IP Library › Granted Patent US 12,338,394
Granted Patent B2
US 12,338,394 · App. 17/222,886 · Granted Jun 24, 2025

Multi-modal beds of coking material

Inventors: John Francis Quanci (Haddonfield, NJ); Syed Ahmed (Aurora, IL); Jake Sarpen (Lisle, IL); Jonathan Perkins (Lisle, IL); Jeff Wozek (Lisle, IL)
Assignee: SUNCOKE TECHNOLOGY AND DEVELOPMENT LLC
C10B57/04C10B57/06C10L5/04C10L5/36C10L5/366
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Quick Facts
Patent No.
US 12,338,394
App. No.
17/222,886
Granted
Jun 24, 2025
Kind
B2
Abstract

The present technology is generally directed to providing beds of coking material to charge a coking oven. In various embodiments, a quantity of first particulate material, having a first particulate size and bulk density, is combined with a second particulate material, having a second particulate size and bulk density, to define a multi-modal bed of coking material. The multi-modal bed of coking material exhibits an optimized bulk density that is greater than an ideal bulk density predicted by a linear combination of the bulk densities of the individual materials.

Claims (33)

1. A multi-modal bed of coking material comprising:

a first particulate coking material having a first bulk density; and

a second particulate coking material having a second bulk density less than the first bulk density,

the first particulate coking material being distributed with the second particulate coking material such that the multi-modal bed of coking material comprises a generally uniform distribution of the first particulate material and the second particulate material from a bottom portion of the multi-modal bed of material to an upper portion of the multi-modal bed of material, wherein the multi-modal bed of material includes a third density higher than an ideal bulk density based on (i) a weight fraction of the first particulate material and the first bulk density and (ii) a weight fraction of the second particulate material and the second bulk density,

wherein—

the first particulate coking material comprises a carbon containing material and the second particulate coking material comprises breeze having an ash content between 15-40%,

in operation, when the first particulate coking material is processed in a coke oven, the first particulate produces a first coke product having a first CSR, and

in operation, when the multi-modal bed of material is processed in a coke oven, the multi-modal bed of material produces a second coke product having a second CSR (i) of 58 or greater and (ii) no more than 10% less than the first CSR.

2. The multi-modal bed of claim 1 , wherein, within the multi-modal bed of material, the first particulate material is distributed in a manner that defines a plurality of void spaces at least partially filled with the second particulate material.

3. The multi-modal bed of claim 1 , wherein the second particulate material comprises less than 5% by weight of the multi-modal bed of material.

4. The multi-modal bed of claim 1 , wherein the second particulate coking material comprises coal.

5. The multi-modal bed of claim 1 , wherein the second particulate coking material consists of the breeze.

6. The multi-modal bed of claim 1 , wherein the first particulate coking material includes a first moisture content, and the second particulate coking material includes a second moisture content different than the first moisture content.

7. The multi-modal bed of claim 6 , wherein a difference between the first moisture content and the second moisture content is less than 14%.

8. The multi-modal bed of claim 1 , wherein the first particulate coking material is defined by a first particulate size distribution, and the second particulate coking material is defined by a second particulate size distribution different than the first particulate size distribution.

9. The multi-modal bed of claim 1 , wherein the first particulate material has a first average particulate size and the second particulate material has a second average particulate size smaller than the first particulate size.

10. A multi-modal bed of coking material comprising:

a first particulate coking material having a first moisture content and a first particulate size; and

a second particulate coking material having a second moisture content different than the first moisture content and a second particulate size different than the first particulate size,

wherein—

the first particulate coking material comprises a carbon containing material and the second particulate coking material comprises breeze having an ash content between 15-40%,

the first particulate coking material being distributed with the second particulate coking material to define a multi-modal bed of material including a generally uniform distribution of the first particulate material and the second particulate material from a bottom portion of the bed of material to an upper portion of the bed of material,

the bed of material has a density that is higher than an ideal bulk density based on a weight fraction of individual bulk densities of the first particulate coking material and the second particulate coking material, and wherein the bed of material has a third CSR higher than the first CSR,

in operation, when the first particulate coking material is processed in a coke oven, the first particulate coking material produces a coke product having a first CSR, and

in operation, when the multi-modal bed of material is processed in a coke oven, the multi-modal bed of material produces a coke product having a second CSR (i) of 58 or greater and (ii) no more than 10% less than the first CSR.

11. The multi-model bed of claim 10 , wherein, within the bed of material, the first particulate material is distributed in a manner that defines a plurality of void spaces at least partially filled with the second particulate material.

12. The multi-modal bed of claim 10 , wherein the second particulate material comprises less than 5% by weight of the bed of material.

13. The multi-modal bed of claim 10 , wherein the second particulate coking material comprises biachar.

14. The multi-modal bed of claim 10 , wherein the second particulate coking material consists of the breeze.

15. The multi-modal bed of claim 10 , wherein the first particulate coking material includes a first bulk density, and the second particulate coking material includes a second bulk density different than the first bulk density.

16. The multi-modal bed of claim 10 , wherein a difference between the first moisture content and the second moisture content is less than 14%.

17. The multi-modal bed of claim 10 , wherein the first particulate coking material is defined by a first particulate size distribution, and the second particulate coking material is defined by a second particulate size distribution different than the first particulate size distribution.

18. The multi-modal bed of claim 10 , wherein the first particulate size of the first particulate material is greater than the second particulate size of the second particulate material.

Assignments (3)
SECURITY INTEREST Recorded Jul 25, 2025
From: SUNCOKE TECHNOLOGY AND DEVELOPMENT LLC
To: BANK OF AMERICA, N.A., AS ADMINISTRATIVE AGENT
Reel/Frame 072254/0272 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Jul 27, 2021
From: QUANCI, JOHN FRANCIS; AHMED, SYED; SARPEN, JAKE; PERKINS, JONATHAN; WOZEK, JEFF
To: SUNCOKE TECHNOLOGY AND DEVELOPMENT LLC
Reel/Frame 056993/0840 →
SECURITY INTEREST Recorded Jul 13, 2021
From: SUNCOKE TECHNOLOGY AND DEVELOPMENT LLC
To: THE BANK OF NEW YORK MELLON TRUST COMPANY, N.A., AS COLLATERAL AGENT
Reel/Frame 056846/0548 →
Continuity (3)
Continuation 14983837 · Dec 30, 2015
Provisional Application 62098935 · Dec 31, 2014
Related Publication 20220056342A1 · Feb 24, 2022
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