Introduction to the Field of Invention:

Objects of the Invention;
It is therefore a primary object of this invention to propose an improved process for the manufacture
of coal blend suited to coke oven operation in a manner better than possible so far.
It is another object of this invention to propose such a process, which will reduce the production of
fines in the crushed coal blend before charging to the coke oven.
It is a further object of the invention to propose such a process, which will decrease the carry over of
fines in the gas lines of the slot oven.
It is still further object of the invention to propose such a process, which will provide a coal blend with
improved bulk density.
It is yet another object of the invention to propose such a process in which the overall consumption of
electrical energy will be less compared to the conventional process of preparing coal blend.
It is a still further object of the invention, which will help in the production of coke with reduced
possibilities of cracking of fines and less graphite generation while improving the tar quality.
These and other objects of the invention will be apparent from the following paragraphs.
Brief Statement of the Invention:
Thus, according to this invention, there is provided a method for preparation of coal blend for BF coke
making comprising preparing said coal blend first by introducing low ash, having ash content of less
than 10% by weight, hard coal having average reflectance (RoR, v/v%) 1.10 to 1.30 and volatile
matter between 22-25% on air dried basis with other types of coal in aliquot(predetermined)
proportions to obtain coal blend in crushed form in a crusher such that at least 80% of the particles
passing through a 3.2mm BSS and thereafter mixing 15-25% of a further amount of uncrushed low
ash aforesaid hard coal to said coal blend, based on the weight of the crushed coal, and blending the
same thoroughly such that the overall crushed coal in the final blend obtained having 80% of the
particles passing through a 3.2 mm BSS with advantageously lesser fines generated (-0.5mm), and an
improved bulk density of the prepared coal blend due to better blend homogeneity, before feeding the
same to the coke oven for making of BF coke used in high capacity blast furnaces.
In this process, the following details are important for the success of the process.
a. The uncrushed low ash hard coal added has an ash content of less than 10% by weight.
b. The particle size of the uncrushed low ash hard coal has top size of -50 mm BSS.
c. The low ash hard uncrushed coal has 20-30% of its particle of -10 mm BSS and 55-65% less
than 3mm BSS.
d. The low ash uncrushed coal has vitrinite >50 and rank Ro max of 1.15 to 1.35 and rank of the
final blend lies between Ro max of 1.15 to 1.25.
e. The coarse size fraction of the low ash hard coal of -10 to +6 mm and -6 to +3 mm has
positive dilatation, which helps in producing good coke.
f. The overall crushing index (-3.2 mm) of the final coal blend charge is'64% to 82%.
g. The final blend charge contains about 21% to 45% of particles of -0.6 mm BSS.
h. The bulk density of the final blend charge is up to 810 kg/m3 depending on the granulometry
(size consistencies) of the blend, and preferably 680 to 780 kg/m3.
In our process, we add a certain amounts of uncrushed coal to the crushed coal blend. After intensive
study, analysis and experiments, we have decided to add a certain amount of lowest ash hard coal in
the uncrushed form to the crushed coal blend to be charged in the slot oven.
The ash content and particle size of the addition is as follows:
Ash: < 10% by weight of coal
Particle Size: all passing through - 50 mm British Standard Screen (BSS) of which 60 to
70% is below 10 mm Low ash hard coal of -10 to +6 mm and -6 to +3 mm
also show positive dilatation.
The addition of uncrushed coal is preferably 15-25% of the total of low ash hard coal (which may vary
40% to 70% of the blend).
The blend itself subjected to crushing is made of 50% low ash hard coal and 50% other coals.
The low ash hard coal and other coals blend is crushed in a crusher such that at least 80% of the
particles passing through 3.2 mm BSS.
In view of addition of a certain amount of uncrushed low ash hard coal, the overall crushing level is
such that the final blend obtained having 80% of the particles passing through 3.2 mm BSS and
changes depending upon the quantity of low ash uncrushed hard coal used in the blend.
Due to this addition of uncrushed low ash hard coal, the overall fines generated (-0.5 mm) is also less
and the fines carry over in the gas is also reduced.
We have observed that the addition of uncrushed low ash hard coal does not affect the coke
quantity since coarser size fractions of low ash hard coking coal show positive dilatation.
Furthermore, the bulk density of this blend (mixture of part uncrushed low ash hard coal and
crushed mixture of other part) would improve since the average size increases at the same
moisture level in the blend. This will help in improved oven throughput.
Experimental Study and Verification of the Invention;
The following example more fully illustrates the features of the invention,
A pilot plant study was carried out in strict confidence in a pilot oven (Carbolrte make, 250 kg,
variable width, electrically heated movable wall type) carbonizations on one of the steel plants
coal blend in India showed the following:
We also verified our findings in a running coke oven plant,
Sustained industrial trials conducted for about 2 months in one of the Indian steel plants coke
ovens where total quantity of low ash hard coal (constituted about 70% of the blend) was added
in uncrushed form. No deterioration in coke quality observed. Slight improvement in fines content
(4% less fines generated) and coke cold strength improved M 10 improved by 0.2 points.
Advantages of the invention:
i. Less generation fines,
ii. Improved bulk density of the blend i.e. more oven throughput.
iii. Saving in electrical energy since some amount of coal added uncrushed in the blend.
iv. Ease of battery operation i.e. smoother charging in the oven due to less fines in the
blend,
v. Less fines carry over to gas lines.
vi. Reduced possibilities of cracking and less graphite generation.
vii. Improved tar quality.
We Claim:
1. A method for preparation of coal blend for BF coke making comprising preparing
said coal blend first by introducing low ash, having ash content of less than 10%
by weight, hard coal having average reflectance (RoR, v/v%) 1.10 to 1.30 and
volatile matter between 22-25% on air dried basis with other types of coal in
aliquot (predetermined) proportions to obtain coal blend in crushed form in a
crusher such that at least 80% of the particles passing through a 3.2mm BSS and
thereafter mixing 15-25% of a further amount of uncrushed low ash aforesaid
hard coal to said coal blend, based on the weight of the crushed coal, and
blending the same thoroughly such that the overall crushed coal in the final blend
obtained having 80% of the particles passing through a 3.2 mm BSS with
advantageously lesser fines generated (-0.5mm), and an improved bulk density
of the prepared coal blend due to better blend homogeneity, before feeding the
same to the coke oven for making of BF coke used in high capacity blast
furnaces.
2. A method as claimed in claims 1, wherein said low ash hard uncrushed coal has a
top size of -50 mm BSS, with 20-30% of its particle of -10mm BSS and 55-65%
less than 3mm .
3. A method as claimed in claims 1 and 2, wherein, the low ash hard uncrushed coal
has vitrinite content greater than 50 and rank Ro max of 1.15 to 1.35 and the
rank of the final blend lies between Ro max of 1.15 to 1.25.
4. A method as claimed in claims 1 to 3, wherein, the coarse size fraction of the low
ash hard coal of -10 to +6 mm and -6 to +3 mm has positive dilatation which
helps in producing good coke.
5. A method as claimed in claims 1 to 4, wherein, the overall crushing index (-3.2
mm) of the final coal blend charge is 64% to 82%.
6. A method as claimed in claims 1 to 5, wherein, the final blend charge contains
about 21% to 45% of particles of -0.6 mm BSS.

7. A method as claimed in claims 1 to 8, wherein, the bulk density of the final blend
charge is up to 810 kg/m3 depending on the granulometry (size consistencies),
preferably 680 to 780 kg/m3.
8. A method substantially as herein described with reference to the examples.

There is disclosed an improved method for preparation of coal blend for use in coke making
which comprises preparing a coal blend by mixing low ash hard coal and other coals in equal
proportions in a slot oven in a conventional manner, then subjecting the blend to a crushing step
in a conventional manner to obtain crushed coal blend with at least 80% of the particles passing
through a 3.2 mm BSS and there after mixing 15 to 25% based on the weight of the crushed coal,
a further amount of non-crushed low ash hard coal and blending the same thoroughly such that
the overall crushed coal in the final blend is of particles of less than 80% passing through a
3.2 mm BSS before feeding same to the coke oven.