Granted Patent B2

US 12,286,591 · App. 18/501,795 · Granted Apr 29, 2025

Inventors: John Francis Quanci (Haddonfield, NJ); John Michael Richardson (Devon, PA); Jonathan Hale Perkins (Lisle, IL)

Assignee: SUNCOKE TECHNOLOGY AND DEVELOPMENT LLC

C10B57/06C10B5/02C10B15/02C10B21/10C10B41/00C10B53/00C10B57/04C10B57/16C10L5/04C10L5/442C10L5/48G01N33/222C10L2290/24C10L2290/60

Abstract

Claims (39)

1. A method of producing a coke product, the method comprising:

adding water to a coal blend;

charging the coal blend into a coke oven; and

heating the charged coal blend such that, during a pyrolysis duration of a coking cycle for the charged coal blend, a crown temperature of the coke oven is greater than a lower bound coking temperature,

wherein:

the lower bound coking temperature is within a range of 1200-2300° F.;

the pyrolysis duration begins when the crown temperature of the oven is greater than the lower bound coking temperature;

the pyrolysis duration ends when the crown temperature of the oven is less than the lower bound coking temperature;

the crown temperature is greater than a sole flue temperature of the coke oven throughout the pyrolysis duration; and

the pyrolysis duration is greater than 24 hours.

2. The method of claim 1 , wherein the lower bound coking temperature is within a range of 1800-2200° F.

3. The method of claim 1 , wherein an upper limit of the crown temperature is limited by an upper bound coking temperature that is greater than 2300° F.

4. The method of claim 1 , wherein the crown temperature of the coke oven during the pyrolysis duration is 2100-2300° F.

5. The method of claim 1 , wherein the crown temperature is within a 100° F. temperature range during at least twelve hours of the pyrolysis duration.

6. The method of claim 1 , wherein, during the pyrolysis duration, a sole flue temperature is below 2000° F.

7. The method of claim 1 , wherein, during the pyrolysis duration, a sole flue temperature is 1400-1800° F.

8. The method of claim 1 , wherein a soak time of the charged coal blend is less than 10.0 hours.

9. The method of claim 1 , wherein adding water to the coal blend comprises:

determining whether a testing moisture of the coal blend satisfies a target moisture value; and

in response to a determination that the testing moisture of the coal blend does not satisfy the target moisture values, adding water to the coal blend.

10. The method of claim 1 , wherein a moisture weight fraction of the coal blend charged into the coke oven is at least 8.0%.

11. The method of claim 1 , wherein adding water to the coal blend comprises adding water to a belt carrying the coal blend.

12. The method of claim 1 wherein adding water to the coal blend is based on a volatile matter of the coal blend.

13. The method of claim 1 , wherein adding water to the coal blend comprises adding water such that a moisture content of the charged coal is no more than 5% smaller or larger than a volatile matter mass fraction of the coal blend.

14. The method of claim 1 , wherein the pyrolysis duration is approximately 48 hours.

15. The method of claim 1 , wherein a volatile matter mass fraction of the coal blend is less than 27.0%.

16. The method of claim 1 , wherein the coke oven includes an uptake damper movable to a plurality of positions between open and closed, and wherein heating the coal blend comprises maintaining the uptake damper of the coke oven in a position less than half-way open during a majority of an initial 24 hours of the coking cycle.

17. The method of claim 1 , wherein heating the coal blend is based on a temperature change rate being no more than a temperature rate threshold that is less than or equal to 50° F. per hour.

18. The method of claim 1 , wherein heating the coal blend comprises closing a sole flue damper or maintaining the sole flue damper in a closed position for a majority of the pyrolysis duration.

19. The method of claim 1 , wherein a ratio of a soak time of the charged coal blend to a cycle duration of the charged coal blend is less than 33.0%.

20. A method, comprising:

heating a coal blend within a coke oven to a coking temperature during a pyrolysis duration of a coking,

wherein:

the pyrolysis duration begins when a crown temperature of the oven is greater than a lower bound coking temperature;

the pyrolysis duration ends when the crown temperature of the oven is less than the lower bound coking temperature;

the lower bound coking temperature is within a range of 1200-2300° F.;

the crown temperature is greater than a sole flue temperature of the coke oven throughout the pyrolysis duration; and

the pyrolysis duration is greater than 24 hours.

21. The method of claim 20 , wherein, for at least 12 hours of the pyrolysis duration, the coking temperature varies no more than 75° F.

Assignments (2)

Continuity (2)

References Cited (400)