200° F., and the target temperature can be 1850° F., 1950° F., 2050° F., 2200° F., 2400° F., or 2600° F. or less.

[0068] Despite fluctuations in crown temperature, some embodiments of the present technology can regulate the crown temperature and soleflux temperature so that the crown temperature is higher than the soleflux temperature throughout the pyrolysis duration. Some embodiments can achieve this control by operating an intake damper, which controls flow through an intake duct, or a soleflux damper, which controls flow through a soleflux. Some embodiments can control the state of the damper and the period between changes in the particular state of the damper for each sub-period of the pyrolysis duration. For example, some embodiments of the present technology can perform a sequence of closing the intake damper or soleflux damper from a fully open configuration to a partially closed configuration, and then reopening the damper to the fully open configuration. In some embodiments, the sequence of damper closing and opening operations can be more complex than a simple open / close operation. For example, some embodiments of the present technology may maintain the damper in an open state for a first period of time, partially close the damper within four hours of closing (e.g., beginning the closing operation within two hours of the start of the pyrolysis duration), reopen the damper to a fully open configuration, close the damper to a fully closed configuration, reopen the damper to a partially open configuration, fully open the damper for a fully open period, and then fully close the damper to a fully closed configuration.

[0069] In some embodiments, the pyrolysis duration or coking cycle may be 12 hours or more, 24 hours or more, 48 hours or more, 72 hours or more, or 96 hours or more. In some embodiments, increasing the moisture content of the coal blend allows the furnace to maintain a longer pyrolysis duration, such as about 96 hours, about 72 hours, about 48 hours, or another duration greater than 24 hours. For example, after increasing the moisture content of the coal blend as described in block 812, some embodiments of the present technology may enable the extension of the time the coal blend is exposed to coking temperatures from 24 hours to 48 hours, or greater than 48 hours.

[0070] Some embodiments can maintain a relatively isothermal temperature profile for crown temperature during the pyrolysis duration, where a relatively isothermal temperature profile can mean that the crown temperature is within a predetermined range that is within 10% or 20% of a median or mean value. For example, some embodiments of the present technology can maintain a crown temperature that fills a temperature range of 2000°F to 50°F during the pyrolysis duration, such that the crown temperature is between 1950°F and 2050°F during the pyrolysis duration. Alternatively, some embodiments of the present technology can maintain the crown temperature within a crown temperature range during a sub-duration of the pyrolysis duration. For example, during a 24-hour pyrolysis duration, some embodiments of the present technology can operate a set of valves to maintain a crown temperature between 2000°F and 2080°F during the sub-duration if the pyrolysis duration is at least 12 hours long. The boundaries of the temperature range can include various temperature ranges, such as a temperature of 20°F, a temperature of 40°F, or some other value below 200°F. Furthermore, the temperature range can revolve around a particular value, such as 1900° F., 2000° F., 2100° F., or some other temperature value. Additionally, some embodiments of the present technology can be pre-configured to use a particular temperature range.

[0071] Some embodiments may recover a coke product population from the coke oven, as represented by block 844. The coke oven may produce a coke product population including a foundry coke product, a nodule coke product, and a coke breeze. The operations described herein may result in various desirable properties, dimensions, or other attributes of the coke product, e.g., a foundry coke product population. Some embodiments may control the coke oven to engineer a target distribution of coke products among the coke product population. For example, an operation that maintains a near-isothermal pyrolysis duration such that at least 60.0% of the population is foundry coke product and at least 20% of the population is breeze or nodule coke product. By using an operation that converts a majority of the output of the coking operation to foundry coke product, some embodiments of the present technology may improve the efficiency of downstream foundry operations. Furthermore, as used herein, nodule coke product may include the coke product remaining after screening at 2-inch to 4-inch screens.

[0072] As discussed elsewhere in this disclosure, some embodiments of the present technology can produce foundry coke products with advantageous falling shutter characteristics. Coke products with higher falling shutter survival rates can retain product shape useful in downstream foundry operations. For example, some embodiments of the present technology can produce coke products with 80% or more 4-inch falling shutters, where 4-inch falling shutters represent the expected percentage of the coke product that will not exhibit significant breakage when dropped from a height of 4 inches. Similarly, the same or a different coke product can have 90% or more 2-inch falling shutters, where greater than 90% falling shutters can represent significant product strength.

[0073] As discussed elsewhere in this disclosure, some embodiments of the present technology can produce foundry coke products with advantageous fluidity values. A product with higher drop shutter survival rates can help maintain the shape of the product for use in downstream casting operations. For example, some embodiments of the present technology can produce coke products with fluidity above a fluidity threshold, e.g., 200 ddpm or greater. Higher fluidity can improve reaction efficiency in downstream casting operations.

[0074] As discussed elsewhere in this disclosure, some embodiments of the present technology can produce foundry coke products with advantageous AFTs and coke products with lower AFTs. For example, some embodiments of the present technology can produce coke products with fluidities higher than a fluidity threshold, e.g., 100 divisions per minute (ddpm) or greater, 150 ddpm or greater, or some other value, i.e., 200 ddpm or greater, e.g., 250 ddpm, 260 ddpm, 270 ddpm, 280 ddpm, 290 ddpm, or within the range of 250-300 ddpm. Higher fluidity can improve reaction efficiency in downstream casting operations.

[0075] FIG. 9 is a chart illustrating a combustion profile for blast furnace coke production operations. Chart 900 illustrates blast furnace operation of a coke oven during a coking cycle. Line 950 indicates the position of the coke oven intake damper. The oven damper remains fully open for 12 hours, as shown in a first sub-duration outlined by first region 901. As shown by the drop in line 950 at the end of the first sub-duration, the damper can be controlled and placed in another partially closed state, as shown in a second sub-duration outlined in second region 902, for the next 36 hours. The damper is then fully closed, as shown in a third sub-duration outlined in third region 903.

[0076] As shown by crown temperature measurement line 910, the crown temperature of blast furnace coke can vary significantly over time and can vary by more than 400°F. For example, the crown temperature can be 2004°F at time 911 and 2449°F at time 912. Furthermore, the relative difference of the crown temperature to the intake temperature can switch during the coking cycle represented by chart 900. As shown by intake temperature line 920, the intake temperature is lower than the crown temperature until time 921, remains higher than the crown temperature until time 922, and remains lower than the crown temperature until time 923. Both the temperature fluctuations in the crown temperature and the repeated switching of relative temperatures can result in heterogeneity and poor crystallinity in any coke product produced by the operation represented by chart 900.

[0077] 10 is a chart illustrating a combustion profile for a foundry coke production operation in accordance with one or more embodiments of the present technology. Chart 1000 illustrates the operation of a coke oven foundry coke during a coking cycle. Line 1050 indicates the position of the coke oven intake damper. As shown in a first sub-duration outlined by first region 1001, the oven damper remains fully open for approximately two hours. As shown by the drop in line 1050 at the end of the first sub-duration, the damper may be controlled and placed in a first partially closed state, greater than 50% closed, and held in this state for a second sub-duration, represented by second region 1002.

[0078] After the initial closing operation, the damper may be held for a predetermined time (e.g., 10 hours, 20 hours, or another duration greater than 2 hours). Alternatively, or in addition, the damper may be operated to open again later based on temperature measurements. For example, some embodiments of the present technology may detect when the crown temperature represented by line 1050 meets a temperature threshold (e.g., exceeds a maximum threshold or is less than a minimum threshold) and, in response, operate the damper to open. As indicated by the times represented by regions 1003, 1004, 1005, 1006, and 1007, the damper may be repeatedly operated according to a predetermined schedule or set of thresholds for opening and closing the damper, which may change the damper to a fully open, partially closed, or fully closed state. The operations for opening and closing the damper, represented by line 1050, are shown in chart 1000 as (1) closing the damper to a first partially closed state, (2) reopening the damper to a fully open state, (3) closing the damper to a second partially closed state, (4) reopening the damper to the fully open state, (5) closing the damper to a second partially closed state, (6) closing the damper to a fully closed state, (7) reopening the damper to the second partially closed state, (8) reopening the damper to the fully open state, and then (9) closing the damper to a fully closed state. However, other sequences of damper operations are possible, such as closing to a fully closed state in a second sub-duration represented by second region 1002.

[0079] Some embodiments may treat the time when the oven temperature reaches a lower coking temperature threshold as the start of the pyrolysis duration, during which the bulk of the coking reaction to produce coke products from the coal blend in the coke oven occurs. Some embodiments may have multiple criteria for determining that the start of the pyrolysis duration has occurred, such as a first criterion requiring a temperature threshold to be reached by the crown temperature and a second criterion requiring the crown temperature to be higher than the sole-flue temperature. As can be seen from a comparison of the crown temperature 1010 and the sole-flue temperature 1020, the crown temperature may be higher than the sole-flue temperature for the entire pyrolysis duration when operating to produce foundry coke products. Furthermore, as can be seen from chart 1000, the crown temperature 1010 may be relatively isothermal with respect to the target temperature of 2100°F and the allowable temperature difference of 100°F for the pyrolysis sub-duration, represented by regions 1003-1006. By maintaining this relatively isothermal temperature, some embodiments of the present technology may increase crystallization efficiency, which may allow for more efficient carbon release during the casting operation.

[0080] IV. FOUNDRY COKE PRODUCTS AND RELATED SYSTEMS, APPARATUS, AND METHODS 11 illustrates a coke particle configured to be heated in a casting cupola in accordance with one or more embodiments of the present technique. As shown in FIG. 11, C(b) = bulk carbon, S(b) = bulk sulfur, Ash(b) = bulk ash, C(s) = surface carbon, S(s) = surface sulfur, Ash(s) = surface ash (accumulating from the shrinking core), Fe(s) = surface Fe, C * (s) = activated carbon surface, FeC, S *(s) = active sulfur surface, FeS, C(l) = carbon in the liquid, and S(l) = sulfur in the liquid. Coke particle 1100 includes a core 1105 that shrinks due to carbon dissolution in the cupola, and the coke particle 1100 may be surrounded by bulk liquid 1120. As the core 1105 of the coke particle 1100 shrinks, for example, due to oxidation and / or combustion of the carbon in the coke particle 1100, a diffuse layer containing ash and iron radially outward of the core 1105 begins to form. For example, the coke particle 1100 may include a first or ash diffusion layer 1110 ("first diffusion layer 1110") containing ash that at least partially surrounds the core 1105 radially outward of the core 1105, and a second or iron diffusion layer 1115 ("second diffusion layer 1115") that at least partially surrounds the first diffusion layer 1110 radially outward of the core 1105 and the first diffusion layer 1110.

[0081] The first diffusion layer 1110 may be solid or liquid and may effectively block the coke surface or provide a smaller mass transfer area beyond the coke surface to the surrounding liquid metal. Additionally or alternatively, the first diffusion layer 1110 may delay in time and / or temperature the oxidation and / or combustion of carbon in the coke particles so that the coke does not produce carbon monoxide in the drying zone but instead oxidizes and combusts in the reaction zone of the cupola. The formation of the ash-containing first diffusion layer 1110 is due in part to the ash fusion temperature of the coke product, which is directly related to the composition of the coke particles 1100. As described elsewhere herein, the ash fusion temperature of the coke is lower than conventional coke products and can be as low as 2650° F., 2600° F., 2550° F., 2500° F., 2450° F., 2400° F., 2350° F., 2300° F., 2250° F., 2200° F., 2150° F., 2100° F., 2050° F., 2000° F., 1950° F., 1900° F., 1850° F., or in the range of 1800-2600° F., 1800-2500° F., 1900-1300° F., or 2000-2200° F. This relatively low ash fusion temperature can allow for the formation of a diffuse ash layer that prevents heating of the coke prior to the reaction zone, or more specifically, the core 1105, for example, in the drying zone of the cupola. Additionally or alternatively, this relatively low ash fusion temperature may optimize contact time between the coke 1100 and the metal in the cupola after the metal has melted and become molten in the reaction zone of the cupola. As a result, more carbon can be transferred from the coke 1100 to the metal. This is in contrast to conventional coke products, which may have a higher ash fusion temperature, which causes ash to form deeper (i.e., downstream) in the reaction zone, thus limiting contact time between the coke and molten metal and resulting in relatively less carbon transfer.

[0082] A second diffusion layer 1115 forms as the coke particles 1100 heat in the cupola and the coke core 1105 shrinks. The second diffusion layer can further limit heating of the coke in the drying zone and / or help prevent most of the combustion and oxidation of the coke 1100 from occurring until it reaches the reaction zone. Additionally or alternatively, carbon and sulfur may compete with each other for passage through the second diffusion layer 1115. That is, the presence of sulfur may unnecessarily slow the rate of carbon migration out of the coke 1100.

[0083] In some embodiments, the coke can be pre-fluxed and / or include (e.g., doped with) additives that act as catalytic materials (e.g., calcium, iron, calcium oxide, magnesium oxide, iron oxide, sodium oxide, and potassium oxide, and / or other oxides with relatively low melting points). As an example, sodium can act as a pre-fluxing agent, and iron can act as a pre-fluxing agent and catalyst. The catalytic materials can be used to capture sulfur and therein dissolve it from the coke. In some embodiments, the pre-fluxed coke is the result of selecting coals to produce coke with ash materials that are relatively high in the oxides listed above. This is in contrast to coke products, where calcium oxide or calcium carbonate particles / rocks can be added as fluxes to remove ash; such methods are inefficient because the surface area-to-volume ratio is too low for actual dissolution to occur. Additionally, the pre-fluxed coke and / or catalyst can promote carbon deposition via the Boudouard reaction, which generates more heat and increases the amount of carbon present in the reaction region (e.g., combustion zone) of the cupola. Without being bound by theory, the pre-fluxing agent can change the liquid temperature of the slag (e.g., slag 116, FIG. 1), or more specifically, the liquid temperature of the ash on or within the coke blended into the bulk slag.

[0084] The improvement in coke chemistry aims to increase carbon dissolution from the coke particles 1100 into the metal (i.e., iron or steel) within the cupola. During operation, as carbon dissolves in the bulk liquid iron within the cupola, the coke core 1105 shrinks, and ash and impurities accumulate on the surface. Furthermore, both carbon and sulfur dissociate from the surface, which can be facilitated by the catalytic activity of Fe, Ni, and other metals. A lower ash fusion temperature (represented by the ash fusion temperature, as described elsewhere herein) improves ash removal through faster ash conversion to the liquid phase and reduces ash blockage. Carbon and sulfur diffuse through the thin iron diffusion layer. Furthermore, carbon and sulfur are competitive and do not readily dissolve or migrate with each other. Thus, a lower sulfur content in the coke improves carbon migration. Furthermore, coke products with a higher coke reactivity index (CRI) or lower coke post-reaction strength (CSR) (as described elsewhere herein) dissociate more reactive carbon forms from the surface, thereby increasing the carbon dissolution rate.

[0085] Various metals added to foundry coke products produced from coal blends via ash in the coal blend or otherwise introduced into the foundry coke product can provide catalytic functionality that enhances the rate of carbon dissolution. In some embodiments, elements (e.g., metals) in multiple oxidation states can change oxidation state to provide catalytic activity in the coke product. For example, the coke product may contain sodium, which can be converted from its unoxidized state, Na, to its first ionic oxidation state, Na. + Alternatively, or in addition, the coke product may contain iron, which may transition from the unoxidized Fe to the oxidized Fe 2+ or Fe 3+ Additionally, the coke product may contain multiple oxidation state elements in one oxidation form. For example, the coke product may contain Na + It may contain Fe in the form of a salt. 3+In some cases, the coke product contains FeO in the form of FeO. The coke product may also contain other types of metals, such as nickel, copper, etc. Because at least a portion of the catalytic material embedded in the coke product remains in contact with the interface between the coke product and a liquid iron bath during steel production, the catalytic material increases carbon dissolution during steel production.

[0086] FIG. 12 shows a table of exemplary foundry coke products and foundry coke properties, according to one or more embodiments of the present technique. Some embodiments may use a coke oven, such as furnace 200 of FIG. 2, to produce foundry coke product 1200. In some embodiments, foundry coke product 1200 may be generally oblong and may have different or similar dimensions along first length 1212, second length 1214, or third length 1216. For example, first length 1212 may be greater than 6.0 inches (e.g., 9.0 inches), the second length may be greater than 2.5 inches (e.g., 4.0 inches), and the third length may be greater than 2.5 inches (e.g., 4.0 inches). In some embodiments, one or more lengths of the shape of foundry coke product 1200 may be limited to a maximum value. For example, first length 1212 may be between 6.0 inches and 12.0 inches.

[0087] Due to variations in the specific shape of the foundry coke product, the foundry coke product may be characterized by a variety of hydraulic diameters. For example, foundry coke product 1200 may have a hydraulic diameter of 1.0 inch or more, 2.0 inches or more, or 3.0 inches or more, etc. In some embodiments, the hydraulic diameter of the foundry coke product may be greater than the actual diameter of the foundry coke product due to the cross-sectional shape of the foundry coke product.

[0088] Table 1250 includes a set of attributes of foundry coke product 1200. The foundry coke product attributes shown in Table 1250 can characterize the coke product produced by the operations described in this disclosure. Such attributes can be advantageous to a foundry operation, such as having a lower AFT value compared to conventional coke products. Such a low AFT value can be expressed in various ways, such as an IDT or ST value. For example, specimen "S4" shown in Table 1250 has an ash fusion IDT equal to 2150°F (1177°C). Some embodiments can perform operations to convert the low ash fusion into a coke product based on an AFT threshold or target ash fusion range.

[0089] In some embodiments, the target AFT value or AFT range may vary based on the type of ash melting value used. In some embodiments, the coke product produced may have an IDT between 2100°F and 2400°F. Some embodiments may include stricter limits on the coke product. For example, some embodiments of the present technology may include a coke product with an IDT between 2100°F (1149°C) and 2250°F (1232°C). Some embodiments may vary the coal blend, soak time, or duration at different damper positions to meet the target IDT. For example, some embodiments of the present technology may select a coal blend or determine furnace operation based on a target IDT value of about 2100°F, about 2150°F, about 2200°F, about 2250°F, about 2300°F, about 2350°F, or about 2400°F. In some embodiments, the soak time may be established to begin after the peak crown temperature or other peak temperature is reached. Alternatively, the soak time can be established as beginning after the soak flue temperature or crown temperature begins to drop without gas flow. Additionally, the soak time can be shortened by extending the coking time of the pyrolysis duration, and the soak time can be less than 10.0 hours, less than 5.0 hours, or less than 1.0 hour. Furthermore, some embodiments of the present technology can use various total cycle times and can characterize operations based on the ratio of soak time to pyrolysis duration, which can be less than some other threshold, such as less than 33.0%, less than 15.0%, less than 5.0%, or less than 50%.

[0090] Similarly, some embodiments of the present technology may produce coke products using the operations described herein with STs within a specified range, e.g., 2150°F to 2500°F. Some embodiments may implement operations to meet a tighter ST range, such as modifying the operation to produce coke products with STs between 2150°F and 2300°F. Additionally, some embodiments of the present technology may vary the coal blend, soak time, or duration at different damper positions to meet a target ST. For example, some embodiments of the present technology may select a coal blend or determine furnace operation based on a target ST value of about 2100°F, about 2150°F, about 2200°F, about 2250°F, about 2300°F, about 2350°F, about 2400°F, about 2450°F, or about 2500°F. Additionally, some embodiments of the present technology may set a target IDT value as a function of the target ST value.

[0091] Similarly, some embodiments of the present technology may produce coke products using the operations described herein where the HT is within a specified range, e.g., 2200°F to 2350°F. Some embodiments may implement operations to meet a tighter HT range, such as modifying the operation to produce coke products with an HT of 2150°F to 2300°F. Additionally, some embodiments of the present technology may vary the coal blend, soak time, or duration at different damper positions to meet the target HT. For example, some embodiments of the present technology may select a coal blend or determine furnace operation based on a target HT value of about 2200°F, about 2250°F, about 2300°F, about 2350°F, about 2400°F, about 2450°F, or about 2500°F.

[0092] Similarly, some embodiments of the present technology may produce coke products using the operations described herein with a FT within a specified range, e.g., FT between 2250°F and 2600°F. Some embodiments may implement operations to meet a stricter FT range, such as modifying the operation to produce a coke product with a FT between 2250°F and 2400°F. Additionally, some embodiments of the present technology may vary the coal blend, soak time, or duration at different damper positions to meet a target FT. For example, some embodiments of the present technology may select a coal blend or determine furnace operation based on a target FT value of about 2250°F, about 2300°F, about 2350°F, about 2400°F, about 2450°F, about 2500°F, about 2550°F, or about 2600°F.

[0093] Some embodiments may produce a coke product that meets multiple target ranges for different types of AFT values. For example, some embodiments of the present technology may include a coke product having an IDT of 2100°F to 2250°F, an ST of 2150°F to 2300°F, a HT of 2200°F to 2350°F, or an FT of 2250°F to 2400°F. Alternatively, or in addition, various other combinations of target ranges for the coke product are possible. For example, some embodiments of the present technology may include a coke product having an IDT of 2100°F to 2250°F, an ST of 2150°F to 2300°F, an HT of 2200°F to 2350°F, and an FT of 2250°F to 2400°F.

[0094] Some embodiments may produce coke products with AFTs that fall within various compositional boundaries for meeting certain AFT values. For example, some embodiments produce coke products with AFTs greater than 2300° F. or less than 2600° F. Some embodiments may include tighter tolerances for the production or selection of coke products for downstream use, such as 1800° F. to 2600° F., 2200° F. to 2500° F., 2300° F. to 2400° F., 2400° F. to 2600° F., or 2500° F. to 2600° F.

[0095] Some embodiments may use the procedures described herein to produce coke products characterized by specific types of AFT values. For example, some embodiments of the present technology may produce coke products having an AFT ST of 982°C (1800°F) to 1427°C (2600°F), 1177°C (2150°F) to 1371°C (2500°F), or an AFT HT of 1204°C (2200°F) to 1371°C (2500°F), or an AFT flow temperature (FT) of 1232°C (2250°F) to 1371°C (2500°F).

[0096] As shown in Table 1250, the CRI value of the foundry coke product can be 36.5%, or another value greater than 35%. Some embodiments can implement coke production operations to produce batches of foundry coke that meet one or more CRI thresholds. For example, some embodiments of the present technology can vary the duration between changes in damper configuration or select from different damper positions based on a CRI threshold. For example, some embodiments of the present technology can produce castings with CRIs of at least 25.0%, at least 30.0%, at least 35.0%, at least 40.0%, at least 45.0%, or another value of at least 30.0%. Some embodiments can implement operations to select a coke product with a CRI greater than a minimum CRI threshold for downstream use. In some embodiments, the CRI of a coke product can indicate mass loss due to reactions, and a higher CRI of a coke product can indicate greater efficiency or utility of the coke product. In some embodiments, the CRI may be calculated using a model based on known properties of the coke product or the coal blend used to produce the coke product. Alternatively, or in addition, the CRI may be obtained experimentally as measured weight loss using established testing protocols. For example, some embodiments may use a CRI measurement method such as ASTM method D5341 to determine the CRI value.

[0097] As shown in table 1250, the CSR value of the foundry coke product can be 26%, 15.6%, or another value above a CSR threshold, e.g., 7.0%. Some embodiments may implement coke production operations that produce batches of foundry coke that meet one or more CSR thresholds. For example, some embodiments of the present technology may vary the duration between changes in damper configuration or select from different damper positions based on meeting a target CSR threshold, e.g., a CSR threshold that requires the foundry coke to have a CSR that is 40.0% or less, 35.0% or less, 30.0% or less, 25.0% or less, 20.0% or less, 15.0% or less, 10.0% or less, or 7.0% or less.

[0098] As shown in Table 1250, the SiO2 composition in the ash content of the coke product may include 49.4%, 48.9%, 48.8%, 49.1%, or 46.0%. Other embodiments may include other SiO2 mass fractions in the ash content, such as less than 70%, less than 50.0%, less than 45.0%, etc. In some embodiments, a mass fraction of SiO2 of about 50.0% in the ash content of the coke product may correspond to a small amount of SiO2 in the coke product itself.

[0099] Additionally, some embodiments of the present technology can produce coke products having fixed carbon contents (e.g., fixed carbon mass fractions) that are equal to or greater than a fixed carbon threshold. For example, some embodiments of the present technology can produce foundry coke products having fixed carbon mass fractions greater than 80.0%, 85.0%, 90.0%, 90.5%, 91.0%, or some other value. In some embodiments, the fixed carbon content can be a target range. For example, some embodiments of the present technology can perform a series of operations to produce coke products having fixed carbon contents of 94.5% or less but 85.0% or greater (although other ranges of values ​​are possible), e.g., 94.5% to 85.0%. Coke products having various other target ranges are possible, e.g., 90.0% to 95.0%, 85% to 99%, etc.

[0100] Additionally, some embodiments of the present technology may produce coke products having mass ash fractions within a target bounded or unbounded range. For example, some embodiments of the present technology may produce foundry coke products with mass ash fractions of 1.0%, 5.0%, 8.0%, 9.0%, 10.0%, or greater than 10.0%. Additionally, some embodiments of the present technology may include upper limits on mass ash fractions. For example, some embodiments of the present technology may produce foundry coke products with mass ash fractions of less than 1.0%, 5.0%, 9.0%, 10.0%, or greater than 10.0%. Some embodiments may combine these upper and lower mass ash fraction limits to produce coke products with ranges such as 5.0%-10.0%, 8.5%-9.0%, 8.0%-10.0%, 5.0%-15.0%, etc.

[0101] FIG. 13 is a chart illustrating foundry coke product yields according to one or more embodiments of the present technology. As shown in chart 1300, foundry yields for different batches of coke product produced from coal blends using the operations described herein can vary. As shown by range 1302, the yield can range from about 40% to 60% in some embodiments, and this yield can be a dry yield (i.e., the dry mass fraction of the foundry coke product can be 40% or 60% of the dry mass fraction of the total population of coke products). As shown by data point 1353, some embodiments perform an operation that results in a yield of about 57%, although the yield can be lower in other cases. For example, as shown by data point 1351, the yield in some coke production operations can be lower, e.g., as low as 41%. In many cases, some embodiments of the present technology may perform operations that meet a minimum yield threshold, e.g., operations that result in a yield that is at least 25%, at least 30%, at least 40%, at least 50%, at least 60%, etc. Some embodiments of the present technology may perform controller optimization operations to improve yield, although some embodiments of the present technology may accept that the predicted yield will be lower than the expected maximum yield in order to meet other target coke product parameters.

[0102] FIG. 14 is a chart illustrating particle size, according to one or more embodiments of the present technology. As shown in chart 1400, the average batch length in inches for different batches of coke product produced from a coal blend using the operations described herein can vary. As shown by range 1402, the average length of the coke product can range from about 5.5 inches to about 7.5 inches in some embodiments. As shown by data point 1453, some embodiments perform an operation that results in an average length of the coke product being about 7.4 inches, although the average length of the coke product can be shorter in other cases. For example, as shown by data point 1451, the average length of the coke product in some coke production operations can be shorter, e.g., as short as 5.5 inches. In many cases, some embodiments of the present technology can perform an operation that meets a minimum threshold for the average length of the coke product, e.g., an average length of the coke product that is at least 2.5 inches, 4.0 inches, 5.0 inches, 6.0 inches, 7.0 inches, 8.0 inches, 9.0 inches, or some other length. In some embodiments, a larger coke product may result in a more efficient casting operation. Although some embodiments of the present technology may perform controller optimization operations to increase the average length of the coke products, some embodiments of the present technology may allow the predicted average coke product length to be shorter than the expected maximum average coke product length in order to meet other target coke product parameters.

[0103] FIG. 15 is a chart illustrating 4-inch drop shutter characteristics according to one or more embodiments of the present technology. As shown in chart 1500, 4-inch drop shutter survival rates for different batches of coke product produced from coal blends using operations described herein can vary. As indicated by range 1502, 4-inch drop shutter survival rates can range from about 80% to about 95% in some embodiments. As indicated by data point 1553, some embodiments perform operations that result in a 4-inch drop shutter survival rate of about 93%, although the 4-inch drop shutter survival rate can be lower in other cases. For example, as indicated by data point 1551, 4-inch drop shutter survival rates in some coke production operations can be lower, e.g., as low as 81%. In many cases, some embodiments of the present technology can perform operations that meet minimum 4-inch drop shutter survival rate thresholds, e.g., result in a 4-inch drop shutter survival rate that is at least 80%, at least 85%, at least 90%, or at least 95%, or at least some other 4-inch drop shutter threshold. In many cases, a higher falling shutter survival rate is more beneficial to downstream casting operations, as more coke product survives transportation and downstream processing.

[0104] FIG. 16 is a chart illustrating 6-inch drop shutter characteristics according to one or more embodiments of the present technology. As shown in chart 1600, 6-inch drop shutter survival rates for different batches of coke product produced from coal blends using operations described herein can vary. As indicated by range 1602, 6-inch drop shutter survival rates can range from about 30% to about 80% in some embodiments. As indicated by data point 1653, some embodiments perform operations that result in a 6-inch drop shutter survival rate of about 80%, while the 6-inch drop shutter survival rate can be lower in other cases. For example, as indicated by data point 1651, the 6-inch drop shutter survival rate in some coke production operations can be lower, e.g., as low as 30%. In many cases, some embodiments of the present technology may perform operations that meet a minimum 6-inch drop shutter survival rate threshold, e.g., result in a 6-inch drop shutter survival rate that is at least 60%, at least 70%, at least 80%, or at least some other 6-inch drop shutter threshold, which may be less than the 4-inch drop shutter threshold.

[0105] FIG. 17 is a chart illustrating ash mass fraction according to one or more embodiments of the present technology. As shown in chart 1700, the ash mass fraction for different batches of coke product produced from a coal blend using the operations described herein can vary. As shown by range 1702, the ash mass fraction can range from about 7% to about 10% in some embodiments. As shown by data point 1753, some embodiments perform operations that result in an ash mass fraction of about 9.7%, although the ash mass fraction can be lower in other cases. For example, as shown by data point 1754, the ash mass fraction in some coke production operations can be 8.8%. Additionally or alternatively, as shown by data point 1751, the ash mass fraction in some coke production operations can be lower, for example, as low as 7.2%.

[0106] In some embodiments, the ash content of coke products produced using the operations described herein can be less than an ash mass fraction threshold, which can be 10.0%, 9.0%, 8.5%, 8.0%, 7.5%, or another value less than 50.0%. In some embodiments, the ash mass fraction can be unconventionally high, for example, greater than 10.0%. Alternatively, or in addition, some embodiments of the present technology can produce coke products having an ash mass fraction threshold that meets an ash mass fraction threshold that is less than 10.0%, less than 9.0%, less than 8.5%, less than 8.0%, less than 7.5%, or less than 7.0%. Some embodiments can include ash within a range, e.g., between 5.5% and 7.0%, 6.0% and 6.5%, 8.0% and 10.0%, or some other value. Furthermore, some embodiments of the present technology can produce a set of coke products that meet a target mass fraction value. For example, some embodiments of the present technology may produce a coke product having an ash mass fraction that meets a target ash mass fraction, which may be about 9.0%, about 8.5%, about 8.0%, about 7.5%, or about 7.0%.

[0107] In some embodiments, some embodiments of the present technology may perform operations to produce coke products that meet a minimum ash mass fraction threshold, e.g., an ash mass fraction that is at least 7.0%, at least 8.0%, at least 9.0%, or at least some other ash mass fraction. Further, some embodiments of the present technology may determine a coal blend formulation or perform a coke oven operation with an ash mass fraction within a predetermined range, e.g., 7.0% to 10.0%.

[0108] FIG. 18 is a chart illustrating moisture mass fraction according to one or more embodiments of the present technology. As shown in chart 1800, the moisture mass fraction of the coke product for different batches of coke product produced from a coal blend using the operations described herein can vary. As indicated by range 1802, the moisture mass fraction of the coke product can range from about 0% to about 15% in some embodiments. As indicated by data point 1853, some embodiments perform operations that result in a coke product moisture mass fraction of about 15%, although the coke product moisture mass fraction can be lower in other cases. Furthermore, as indicated by data point 1851, the moisture mass fraction of the coke product in some coke production operations can be lower, for example, as low as 0.5%. In many cases, some embodiments of the present technology can perform operations that meet a minimum moisture mass fraction threshold for the coke product, for example, a coke product moisture mass fraction that is at least 7.0%, at least 8.0%, at least 9.0%, or at least some other coke product moisture mass fraction. Furthermore, some embodiments of the present technology may determine a coal blend formulation in which the moisture mass fraction of a coke product is within a predetermined range, for example, 7.0% to 10.0%, or may perform a coke oven operation. Further, some embodiments of the present technology may determine a coal blend formulation in which the moisture mass fraction of a coke product is less than a predetermined value, for example, 10.0% or less, 8.0% or less, 7.0% or less, 5.0% or less, or may perform a coke oven operation.

[0109] FIG. 19 is a chart illustrating sulfur mass fractions according to one or more embodiments of the present technology. As shown in chart 1900, the sulfur mass fractions for different batches of coke product produced from coal blends using operations described herein can vary. As shown by range 1902, the sulfur mass fraction can range from about 0.60% to about 0.75% in some embodiments. As shown by data point 1953, some embodiments perform operations that result in a sulfur mass fraction of about 0.73%, although the sulfur mass fraction can be lower in other cases. Furthermore, as shown by data point 1951, the sulfur mass fraction in some coke production operations can be lower, for example, as low as 0.63%.

[0110] In some embodiments, the sulfur content of the coke product can be less than a sulfur mass fraction threshold. For example, the sulfur content of the coke product can be less than 1.0%, less than 0.9%, less than 0.8%, less than 0.7%, less than 0.6%, less than 0.5%, less than 0.3%, less than 0.2%, or less than 0.1%. Some embodiments determine the composition of the coal blend, determine the soak time, or determine the damper control schedule to reduce the amount of sulfur in the coke product. Furthermore, the coke product can be produced based on a target sulfur content value, for example, a target sulfur mass fraction of 0.65%. As described elsewhere, by reducing the sulfur content of the coke product, some embodiments of the present technology can increase the efficiency of casting operations.

[0111] FIG. 20 is a chart illustrating the mass fraction of SiO to the mass fraction of AlO in the ash of a foundry coke product, according to one or more embodiments of the present technology. In some embodiments, the coke product may be characterized based on the mass fractions of SiO and AlO, or the ratio of these mass fractions. As shown in chart 2000, different coke ash samples may exhibit different mass fractions or mass fraction ratios of SiO and AlO. For example, point 2050 indicates a sample having a mass fraction of SiO of about 48.0% and a mass fraction of AlO of about 24.3%, suggesting that the ash of some coke products may have an approximate 2:1 ratio of SiO to AlO. As shown by range 2001, the mass fraction of SiO for different samples may range from 48.0% to 51.0% in some embodiments. Additionally, as shown by range 2002, the mass fraction of SiO2 for different specimens can range from 24.3% to 28.4% in some embodiments.

[0112] Some embodiments may produce a coke product with minimal or low amounts of Al2O3 and SiO2 in combination. For example, some embodiments of the present technology may operate to produce a coke product such that the ash content of the coke product is 65% or less, with the combined mass fraction of Al2O3 and SiO2. By reducing the amount of Al and Si in the coke product, some embodiments of the present technology may increase the efficiency of the casting operation by reducing interference with carbon dissolution during the casting operation.

[0113] Some embodiments can produce coke products or coal blends used to produce coal blends that meet other thresholds for Al2O3 or SiO2. For example, some embodiments of the present technology can produce coke products such that the ash content of the coke product, or the ash content of the coal blend used to create the coke product, has an Al2O3 mass fraction of less than or about 30%, less than or about 25%, or less than or about 20%. Alternatively, or in addition, some embodiments of the present technology can produce coke products such that the ash content of the coke product, or the ash content of the coal blend used to create the coke product, has an SiO2 mass fraction of less than or about 50%, less than or about 45%, less than or about 40%, or less than or about 35%.

[0114] Alternatively, or in addition, some embodiments of the present technology may produce a coke product such that the sum of the mass fraction of SiO and the mass fraction of AlO in the ash content of the coke product, or the ash content of the coal blend used to create the coke product, is less than or about 80%, less than or about 75%, less than or about 70%, or less than or about 65%.

[0115] FIG. 21 is a chart illustrating the mass fraction of Fe2O3 versus the mass fraction of CaO in the ash of a foundry coke product, in accordance with one or more embodiments of the present technology. In some embodiments, the coke product may be characterized based on the mass fractions of Fe2O3 and CaO, or the ratio of these mass fractions. As shown in chart 2100, data points representing different coke ash samples may represent different mass fractions and mass fraction ratios of Fe2O3 and CaO. For example, point 2151 represents a sample having a mass fraction of Fe2O3 of about 12.1% and a mass fraction of CaO of about 2.4%. Further, point 2152 represents a sample having a mass fraction of Fe2O3 of about 15.0% and a mass fraction of CaO of about 2.8%. Further, point 2152 represents a sample having a mass fraction of Fe2O3 of about 12.0% and a mass fraction of CaO of about 4.5%. Collectively, points 2151 indicate that the mass fraction ratio of Fe2O3 to CaO for some samples may range from about 5:1 to about 5:2 in some embodiments. Further, as indicated by range 2101, the mass fraction of Fe2O3 for different samples may range from 11.0% to 15.0% in some embodiments. Further, as indicated by range 2102, the mass fraction of Fe2O3 to CaO may range from 2.5% to 4.5% in some embodiments.

[0116] Some embodiments may produce a coke product using an operation to increase the amount of CaO in the coke product. For example, some embodiments of the present technology may perform an operation to produce a coke product such that the ash content of the coke product has a CaO mass fraction of 3.0% or greater. Alternatively, or in addition, other maximum CaO thresholds may be used. For example, some embodiments of the present technology may produce a coke product such that the ash content of the coke product has a CaO mass fraction of 10.0% or greater, 9.0% or greater, 8.0% or greater, 7.0% or greater, 6.0% or greater, 5.0% or greater, 4.0% or greater, 3.0% or greater, 2.0% or greater, 1.0% or greater, etc. Some embodiments may create a coke product from a coal blend having a high CaO content, which may be determined by the ash composition. Such a high CaO content may increase the carbon dissolution rate of the coke product.

[0117] FIG. 22 is a chart illustrating ash softening temperature versus model ash melting temperature for different batches of foundry coke products, according to one or more embodiments of the present technology. In some embodiments, the coke products may be characterized based on an ash ST value, a model AFT value, or a ratio of these two values. As shown in chart 2200, different coke ash samples may have different ST and model AFT values. For example, point 2251 indicates a sample having an ash ST value equal to about 2300°F and a model AFT value equal to about 2460°F. Further, point 2252 indicates a sample having an ash ST value equal to about 2550°F and a model AFT value equal to about 2580°F. Furthermore, as shown by range 2201, the ash ST values ​​of the different samples may range from 2300°F to 2600°F in some embodiments. Further, as shown by range 2202, model AFT values ​​for some specimens may range from 2450°F to 2600°F in some embodiments.

[0118] FIG. 23 is a chart illustrating ash softening temperature versus ash mass fraction for different batches of foundry coke products, according to one or more embodiments of the present technology. In some embodiments, the coke products may be characterized based on ash mass fraction or observed ash ST values. As shown in chart 2300, samples of different coke ash may exhibit different ash mass fractions and observed ST values ​​for the different ash samples. For example, point 2351 indicates a sample having an ST value equal to about 2350°F and an ash mass fraction of about 7.8%. Further, point 2152 indicates a sample having an ST value equal to about 2560°F and an ash mass fraction of about 8.1%. Further, point 2153 indicates a sample having an ST value equal to about 2500°F and an ash mass fraction of about 8.8%. Some embodiments may produce coke products with lower ash content and lower AFT than coke products using conventional coal blends or conventional operations. By reducing the ash content of the coke product available to build up the coke surface, some embodiments of the present technology can improve the carbon dissolution rate during the casting operation. Similarly, by reducing the ash fusion temperature of the coke product, some embodiments of the present technology can improve the ash dissolution rate by reducing the temperature required to dissolve the ash from the coke surface during the casting operation.

[0119] In some embodiments, ash content values ​​for different samples may range from 2300°F to 2560°F, as shown by range 2301. Further, the ash content may be between approximately 7.8% and 8.8%, as shown by range 2302. As shown in chart 2300, some embodiments of the present technology may produce coke products having ash mass fractions that are less than 10.0%, less than 9.0%, or less than another maximum ash mass fraction threshold. Furthermore, some embodiments of the present technology may operate to maintain a minimum amount of ash production. For example, some embodiments of the present technology may operate a coke oven to produce coke products having at least 1.0% ash, 5.0% ash, 7.0% ash, etc.

[0120] 24 is a chart illustrating observed ash fusion temperature versus modeled ash fusion temperature for different batches of foundry coke products, in accordance with one or more embodiments of the present technique. Chart 2400 includes a first range 2401 illustrating a range of observed AFT values ​​ranging from about 1990°F to about 2800°F. Chart 2400 includes a second range 2401 illustrating a range of modeled AFT values ​​ranging from 1900°F to 2750°F. As illustrated by chart 2400, coke products may exhibit an approximately direct correlation between modeled AFT values ​​and observed AFT values.

[0121] From the foregoing, it will be understood that, although specific embodiments of the present technology have been described herein for illustrative purposes, various modifications can be made without departing from the spirit and scope of the present technology. Furthermore, certain aspects of the new technology described in the context of particular embodiments may be combined or eliminated in other embodiments. Furthermore, while advantages associated with particular embodiments of the present technology have been described in the context of those embodiments, other embodiments may also exhibit such advantages, and not all embodiments necessarily exhibit such advantages to fall within the scope of the technology. Thus, the present disclosure and associated technology can encompass other embodiments not expressly shown or described herein. Accordingly, the present disclosure is not limited, except as by the appended claims.

[0122] V. Conclusion It will be apparent to those skilled in the art that changes may be made to the details of the above-described embodiments without departing from the underlying principles of the present disclosure. In some instances, well-known structures and functions have not been shown or described in detail to avoid unnecessarily obscuring the description of embodiments of the present technology. While method steps may be presented herein in a particular order, in alternative embodiments, the steps may be performed in a different order. Similarly, certain aspects of the present technology that are disclosed in the context of particular embodiments may be combined or eliminated in other embodiments. Furthermore, while advantages associated with particular embodiments of the present technology may be disclosed in the context of those embodiments, other embodiments may also exhibit such advantages, and not all embodiments need necessarily exhibit such advantages or other advantages disclosed herein to fall within the scope of the technology. Thus, the present disclosure and related technology may encompass other embodiments not expressly shown or described herein, and the present invention is not limited except as by the appended claims.

[0123] References herein to "one embodiment," "an embodiment," "some embodiments," or similar formulations mean that a particular feature, structure, operation, or characteristic described in connection with an embodiment may be included in at least one embodiment of the technology. Thus, appearances of such phrases or formulations herein are not necessarily all referring to the same embodiments. Furthermore, various particular features, structures, operations, or characteristics may be combined in any suitable manner in one or more embodiments.

[0124] Unless otherwise specified, all numbers used in the specification and claims expressing weight percentages, concentrations, compositions, and other numerical values ​​should be understood to be modified in all instances by the term "about." Thus, unless indicated to the contrary, the numerical parameters set forth in the following specification and appended claims are approximations that may vary depending on the desired properties sought to be obtained by the technology. As used in this disclosure, unless otherwise disclosed, a value can be considered to be approximately the target value if the difference between the target value and the value is 10% or less of the target value. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter should be construed in light of at least the number of reported significant digits and by applying ordinary rounding techniques. Furthermore, all ranges disclosed herein should be understood to encompass any and all subranges encompassed therein. For example, a range of "1 to 10" includes any and all subranges between (and including) a minimum value of 1 and a maximum value of 10 (i.e., any and all subranges having a minimum value of 1 or greater and a maximum value of 10 or less, e.g., 5.5 to 10).

[0125] While the present invention has been described in detail for purposes of illustration, based on what are presently considered to be the most practical and preferred embodiments, such detail is for the purposes only, and the invention is not limited to the disclosed embodiments, but rather is intended to cover modifications and equivalent arrangements within the scope of the appended claims. For example, it will be understood that the present invention contemplates that, to the extent possible, one or more features of any embodiment can be combined with one or more features of any other embodiment.

[0126] As used throughout this application, the word "may" is used in its permissive sense (i.e., meaning that it may) rather than its required sense (i.e., meaning that it must). The words "comprise," "comprising," "include," "including," "includes," and the like mean including, but not limited to. As used throughout this disclosure, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to an "element" or "element" includes a combination of two or more elements, regardless of the use of other terms and phrases for one or more elements, e.g., "one or more."

[0127] Various other aspects, features, and advantages will become apparent through the detailed description of the present disclosure and the drawings attached hereto. It should also be understood that the description of the present disclosure is by way of example and not a limitation on the scope of the present invention. As used in this specification and claims, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise. Furthermore, as used herein, "a portion" refers to a portion or the whole (i.e., the entire portion) of a known item (e.g., data) unless the context clearly dictates otherwise. Furthermore, a "set" can refer to either the singular or the plural, and a "set of items" can refer to one item or multiple items.

[0128] The term "or" is non-exclusive (i.e., encompasses both "and" and "or") unless the context clearly dictates otherwise. Terms describing conditional relationships (e.g., "in response to X, Y," "after X, Y," "if X, Y," "in the event of X, Y," etc.) encompass causal conditions in which the antecedent is a necessary causal condition, a sufficient causal condition, or a causal condition in which the antecedent is a contributing causal condition to the outcome (e.g., "state X occurs after condition Y obtains" is generally "X occurs only after Y" and "X occurs after Y and Z"). Such conditional relationships are not limited to outcomes immediately after the antecedent obtains, because some outcomes can be delayed; in conditional statements, the antecedent is relevant to those outcomes (e.g., the antecedent relates to the likelihood of the outcome occurring). A statement that multiple attributes or functions map to multiple objects (e.g., one or more processors performing steps / operations A, B, C, and D) encompasses both all such attributes or functions mapped to all such objects and a subset of attributes or functions mapped to a subset of such objects (e.g., both the case where all processors each perform steps / operations A-D and the case where processor 1 performs step / operation A, processor 2 performs step / operation B and part of step / operation C, and processor 3 performs part of step / operation C and step / operation D), unless otherwise indicated. Furthermore, unless otherwise indicated, a statement that a value or action is "based on" another condition or value encompasses both the case where the condition or value is the only factor and the case where the condition or value is one factor among multiple factors.

[0129] Unless the context clearly dictates otherwise, a statement that "each" instance of a set has a certain characteristic should not be read to exclude cases where some otherwise identical or similar members of the larger set do not have that characteristic (i.e., "each" does not necessarily mean "every"). Restrictions on the order of recited steps should not be read into a claim unless they are clearly specified (e.g., in clear language such as "after doing X," as opposed to statements that may be improperly argued to imply order limitations (e.g., "do X on the items, then do Y on the items on which X was done"), which are used for the purpose of creating more readable claims rather than specifying an order. References to "at least Z of A, B, and C," etc. (e.g., "at least Z of A, B, or C") refer to at least Z of the recited categories (A, B, and C) and do not require that each category contain at least Z units. Unless the context clearly dictates otherwise, throughout this specification, discussions using terms such as "processing," "computing," "calculating," "determining," etc. refer to the operations or processes of a particular apparatus, e.g., a special purpose computer or similar special purpose electronic processing / computing device.

[0130] Enumeration of Embodiments The present technology is described according to various aspects, for example, described below as numbered embodiments (1, 2, 3, etc.) for convenience. These are provided as examples and are not intended to limit the present technology. It is noted that any of the dependent embodiments can be combined in any combination and can be included in each independent embodiment.

[0131] A1. A coal blend comprising: a first coal having a first volatile matter mass fraction less than or equal to a first threshold; and a second coal having a second volatile matter mass fraction equal to or greater than a second threshold; the first threshold is at least 4.0% less than the second threshold; The ash fusion temperature is less than 2600°F; The coal blend has a total volatile matter mass fraction of 15% to 25%.

[0132] A2. A coal blend, a first coal having a first vitrinite fraction comprising a V8 vitrinite fraction, a V9 vitrinite fraction, a V10 vitrinite fraction, and a V11 vitrinite fraction, wherein the sum of the V8 vitrinite fraction, the V9 vitrinite fraction, the V10 vitrinite fraction, and the V11 vitrinite fraction is greater than 50%; and The coal blend comprises a first coal having a first vitrinite fraction comprising a V14 vitrinite fraction, a V15 vitrinite fraction, a V16 vitrinite fraction, a V17 vitrinite fraction, and a V18 vitrinite fraction, wherein the sum of the V14 vitrinite fraction, the V15 vitrinite fraction, the V16 vitrinite fraction, the V17 vitrinite fraction, and the V18 vitrinite fraction is greater than 50%.

[0133] A3. The coal blend of any one of embodiments A1-A2, wherein the coal blend does not include any coal having a volatile matter mass fraction greater than the first threshold and less than the second threshold.

[0134] A4. The coal blend of any one of embodiments 1-A3, comprising only the first coal and the second coal.

[0135] A5. The coal blend of any one of embodiments A1-A4, wherein the first threshold is less than 21.0% and the second threshold is greater than 25.0%.

[0136] A6. The coal blend of any one of embodiments A1-A5, wherein the ash fusion temperature is no greater than 2450°F, 2400°F, 2350°F, 2300°F, 2250°F, 2200°F, or 1800°F.

[0137] A7. The coal blend of any one of embodiments A1-A6, further comprising coke breeze.

[0138] A8. The coal blend of embodiment 6, wherein the coke breeze comprises 1-20% of the coal blend.

[0139] A9. The coal blend of any one of embodiments A7-A8, wherein 5.0% or less of the coke breeze is characterized as 10 mesh or larger coke breeze.

[0140] A10. The coal blend of any one of embodiments A6-A8, wherein no more than 10.0% of the coke breeze is characterized as 20 mesh or larger, or as 90 mesh or smaller (15-25%).

[0141] A11. The coal blend of any one of embodiments A1-A10, the first coal is at least 60% of the coal blend; The coal blend, wherein the second coal is greater than or equal to 15% of the coal blend.

[0142] A12. The coal blend of any one of embodiments A1-A11, the first coal is greater than or equal to 15% of the coal blend; The coal blend, wherein the second coal is greater than or equal to 60% of the coal blend.

[0143] A13. The coal blend of any one of embodiments A1-A12, wherein the mass fraction of calcium oxide, mass fraction of lime, mass fraction of trona, mass fraction of soda ash, mass fraction of caustic soda, mass fraction of low-ash melting slag, mass fraction of basic oxygen furnace (BOF) slag, mass fraction of cupola slag, mass fraction of iron, mass fraction of nickel, mass fraction of potassium, mass fraction of magnesium, mass fraction of sodium, mass fraction of calcium sulfate, mass fraction of rock wool, or mass fraction of biomass is less than 5.0%, or less than 3.0%, or less than 1.0%.

[0144] A14. The coal blend of any one of embodiments A1-A13, wherein the ash mass fraction is greater than 10.0%, or between 8.0% and 10.0%, or between 5.5 and 7.0%.

[0145] A15. The coal blend of any one of embodiments A1-A14, wherein the fluidity is at least 100 divisions per minute (ddpm), 150 ddpm, 200 ddpm, 250 ddpm, 260 ddpm, 270 ddpm, 280 ddpm, 290 ddpm, or in the range of 250-300 ddpm.

[0146] A16. The coal blend of any one of embodiments A1-A15, further comprising a third coal having a third volatile matter mass fraction less than or equal to the first threshold.

[0147] A17. The coal blend of any one of embodiments A1-A16, wherein the first coal has a V16 vitrinite mass fraction greater than 25%.

[0148] A18. The coal blend of any one of embodiments A1-A17, wherein the sum of the V8 vitrinite fraction, the V9 vitrinite fraction, and the V10 vitrinite fraction of the second coal is greater than 40%.

[0149] A19. The coal blend of any one of embodiments A1-A18, wherein the sulfur mass weight fraction is at least 5.0%.

[0150] A20. The coal blend of any one of embodiments A1-A19, wherein the calcium weight fraction is at least 5.0%.

[0151] A21. The coal blend of any one of embodiments A1-A20, wherein the inerts content is greater than or equal to 32.0%, between 33.0% and 35.0%, or between 28.0% and 40.0%.

[0152] A22. The coal blend of any one of embodiments A1-A21, wherein the alumina content of the ash is less than 7.0%.

[0153] A23. The coal blend of any one of embodiments A1-A22, wherein the first threshold is 20% and the second threshold is 30%.

[0154] A24. Coal blends, a first coal having a first volatile matter mass fraction less than or equal to a first threshold; and a second coal having a second volatile matter mass fraction equal to or greater than a second threshold; the first threshold is less than 21.0%, the second threshold is greater than 25.0%, the ash fusion temperature is less than 2600°F or less than 2450°F; The coal blend has a total volatile matter mass fraction of 15% to 25%.

[0155] A25. The coal blend of embodiment A24, wherein the ash fusion temperature is less than 2300°F.

[0156] A26. The coal blend of any one of embodiments A24-A25, wherein the ash fusion temperature is less than 2100°F.

[0157] A27. The coal blend of any one of embodiments A24-A26, further comprising a third coal having a third volatile matter mass fraction less than or equal to the first threshold, the first coal and third coal comprising V14 vitrinite, V15 vitrinite, V16 vitrinite, and V17 vitrinite, respectively.

[0158] A28. The coal blend of any one of embodiments A24-A27, the first coal comprises V14 vitrinite, V15 vitrinite, and V16 vitrinite; the fraction of V16 vitrinite in the first coal is greater than the fraction of V15 vitrinite in the first coal; The coal blend, wherein the fraction of V15 vitrinite in the first coal is greater than the fraction of V14 vitrinite in the first coal.

[0159] A29. The coal blend of any one of embodiments A24-A28, wherein the first threshold value is less than 20.0%.

[0160] A30. The coal blend of any one of embodiments A24-A29, wherein the second threshold is greater than 28%.

[0161] A31. The coal blend of any one of embodiments A24-A30, wherein the difference between the first threshold value and the second threshold value is greater than 10%.

[0162] A32. A method for determining a coal blend for the production of a coke product, comprising: obtaining a plurality of coal parameters corresponding to a first coal and a second coal; the first coal having a first volatile matter mass fraction less than or equal to a first threshold; obtaining said parameters, wherein said second coal has a second volatile matter mass fraction greater than or equal to a second threshold, said first threshold being at least 4.0% less than said second threshold; Obtaining target coke product parameters; determining a plurality of coke product parameters based on the plurality of coal parameters and the target coke product parameter; and determining a coal blend formulation for a coal blend comprising a combination of the first coal and the second coal based on the plurality of coke product parameters.

[0163] A33. Further, obtaining breeze parameters of coke breeze, obtaining a breeze parameter indicative of at least one of a volatile matter mass fraction of the breeze, an ash mass fraction of the breeze, or a sulfur mass fraction of the breeze; and The method of embodiment A32, comprising determining a formulation of the coal blend, comprising determining an amount of coke breeze to add to the coal blend based on the breeze parameters.

[0164] A34. The method of any one of embodiments A32-A33, wherein the first threshold is less than 21.0% and the second threshold is greater than 28.0%.

[0165] B1. A method for producing a coke product, comprising: adding water to the coal blend to increase the moisture content of the coal blend; Charging the coal blend into a coke oven; and heating the charged coal blend so that a crown temperature of the coke oven is above a lower coking temperature limit for a pyrolysis duration of a coking cycle of the charged coal blend; The lower limit coking temperature is in the range of 1200 to 2300°F, the pyrolysis duration begins when the furnace crown is above the lower coking temperature limit; the pyrolysis duration ends when the furnace crown temperature falls below the lower coking temperature limit; The method, wherein the duration of the pyrolysis is greater than 24 hours.

[0166] B2. The method of embodiment B1, wherein the lower coking temperature limit is within the range of 1800 to 2200°F.

[0167] B3. The method of any one of embodiments B1-B2, wherein the upper crown temperature limit is limited by an upper coking temperature limit of greater than 2300°F.

[0168] B4. The method of any one of embodiments B1-B3, wherein the upper crown temperature limit is limited by an upper coking temperature limit of greater than 2500°F.

[0169] B5. The method of embodiment B4, wherein the crown temperature is greater than the sole flue temperature of the coke oven throughout the duration of the pyrolysis.

[0170] B6. The method of any one of embodiments B1-B5, wherein the crown temperature of the coke oven during the pyrolysis duration is 2100-2300°F.

[0171] B7. The method of any one of embodiments B1-B6, wherein the crown temperature is within a 100°F temperature range for at least 12 hours of the pyrolysis duration.

[0172] B8. The method of any one of embodiments B1-B7, wherein the soleflue temperature is less than 2000°F, 1900°F, 1800°F, or 1700°F during the pyrolysis duration.

[0173] B9. The method of any one of embodiments B1-B8, wherein the soleflux temperature is 1400-1800°F during the duration of the pyrolysis.

[0174] B10. The method of any one of embodiments B1-B9, wherein the soak time of the loaded coal blend is less than 1.0 hour, 5.0 hours, or 10.0 hours.

[0175] B11. Adding water to the coal blend determining whether the test moisture of the coal blend meets a set of target moisture values; and The method of any one of embodiments B1-B10, comprising, in response to determining that the test moisture of the coal blend does not meet the set of target moisture values, exposing the coal blend to more water.

[0176] B12. The method of any one of embodiments B1-B11, wherein the moisture weight fraction of the coal blend charged to the coke oven is at least 8.0%, 9.0%, 10.0%, 11.0%, 12.0%, or 8.0-13%.

[0177] B13. The method of any one of embodiments B1-B12, wherein adding water to the coal blend comprises adding water to a belt transporting the coal blend.

[0178] B14. The method of any one of embodiments B1-B13, wherein adding water to the coal blend is based on volatile matter of the coal blend.

[0179] B15. The method of any one of embodiments B1-B14, wherein adding water to the coal blend comprises adding water such that the moisture content of the charged coal is approximately equal to, or within 1-5% of, the volatile matter mass fraction of the coal blend.

[0180] B16. The method of any one of embodiments B1-B15, wherein the pyrolysis duration is about 48 hours.

[0181] B17. The method of embodiment B16, wherein said pyrolysis duration is about 72 hours.

[0182] B18. The method of any one of embodiments B1-B17, wherein the volatile matter mass fraction of the coal blend is less than 27.0%.

[0183] B19. The method of any one of embodiments B1-B18, wherein the coke oven includes an intake damper movable to a plurality of positions between open and closed, and wherein heating the coal blend includes maintaining the coke oven intake damper in a position that is less than half open for a majority of the first 24 hours of the coking cycle.

[0184] B20. The method of any one of embodiments B1-B19, wherein the coke oven includes an intake damper movable to a plurality of positions between open and closed, and wherein heating the coal blend includes maintaining the coke oven intake damper in a position that is less than half open during a majority of the coking cycle.

[0185] B21. Heating the coal blend opening an intake damper at the start of the coking cycle; The method of any one of embodiments B1-B20, comprising performing a first closing operation of the intake damper from a first configuration to a second configuration within two hours of loading the coal blend, wherein a flow through an intake duct of the coke oven while the intake damper is in the second configuration is less than a flow through the intake duct while the intake damper is in the first configuration.

[0186] B22. The method of embodiment B21, wherein heating the coal blend is based on a temperature change rate that is less than or equal to a temperature change rate threshold, the temperature change rate threshold being less than or equal to 50°F per hour.

[0187] B23. The method of any one of embodiments B1-B22, wherein heating the coal blend comprises closing a solflubricating damper or maintaining the solflubricating damper in a closed position for a majority of the pyrolysis duration.

[0188] B24. The method of any one of embodiments B1-B23, wherein heating the coal blend comprises closing a soleflue damper or maintaining the soleflue damper in a closed position during a majority of the coking cycle.

[0189] B25. The method of any one of embodiments B1-B24, wherein the ratio of the soak time to the cycle duration of the loaded coal blend is less than 33.0%, 15%, or 5%.

[0190] B26. A method comprising heating the coal blend to a coking temperature in a coke oven for a coking pyrolysis duration, the pyrolysis duration begins when the furnace crown is above a lower coking temperature limit; the pyrolysis duration ends when the furnace crown drops below the lower coking temperature limit; The method, wherein the lower coking temperature limit is within the range of 1200 to 2300°F.

[0191] B27. The method of embodiment B26, wherein the coking temperature varies by no more than 75°F, 60°F, 50°F, 40°F, or 35°F during at least 12 hours of the pyrolysis duration.

[0192] B28.Furthermore, opening an intake damper of the coke oven; initiating a closing operation of the intake damper at least 2 hours, 4 hours, 6 hours, 8 hours, 10 hours, or 12 hours after opening the intake, the closing operation comprising closing the intake damper to a position less than halfway open; and The method of any one of embodiments B26-B27, comprising maintaining the intake damper no further open than said position for at least 12, 16, or 20 hours after initiating the closing operation.

[0193] B29. The method of any one of embodiments B26-B28, wherein the coal blend comprises coke breeze, and the ash mass fraction of the coke breeze is 6.5%, 7.0%, 10.0%, 13%, 15%, or 20% or greater.

[0194] B30. The method of any one of embodiments B26-B29, wherein the coal blend comprises coke breeze, and the ash mass fraction of the coke breeze is 15.0% or greater.

[0195] B31. The method of any one of embodiments B26-B30, wherein the coal blend has an ash fusion temperature of no more than 2400°F, 2350°F, 2300°F, 2250°F, 2200°F, 2000°F, or 1800°F.

[0196] B32. The method of any one of embodiments B26-B31, wherein the flowability of the coal blend is at least 100 divisions per minute (ddpm), 150 ddpm, 250 ddpm, 260 ddpm, 270 ddpm, 280 ddpm, 290 ddpm, 300 ddpm, 350 ddpm, 400 ddpm, or between 100 and 400 ddpm.

[0197] B33. The method of any one of embodiments B26-B35, wherein the total volatile matter mass fraction of the coal blend is 18-22%.

[0198] B34. A coke oven, a furnace chamber including a crown and a sole flue; an intake duct in fluid communication with the furnace chamber, the intake duct configured to receive exhaust gases from the furnace chamber; an intake damper in fluid communication with the intake duct, the intake damper being disposed in any one of a plurality of positions including a fully open position and a fully closed position, wherein operation of the intake damper between positions creates an airflow through the intake duct; a damper actuator configured to change the position of the intake damper between the plurality of positions; a common tunnel in fluid communication with the intake duct, the common tunnel configured to receive exhaust gases from the intake duct; a controller configured to perform an operation during a coking cycle, the operation including heating a coal blend in a coke oven to a coking temperature for a pyrolysis duration of the coking cycle; the pyrolysis duration begins when the furnace crown is above a lower coking temperature limit; the pyrolysis duration ends when the furnace crown drops below the lower coking temperature limit; The lower limit coking temperature is in the range of 1200 to 2300°F, The coke oven, including the controller, wherein the sole flue temperature is maintained below the crown temperature throughout the duration of the pyrolysis.

[0199] B35. The controller further comprises: opening an intake damper at the start of the coking cycle; The coke oven of embodiment B34, configured to perform an operation including performing a first closing operation of the intake damper from a first configuration to a second configuration within two hours of loading the coal blend, wherein a flow through an intake duct of the coke oven while the intake damper is in the second configuration is less than a flow through the intake duct while the intake damper is in the first configuration.

[0200] B36. The coke oven of any of embodiments B34-B35, wherein the moisture weight fraction of the coal blend is 10-12% before heating the coal blend.

[0201] C1. A coke product configured to be burned in a cupola furnace, heating the coal blend in a coke oven to a lower coking temperature limit, wherein a pyrolysis duration begins when a crown temperature of the coke oven reaches the lower coking temperature limit, and the crown temperature is greater than a sole flue temperature of the coke oven during the pyrolysis duration; and and removing from said coke oven a coke product produced from said coal blend, said coke product having a coke reactivity index of at least 30%.

[0202] C2. The coke product of embodiment C1, long oval, a first dimension between 6.0 and 12.0 inches, and The coke product includes a second dimension perpendicular to the first dimension that is greater than 2.5 inches.

[0203] C3. The operation further comprises: loading the coal blend into the coke oven before heating the coal blend; the coal blend comprises a first coal and a second coal; the first coal having a first volatile matter mass fraction less than or equal to 21.0%; the second coal having a second volatile matter mass fraction of 27.0% or greater; The coke product of any one of embodiments C1-C2, wherein the coal blend does not include a coal having a volatile matter mass fraction between 15.0% and 27.0%.

[0204] C4. The coke product of any one of embodiments C1-C3, wherein the coking rate is less than 1 ton of coal blend charged per hour, less than 0.75 ton of coal blend charged per hour, or less than 0.5 ton of coal blend charged per hour.

[0205] C5. The coke product of any one of embodiments C1-C4, wherein the ash fusion temperature is less than 1800°F or less than 2450°F.

[0206] C6. The coke product of any one of embodiments C1-C5, wherein the coke reactivity index is at least 35.0%, 40.0%, or 45.0%.

[0207] C7. The coke product of any one of embodiments C1-C6 having a coke reaction strength (CSR) of 1.0% or greater.

[0208] C8. The coke product of any one of embodiments C1-C7 having a coke reactivity index (CRI) of 25% to 65% and a coke post reaction strength (CSR) of 1% or greater.

[0209] C9. The coke product of any one of embodiments C1-C8 having 90% or more 2-inch falling shutters.

[0210] C10. The coke product of any one of embodiments C1-C9 having 80% or more 4-inch falling shutters.

[0211] C11. The coke product of any one of embodiments C1-C10, wherein producing the coke product further comprises operating a closing of an intake damper of the coke oven within 4 hours of the start of the pyrolysis duration.

[0212] C12. A group of coke products, heating the coal blend in a coke oven to a lower coking temperature limit, wherein a pyrolysis duration begins when a crown temperature of the coke oven reaches the lower coking temperature limit; and a coke oven crown temperature during said pyrolysis duration being greater than a sole flue temperature, said coke product population comprising foundry coke products having a coke reactivity index of at least 30%, a nodule coke product, and a coke breeze product, said coke products being produced by an operation comprising closing an intake damper of said coke oven within four hours of the start of said pyrolysis duration;

[0213] C13. A population of coke products according to any one of embodiments C12, the foundry coke product comprises at least 40% of the population of coke products; The population of coke products, wherein the nodule coke product and the coke breeze product comprise at least 20% of the population.

[0214] C14. A population of coke products according to embodiment C13, the foundry coke product comprises at least 60% of the population of coke products; The population of coke products, wherein the nodule coke product and the coke breeze product comprise at least 20% of the population of coke products.

[0215] C15. The population of coke products of any one of embodiments C12-C14, wherein the ash mass fraction in the foundry coke product is 5.0% to 10.0%.

[0216] C16. The population of coke products of any one of embodiments C12-C15, wherein the volatile matter mass fraction in the foundry coke product is less than 1.0%.

[0217] C17. The population of coke products of any one of embodiments C12-C16, wherein the foundry coke product products have 80% or more 4-inch falling shutters.

[0218] C18. The population of coke products of any one of embodiments C12-C17, wherein the coal blend has 15% to 40% volatile matter, and the coal blend has a fluidity of 100 divisions per minute or greater.

[0219] C19. The population of coke products of any one of embodiments C12-C18, wherein the nodule coke product products have a hydraulic diameter of less than 2.0 inches.

[0220] C20. A coke product produced by an operation comprising heating a coal blend in a coke oven to a lower coking temperature to produce a coke product; the pyrolysis duration begins when the crown temperature of the coke oven reaches the lower coking temperature limit; the crown temperature is greater than the sole flue temperature of the coke oven throughout the duration of the pyrolysis; The coke product has an ash fusion temperature of less than 2300°F, less than 2400°F, or less than 2600°F.

[0221] C21. The operation further comprises: increasing the moisture content of the coal blend to at least 5.0%, 7.5%, or 10.0% moisture; and The coke product of embodiment C20, comprising increasing the moisture of the coal blend before loading the coal blend into the coke oven.

[0222] D1. Coke Reactivity Index (CRI) of at least 30%, and Coke products containing an ash fusion temperature (AFT) below 1316°C.

[0223] D2. A coke product containing ash having a composition satisfying the following formula: Ash melting temperature (AFT)=19×(Al2O3_mass_fraction)+15×(SiO2_mass_fraction+TiO2_mass_fraction)+10×(CaO_mass_fraction+MgO_mass_fraction)+6×(Fe2O3_mass_fraction+Na2O_mass_fraction), During the ceremony, The AFT is a value of 1204°C to 1426°C, the SiO2_mass_fraction is the SiO2 mass fraction of the ash; the Al2O3_mass_fraction is the Al2O3 mass fraction of the ash, the Fe2O3_mass_fraction is the Fe2O3 mass fraction of the ash, The CaO_mass_fraction is the CaO mass fraction of the ash, The MgO_mass_fraction is the MgO mass fraction of the ash.

[0224] D3. Coke product containing ash having a composition satisfying the following formula: Ash melting temperature (AFT)=19×(Al2O3_mass_fraction)+15×(SiO2_mass_fraction+TiO2_mass_fraction)+10×(CaO_mass_fraction+MgO_mass_fraction)+6×(Fe2O3_mass_fraction+Na2O_mass_fraction+K2O_mass_fraction), During the ceremony, The AFT is a value of 982°C to 1426°C, the SiO2_mass_fraction is the SiO2 mass fraction of the ash; the Al2O3_mass_fraction is the Al2O3 mass fraction of the ash, the Fe2O3_mass_fraction is the Fe2O3 mass fraction of the ash, The CaO_mass_fraction is the CaO mass fraction of the ash, The MgO_mass_fraction is the MgO mass fraction of the ash, The K2O_mass_fraction is the K2O mass fraction of the ash.

[0225] D4. Coke product containing ash having a composition satisfying the following formula: Ash fusion temperature (AFT) = 401.5 + 26.3 × SiO2 mass fraction + 40.7 × Al2O3 mass fraction - 11.0 × Fe2O3 mass fraction - 7.9 × CaO mass fraction - 112 × MgO mass fraction, During the ceremony, The AFT is a value of 982°C to 1204°C, the SiO2_mass_fraction is the SiO2 mass fraction of the ash; the Al2O3_mass_fraction is the Al2O3 mass fraction of the ash, the Fe2O3_mass_fraction is the Fe2O3 mass fraction of the ash, The CaO_mass_fraction is the CaO mass fraction of the ash, The MgO_mass_fraction is the MgO mass fraction of the ash.

[0226] D5. The coke product of any one of embodiments D1-D4, wherein the AFT is approximately equal to at least one of 1204°C, 1260°C, 1288°C, 1316°C, 1343°C, 1371°C, 1399°C, or 1427°C.

[0227] D6. The coke product of any one of embodiments D1-D5, having an initial deformation temperature of 1149°C to 1316°C.

[0228] D7. The coke product of any one of embodiments D1-D6 having a softening temperature of 1177°C to 1371°C.

[0229] D8. The coke product of any one of embodiments D1-D7 having a hemispherical temperature of 1204°C to 1371°C.

[0230] D9. The coke product of any one of embodiments D1-D8, having a flow temperature of 1232°C to 1427°C.

[0231] D10. The coke product of any one of embodiments D1-D9, wherein the ash mass fraction is 10.0% or less.

[0232] D11. The coke product of any one of embodiments D1-D10, wherein the mass fraction of sulfur or sulfur oxides is 1.0% or less.

[0233] D12. The coke product of any one of embodiments D1-D11, Produced from a coal blend containing ash containing Al2O3 and SiO2, The coke product, wherein the total mass fraction of Al2O3 and SiO2 in the ash is 65% or less.

[0234] D13. The coke product of any one of embodiments D1-D12, wherein the AFT is about 1204°C.

[0235] D14. The coke product of any one of embodiments D1-D13, Produced from a coal blend containing ash containing Al2O3 and SiO2, The coke product, wherein the total mass fraction of Al2O3 and SiO2 in the ash is 65% to 80%.

[0236] D15. The coke product of any one of embodiments D1-D14, wherein the AFT is 1204°C to 1260°C.

[0237] D16. The coke product of any one of embodiments D1-D15, Made from a coal blend containing ash containing CaO, The coke product, wherein the CaO mass fraction of the ash is at least 2.0%.

[0238] D17. The coke product of any one of embodiments D1-D16, wherein the coke reactivity index (CRI) is at least 25.0%.

[0239] D18. The coke product of any one of embodiments D1-D17, having a coke reaction strength (CSR) of 40.0% or greater.

[0240] D19. The coke product of any one of embodiments D1-D18, having at least 90% 2-inch falling shutters.

[0241] D20. The coke product of any one of embodiments D1-D19, having at least 80% 4-inch falling shutters.

[0242] D21. The coke product of any one of embodiments D1-D20, wherein the ash mass fraction is at least 8.0%.

[0243] D22. The coke product of any one of embodiments D1-D21, wherein the volatile matter mass fraction is 1.0% or less.

[0244] D23. The coke product of any one of embodiments D1-D22, wherein the fixed carbon content is at least 94.5%.

[0245] D24. The coke product of any one of embodiments D1-D23, wherein the fixed carbon content is at least 85.0%.

[0246] D25. At least Na +1 , Fe 2+ , or F 3+ The coke product of any one of embodiments D1-D24, comprising:

Claims

1. A method for producing coke products, Adding water to the coal blend, Loading the aforementioned coal blend into a coke oven, and The process includes heating the loaded coal blend such that the crown temperature of the coke oven is higher than the lower coking temperature for the duration of the thermal decomposition of the coking cycle of the loaded coal blend. The lower limit coking temperature is in the range of 1200 to 2300°F. The thermal decomposition duration begins when the crown temperature of the furnace becomes higher than the lower limit coking temperature. The thermal decomposition duration ends when the crown temperature of the furnace falls below the lower limit coking temperature. The crown temperature remains higher than the sole flue temperature of the coke oven throughout the thermal decomposition duration. If the aforementioned thermal decomposition duration is longer than 24 hours, method.

2. The method according to claim 1, wherein the lower limit coking temperature is in the range of 1800 to 2200°F.

3. The method according to claim 1, wherein the upper limit of the crown temperature is limited by an upper limit coking temperature higher than 2300°F.

4. The method according to claim 1, wherein the crown temperature of the coke oven during the thermal decomposition duration is 2100 to 2300°F.

5. The method according to claim 1, wherein the crown temperature is within a temperature range of 100°F for at least 12 hours of the thermal decomposition duration.

6. The method according to claim 1, wherein the Sohlfleu temperature is less than 2000°F during the thermal decomposition duration.

7. The method according to claim 1, wherein the Sohlfleu temperature is 1400 to 1800°F during the thermal decomposition duration.

8. The method according to claim 1, wherein the soaking time of the loaded coal blend is less than 10.0 hours.

9. Adding water to the aforementioned coal blend To determine whether the test moisture content of the coal blend meets the target moisture content, and In response to the determination that the test moisture content of the coal blend does not meet the set of target moisture values, water is added to the coal blend. The method according to claim 1, including the method described in claim 1.

10. The method according to claim 1, wherein the moisture content by weight of the coal blend loaded into the coke oven is at least 8.0%.

11. The method according to claim 1, wherein adding water to the coal blend includes adding water to a belt that carries the coal blend.

12. The method according to claim 1, wherein water is added to the coal blend based on the volatile substances of the coal blend.

13. The method according to claim 1, wherein the addition of water to the coal blend is such that the moisture content of the loaded coal is approximately equal to, or within 1 to 5%, the volatile matter mass fraction of the coal blend.

14. The method according to claim 1, wherein the duration of thermal decomposition is approximately 48 hours.

15. The method according to claim 1, wherein the volatile matter mass fraction of the coal blend is less than 27.0%.

16. The method according to claim 1, wherein the coke oven includes an intake damper that is movable between open and closed positions, and the heating of the coal blend includes keeping the intake damper of the coke oven in a position where it is less than half open for most of the first 24 hours of the coking cycle.

17. The method according to claim 1, wherein heating the coal blend is based on a rate of temperature change below a temperature change threshold, and the temperature change threshold is 50°F per hour or less.

18. The method according to claim 1, wherein heating the coal blend includes closing or maintaining the sole flue damper in the closed position for most of the duration of the thermal decomposition.

19. The method according to claim 1, wherein the ratio of the soak time of the loaded coal blend to the cycle duration of the loaded coal blend is less than 33.0%.

20. A method comprising heating a coal blend in a coke oven to the coking temperature for the duration of the coking thermal decomposition period, The aforementioned pyrolysis duration begins when the crown temperature of the furnace rises above the lower limit coking temperature. The thermal decomposition duration ends when the crown temperature of the furnace falls below the lower limit coking temperature. The lower limit coking temperature is in the range of 1200 to 2300°F. The crown temperature remains higher than the sole flue temperature of the coke oven throughout the thermal decomposition duration. If the aforementioned thermal decomposition duration is longer than 24 hours, method.

21. The method according to claim 20, wherein the coking temperature changes at 75°F or less for at least 12 hours of the thermal decomposition duration.

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