Coke Processing Energy Production via Waste Feedstock Blending
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Solution Overview
Problem
Current coke processing methods face challenges in efficiently producing high-quality coke without pollution and require high-quality coals, are limited by the use of only two carbonaceous materials, and lack universal prediction models for custom coke production, leading to inefficiencies and environmental concerns.
Innovation Solution
A method involving mixing a first and second source of carbonaceous materials, such as coal fines and coke waste fines, to create a single feedstock that is pyrolyzed to produce high-grade coke, with the gaseous by-product treated and utilized externally, allowing for environmentally friendly and energy-efficient production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional coke processing methods use high-quality coals only, then coke quality is improved, but material cost and resource waste increase
Solution Approach 1:
The invention changes the chemical composition parameters of the feedstock by blending different carbonaceous materials (coal fines, coke waste fines, petroleum coke) in specific ratios. This allows the use of lower-quality materials that individually would not produce high-quality coke, yet their combination achieves the desired coke strength and reactivity properties
Solution Approach 2:
The invention creates a composite feedstock material by combining multiple types of carbonaceous materials with different properties. The composite blend compensates for the weaknesses of individual components, enabling high-quality coke production from waste and low-grade materials that would otherwise be discarded
2Device complexity
If traditional coke processing uses limited carbonaceous materials, then process simplicity is maintained, but production flexibility and adaptability decrease
Solution Approach 1:
The invention creates a universal feedstock formulation that can accommodate multiple types of carbonaceous materials (coal fines, coke waste fines, petroleum coke, biomass). The blending process and pyrolysis method remain the same regardless of the specific materials used, providing flexibility to adapt to different material availabilities and market conditions
3Power
If coke processing produces gas by-products, then energy production increases, but environmental pollution worsens
Solution Approach 1:
The invention converts the harmful gas by-products (CO, H2, CH4) that would normally be pollutants into a beneficial energy resource. The gas is captured and used to generate electricity and heat within the coking plant, and excess gas is sold to external energy providers, transforming an environmental problem into an energy asset
4Strength
If coke processing requires high-quality coals, then coke strength is improved, but energy consumption increases
Solution Approach 1:
The invention makes the coking process self-sufficient by using the gas generated during pyrolysis to provide the heating energy required for the process. The system captures its own by-products and uses them to fuel its own operation, eliminating the need for external high-quality coal inputs and reducing overall energy consumption
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method enables the production of high-quality coke using waste materials, reduces energy consumption, and avoids environmental pollution by utilizing waste products, while not being limited to specific coal types, thus enhancing efficiency and sustainability.
Implementation Method 1
The single feedstock is pyrolyzed in a pyrolyzer to produce coke material. A gas by-product is harnessed during the pyrolyzing
Data Source
AI summary
A method is disclosed, for producing coke in which at least a first and second source of carbonaceous materials are introduced as feedstock into a mixer. The materials are mixed into a single feedstock, and the single feedstock is analyzed to determine its coking feasibility. The single feedstock is pyrolyzed in a pyrolyzer to produce at least a coke material and a gaseous by-product. At least a portion of the gaseous by-product is used outside of the pyrolyzer. Other embodiments are also disclosed.