Description:FIELD OF THE INVENTION
001 The present invention relates to an integrated and automated method and system for producing tailored coke particles from pitch-derived mesophase coke. The invention enables scalable, energy-efficient, and dust-free processing that achieves scalable, cost-efficient processing. It is particularly applicable to producing high-performance materials used in electrodes, battery anodes, and structural composites.

BACKGROUND OF THE INVENTION
002 Pitch-derived mesophase coke serves as a vital precursor in the production of advanced carbon materials, including electrodes, battery anodes, and structural composites. During carbonization, raw pitch material such as coal-tar or petroleum pitch undergoes thermal transformation, forming bulky coke lumps characterized by extreme hardness, irregular morphology, and high density. These properties render conventional processing methods, such as manual cutting, basic crushers, or laboratory-scale slicing tools, ineffective for industrial-scale applications. Existing techniques are labor-intensive, require specialized personnel, and often result in inconsistent particle sizes, excessive tool wear, and operational inefficiencies. Furthermore, disjointed workflows between cutting, crushing, and shredding stages necessitate manual material handling, introducing safety risks and variability in output quality.

003 Conventional approaches to coke processing are further hampered by fragmented workflows. For instance, CN112916105A discloses a manual cutting apparatus with fixed-angle blades designed for laboratory-scale coke processing. While this system enables basic size reduction, its reliance on human intervention and inability to scale for industrial throughput render it impractical for high-volume production. Moreover, such systems are not designed for the harder, more irregular mesophase coke and lack scalability for bulk processing. WO2013159826A1 discloses a semi-automated crusher with a horizontal conveyor for material transport. However, this system isolates crushing from upstream cutting and downstream shredding stages, perpetuating workflow bottlenecks and manual material transfer. Neither reference addresses modular integration, adaptability to variable coke hardness, or automation of material handling—key shortcomings that result in inefficiencies, safety hazards, and inconsistent particle morphology. Despite advancements in coke synthesis technologies, no prior art has addressed the critical need for an integrated, automated system capable of converting bulk coke into tailored particles suitable for downstream industrial applications. Additionally, prior systems lack mechanisms to tailor particle size and shape for specific uses, such as battery anodes requiring uniform particle dimensions.

004 To address these systemic shortcomings, the present invention reimagines coke processing through an integrated, automated workflow. At its core, the system introduces an adaptive cutting unit equipped with dynamically adjustable blades that conform to the irregular contours of mesophase coke, minimizing energy expenditure and reducing mechanical stress on tools. Following initial processing, a hydraulic crucible-tilting mechanism, powered by dual-action actuators, autonomously transfers crushed material to subsequent stages, eliminating manual handling and ensuring seamless continuity. The crushed coke is then fed into modular shredding units, which refine the particles to application-specific sizes and shapes while preserving structural integrity. This modularity allows the system to be tailored to diverse industrial needs, such as producing custom coke particles for battery anodes or other applications. By unifying adaptive mechanics, automation, and modularity, the invention achieves scalable, cost-efficient processing. This method and system bridge the gap between laboratory research and high-volume production, positioning coke as a viable cornerstone for next-generation carbon materials in sustainable energy technologies.

OBJECTS OF THE INVENTION
005 The objective of the present invention is to provide an integrated, automated method and system for producing tailored coke particles from pitch-derived coke. This system incorporates sequential operations, including cutting, tilting, crushing, shredding, separating, and conveying, to ensure continuous, efficient, and dust-free processing.

006 Another object of the invention is to provide a plurality of cutters equipped with blades of the core cutting unit that are mounted at a 75° to 95° angle relative to an inner wall of a crucible, which is configured to cut coke material.

007 A further object of the invention is to provide a conveyor system configured to transfer the crucible to a designated discharge zone, and a crucible tilter mechanism operatively connected to a dual-action hydraulic actuator. The tilter mechanism is adapted to tilt the crucible at an angle ranging from 100° to 140° to facilitate the complete discharge of coke material. The crucible tilter mechanism comprises a structurally reinforced fixing plate, a fail-safe locking system, and a precision-controlled geared motor, ensuring safe, controlled, and efficient transfer of coke segments via apron feeder into a downstream crushing unit.

008 Yet another object of the invention is to integrate a rotary drum crusher or a feeder breaker capacity, enabling precise control over particle size reduction and achieving an intermediate particle size distribution. The intermediate particle size is further subjected to the shredder unit, where the coke particles are reduced to a tailored particle size.

009 Yet another object of the invention is to employ a tubular disc chain conveyor, which ensures smooth, continuous, and controlled transportation of coke particles between processing units, culminating in delivery to storage bags or downstream systems.

SUMMARY OF THE INVENTION
010 This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the detailed description section. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to determine the scope of the claimed subject matter. The difficulties and drawbacks of previous approaches are addressed in the present invention.

011 In an aspect of the invention, a method for producing tailored coke particles from pitch-derived coke through a fully integrated and automated process. The method involves initially cutting the pitch-derived coke using a cutting unit, where the material is cut within a crucible by a core cutting unit equipped with blades mounted at a predetermined angle of 75° to 95° relative to the inner wall of the crucible. The crucible is then conveyed to a designated discharge zone, where it is tilted at a second predetermined angle of 100° to 140° using a dual-action hydraulic actuator to discharge the coke material. The discharged coke is transferred via an apron feeder to a crushing unit, where it is processed into intermediate-sized particles. These intermediate particles in the range of 10 mm to 300 mm are subsequently shredded in a shredder to achieve tailored coke particles in the range of 0.05 mm to 10 mm with specific size and morphology, suitable for various industrial applications.

012 In another aspect of the present invention, relates to system for producing tailored coke particles from pitch-derived coke, includes a core cutting unit with blades mounted at a first predetermined angle of 75° to 95° relative to the inner wall of a crucible, which is used for cutting coke material within the crucible. A conveyor system is configured to transfer the crucible to a discharge zone. A crucible tilting mechanism, mechanically connected to a dual-action hydraulic actuator, is designed to tilt the crucible at a second predetermined angle of 100° to 140° to discharge the coke material into a crushing unit through an apron feeder. The crushing unit reduces the discharged coke material into intermediate particles with sizes ranging from 10 mm to 100 mm. These intermediate particles are then further processed in a shredder, which shreds them into fine coke particles having a size in the range of 0.05 mm to 10 mm.

013 In one aspect of the present invention, the method and system are exclusively designed for processing bulk masses of coke, such as large, unprocessed lumps of bulk mesophase coke, calcined needle coke, and green coke. By focusing on raw, industrial-scale coke aggregate characterized by extreme hardness, irregular morphology, and dense structure, the invention integrates different stages to directly convert bulky coke into application-specific particles. The system eliminates manual handling of these challenging bulk masses through a crucible-based workflow, ensuring seamless processing from raw, bulky coke to tailored, uniform particles. Modular components adapt to the unique demands of bulk coke, addressing inefficiencies in conventional methods that struggle with scale, safety, and material integrity during bulk processing.

014 In one aspect of the present invention relates to a dual-station automated core cutter mechanism is provided for processing mesophase coke into uniform cylindrical sections. Each station includes a plurality of carbon steel pipe assemblies with spiral-arranged tungsten carbide-tipped rotating cutting heads, driven by a hydraulic system operating at 500 RPM to 1000 RPM. The setup processes coke blocks into sections with a diameter and length, achieving ±5% dimensional uniformity. A PLC synchronizes both stations, allowing continuous operation, while cutting heads are angled for optimal material removal within the crucible. Dust generated (~0.5% w/w) is extracted via a vacuum system-bag filter and filtered through a polypropylene bag. The crucible tilts to discharge material into heat-resistant containers transported by a chain conveyor to the crushing system.

015 In one aspect of the present invention, the core cutting unit includes a plurality of cutting assemblies mounted along the inner wall of the crucible, each assembly including a blade configured to cut the coke material placed within the crucible.

016 In another aspect of the present invention, the shredder includes a magnetic separator, either drum-based or belt-suspended, which extracts ferromagnetic contaminants from the coke stream to ensure high product purity.

017 In one aspect of the present invention, both the cutting unit and crushing unit include a bag filter system configured to operate under negative pressure generated by a blower driven by an electric motor, thereby enabling the extraction of dust produced during cutting and crushing operations.

018 This, together with the other aspects of the present invention, along with the various features of novelty that characterize the present disclosure, is pointed out with particularity in the claims annexed hereto and forms a part of the present invention. For a better understanding of the present disclosure, its operating advantages, and the specified objective attained by its uses, reference should be made to the accompanying descriptive matter in which there are illustrated exemplary embodiments of the present invention.

DESCRIPTION OF THE DRAWINGS
019 The advantages and features of the present invention will become better understood with reference to the following detailed description taken in conjunction with the accompanying drawings:

020 Fig. 1 illustrates a flow chart of the method for producing tailored coke particles from pitch-derived coke.

021 Fig. 2 illustrates a drawing of the core cutting unit for bulk coke.

022 Fig. 3 illustrates a drawing of the crucible tilter mechanism unit.

023 Fig. 4 illustrates a drawing of the apron feeder.

024 Fig. 5 illustrates a drawing of the rotary drum crusher unit.

025 Fig.6 illustrates a drawing of the shredder unit.

026 Fig.7 illustrates a drawing of the tubular disc chain conveyor unit.
DETAILED DESCRIPTION
027 The exemplary embodiments described herein detail for illustrative purposes, are subjected to many variations. It should be emphasized, however, that the present invention is not limited to a negative material electrode and its method of preparation as disclosed. It is understood that various omissions and substitutions of equivalents are contemplated as circumstances may suggest or render expedient, but these are intended to cover the application or implementation without departing from the spirit or scope of the present invention.

028 Unless otherwise specified, the terms used in the specification and claims have the meanings commonly used in the field of negative electrode material and the method of preparation involved therein. Specifically, the following terms have the meanings indicated below.

029 Embodiments are provided thoroughly and fully convey the scope of the present disclosure to a person skilled in art. Numerous details are set forth relating to specific components and methods to provide a complete understanding of the embodiments of the present disclosure. It will be apparent to the person skilled in the art that the details provided in the embodiments should not be construed to limit the scope of the present disclosure. In some embodiments, known processes, well-known apparatus or structures, and well-known techniques are not described in detail.

030 The terminology used in the present disclosure is only to explain a particular embodiment, and such terminology should not be considered to limit the scope of the present disclosure. As used in the present disclosure, the forms "a,” "an," and "the" may be intended to include the plural forms as well unless the context suggests otherwise. The terms "comprises," "comprising," “including,” and “having,” are open-ended transitional phrases and therefore specify the presence of stated features, integers, steps, operations, elements, modules, units, and/or components, but do not forbid the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The order of steps disclosed in the method and process of the present disclosure is not to be construed as necessarily requiring their performance as described or illustrated. It is also to be understood that additional or alternative steps may be employed.

031 As used herein, “combinations thereof” is inclusive of one or more of the recited elements, optionally together with a like element not recited, e.g., inclusive of a combination of one or more of the named components, optionally with one or more other components not specifically named that have essentially the same function. As used herein, the term “combination” is inclusive of blends, mixtures, alloys, reaction products, and the like.

032 The term “tubular disc chain conveyor” refers to a closed-loop mechanical conveying system consisting of discs attached to a continuous chain running through a sealed tubular structure. It ensures gentle, dust-free handling of tailored coke particles, minimizing degradation and contamination during transfer from the processing unit to storage or packaging units such as jumbo bags.

033 The term “dual-action hydraulic actuator” refers to a device that uses hydraulic pressure to move in both directions, extending and retracting, by applying force through two fluid input ports. This allows for precise and controlled motion, making it suitable for operations requiring both push and pull actions. In the tilter mechanism unit, the dual-action hydraulic actuator receives coke material from the cutting unit and enables the controlled tilting of the material onto an apron feeder, ensuring efficient and continuous transfer for further handling or processing.

034 The term “tailored coke particles” refers to coke material that has been processed, typically through cutting, crushing, and shredding, to achieve specific particle sizes, shapes, or quality characteristics suited for a particular application or handling process. This tailoring ensures uniformity, better flowability, reduced dust, and compatibility with downstream equipment like conveyors, feeders, or packaging units.

035 The term “rotary drum crusher” refers to the mechanical device used to crush or break down bulk materials, such as coal, coke, or minerals, employing a rotating cylindrical drum fitted with crushing elements like teeth and blades. As the drum rotates, the material is fed into it and is crushed by the impact and shearing action, producing smaller, more uniform particles suitable for further processing or handling. The rotary drum crusher is used to reduce the size of raw coke material before it is sent to the tilter mechanism, ensuring consistent particle size for smoother transfer and handling.

036 The term “volatile matter content” refers to the portion of the material that is released as gas or vapor when the coke is heated in the absence of air. It primarily includes hydrocarbons, moisture, and other organic compounds. The volatile matter is measured as a percentage of the total mass and is an important parameter in determining the quality, combustion behavior, and reactivity of coke. The volatile matter content in coke is a key quality indicator, as lower volatile content typically signifies better carbonization and higher fixed carbon levels, which are crucial for efficient performance in metallurgical and industrial processes.

037 The term “moisture content” refers to the amount of water present in the coke material, typically measured as a percentage of the total mass. High moisture content can affect the efficiency of combustion and the overall quality of the coke. The moisture content in coke is an important factor in determining its heating value and combustion efficiency, with lower moisture content generally resulting in better performance.

038 The term "negative pressure,” as referred to in the context of the cutting and crushing unit of coke, is the pressure applied in the bag filter to effectively capture and remove dust generated during the cutting and crushing of coke material. The system pulls the dust-laden air into the filter, where it is separated and contained, ensuring a clean and safe working environment.

039 The term "tilting mechanism" refers to a mechanical system used to discharge coke material by tilting it onto the next stage of the process. In this context, the tilting mechanism receives coke material from the cutting or shredder unit and uses a hydraulic actuator to tilt and transfer the material onto the apron feeder, ensuring controlled and efficient material flow for further processing.

040 The term "magnetic separator," as referred to in the context of the shredder unit, denotes a device integrated into the system to remove ferromagnetic impurities from the tailored coke particles. It uses magnetic fields to attract and separate metal contaminants, ensuring the purity of the processed coke and protecting downstream equipment from potential damage.

041 The term "apron feeder" refers to a heavy-duty mechanical conveying system used to transport coke material. In this context, the coke material received from the tilter mechanism is discharged onto the apron feeder, which then conveys it in a controlled and consistent manner to the crusher unit for further size reduction. The apron feeder ensures smooth material flow and handles heavy, abrasive materials effectively.

042 The term "PLC synchronizes both stations" refers to the role of a Programmable Logic Controller (PLC) in coordinating and controlling the operation of two interconnected process units or stations. In this context, the PLC ensures that both stations operate in a synchronized manner, maintaining proper timing, communication, and sequence of actions to achieve a smooth, automated, and efficient workflow across the system.

043 In one of the embodiments, as disclosed in the prior art “IN366839,” a process is described for producing bulk mesophase coke from an isotropic pitch. This process involves feeding the pitch into a crucible positioned in the entry zone of a reactor, which is then physically moved in a linear motion through the reactor using a pusher unit. The crucible is first transferred to a first heating zone, where the isotropic pitch is pretreated at a temperature of 250°C to 350°C under atmospheric pressure. Subsequently, the crucible is moved to a second heating zone via the pusher unit, where the pitch is heated at 350°C to 500°C under atmospheric pressure to form mesophase pitch. The crucible is then advanced to a third heating zone through the pusher unit, where the mesophase pitch is further heated at 500°C to 800°C under atmospheric pressure to obtain mesophase coke. Finally, the crucible is transferred to a cooling zone, and the resulting mesophase coke is discharged from the exit zone of the reactor. However, while the cited prior art provides a comprehensive description of coke formation from pitch, it does not elaborate on the subsequent processing of the mesophase coke obtained. According to the present invention, the coke material discharged from the reactor is further subjected to a series of post-processing operations namely cutting, crushing, and shredding—using integrated and automated systems designed to convert the mesophase coke into tailored coke particles. These particles are then handled through interconnected material handling units for transfer and packaging as bulk coke material, thereby establishing a continuous and streamlined production line from pitch to packaged coke.

044 In one embodiment, the method and system are configured specifically for the processing of bulk masses of coke material, including but not limited to large, unprocessed lumps of mesophase coke, calcined needle coke, and green coke. These coke materials typically exhibit high hardness, irregular shapes, and dense structures, making them difficult to handle using conventional methods. The system comprises a crucible-based workflow that eliminates the need for manual handling, enabling automated loading, positioning, and processing of raw coke within a modular framework. The crucible holds the bulk coke material securely, allowing it to undergo precise cutting, size reduction, and classification into application-specific particle sizes. Integrated subsystems automate each stage of processing from initial placement to final output, ensuring consistent particle uniformity while preserving material integrity. The modular design allows the system to be scaled or customized for varying industrial demands, addressing common issues related to safety, throughput, and the mechanical limitations of traditional coke processing methods.

045 In one embodiment, the bulk mesophase coke material obtained from the pitch is subjected to a cutting operation using a specialized core cutting unit. This unit comprises a dual-station automated system designed for high-efficiency processing. Each station includes a plurality of high-strength carbon steel pipe assemblies, each equipped at the end with rotating cutting heads. These cutting heads are fitted with a plurality of tungsten carbide bits arranged in a spiral pattern, enabling precise and uniform cutting action. The entire system is operated hydraulically, with the core cutter driven by high-pressure hydraulic pumps and motors. The dual-station setup allows simultaneous operations while one station performs the cutting task, the other retracts and repositions laterally via linear horizontal conveyors, ensuring continuous throughput.

046 In another embodiment, the cutting heads operate at variable rotational speeds and advance vertically through a controlled hydraulic feed mechanism. This configuration enables the segmentation of large coke blocks into uniform cylindrical sections with consistent dimensional accuracy. A programmable logic controller (PLC) coordinates both stations, utilizing feedback from position sensors and cutting assemblies to ensure continuous, automated operation. The cutting heads are aligned perpendicularly to the base of the crucibles and are positioned parallel to the crucible walls to facilitate efficient material breakdown. During the cutting operation, a small amount of dust is generated, which is effectively captured by an enclosed vacuum system operating under negative pressure. The collected dust is directed to a polyester bag filter system powered by a motor, maintaining a clean and environmentally safe processing environment.

047 In one embodiment, the coke material obtained from the cutting unit is transferred to a crucible tilter mechanism. This mechanism incorporates a dual-action hydraulic actuator, enabling controlled tilting of the crucible for subsequent material transfer. The actuator facilitates stable and precise dumping of coke material onto an apron feeder. The crucible tilter assembly includes a geared motor, structural framework, support elements, a fixing plate, and a locking system. It is equipped with a twin-rod, double-acting, parallel gripper cylinder designed for industrial-grade performance. The structure is fabricated using steel square tubes, with the supports constructed from a larger profile (150x150x5 mm) to enhance stability, and the framework from 80x80x5 mm tubes. The geared motor, rated at 10 HP and operating at 8 RPM, provides sufficient torque to tilt heavy crucibles efficiently, ensuring smooth integration into the automated coke handling sequence.

048 In one embodiment, the apron feeder receives coke material discharged from the crucible tilter mechanism. The apron feeder is a robust, mechanical conveying system designed to handle bulk, heavy, and abrasive materials like coke. It consists of overlapping metal pans or plates mounted on two or more strands of heavy-duty roller chain, forming a continuous conveying surface. These pans are supported by rollers and driven by a motorized drive system, allowing controlled, linear movement of the coke material. The apron feeder regulates the flow of coke from the tilter to the subsequent crusher unit, ensuring a consistent feed rate and preventing blockages. Its rugged construction and slow-operating speed are specifically suited for handling large, dense coke pieces while minimizing material degradation. The feeder also helps meter the material into the crusher for uniform size reduction, thereby supporting continuous and stable downstream processing.

049 In one embodiment, the coke material received from the apron feeder is transferred into a crusher unit, which comprises a feeder breaker integrated with a rotary crushing mechanism for producing intermediate-sized coke particles. The feeder breaker is capable of processing up to 5 tons per hour and includes a reinforced tunnel with 12 x 50 mm ribs, a 10 mm-thick plated top cover, and an end cover constructed with a 10 mm plate, incorporating an 80 mm diameter bore and a 40 mm shaft. The unit's vertical access door operates via pneumatic cylinders with a 1800 mm stroke, enabling efficient material loading and maintenance. The crushing system includes a heavy-duty breaker roller (1400 mm diameter × 2000 mm length × 12 mm thick) and a 160 mm diameter, 3500 mm long drive shaft, supported by oil-cooled split plummer block bearings for enhanced operational stability. Integrated into this setup is a rotary crusher equipped with carbide-tipped tool bits, specifically RL 11 picks mounted in C11 holder blocks. These carbide bits perform high efficiency crushing of the coke to achieve uniform intermediate coke particle sizes. A geared motor delivers the required torque and rotation for both the feeder and crusher operations.

050 In one embodiment, the intermediate-sized coke particles obtained from the crushing unit are directed into a shredder unit for further size reduction and material conditioning. The shredder features a robust feed assembly, including a 16 mm-thick steel outer shell and a 5 mm-thick steel hopper, integrated with an 8-inch knife gate valve to regulate material flow. At the core of the shredding mechanism is a drive shaft measuring 120 mm in diameter and 2600 mm in length, fabricated from EN24 steel and heat-treated to a hardness of HRC 52–55. The shaft is mounted on high-strength bearings and powered by two 10 HP, 144 RPM bevel-helical geared motors, providing the necessary torque for consistent, high-efficiency shredding. To eliminate ferromagnetic contaminants, the system incorporates an integrated magnetic separation unit. This includes a 28 mm drawer-type grate separator equipped with pneumatic cylinders and a manual sliding cleaning mechanism. A downstream magnetic separator conveyor is also provided, consisting of powder-coated MS side panels, a 3 mm thick removable deck plate, a detachable collection box, and a 165 mm diameter, 2000 mm long magnetic pulley utilizing rare earth permanent magnets rated at 8500 Gauss. The conveyor assembly includes a non-drive pulley, support bearings, and a dedicated geared motor to ensure smooth, uninterrupted operation. The processed, tailored coke particles emerging from the shredder are subsequently transported via a tubular disk chain conveyor to jumbo bag filling stations for bulk material handling and packaging, seamlessly integrating with the downstream logistics chain.

051 In one embodiment, the tailored coke particles obtained from the shredder unit are transferred to a tubular disk chain conveyor for onward movement to a storage unit, a jumbo bag for further processing. This conveyor system comprises a mild steel powder-coated tube with an overall length of approximately 30 meters, ensuring enclosed and contamination-free transport of coke particles. The conveyor tube is constructed in 5-inch flanged segments, facilitating modular assembly and maintenance. The conveying action is performed by a sealed pin chain of 5-inch diameter, equipped with Delrin discs for smooth and abrasion-resistant operation. The chain runs over sprockets made from stainless steel (SS 304), providing corrosion resistance and long service life. The drive mechanism includes a worm gearbox rated at 7.5 HP, operating at 18 RPM, and is powered by a roto motive motor, delivering the required torque and speed control for consistent material movement. The conveyor system is supported by a structural frame made of 50 × 50 × 2 mm thick square mild steel tubes, which are powder-coated for durability and protection against environmental conditions. This configuration ensures reliable, enclosed transport of coke particles with minimal spillage and mechanical wear, contributing to an efficient and dust-free handling system.

052 In an embodiment, a method for producing tailored coke particles from pitch-derived coke comprises subjecting the coke to a cutting operation using a dual-station automated core cutting unit comprising one or more carbide-toothed cutting heads configured to extract cylindrical sections. The coke material is cut within a crucible, wherein the cutting blades are positioned at a 75° to 95° angle relative to the inner wall of the crucible. Following cutting, the crucible containing the coke sections is conveyed to a discharge zone via a conveyor system. At the discharge zone, the crucible is tilted at a 100° to 140° angle by a tilting mechanism mechanically linked to a dual-action hydraulic actuator to discharge the coke material. The discharged coke is then fed into a crushing unit via an apron feeder and crushed to form intermediate coke particles of a predetermined size. These intermediate particles are subsequently shredded in a shredder to obtain tailored coke particles with a defined size and morphology.

053 In an embodiment a system for producing tailored coke particles from pitch-derived coke comprises a cutting unit configured to perform an initial cutting operation on the pitch-derived coke using one or more carbide-toothed cutting heads and a core cutting unit with blades mounted at an angle of 75° to 95° relative to the inner wall of a crucible and configured to cut coke material within the crucible and a conveyor system configured to transfer the crucible to a discharge zone and a crucible tilting mechanism mechanically connected to a dual-action hydraulic actuator and configured to tilt the crucible at a angle ranging from 100° to 140° to discharge the coke material and a crushing unit configured to crush the discharged coke into intermediate particles having a size in the range of 10 millimeters to 300 millimeters and a shredder configured to shred the intermediate particles into fine tailored coke particles having a size in the range of 0.05 millimeters to 10 millimeters.

054 In an embodiment, the cutting operation is performed using a dual-station automated core cutting unit comprising carbon steel pipe assemblies, each with a rotating cutting head fitted with tungsten carbide bits arranged in a spiral pattern, the unit being hydraulically operated and designed for continuous operation using alternating cutting and retraction cycles via a horizontal conveyor.

055 In an embodiment, the cutting heads are oriented perpendicularly to the base and parallel to the inner walls of the crucible, and wherein dust generated during cutting is extracted by a sealed vacuum system connected to a bag filter operating under negative pressure.

056 In an embodiment, the coke material has a volatile matter content in the range of 0.5% to 8%, preferably 2% to 6%, and has a moisture content in the range from 0.5% to 6% by weight, preferably 1.5% to 4% by weight.

057 In an embodiment, the first predetermined angle relative to the inner wall of the crucible is in the range of 75° to 100°, preferably 80° to 90°, and the second predetermined angle of the crucible tilter is in the range of 90° to 150°, preferably 100° to 135°.

058 In an embodiment, the cutting unit and the crushing unit each include a bag filter configured to operate under negative pressure generated by a blower driven by an electric motor, thereby enabling the extraction of dust produced during cutting and crushing operations.

059 In an embodiment, the crushing unit comprises a rotating drum crusher with helically arranged teeth composed of carbide material. The crushing unit is operatively connected to a motorized conveyor system comprising clamps configured to grip and transfer the crucible.

060 In an embodiment, the shredder includes a magnetic separator configured to remove ferromagnetic impurities from the shredded coke.

061 In an embodiment, the tailored coke particles are collected and conveyed through a tubular disc chain conveyor to a storage jumbo bag.

062 In an embodiment, the blades of the core cutting unit are selected from the group consisting of carbide-tipped blades, diamond-coated blades, serrated blades, rotary blades, hardened steel, circular blades, guillotine shear blades, and ceramic-tipped blades and a plurality of cutting assemblies mounted along the inner wall of the crucible, each assembly having a blade configured to cut the coke material placed within the crucible.

063 In an embodiment, the crushing unit is selected from the group consisting of a rotating drum crusher, a jaw crusher, a roller crusher, a cone crusher, and a pneumatic crusher.

064 In an embodiment, the shredder is selected from the group consisting of a teeth roller crusher, twin shaft shredder, single shaft shredder, hammer mill, cone mill, granulator, disc shredder, and rotor shear shredder.

065 In an embodiment, the intermediate coke particles have a particle size in the range of 11 mm to 300 mm, and the tailored coke particles have a particle size in the range of 0.05 mm to 10 mm.

066 In one embodiment, tailored coke particles are provided, exhibiting reduced internal stress and lower structural disorder. These tailored particles, often characterized as low-energy particles due to their favorable microstructural attributes, are particularly suitable for subsequent processing steps. The improved structural characteristics of the particles contribute to enhanced material transformation, energy efficiency, and product quality in the downstream processes.

067 Referring to Fig. 1, the flow diagram illustrates the method (100) for producing tailored coke particles from pitch-based coke. The process begins at step 101, where bulk coke, obtained from pitch coke and placed in a crucible, is transported to a cutting unit via a conveyor system. In step 102, the cutting unit an automated dual-station core cutter equipped with carbide-toothed blades, cuts cylindrical cores from the coke material. These cores are then transferred to a cleaning station to remove any dust or residue generated during the cutting process. Subsequently, in step 103, the crucibles containing the cleaned coke cores are moved to the crucible tilter mechanism. This unit utilizes a hydraulic actuator to tilt the crucible between 100° and 140°, enabling the coke material to be discharged onto the apron feeder. At step 104, the apron feeder transfers the coke material to a rotary drum crusher equipped with carbide teeth. This crusher reduces the coke into intermediate-sized particles ranging from 10 mm to 300 mm. In step 105, the intermediate-sized particles are fed into a shredder unit, which further processes them into tailored particle sizes ranging from 0.05 mm to 10 mm. A magnetic separator integrated within the shredder unit removes any ferromagnetic impurities. Finally, in step 106, the tailored coke particles are conveyed through a tubular disc chain conveyor and collected in a jumbo bag for subsequent processing.

068 Referring to Fig. 2 illustrates that the core cutter operates by first activating its hydraulic gearbox (201), which generates the hydraulic pressure needed to power the system. This pressure drives the hydraulic cylinder (205), initiating both linear and rotational motion: the cylinder pushes the cutting assembly forward while simultaneously rotating it. The core cutter cylinder (202), a robust steel pipe housing the cutting tool, positions the carbide-tipped cutting teeth (203) to engage with the coke block secured in the crucible (206). As the teeth drill into the material, the guide rod (204) ensures straight, balanced movement, while the support structure (208), equipped with a rack and pinion system, stabilizes the assembly’s advance through a hollow tube. Once the cylindrical core is fully carved out, it drops onto a conveyor (207) for transport to a cleaning station, where debris is removed. The cleaned core is then transferred to a tilter mechanism, which reorients it for packaging, further processing, or transport. This integrated process combines hydraulic power, precision cutting, and guided mechanics to efficiently transform bulk materials like coke blocks into uniform, manageable cores.

069 Referring to Fig. 3, the crucible tilter mechanism facilitates the precise and efficient discharge of coke material onto an apron feeder. As illustrated in the accompanying diagram, it comprises a geared motor (301) that provides the necessary torque to initiate and sustain the tilting motion. The crucible (303), which holds the coke material, is mounted within a structurally reinforced steel cage (302) to ensure proper alignment and operational stability. A dual actuator system (304) works in coordination with the geared motor to accurately control the tilting angle and speed. The entire tilter assembly is constructed from robust steel to withstand mechanical stress and high thermal loads. During operation, the actuators and motor work in unison to tilt the crucible smoothly, allowing the coke material to be discharged directly onto the apron feeder below. This design ensures consistent material flow while minimizing spillage and reducing operational interruptions.

070 Referring to Fig. 4, the apron feeder is a robust material handling system designed to ensure the consistent and controlled transfer of coke material discharged from the crucible tilter. As illustrated in the accompanying diagram, the feeder comprises several key components. The head shaft (401) serves as the primary rotating element, driving the motion of the chain (402), which runs along the length of the feeder. Attached to the chain are carry flights (403) that transport the coke material along the feeder path. The drive system consists of a gearbox (404), which regulates torque and speed, and a motor (405) that supplies the driving force. Power is transmitted from the motor to the head shaft through the gearbox, enabling continuous operation under heavy loads. Sprockets (406) are employed to guide and engage the chain, ensuring smooth and synchronized movement. Although the mainframe is not explicitly labeled in the diagram, it forms the structural backbone of the system, supporting all major components and maintaining proper alignment during operation. The overall configuration is engineered to withstand abrasive conditions and heavy material loads, making it ideally suited for coke handling applications in industrial environments.

071 Referring to Fig. 5, the drum roll crusher is an integral component of the coke material handling system, designed to reduce coke particles ranging in size from 10 mm to 300 mm, which are discharged from the cutting unit. As illustrated in the accompanying diagram, the crusher comprises a drive shaft (501) that transmits rotational motion to the crushing assembly. The shaft is supported by bearings (502), which ensure proper alignment and stable operation under high-load conditions. Mounted along the shaft are multiple crushing picks (503) made from carbide teeth material, which engage the coke material during rotation to achieve effective size reduction. A geared motor (504) supplies the necessary torque and rotational speed to drive the assembly efficiently. The coordinated function of these components enables reliable, continuous crushing with minimal maintenance, ensuring durable and efficient performance in demanding industrial environments.

072 Referring to Fig. 6, the shredder unit is designed to further reduce coke material into smaller particle sizes ranging from 0.05 mm to 10 mm, tailored to the requirements of the material handling system. As shown in the accompanying diagram, the system includes a drive shaft (601) that transmits rotational motion to the internal cutting mechanism. The material is introduced into the shredder through a hopper (602), which is equipped with a knife gate valve to regulate and control the feed rate. Bearings (603) support the drive shaft, ensuring precise alignment and smooth operation under load. Internally, the shredder incorporates cutting gears (not labeled in the diagram) that are coupled to the drive shaft and are responsible for the actual size reduction of the coke material. A magnetic separator (604) is positioned within the discharge path to remove iron impurities from the shredded output. A geared motor (605) powers the entire assembly, delivering the required torque and rotational speed for continuous and efficient operation. This integrated configuration ensures reliable shredding performance, enhanced material handling, and reduced maintenance in demanding industrial environments.

073 Referring to Fig. 7, the tubular disk chain conveyor is designed for the enclosed and efficient transfer of coke particles from the shredder unit to the next stage of processing. As illustrated in the accompanying diagram, the system begins with a chute (701), which guides the shredded coke into the conveying assembly. The coke material travels through a tube (702) composed of flanged segments, providing a sealed path that minimizes spillage and dust generation. The motion of the conveyor is powered by a gearbox (703) coupled with a roto motive motor (704), which together ensure consistent and reliable drive for the chain and attached disks. A hopper (705) regulates the input of material into the system, allowing for controlled flow. At the discharge end, the coke particles are directed into a jumbo bag (706) for collection and subsequent transport to the next processing facility. A pipe conveyor (707) is also integrated into the system, offering an extended and enclosed transfer route. This configuration ensures smooth, dust-free conveying, making it ideal for high-efficiency industrial operations.

EXAMPLES
074 Example 1: Exemplary Method for Determining Volatile Matter Content (VMC) in Coke Particles
A representative sample of coke weighing 1.000 g air-dried and moisture-free was placed in a covered crucible and heated in a pre-calibrated muffle furnace at 900°C ± 10°C for 7 minutes, as per the IS-1350-1984, 2019. After the heating period, the crucible was cooled in a desiccator to avoid moisture absorption and then reweighed. The final recorded weight of the sample was 0.975 g.
The volatile matter content (VMC) was calculated as follows:
VMC (%) =[Winitial−Wfinal/Winitial] X 100
VMC (%) = [1.00 g – 0.975 g/ 1.00 g] X 100 = 2.5%
This demonstrates that the sample has a VMC of 2.5%, which falls within the targeted range of 0.5% to 8.0% suitable for subsequent processing steps
075 Table 1 Example calculations of volatile matter content (VMC) in coke samples based on mass loss after heating
Target VMC (%) Initial Weight (g) Final Weight (g) Mass Loss (g)
0.5 1.0 0.995 0.005
1.5 1.0 0.985 0.015
2.5 1.0 0.975 0.025
3.5 1.0 0.965 0.035
4.5 1.0 0.955 0.045
6.0 1.0 0.94 0.06
8.0 1.0 0.92 0.08

076 The table presents the calculated Volatile Matter Content (VMC) values for coke material, with different target VMC percentages ranging from 0.5% to 8.0%. In the table, the Initial Weight of each coke sample is assumed to be 1.000 g. After heating the sample at 950°C for 7 minutes under oxygen-limited conditions, the Final Weight is measured, and the Mass Loss (difference between initial and final weight) is calculated. The VMC is then determined using the formula:

VMC (%) = (Initial Weight- Final Weight/Initial Weight) X 100
For example, with a target VMC of 2.5%, if the initial weight is 1.000 g and the final weight is 0.975 g, the mass loss is 0.025 g, resulting in a VMC of 2.5%. The table shows the relationship between the target VMC percentage and mass loss, helping to understand how
the volatile matter content in the coke can be controlled and adjusted for specific processing requirements. This method is crucial for industries, such as steel production, where controlling the VMC of coke is essential for optimizing the quality and efficiency of the manufacturing process.

077 Example 2: Exemplary method for determining moisture content (MC) in coke particles

In one embodiment, the coke material used in the present process possesses a moisture content ranging from 0.5% to 6.0% by weight. The moisture content is measured using a standard oven-drying gravimetric method, such as ASTM C562-23. In this method, a known quantity of coke (e.g., 25.0 g) is weighed in its wet state, dried in an oven at 110°C ± 2°C until it reaches a constant weight, and then cooled in a desiccator before weighing again. The moisture content is calculated by subtracting the final dry weight from the initial wet weight, dividing by the initial weight, and multiplying by 100. This method ensures reliable and reproducible control of the moisture level in coke particles to suit the requirements of the subsequent processing steps.

Moisture Content (%) = [Initial Weight- Final Weight)/Initial Weight] X 100

078 Table 2 Representative Moisture Content (MC) Values in Coke Samples
Target Moisture Content (%) Initial Weight (g) Final Weight (g) Moisture Loss (g)
0.5% 100.0 99.5 0.5
1.5% 100.0 98.5 1.5
2.5% 100.0 97.5 2.5
3.5% 100.0 96.5 3.5
4.5% 100.0 95.5 4.5
6.0% 100.0 94.0 6.0

As an example, several coke samples with different target moisture content values were analyzed using the method described. A sample with a final dry weight of 99.5 g (from an initial 100.0 g) corresponds to a moisture content of 0.5%, while weights of 98.5 g, 97.5 g, 96.5 g, 95.5 g, and 94.0 g correspond to moisture contents of 1.5%, 2.5%, 3.5%, 4.5%, and 6.0%, respectively. These examples illustrate the correlation between weight loss during drying and the corresponding moisture percentages, thereby demonstrating how target moisture contents can be achieved through controlled drying.

079 Example 3: Sieve Analysis for Coke Particles
Sieve analysis is conducted to characterize the particle size distribution of coke materials. Intermediate particle sizes generally range from 10 mm to 300 mm, while tailored particle sizes intended for specific applications are typically within 0.05 mm to 10 mm. Below is an illustrative example showing different sieve fractions, their corresponding size ranges, and percentage retained in both intermediate and tailored particle size classifications.

080 Table 3 Representative sieve analysis for coke particle size distribution
Sieve Size Range (mm) Classification Typical Retained Weight (%)
300 – 150 Intermediate 10%
150 – 75 Intermediate 20%
75 – 25 Intermediate 30%
25 – 10 Intermediate 25%
10 – 5 Tailored 5%
5 – 1 Tailored 4%
1 – 0.1 Tailored 3%
0.1 – 0.05 Tailored 2%

The sieve analysis table illustrates the distribution of coke particles across various size ranges, categorized into intermediate and tailored classifications. Intermediate particles, ranging from 10 mm to 300 mm, typically represent coarser material obtained after the initial crushing and are often subjected to further processing. Tailored particles, which fall within the 0.05 mm to 10 mm range, are refined fractions intended for specific downstream applications requiring controlled particle size. The table also includes the typical retained weight percentage for each size range, indicating how much of the total material remains at each level of separation. Larger fractions (e.g., 300–150 mm) are coarse lumps needing reduction, while finer fractions (e.g., 1–0.1 mm or 0.1–0.05 mm) are ideal for applications requiring precision. This data provides insight into material preparation efficiency and ensures particle size is optimized for subsequent processing steps.

081 While the foregoing describes various embodiments of the disclosure, other and further embodiments of the disclosure may be devised without departing from the basic scope thereof. The invention is not limited to the described embodiments, versions, or examples, which are included to enable a person having ordinary skill in the art to make and use the invention when combined with information and knowledge available to the person having ordinary skill in the art.

ADVANTAGES OF THE INVENTION
082 The technical advantages offered by the present invention are as follows:
083 The present invention provides full automation of the coke handling process, from pitch charging to final packaging, significantly reducing manual intervention and enhancing operational efficiency.
084 The present invention enhances handling of hard, irregular coke lumps by using modular systems designed for safety, scalability, and adaptability to varied production scales.
085 The present invention achieves precise and efficient coke cutting, employing a hydraulically driven, dual-station cutter for consistent and accurate operation.
086 The present invention improves coke cutting quality and safety through sensor-controlled, dust-minimizing, and fully automated operations.
087 The present invention provides a safe and efficient discharge of hot coke, using a rugged crucible tilting system designed for heavy load handling.
088 The present invention improves coke flow consistency, ensuring uniform feeding into downstream crushers for optimal performance.
089 The present invention enhances coke size reduction by employing a robust intermediate crusher capable of handling large volumes and variable hardness.
090 The present invention achieves final coke refinement through shredding, screening, and magnetic separation to produce clean, size-specific particles.
091 The present invention improves coke transfer operations, using enclosed conveyors to prevent material loss, contamination, and equipment wear.
, Claims:We Claim
1. A method for producing tailored coke particles from pitch-derived coke, the method comprising:
(a) subjecting pitch-derived coke to a cutting operation using a cutting unit comprising one or more cutting heads;
(b) cutting the coke material within a crucible using a core cutting unit, wherein blades of the core cutting unit are mounted at a first predetermined angle relative to an inner wall of the crucible;
(c) transferring the crucible to a discharge zone via a conveyor system;
(d) tilting the crucible at a second predetermined angle using a crucible tilting mechanism mechanically connected to a dual-action hydraulic actuator to discharge the coke material, wherein the discharged coke material is fed into a crushing unit via an apron feeder;
(e) crushing the discharged coke material in the crushing unit to obtain intermediate coke particles having a predetermined intermediate size; and
(f) shredding the intermediate particles in a shredder to obtain tailored coke particles having a predetermined size and morphology.
2. The method as claimed in claim 1, wherein the cutting operation is performed using a dual-station automated core cutting unit comprising carbon steel pipe assemblies, each with a rotating cutting head fitted with tungsten carbide bits arranged in a spiral pattern, the unit being hydraulically operated and designed for continuous operation using alternating cutting and retraction cycles via a horizontal conveyor.
3. The method as claimed in claim 3, wherein the cutting heads are oriented perpendicularly to the base and parallel to the inner walls of the crucible, and wherein dust generated during cutting is extracted by a sealed vacuum system connected to a bag filter operating under negative pressure.
4. The method as claimed in claim 1, wherein the coke material has a volatile matter content in the range of 0.5% to 8%.
5. The method as claimed in claim 1, wherein the coke material has a moisture content, a moisture content is in the range from 0.5% to 6% by weight.
6. The method as claimed in claim 1, wherein the first predetermined angle relative to an inner wall of the crucible is in the range of 75° to 95°.
7. The method as claimed in claim 1, wherein the second predetermined angle of the crucible tilter is in the range of 90° to 150°.
8. The method as claimed in claim 1, wherein the cutting unit and the crushing unit each comprise a bag filter system configured to operate under negative pressure generated by a blower driven by an electric motor, thereby enabling the extraction of dust produced during cutting and crushing operations.
9. The method as claimed in claim 1, wherein the crushing unit comprises a rotating drum crusher with helically arranged teeth composed of carbide material.
10. The method as claimed in claim 1, wherein the crushing unit is operatively connected to a motorized conveyor system comprising clamps configured to grip and transfer the crucible.
11. The method as claimed in claim 1, wherein the shredder comprises a magnetic separator configured to remove ferromagnetic impurities from the shredded coke.
12. The method as claimed in claim 1, wherein the tailored coke particles are collected and conveyed through a tubular disc chain conveyor to a storage jumbo bag.
13. The method as claimed in claim 1, wherein the blades of the core cutting unit are selected from the group consisting of carbide-tipped blades, diamond-coated blades, serrated blades, rotary blades, hardened steel, circular blades, guillotine shear blades, and ceramic-tipped blades.
14. The method as claimed in claim 1, wherein the core cutting unit comprises a plurality of cutting assemblies mounted along the inner wall of the crucible, each assembly having a blade configured to cut the coke material placed within the crucible.
15. The method as claimed in claim 1, wherein the crushing unit is selected from the group consisting of a rotating drum crusher, jaw crusher, roller crusher, cone crusher, and pneumatic crusher.
16. The method as claimed in claim 1, wherein the shredder is selected from the group consisting of a teeth roller crusher, twin shaft shredder, single shaft shredder, hammer mill, cone mill, granulator, disc shredder, and rotor shear shredder.
17. The method as claimed in claim 1, wherein the intermediate coke particles have a particle size in the range of 10 mm to 300 mm.
18. The method as claimed in claim 1, wherein the tailored coke particles have a particle size in the range of 0.05 mm to 10 mm.
19. A system for producing tailored coke particles from pitch-derived coke, the system comprising:
(a) a cutting unit configured to cut pitch-derived coke;`
(b) a core cutting unit comprising blades mounted at a first predetermined angle of 90° relative to an inner wall of a crucible, configured to cut coke material within the crucible;
(c) a conveyor system configured to transfer the crucible to a discharge zone;
(d) a crucible tilting mechanism mechanically connected to a dual-action hydraulic actuator, configured to tilt the crucible at a second predetermined angle of 90° to 150°;
(e) a crushing unit configured to crush the discharged coke material into intermediate particles having a size in the range of 10 mm to 300 mm; and

(f) a shredder configured to shred the intermediate particles into fine coke particles having a size in the range of 0.05 mm to 10 mm.