FIELD OF THE INVENTION
The present invention relates to utilization of non-coking coal for metallurgical
coke making with the addition of different special class of polymers which can
generate hydrogen in a specific temperature range through a specific mechanism.
BACKGROUND AND PRIOR ARTS OF THE PRESENT INVENTION
10 Coke serves very important purposes in a blast furnace process; it is a fuel,
reducing agent and is responsible for the permeability of the charge. Because of
the numerous functions of coke in blast furnace, stringent quality parameters of its
physical and chemical properties are required to ensure smooth operation of high
productivity in modern blast furnaces.
15 As the price of prime coking coal is high and the worldwide reserve of prime
coking coal is low, research is going on to develop some alternate carbonaceous
material, which can improve the coke quality. Fluidity is one of the main criteria
for a coal to become coking. World-wide research is going on for improvement of
fluidity with addition of external agent. Based on this philosophy, Tata Steel has
20 tried phenol-formaldehyde resin which is a condensation product of phenol and
formaldehyde as an additive. Successful trials were conducted in heat recovery
oven of Tata Steel.
Literature review as revealed in the reference list reveals that the fluidity of coal
matrix is equivalent to the Hydrogen present in the coal matrix. Also, the
25 evolution of hydrogen plays an important role to stabilise the metaplast in fluidic
regime. R&D has studied both coking & non-coking coals using TG-MS
(Thermo-Gravimetry coupled with Mass Spectroscopy) and established that the
liberation of Hydrogen in the temperature range of 300-6000
is essential for
development of coal fluidity. This is a new finding and may open many avenues
30 to improve the coking potential of non-coking coal.
3
5 Based on this background R&D has developed/ explored different types of
alternate carbonaceous material to improve the hydrogen liberation of the coal
matrix. This phenomenon helps to generate the more non-coking coal in the blend.
References:
1. A. Grint, H. Marsh, Carbonization and liquid-crystal (mesophase)
10 development-Co-carbonization of a high-volatile caking coal with several
petroleum pitches, Fuel, 60 (1981), 513-521.
2. G. Collin, B. Bujnowska, Co-carbonization of pitches with coal mixtures for
the production of metallurgical cokes, Carbon, 32 (1994), 547-552.
3. R. Alvarez, M. A. Diez, C. Barriocanal, C. S. Canga, C. S., and J. L.
15 Verduras, Use of waste lubricant oil from steel rolling mills in the coking
process, ISSJ International, 38 (1998), 23-27.
4. C. Barriocanal, R. Alvarez, C. S. Canga, M. A. Diez, On the possibility of
using coking plant waste materials as additives for coke production, Energy &
Fuels, 12 (1998), 981-989.
20 5. S. Nomura, K. Kato, T. Nakagawa, I. Komaki, The effect of plastic addition
on coal caking properties during carbonization, Fuel, 82 (2003), 1775-1782.
6. M. A. Diez, C. Barriocanal, R. Alvarez, Plastic wastes as modifiers of the
thermoplasticity of coal, Energy & Fuels, 19 (2005), 2304-2316.
7. A. B. Grigorova, O. I Zelenskii, Organic Clinkering Additives in Coking
25 Batch: A Review, Coke and Chemistry, 56 (2013), 248–252.
8. R. Barranco, J. Patrick, C. Snape, A. Thompson, Impact of low-cost filler
material on coke quality, Fuel, 86 (2007), 2179–2185.
9. Formed coke process, Research and development: Japan Coal Energy Center;
and Japan Iron and Steel Federation, 1986.
4
5 10. A. Benka, M. Talub, A. Cobana, Phenolic resin binder for the production of
metallurgical quality briquettes from coke breeze: Part I, Fuel Processing
Technology, 89 (2008), 28-37.
11. Andrew, T.H. and Lees, P., 1999, UK Patent, (GB 2330150).
12. Sameshima, K., Mort, K., and Inoue,T., 2002, US Patent, (US
10 2002/0016441).
13. Qureshi, S.P. and Chan, C., 1999, US Patent (US 5864003).
14. A. Benka, M. Talub, A. Cobana, Phenolic resin binder for the production of
metallurgical quality briquettes from coke breeze: Part II the effect of the type
of the basic catalyst used in the resol production on the tensile strength of the
15 formed coke, Fuel Processing Technology, 89 (2008), 38-46.
15. A. Benka, M. Talub, A. Cobana, Phenolic resin binder for the production of
metallurgical quality briquettes from coke breeze: Part III the effect of the
type of acidic hardeners on the quality of the formed coke and the possibility
to avoid the curing stage to produce metallurgical briquettes with enough
20 strength, Fuel Processing Technology, 90 (2009), 971-979.
16. M. Ibrahim, E. Hopkins, M.S. Seehra, Thermal and catalytic degradation of
commingled plastics. Fuel Processing Technology, 49 (1996), 65-73.
17. M.A. Diez, C. Barriocanal, R. Alvarez, Plastic wastes as modifiers of the
thermoplasticity of coal, Energy Fuels, 19 (2005), 2304-2316.
25 18. S. Nomura, K. Kato, 2006, The effect of plastic size on coke quality and
coking pressure in the co-carbonization of coal/plastic in coke oven, Fuel, 85
(2006), 47-56.
19. C. Barriocanal, R. Alvarez, C.S. Canga, M. A. Diez, On the possibility of
using coking plant waste materials as additives for coke production, Energy
30 Fuels, 12 (1988), 981-989.
5
5 20. H. Marsh, R.C Neavel, Carbonization and liquid crystal (mesophase)
development: A common stage in mechanisms of coal liquefication and of
coal blends for coke making, Fuel, 59 (1980), 511-513
21. Y. S. Nagoruyi, V.M. Gulyaev, L.I. Glushchenko, Use of tar containing waste
product from by-product coke production in coking charge, Coke and
10 Chemistry, 1 (1993),15-17.
22. N. I. Panchenko, V. M. Gulyaev, L.I. Glushchenko, T.G. Morgui, Coke Chem.
1993, 21-24.
23. P. Biswas, J. Panda
24. N. N. Ghosh, B. Kiskan, Y. Yagci, Polybenzoxazines-new high performance
15 thermosetting resins: synthesis and properties, Prog. Polymer. Sci., 32 (2007),
1344-1391.
25. J. Liu, H. Ishida, In: J. C. Salamone JC, editor. A new class of phenolic resins
with ring-opening polymerization. The polymeric materials encyclopedia.
Florida: CRC Press; 1996. p. 484–94.
20 26.CPR. Nair, Advances in addition-cure phenolic resins. Prog. Polym Sci 2004;
29:401–98.
OBJECTS OF THE PRESENT INVENTION:
It is therefore an object of this invention to provide a process where maximum
25 non-coking coal can be incorporated in metallurgical coke making without
deterioration of coke properties.
Another object of this invention is to utilize the phenomena of hydrogen
generation by specific mechanism in the coal matrix at specific temperature range
by addition of a special types of compounds.
6
5 Yet another object of this invention is to propose a blend design which can use
very small percentage of special class compounds to incorporate non-coking coal
in blend.
Still another object of this invention is to replace the hard-coking coal in the coal
blend by non-coking coal.
10
SUMMARY OF THE INVENTION
This invention is to develop a methodology for incorporation of maximum noncoking coal in blend. As hydrogen generation at a specific temperature range is
essential for coke making, so some special category of compounds have been used
15 for the same. Addition of these compound in small quantity generate the scope for
the accommodation of non-coking coal in place of good hard coking coal in blend
without deterioration of coke properties.
The present invention discloses generally, a method for using maximum inferior
coal and/ or non-coking coal in metallurgical coke making, said method
20 comprising the steps of mixing the non-coking coal (NC) with a coking coal (CC)
blends; and subjecting said mixture to a compound for enabling the generation of
hydrogen (H2) at a temperature 300-600° C for the coal to pass through the fluidic
phase, wherein the compound for enabling the generation of H2 is an organic
compound selected from phenolic resin-based polymers, and wherein the
25 compound is having a phenolic OH group of common molecular formula (XOH)n, wherein ‘n’ is any integer 80-100, and X is any reactive organic aromatic
group comprising of single or multiple benzene/ phenyl ring with aromatic
ethylene (C=C) bonds.
The coking coal (CC) blend comprises of a mixture of 20-40% of Medium Coking
30 Coal-1 (MC1), 20-40% of Medium Coking Coal-2 (MC2), 5-20 % of Prime
Coking Coal-1 (PC1), 10-20% of Prime Coking Coal-2 (PC2) and 5-15% of
Inferior Coal (IC), and the Non-Coking Coal (NC) is optionally added in 0-15% to
7
5 a blend replacing primer coking coal, preferably PC1, to which, further, the
organic phenolic resin-based compound is further added in 0.3 – 1% replacing
same amount of NC in blend. The ash content of MC1, MC2, PC1, PC2 and IC
are 15.5-17.0, 7-8, 17-18.5, 8.5-9.5 and 5.5 -6.5 respectively. The MC1, MC2,
PC1, PC2 and IC comprises volatile matter of 24-25.5, 18-19.5, 20.3-21.5, and
10 24-24.5 and 33.5 – 34.5 respectively. The Crucible Swelling number (CSN) of
MC1, MC2, PC1, PC2 and IC are 4-5, 5-6, 6-7, 7.9-8.5 and 3-4 respectively.
Whereas, NC has ash content of 8-12, volatile matter (VM) content of 33.5-34.5,
and CSN of 0-3.
The coking coal (CC) including PC1, PC2, MC1, MC2 and IC have fluidity 200-
15 2000 ddpm, and the non-coking coal (NC) have zero fluidity.
BRIEF DESCRIPTION OF ACCOMPANYING DRAWINGS
The illustrated embodiments of the subject matter will be best understood by
reference to the drawings, wherein like parts are designated by like numerals
20 throughout. The following description is intended only by way of example, and
simply illustrates certain selected embodiments of devices, systems, and processes
that are consistent with the subject matter as claimed herein, wherein:
Figure 1: Pictorial representation of the difference of hydrogen generation of
coking and non-coking coal along with the mechanism thereof,
25 wherein A represents original prime coking coal; B represents
before softening wherein volatile substances are removed and
transferable H remain; C represents plastic range wherein higher
fluidity is seen and the radicals are stabilized; and D represents
good coke after re-solidification. On the contrary, W represents
30 non coking coal; X represents the same before softening wherein
transferable H are consumed; Y represents the plastic range of non-
8
5 coking coal with lower fluidity wherein the radicals are
recombined; and Z represents a coke of poor quality.
Figure 2: FTIR analysis for the phenolic resin based polymers having a
common molecular formula (X-OH)n.
Figure 3: A general layout for polymer mixing and dosing, wherein A
10 represents coal bins; B represents a belt conveyer with CL-24 at
700 tph; C represents a standard 10 ton polymer tank/ 7.7 kL from
where the polymer goes into the reaction chambers X and Y fitted
with agitators; D represents 0.7% polymer mixed with E
representing 0.3% of water in reaction chamber Z with agitator; F
15 representing spraying station; G represents coal tower bat. # 9 of
2500 ton X2
Figure 4: Coke Strength after Reaction (CSR) and Coke Reactivity Indices
(CRI) showing it is possible to replace prime coking coal with noncoking coal.
20 DETAILED DESCRIPTION OF THE INVENTION
At the very outset of the detailed description, it may be understood that the
ensuing description only illustrates a form of this invention. However, such a form
is only exemplary embodiment, and without intending to imply any limitation on
the scope of this invention. Accordingly, the description is to be understood as an
25 exemplary embodiment and teaching of invention and not intended to be taken
restrictively.
Throughout the description and claims of this specification, the phrases
“comprise” and “contain” and variations of them mean “including but not limited
to”, and are not intended to exclude other moieties, additives, components,
30 integers or steps. Thus, the singular encompasses the plural unless the context
otherwise requires. Wherever there is an indefinite article used, the specification
9
5 is to be understood as contemplating plurality as well as singularity, unless the
context requires otherwise.
Thus, the terms “comprises”, “comprising”, or any other variations thereof used in
the disclosure, are intended to cover a non-exclusive inclusion, such that a device,
system, assembly that comprises a list of components does not include- only those
10 components but may include other components not expressly listed or inherent to
such system, or assembly, or device.
In other words, one or more elements in a system or device proceeded by
“comprises… a” does not, without more constraints, preclude the existence of
other elements or additional elements in the system, apparatus or device.
15 Features, integers, characteristics, compounds, chemical moieties or groups
described in conjunction with an aspect, embodiment or example of the invention
are to be understood to be applicable to any other aspect, embodiment or example
described herein unless incompatible therewith. All the features disclosed in this
specification (including any accompanying claims, abstract and drawings), and/ or
20 all of the steps of any method or process so disclosed, may be combined in any
combination, except combinations where at least some of such features and/ or
steps are mutually exclusive. The invention is not restricted to the details of any
foregoing embodiments. The invention extends to any novel one, or any novel
combination, of the features disclosed in this specification including any
25 accompanying claims, abstract and drawings or any parts thereof, or to any novel
one, or any novel combination, of the steps of any method or process so disclosed.
The reader's attention is directed to all papers and documents which are filed
concurrently with or before this specification in connection with this application
and which are open to public inspection with this specification, and the contents
30 of all such papers and documents are incorporated herein by reference. Post filing
patents, original peer reviewed research paper shall be published.
The following descriptions of embodiments and examples are offered by way of
illustration and not by way of limitation.
10
5 Unless contraindicated or noted otherwise, throughout this specification, the terms
“a” and “an” mean one or more, and the term “or” means and/or. As used in the
description herein and throughout the claims that follow, the meaning of “a.”
“an,” and “the” includes plural reference unless the context clearly dictates
otherwise. Also, as used in the description herein, the meaning of “in” includes
10 “in” and “on” unless the context clearly dictates otherwise.
Coal is a fossil, predominantly from ancient forests, readily combustible rock
containing at least 50 wt% of carbonaceous material. In initial stage, the fossil
undergoes a peat formation, which when subjected to appropriate heat and burial
pressure, may get converted to lignite with a timescale determinable through other
15 variable factors as mentioned.
The lignite may be considered as an immature form of coal, lighter in colour and
softer in texture, which may get darker and harder corresponding to physicochemical changes with further burial, and converted to sub-bituminous coal and
then to bituminous coal, which ultimately maturates to harder and shinier
20 anthracite coal.
Coke is a porous fossil fuel with fewer impurities, generally made with humanhand, however may also be formed through geologic reasons, usually refers to a
product derived from low-ash and low-sulfur coal, preferably bituminous coal
through coking process, generally grey in color and harder in texture, may be
25 made from coal in absence of air through a destructive distillation process.
When coal heated in absence of air, it may pass through a fluidic range at about
300-6000 C. As mentioned earlier, bituminous and sub-bituminous coal which
generally falls under coking coal category follow this phenomenon. The high
volatile or low volatile coal, which don’t pass through the fluidic phase in heating
30 considered as non-coking coal, which when added to the blend, results in
deterioration of quality.
11
5 By characterization of different coking and non-coking coal, it is found that the
generation of transferrable hydrogen in the temperature range of 300-6000 C is the
key factor for a coal to pass through fluidic phase. Thermogravimetric study
coupled with mass spectroscopy helps to evaluate the hydrogen generation of
different coals. Cracking and condensation reactions compete and finally
10 crosslinking of macromolecules takes place. In this process hydrogen (H2) should
evolve in enough to act as feed for the cracked molecules. Simultaneously, H2
evolution may also be a measure of aromatization process and reaches its
maximum at the maximum fluidity temperature.
The presence of transferrable hydrogen is essential for coking coal. In the case of
15 non-coking coal, the transferrable hydrogen is largely consumed during the
heating up to start of fluidic temperature, while with a strongly coking coal, this
transferrable hydrogen could not be taken up to the same extent. Therefore, in the
following heating period from start of fluidic zone, enough transferrable hydrogen
remains, and it can play a role to stabilize cleaved fragment of coal.
20 As per the fluidity value, the coking coal (CC) may have a fluidity of around 200
– 2000 ddpm, wherein the prime coking coal is having a fluidity of 300 – 1600
ddpm; the medium coking coal (MC) having a fluidity of around 20-50 ddpm, and
non-coking coal (NC) may have a negligible or zero (0) fluidity.
Amongst the prime coking coal, the prime coking coal 1 (PC 1) has a fluidity of
25 377 ddpm; and the prime coking coal 2 (PC2) having a fluidity of 1573 ddpm, and
the medium coking coal 1 (MC1) having a fluidity of 27.
So, based on this phenomenon, in this innovation, a class of compounds have
been chosen, which are able to generate hydrogen at the above-mentioned specific
temperature range when mixed with blend. Thus, it may give an opportunity to
30 incorporate more non-coking coal in the blend.
The compound may be an inorganic or organic compound. If the compound is
organic, then it may comprise aliphatic or aromatic ring, with a phenolic OH
12
5 group of common molecular formula (X-OH)n, wherein “n” is an integer. The
compound may be mixed in in 0.3-1% proportion to any blend.
In different embodiments, the nature of the compound may vary, however, since
the underlying process is aromatization, preferable embodiment may comprise an
aromatic ring in the compound.
10 As earlier mentioned, one of the ways of classifying coals may be coking
efficiency, wherein in this disclosure, PC1 and PC2 are designated as prime hard
coking coals, MC1 and MC2 as medium coking coals, IC as inferior coal, and NC
as non-coking coal, something still inferior than that of IC in terms of coking
efficiency. For experiment purpose, a NC may be specified as having ash around
15 8% and Crucible Swelling Number (CSN) 1.5. Regarding the explanation of
terminology, which are general to the state of the art, it may be essential to
describe and explain certain terms and terminology.
For the experimentation part, the ash is determined by following ASTM standard
D 3174-11. 1 gm of 250 mm size sample is taken to a weighed capsule. Then the
20 sample is placed in a cold muffle furnace and heated gradually at such a rate that
the temperature reached 450° C to 500° C by 1 hr. At the end of the 2 hours, it will
reach 950° C. After cooling the weight of the sample then measured and ash is
calculated by weight difference.
For the determination of volatile matter (VM) in coal, ASTM standard D 3175-11
25 has been followed. In this test, 1 gm of 250 mm size sample is taken in a covered
platinum crucible and heated in a furnace of 950° C for 7 min, after which, VM is
calculated by weight difference.
Crucible swelling number (CSN) test has been done by following ASTM D720-91
(2010) standard. 1 gm of sample (-0.212 mm size) is taken in a translucent squat
30 shaped silica crucible and levelled by tapping the crucible 12 times. The crucible
is covered with a lid and heated under standard conditions, either by a special type
of gas burner or muffle furnace. After the test the shape of coke button is
13
5 compared with a standard chart and accordingly, the crucible swelling number (0
to 9) is assigned to the coal sample.
Generally, when a blend is prepared, coal with CSN less than 3 is not considered
for any blend. NCs generally have a negligible CSN of 0-3. However, with the
rapid depletion of natural resources including fossil minerals, in tandem with the
10 challenged faced by alarming level of global warming fuelled by pollution of
several kinds, ways for using IC or even the NC is now considered, either
standalone or in a blend. As India has a dearth of good coking coal, this effort is
even more relevant.
The blend of the four types as described, may comprise 0-100% of any of these
15 four varieties, wherein for a blend, even one of the coking coals may be
represented in 0%. Typically, in a blend there are 30% prime coking coal, 70%
medium coking coal and around 10% of inferior coal used, which may further be
substituted with non-coking coal.
One of the important aspects of the present invention may lie in the effort of
20 conversion of IC or NC to a better coke in terms of the data of coke strength after
reaction (CSR).
The general methodology comprises the steps of selection of coal for blending,
selection of a class of compound(s), characterization of coal and blend leading to
coking potential tests, blend design, followed by carbonization tests, and finally
25 evaluation of coking properties.
The special class of compound enables the generation of hydrogen (H2) at a
temperature 300-6000 C. The compound may be an inorganic or organic
compound. If the compound is organic, then it may comprise aliphatic or aromatic
ring, with a phenolic OH group of common molecular formula (X-OH)n, wherein
30 “n” is an integer. The compound may be mixed in 0.3-1% proportion to any
blend.
14
5 To verify the efficacy of the invention in replacing PC with IC and/ or even NC,
several blends may be prepared of which one (1) should be positive control and
one (1) should be negative control, and the rests may be designed to calibrate the
statistically optimum dosage of the compound in the blend. The phrase “positive
control” is used for this invention to designate a normal blend of PC1, PC2, MC1
10 and MC2 without the compound and likewise, the phrase “negative control” is
used for this invention to designate a blend without not only the compound but
also a substantial portion of PC1 replaced by NC. The biblical meaning of
“positive control” and “negative control” may not be followed, and the definition
of said two (2) phrases may be understood by the above description. Further, at
15 least two (2) more blends are designed to optimize the amount of the compound.
The percentage range for each blend is 5-20 % for PC1, 10-20% of PC2, 20-40%
of MC1 and MC2, 5-15% of IC and optional addition of 0-15% of NC, with
further optional addition of 0.3-1% proportion of the compound.
Table 1: Properties of types of coal used in coke plant blend
Coal Types Ash Value VM Crucible Swelling Number (CSN)
MC1 15.5-17 24-25.5 4-5
MC2 7-8 18-19.5 5-6
PC1 17-18.5 20.3-21.5 6-7
PC2 8.5-9.5 24-24.5 7.9-8.5
IC 5.5-6.5 33.5-34.5 3-4
NC 8-12 33.5-34.5 0-3
20
The fluidity values of each coal types have already been provided in earlier
section.
The present formulation is further clarified by giving the following exhibits. It
must, however, be understood that these exhibits are only illustrative in nature and
25 should not be taken as limitations to the capacity of the invention. Several
amendments and improvements to the disclosed segments will be obvious to those
15
5 skilled in the art. Thus, these amendments and improvements may be made
without deviating from the scope of the invention.
Example 1:
Special class of compound:
The compound enables the generation of hydrogen (H2) at a temperature 300-600
°
10 C. The compound for enabling the generation of H2 for the process is an organic
compound selected from phenolic resin-based polymers, wherein said compound
is having a phenolic OH group of common molecular formula (X-OH)n, wherein
‘n’ is any integer between 80-100, and X is any reactive organic aromatic group,
present as a substituent in single or multiple phenyl/ Benzene ring, wherein
15 further X is having a phenolic ring with aromatic ethylene (C=C) bonds.
The compound used here for hydrogen generation are basically phenolic resinbased Polymers. Which has common molecular formula of (X-OH)n. where X can
be any reactive organic aromatic group. For FTIR analysis Samples for the FTIR
studies were prepared by the KBr pellet technique and the Nicolet 6700 FTIR
spectrometer was used to record the spectra with 256 scans from 4000–400 cm-1 20 .
Spectra were obtained using the standard software package on OMNIC 7a. The
band in the region of 3000-3620 cm-1 might be due to phenolic methylol hydroxyl
(-OH) vibration. A band in the region of 1315-1409 cm-1 might be due to the
presence of hydroxyl groups, (methylol hydroxyls) in the molecules. The band at
1500 cm-1 might be assigned to phenolic ring. The absorption band at 820 cm-1 25
clearly indicates the presence of aromatic ethylene bonds (C=C) of phenolic ring.
A peak near 1200 cm-1
is also appearing in the spectrum is due to the stretching
vibration of phenol-O group. Figure 2 present a common FTIR for the same class
of compounds. Skeletal structure of said compound is hereunder:
16
5
10
17
5 Example 2:
Carbonization Study:
A series of carbonization tests were designed in the 7 kg carbolite oven. Several
carbonization tests were conducted in the 7-kg test oven, under stamp charging
conditions. The series of carbonization tests were carried to study the
10 incorporation of non-coking coal along with the special class of compound in the
blend and its effect on coke properties. The objective is that there should not be
deterioration of coke properties. Water was added to the coal blend to obtain the
desired value of moisture content. The coal cake was made inside a cardboard box
keeping the bulk density 1150 kg/ m3
. Before charging the coal cake into the
15 oven, it was ensured that the empty oven temperature is 900±5° C. After 5 h of
carbonization time, the hot coke was pushed out and quenched with water. The
coke samples were tested for CSR (coke strength after reaction) and CRI (coke
reactivity indices). CSR has been done following the NSC method. In which 200
g coke of 19-21 mm size is heated in a reaction tube (78 mm diameter X 210 mm
length) at 1100 20 ° C for two hours during which CO2 is passed a 5 l/min.
Carbonization studies were done with series of blend. Tests were done with
different blends (Table 2). Initially test carried out with the base blend (referred as
blend no. 1). Then, the hard-coking coal or a portion thereof from the base blend
is replaced by non-coking coal (blend no. 2) resulting in expected deterioration of
25 coke properties in terms of qualitative parameters. In blend no 3, hard coking coal
has been replaced by non-coking coal but with addition of 0.5 % of the
compound. CSR result shows that there is slight improvement of coke properties.
In blend 4, 0.7 % of the compound mentioned, has been added. It has been found
that there is no significant deterioration of coke properties from the base blend.
30 These experimental model has been created to verify the efficacy of the invention
in replacing PC with IC and/ or even NC, several blends may be prepared of
which one (1) should be positive control and one (1) should be negative control,
and the rests may be designed to calibrate the statistically optimum dosage of the
18
5 compound in the blend. Further, at least two (2) more blends are designed to
optimize the amount of the compound.
Table 2: Carbonization Study
Blend 1 2 3 4
Component %
1 PC1 15 5 5 5
2 PC2 15 15 15 15
3 MC1 30 30 30 30
4 MC2 30 30 30 30
5 IC 10 10 10 10
6 NC 0 10 9.5 9.3
7 Special compound 0 0 0.5 0.7
CSR 52 45.5 49.1 52.3
10 From the results, which is reflected in the table 2 above, it may be observed that in
the blend 2, a portion of PC1 has been replaced by NC resulting in substantial
downfall of CSR of the blend. Whereas in the blend 3, 0.5% of the compound has
been added replacing same amount of NC resulting in significant improvement of
the CSR of said blend. A further replacement of NC with 0.7% of compound
15 yielded even better result in terms of CSR than that of the original blend 1
comprising no NC.
Example 3:
Trial Plan:
Further, upscaling of the test is performed for better understanding of efficacy.
20 Based on the lab scale result a small-scale plant trial has been planned with 10
Tonne polymers in battery 9. Mixing and dosing system is available after primary
crusher. Figure 3 shows the process lay out for mixing and dosing. The process
equipped with two storage tank of capacity 5 kl and 7 kl and one mixing-cumdosing tank (capacity of 8 kl), overflow tank and polymer spraying header with
25 nozzle assembly. The polymer is unloaded from the tanker through pump-2 to
19
5 storage tanke-1 and 2. A manual valve is provided at suction and discharge of
pump-2 to have a better control while unloading. Two manual valves are provided
after the pump-2 and before the polymer storage tank-1 and storage tank-2 for
selection of tank for loading the material. The mixing-cum-dosing tank has water
dosing main line and one polymer dosing line. The flow rates of water and
10 polymer are monitored by flow meters. This tank has one overflow line at top and
polymer assay discharge line at the bottom. The agitator assembly provides the
uniform mixing to prepare the required polymer assay. The discharge lines
connect with a pump which transfers the polymer assay to spraying system. Flow
transmitter monitors the flow rate of polymer assay at main discharge line, and
15 necessary changes are made by regulating the manual valve after the flow meter.
Bypass line has also been provided in main discharge line for maintenance
purposes. This tank has a sampling line at the bottom for collecting the sample for
analysis purpose. The tank polymer assay level is monitored by radar type level
transmitter which is fixed at the top of the tank. Figure 4 shows the process flow
20 diagram of mixing and dosing system.
Trial has been carried out in Commercial stamp charge battery 9 on 7-8
th June.
Before charging the coal, polymer mixing, and dosing system has been checked
properly. Polymer percentage was kept around 0.5 - 0.7%. Polymer was mixed
with water in approx. 1: 0.4 ratio and then sprayed over the conveyer belt. Coal
25 prepared with polymer around 1000 Ton. Around 37 number of ovens charged
with the polymer mix blend.
Example 4:
CSR/ CRI study:
Sampling has been done by auto sampler. Samples have been tested for CSR and
30 CRI, the results of which has been expressed under Figure 4. In trial blend around
6-8% of imported prime coking coal has been replaced by non-coking coal with
20
5 polymer. Results indicate that without any significant deterioration of coke
properties replacement of prime coking coal with non-coking coal is possible.
Now, the crux of the invention is claimed implicitly and explicitly through the
following claims.
Each of the appended claims defines a separate invention, which for infringement
10 purposes is recognized as including equivalents to the various elements or
limitations specified in the claims. Depending on the context, all references below
to the “invention” may in some cases refer to certain specific embodiments only.
In other cases, it will be recognized that references to the “invention” will refer to
subject matter recited in one or more, but not necessarily all, of the claims.
15 Groupings of alternative elements or embodiments of the invention disclosed
herein are not to be construed as limitations. Each group member can be referred
to a claimed individually or in any combination with other members of the group
or other elements found herein. One or more members of a group can be included
in or deleted from, a group for reasons of convenience and/ or patentability. When
20 any such inclusion or deletion occurs, the specification is herein deemed to
contain the group as modified thus fulfilling the written description of all groups
used in the appended claims.

We Claim:

1. A method for using maximum inferior coal and/ or non-coking coal in
metallurgical coke making, said method comprising the steps of:
a) mixing the non-coking coal (NC) with a coking coal (CC) to form a
mixture; and
b) subjecting said mixture to a compound for enabling the generation of
hydrogen (H2) at a temperature 300-600° C for the coal to pass through the
fluidic phase.
2. The method as claimed in claim 1, wherein the compound for enabling the
generation of H2 is an organic compound selected from phenolic resin-based
polymers.
3. The method as claimed in claim 2, wherein the compound is having a
phenolic OH group of common molecular formula (X-OH)n, wherein ‘n’ is
any integer 80-100, and X is any reactive organic aromatic group comprising
of single or multiple benzene/ phenyl ring with aromatic ethylene (C=C)
bonds.
4. The method as claimed in claim 1, wherein the coking coal (CC) comprises of
mixture of 20-40% of Medium Coking Coal-1 (MC1), 20-40% of Medium
Coking Coal-2 (MC2), 5-20 % of Prime Coking Coal -1 (PC1), 10-20% of
Prime Coking Coal (PC2) and 5-15% of Inferior Coal (IC).
5. The method as claimed in claim 4, wherein the ash content of MC1, MC2,
PC1, PC2 and IC are 15.5-17.0, 7-8, 17-18.5, 8.5-9.5 and 5.5 -6.5
respectively.
6. The method as claimed in claim 4, wherein MC1, MC2, PC1 and PC2 and IC
comprises volatile matter 24-25.5, 18-19.5, 20.3-21.5, and 24.0-24.5 and 33.5
– 34.5 respectively.
7. The method as claimed in claim 1, wherein Crucible Swelling number (CSN)
of MC1, MC2, PC1, PC2 and IC are 4-5, 5-6, 6-7, 7.9-8.5 and 3-4
respectively.
8. The method as claimed in claim 1, wherein the NC has ash content of 8-12,
volatile matter (VM) content of 33.5-34.5, and CSN of 0-3.
9. The method as claimed in claim 1, wherein the coking coal (CC) have fluidity
200-2000 ddpm, and the non-coking coal (NC) have zero fluidity.
10. The method as claimed in claim 1, wherein 5-20% NC is added by replacing
the prime coking coal, specifically PC1.
11. The method as claimed in claim 10, wherein 0.3 – 1% of the compound is
further added replacing same amount of NC leaving the other components of
the blends unaltered.
12. The method as claimed in claim 11, wherein CSR of the mixture is 49 to 52.5.