How coke is created in a coal testing oven or pilot plant
Thanks to huge advances in metallurgy over the last three decades, 21st century steel production is transforming the globe and the built environment. Of course, a major part of the steel production process is the use of coke, which provides as much as 80% of the furnace's thermal requirements, the majority of the furnace's CO gas (which acts as a reducing reagent) and carbon for dissolution in the molten metal. As with any other manufacturing process, the quality of the raw material has a massive impact on the quality of the end product. It is therefore vital to ensure the coke is comprehensively tested.
On a small testing scale, coke can be created by the slow heating of coking coal in a refractory lined coal testing oven (CTO) to 1000°C for 3 - 4 hours in the absence of air. The coal softens at a temperature of between 400 - 500°C to form a liquid or plastic phase, agglomerates, swells and particles fuse. At temperatures of between 450 - 550°C, there is re-solidification forming semi-coke, which is the first stage of shrinkage. Finally as the temperature of the raw material in the CTO passes 550°C, there is a loss of hydrogen and oxygen and the second stage of shrinkage occurs. Using just 7 kg of 5% moisture coal and a Carbolite Gero CTO, a sufficient sized sample can be created to determine % yield and hot strength (CSR/CRI).
For larger testing/pilot plant scenarios, a moveable wall oven, such as that manufactured by Carbolite Gero, can be used. I Iolding 227 kg of raw coking coal, this pilot plant mirrors real-world coke production over a standard 18 hour processing time. At the end of the cycle, the contents of the oven are expelled at temperature and quenched with water forming a grey mass of coke.
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