Cost contribution from coke

Production of coke
constitute 60% of the hot
metal cost
Approximately 50% of
the finished steel cost is
due to cost of coke
World figure of 53.8% is
the cost of coal against
the finished steel cost
Estimation of coke
consumption
Coke rate ( coke
consumption in kg per ton
of hot metal)
VSP - 530 Kg / thm

Coal to hot metal ratio (
Coking coal consumed for
production of one ton of hot
metal)
VSP 800 KG / thm
Why Coke making
60% of steel produced in
the world still under
conventional route of coke
oven and BF.
Still Blast Furnace route of
iron making is dominant
Added advantage of gas
yield, ease of operation
control in spite of higher
cost of production
With increased focus on
increasing the productivity
of BF, supply of higher
quality coke is a priority
WHAT IS COKE
It is a product of
carbonization of coal in a
oven heated to 1200
O
C,
without the presence of
air. It is a re-crystallized
carbon form
incorporating mineral
matter and other tramp
material.
Role played by coke in blast furnace
Thermal Role
Provide heat for smelting of iron ore
Chemical role
1. Provide reductant such as CO to reduce iron
ore
2. Direct reduction of various oxides
Physical Role
1. Coke supports weight of burden
2. Coke plays a significant role in gas distribution
3. Coke acts as a spacer below the cohesive zone
providing a permeable bed
In high capacity and low coke rate
furnace physical role of coke is critically
influence the technological limit of the
process such as;
Maximum Driving Rate
Fuel utilization
Campaign life
Coking behavior of coal
Testing of plastic property in Plastometer
TEMPERATURE
P
L
A
S
T
I
C
I
T
Y

(
D
D
P
M
)

5 ddpm
5 ddpm
Initial Softening Temp.
(IST)
Final Softening Temp.
(FST)
Maximum Fluidity
Fluidity Range
























What is coke making
Coke is a product of heating
of coking coal in absence of
air at around 1000
O
C by
which time coal loses all its
volatile matter and also the
solid residue gets
recrystalised in to a hard
mass, called coke. This
process of conversion of
coal to coke is called
carbonization. The solid
product of carbonization is
strong and can resists
degradation inside the blast
furnace caused by burden
weight as well as abrasion.
Four facets of coke making
There are four major
steps in producing
metallurgical coke
suitable to blast
furnace. They are:
1. Coal quality and blend
designing
2. Pre-carbonization
treatment
3. Carbonization factors
4. Post carbonization
factors












SCHEME OF COKING
Physical weakening of bond
Devolatalization
Formation of metaplast
/ solvolysis
Agglutination and assimilation
of inerts
Recrystalization in to specific
carbon order
(Semi coke)
Formation of final coke texture
Scheme of Pyrolysis of coal


s
R
OH
O
CH3
C2H5
OH
CH3
R
s R
OH
+
CH3
CH3
CH3
OH
R
+ H2O
OH
s
R
CH3
CH3
OH
R
+ C2H6+2H2
Pyrolysis & Formation of Metaplast

Pyrolysis of coal consists of
two parallel reaction;
Cracking reaction
Condensation reaction
Cracking reaction forms mare
tarry liquid which peptize coal
particles and form plastic mass
Higher mataplast formation is
good for coking
Predominance of cracking
reaction necessitates higher
hydrogen content in coal
Hydrogenation of coal and
macerals rich in hydrogen
content contribute higher
plasticity
Rank of coal & its effect on
plasticity
Hydrogen & oxygen content in
coal strongly influence the
formation of metaplast during
pyrolysis
At lower rank coal richer in
hydroxyl group does not
peptize to form metaplast
As rank increase reduction in
hydroxyl group facilitate initial
cracking followed by
condensation. This help in
coking
At very high rank cracked
product no longer remain in
fulid state.

Effect of coal elementary
composition on coking
Coal at same rank will exhibit
difference in plasticity due to its
elementary composition
Higher hydrogen in coal
facilitate higher plasticity
Higher oxygen in coal has the
opposite effect
Role of Sulfur is similar to that
of the oxygen
Higher H/O index in coal
having same vitrinite
reflectance will give higher
plasticity












Condensation &
resolidification
When coal under pyrolysis get
depleted with hydrogen,
condensation reaction
predominates
More C-C bonds are formed with
joining of aromatic rings
Onset of resolidification starts with
increase viscosity of the melt due
to higher condensation reaction
Occurrence of condensation
reaction necessitates presence of
hydroxyl groups












Coal to coke transformation
Time
T
e
m
p
e
r
a
t
u
r
e

Wet
coal
Water
Driven
off
Dry coal
Heat up
Plastic phase
Tar and oil
Driven off
Semi coke
Gas driven
off
Coke texture
H2 driven
Precarbonization
treatment
Selective crushing
Oil addition in charge
Humidification of charge
Preheating of charge
Hot briqueting
Stamp charging
Blending of coal

Carbonization factors
Heating rate or the rate
of carbonization
Charging methodology
Oven width
Oven height





























































Post carbonization
factors
Dry cooling of coke
Coke Dry cooling

Coke stabilization