Custom Coke Feedstock Blending for High-Quality Pyrolysis
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Solution Overview
Problem
Existing coke processing methods face challenges in producing high-quality coke efficiently and environmentally friendly coke production, particularly in the absence of universal prediction models for custom coke production and inefficient use of carbonaceous materials.
Innovation Solution
A method involving mixing first and second sources of carbonaceous materials, analyzing their coking feasibility, and customizing them into predetermined compositions for pyrolysis to produce high-grade coke, utilizing waste materials like coal fines and coke waste fines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional oven methods are used for coke production, then coke can be produced with established processes, but the production efficiency is low and environmental pollution occurs
Solution Approach 1:
The patent applies parameter changes by transitioning from traditional constant-temperature oven coking to a multi-stage temperature profile in a rotary kiln. The process involves progressive heating stages (e.g., 500°C, 700°C, 900°C, 1100°C) with controlled residence times, allowing optimization of both production efficiency and environmental performance through precise thermal parameter control
Solution Approach 2:
The coking process is segmented into multiple distinct stages within the rotary kiln system. Each stage operates at a different temperature zone and duration, enabling separate optimization of various coking aspects (volatilization, carbonization, graphitization) while maintaining overall high efficiency and reduced pollution
2Quantity of substance
If low-grade carbonaceous materials are used as feedstock, then material cost is reduced, but the quality of produced coke deteriorates
Solution Approach 1:
The patent employs composite material principles by creating optimized blends of different carbonaceous feedstocks (coals, petroleum cokes, biomass) with varying properties. This allows the use of lower-grade, cheaper materials while compensating for their deficiencies through complementary materials in the mixture, achieving both cost reduction and quality maintenance
Solution Approach 2:
The patent applies preliminary action through pre-blending and pre-processing of carbonaceous materials before coking. Feedstocks are prepared, sized, and mixed in specific ratios beforehand to ensure optimal coking behavior, allowing low-grade materials to be pre-conditioned to achieve high-quality coke output
3Adaptability or versatility
If custom coke production with specific properties is pursued, then product versatility is improved, but process complexity increases
Solution Approach 1:
The patent applies dynamics by making the coking process adjustable and adaptable through variable parameters. The rotary kiln system allows dynamic control of rotation speed, temperature profiles, residence times, and feedstock ratios to produce coke with different properties (strength, reactivity, size) as needed, without requiring fundamentally different equipment for each product specification
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
Enables efficient production of high-quality coke with reduced energy consumption and environmental friendliness by utilizing waste materials, overcoming the limitations of traditional methods.
Implementation Method 1
The single feedstock begins to be pyrolyzed and is analyzed to determine its coking feasibility. Depending on the analysis, the single feedstock is customized into a predetermined material composition. This composition then continues to be pyrolyzed in a pyrolyzer to produce coke material.
Data Source
AI summary
In one embodiment, a method for producing coke that includes mixing at least a first and a second carbonaceous material into a single feedstock of carbonaceous material. The coking feasibility of the single feedstock of carbonaceous material is then determined. The single feedstock is customized into a predetermined material composition, and then the customized single feedstock is pyrolyzed to produce coke material and coke by-products. Other embodiments are also disclosed.