Foundry Coke Blends for Lower Ash Fusion and Carbon Transfer
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Solution Overview
Problem
The production of foundry coke is costly due to high manufacturing, transportation, and environmental costs, and traditional coke products have high ash fusion temperatures that limit carbon transfer to molten metal in cupolas.
Innovation Solution
Producing coke with a lower ash fusion temperature by selecting coal blends with specific compositions and additives to enhance carbon transfer, using empirical models to control ash fusion temperatures, and optimizing coal blends to improve coke efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional coke production methods are used, then high quality foundry coke with high carbon content and strength is produced, but production cost including manufacturing, transportation, and environmental cost is high
Solution Approach 1:
The patent changes the ash fusion temperature parameter of coke from traditional high values (>1200°C) to lower values (900-1200°C) by modifying coal blend composition and coking parameters. This parameter change maintains coke quality while reducing production costs by improving carbon transfer efficiency in cupolas, thereby resolving the contradiction between manufacturing precision and ease of manufacture
Solution Approach 2:
The patent uses composite coal blends combining different coal types (bituminous coal, sub-bituminous coal, lignite) with specific ratios to produce coke with optimized properties. This composite approach allows tailoring of ash fusion temperature and carbon content to achieve high quality coke at lower production cost
2Strength
If coke with high ash fusion temperature is used, then coke strength and stability are maintained, but carbon transfer to molten metal in cupolas is limited
Solution Approach 1:
The patent optimizes the ash fusion temperature parameter to a specific range (900-1200°C) that balances coke strength requirements with carbon transfer efficiency. This optimized parameter allows the coke to maintain structural integrity while facilitating better melting and carbon transfer to molten metal, resolving the contradiction between strength and productivity
Solution Approach 2:
The patent employs periodic heating cycles in the cupola furnace that take advantage of the lowered ash fusion temperature. The periodic thermal cycles promote efficient carbon transfer during specific phases of the melting process while maintaining coke strength during other phases, achieving both objectives simultaneously
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
Increased carbon transfer to molten metal in cupolas, leading to better cupola performance and reduced production costs through optimized coke production processes.
Implementation Method 1
producing a coke product from the coal blend
Data Source
AI summary
A coke product configured to be used in foundry cupolas to melt iron and produce cast iron products is disclosed herein. In some embodiments, the coke product has a Coke Reactivity Index (CRI) of at least 30% and an ash fusion temperature (A FT) less than 1316° C. Additionally or alternatively, the coke product can comprise a fixed carbon content of at least 80% and/or a volatile matter content of no more than 1.0%.