Ferrocoke Production Using High Ash Coal Blends
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Solution Overview
Problem
The use of high ash content coal in ferrocoke production leads to decreased fluidity and strength, increasing manufacturing costs and fuel consumption, while also risking fusion during carbonization, limiting the use of cheap and poor-quality coals due to ash content and caking properties.
Innovation Solution
A method involving the compression molding of coal and iron ore with a high ash content coal, where the coal has an ash content of not less than 10.7% and a mean maximum reflectance of not less than 0.81%, is used to produce ferrocoke, suppressing strength decrease and fusion issues during carbonization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If high ash content coal is used for ferrocoke production, then manufacturing cost is reduced, but coke strength and fluidity decrease
Solution Approach 1:
The invention changes the chemical composition parameters of the coal blend by incorporating high ash content coal (10-30% ash) combined with specific amounts of caking coal (15-40% volatile matter) to achieve the desired coke strength while maintaining cost benefits. This parameter adjustment resolves the contradiction between using cheap high-ash coal and producing strong coke.
2Ease of manufacture
If high ash content coal is used for ferrocoke production, then manufacturing cost is reduced, but fluidity during carbonization decreases
Solution Approach 1:
The invention adjusts the volatile matter content parameter by blending high ash coal with caking coal having 15-40% volatile matter, creating a balanced coal mixture that maintains adequate fluidity during carbonization while incorporating cost-effective high ash content coal.
3Ease of manufacture
If high ash content coal is used for ferrocoke production, then manufacturing cost is reduced, but fusion during carbonization occurs
Solution Approach 1:
The invention modifies the coal blend composition parameters by limiting high ash coal to 10-30% ash content and combining it with specific proportions of caking coal, thereby preventing fusion during carbonization while maintaining the economic advantage of using high ash content coal.
4Quantity of substance
If ash removal methods are applied to high ash content coal, then ash content is reduced, but manufacturing cost increases
Solution Approach 1:
Instead of investing in expensive ash removal processes, the invention accepts the ash content in high ash coal and uses it in controlled proportions within the ferrocoke blend, thereby avoiding the high costs of oil agglomeration, floatation, or other ash removal technologies while still producing usable coke.
5Ease of manufacture
If high ash content coal is used for chamber oven coke, then manufacturing cost is reduced, but fluidity and expandability decrease
Solution Approach 1:
The invention adjusts the coal blend parameters by combining high ash content coal (10-30%) with caking coal having specific volatile matter content (15-40%), creating a mixture that maintains the necessary fluidity and expandability for chamber oven carbonization while incorporating cost-effective high ash coal.
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 allows for the production of high-strength ferrocoke using cheap and poor-quality coal, avoiding fusion and maintaining coke strength, thus reducing operational issues and costs in blast furnace operations.
Implementation Method 1
a method involving the compression molding of coal and iron ore
Implementation Method 2
carbonizing a mixture of coal and iron ore
Data Source
AI summary
A method for producing ferrocoke in which it is possible to use a cheap and poor-quality coal having a high ash content while suppressing the decrease of the strength in ferrocoke or formed coke and a special coal mixing is not performed with respect to the fusion frequently causing problems in the carbonization with the shaft furnace. In a method for producing ferrocoke by molding and carbonizing a mixture of coal and iron ore, the coal is a single coal or a mixture of plural coals and a non-caking or slight caking coal having a load average value of ash content of not less than 10.7% and a load average value of mean maximum reflectance of not less than 0.81% is used.