Foundry Coke Blend and Shape Control for Higher Packing Density
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The production of high-quality foundry coke is hindered by high costs, including manufacturing, transportation, and environmental costs, necessitating a more efficient and cost-effective process to produce coke with unique properties.
Innovation Solution
A proprietary coking process using a horizontal oven with a predetermined coal blend and specific inert content produces HD+™ coke products, including oblong-shaped foundry coke with improved hydraulic diameter, low Coke Reactivity Index (CRI), and high Coke Strength after Reaction (CSR), which are then processed to enhance packing density and reduce latent heat loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional coking processes are used to produce foundry coke, then basic coke products are obtained, but production costs including manufacturing, transportation, and environmental costs are high
Solution Approach 1:
The patent applies parameter changes by modifying the coal blend composition (adding 5-50% breeze), changing the coke shape (oblong instead of round), and adjusting size distribution to improve packing density. These parameter changes enable higher yield and reduced transportation costs while maintaining coke quality
Solution Approach 2:
The patent uses composite materials by creating a blended coal charge combining different size fractions including 5-50% breeze with larger coal particles. This composite approach allows efficient packing in the oven, maximizes coke yield from available feedstock, and produces coke with optimized properties for foundry applications
2Quantity of substance
If traditional coke shapes are used, then conventional packing is achieved, but packing density in cupola is suboptimal
Solution Approach 1:
The patent applies asymmetry by producing oblong-shaped coke pieces instead of conventional round coke. The oblong shape has specific length-to-width ratios that optimize packing arrangements in the cupola, allowing tighter packing and higher packing density while maintaining adequate void space for gas flow
Solution Approach 2:
The patent applies segmentation by creating a size-distributed blend of coke pieces rather than uniform size. The blend includes various size fractions (4-10 inches, 2-4 inches, and smaller pieces) that nest together efficiently, maximizing packing density through hierarchical arrangement of different sized particles
3Reliability
If high-quality foundry coke with low CRI and high CSR is produced, then coke strength and reactivity properties are improved, but manufacturing complexity increases
Solution Approach 1:
The patent applies parameter changes by controlling coking conditions (temperature, time, pressure) and coal blend composition to produce coke with target CRI and CSR values. These controlled parameter changes achieve reliable coke properties without requiring complex additional processing equipment or steps
Data Source
AI summary
High quality coke products made in horizontal ovens such as heat recovery, non-recovery or Thompson ovens from an optimized coal blend. The coke products have unique properties such as an oblong shape and improved Coke Strength after Reaction (CSR) and Coke Reactivity Index (CRI) properties.