Foundry coke products, and associated systems, devices, and methods
A coke product configured to be used in foundry cupolas to melt iron and produce cast iron products is disclosed herein. In some embodiments, the coke product has a Coke Reactivity Index (CRI) of at least 30% and an ash fusion temperature (AFT) less than 1316° C. Additionally or alternatively, the coke product can comprise (i) an ash content of at least 8.0%, (ii) a volatile matter content of no more than 1.0%, (iii) a Coke Strength After Reaction (CSR) of no more than 40%, (iv) a 2-inch drop shatter of at least 90%, and//or (v) a fixed carbon content of at least 85%.
1. A coke product, comprising:
a Coke Reactivity Index (CRI) of at least 30%; and
an ash fusion temperature (AFT) no more than 1316° C.
2. The coke product of claim 1 , wherein the coke product has an initial deformation temperature between 1149° C. and 1316° C.
3. The coke product of claim 1 , wherein the coke product has a softening temperature between 1177° C. and 1371° C.
4. The coke product of claim 1 , wherein the coke product has a hemispherical temperature between 1204° C. and 1371° C.
5. The coke product of claim 1 , wherein the coke product has a fluid temperature between and 1232° C. and 1427° C.
6. The coke product of claim 1 , wherein the AFT is between 1204° C. and 1260° C.
7. The coke product of claim 1 , wherein a fixed carbon content of the coke product is at least 85.0%.
8. A coke product, comprising:
ash having a composition that satisfies the following equation:
Ash Fusion Temperature (AFT)=19×(Al 2 O 3 _mass_fraction)+15×(SiO 2 _mass_fraction+TiO 2 _mass_fraction)+10×(CaO_mass_fraction+MgO_mass_fraction)+6×(Fe 2 O 3 _mass_fraction+Na 2 O_mass_fraction+K 2 O_mass_fraction),
wherein:
the AFT is a value between 982° C. and 1426° C.;
the SiO 2 _mass_fraction is an SiO 2 _mass_fraction of the ash;
the Al 2 O 3 _mass_fraction is an Al 2 O 3 _mass_fraction of the ash;
the Fe2O 3 _mass_fraction is an Fe 2 O 3 _mass_fraction of the ash;
the CaO_mass_fraction is a CaO_mass_fraction of the ash;
the MgO_mass_fraction is an MgO_mass_fraction of the ash; and
the K 2 O_mass_fraction is an K 2 O_mass_fraction of the ash.
9. The coke product of claim 8 , wherein a mass fraction of the ash of the coke product is no more than 10.0%.
10. The coke product of claim 8 , wherein a mass fraction of the ash of the coke product is at least 8.0%.
11. The coke product of claim 8 , wherein a volatile matter mass fraction of the coke product is no more than 1.0%.
12. The coke product of claim 8 , wherein a mass fraction of sulfur or sulfur oxide of the coke product is no more than 1.0%.
13. The coke product of claim 8 , wherein:
the coke product is produced from a coal blend comprising ash including Al 2 O 3 and SiO 2 ; and
a combined mass fraction of the Al 2 O 3 and SiO 2 of the ash is no more than 65%.
14. The coke product of claim 8 , wherein:
the coke product is produced from a coal blend comprising ash including Al 2 O 3 and SiO 2 ; and
a combined mass fraction of the Al 2 O 3 and the SiO 2 of the ash is between 65% and 80%.
15. The coke product of claim 8 , wherein the AFT is approximately 1204° C.
16. The coke product of claim 8 , wherein the AFT is between 1204° C. and 1260° C.
17. The coke product of claim 8 , wherein:
the coke product is made from a coal blend comprising ash including CaO; and
a mass fraction of the CaO of the ash is at least 2.0%.
18. The coke product of claim 8 , wherein the coke product has a coke reactivity index (CRI) of at least 25.0%.
19. The coke product of claim 8 , wherein the coke product has a Coke Strength After Reaction (CSR) that is no more than 40.0%.
20. The coke product of claim 8 , wherein the coke product has a 2-inch drop shatter of at least 90%.
21. The coke product of claim 8 , wherein the coke product has a 4-inch drop shatter of at least 80%.
22. The coke product of claim 8 , wherein a fixed carbon content of the coke product is at least 85.0%.
23. The coke product of claim 8 , wherein the AFT is approximately equal to at least one of 1260° C., 1288° C., 1316° C., 1343° C., 1371° C., 1399° C., or 1427° C.
24. A coke product, comprising:
ash having a composition that satisfies the following equation:
Ash Fusion Temperature (AFT)=19×(Al 2 O 3 _mass_fraction)+15×(SiO 2 _mass_fraction+TiO 2 _mass_fraction)+10×(CaO_mass_fraction+MgO_mass_fraction)+6×(Fe 2 O 3 _mass_fraction+Na 2 O_mass_fraction),
wherein:
the AFT is a value between 982° C. and 1204° C.;
the SiO 2 mass fraction is an SiO 2 mass fraction of the ash;
the Al 2 O 3 mass fraction is an Al 2 O 3 mass fraction of the ash;
the Fe 2 O 3 mass fraction is an Fe 2 O 3 mass fraction of the ash;
the CaO_mass_fraction is a CaO_mass_fraction of the ash; and
the MgO_mass_fraction is an MgO_mass_fraction of the ash.
25. A coke product, comprising:
ash having a composition that satisfies the following equation:
Ash Fusion Temperature (AFT)=401.5+26.3×SiO 2 _mass_fraction+40.7×Al 2 O 3 _mass_fraction)−11.0×Fe 2 O 3 _Mass_Fraction−7.9×CaO_mass_fraction−112×MgO_mass_fraction),
wherein:
the AFT is a value between 1204° C. and 1426° C.;
the SiO 2 mass fraction is an SiO 2 mass fraction of the ash;
the Al 2 O 3 mass fraction is an Al 2 O 3 mass fraction of the ash;
the Fe 2 O 3 mass fraction is an Fe 2 O 3 mass fraction of the ash;
the CaO_mass_fraction is a CaO_mass_fraction of the ash; and
the MgO_mass_fraction is an MgO_mass_fraction of the ash.