Granted Patent B2

US 12,331,367 · App. 18/892,228 · Granted Jun 17, 2025

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

Assignee: SUNCOKE TECHNOLOGY AND DEVELOPMENT LLC

C21B5/007

Abstract

Claims (135)

1. A coke product, comprising:

a Coke Reactivity Index (CRI) of at least 30%;

an ash fusion temperature (AFT) no more than 1427° C.; and

a fixed carbon content of at least 80.0%,

wherein the coke product is solid.

2. The coke product of claim 1 , wherein the ash fusion temperature is between 1149° C. and 1427° 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 an initial deformation temperature between 1149° C. and 1316° C.

5. The coke product of claim 1 , wherein the coke product has a hemispherical temperature between 1204° C. and 1371° C.

6. The coke product of claim 1 , wherein the coke product has a fluid temperature between and 1232° C. and 1427° C.

7. The coke product of claim 1 , wherein the fixed carbon content of the coke product is at least 85.0%.

8. The coke product of claim 1 wherein ash of the coke product has 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 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;

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 1 , 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%.

16. The coke product of claim 1 , wherein the coke product has a coke reactivity index (CRI) of at least 25.0%.

17. The coke product of claim 1 , wherein the coke product has a Coke Strength After Reaction (CSR) that is no more than 40.0%.

18. The coke product of claim 1 , wherein the coke product has a 2-inch drop shatter of at least 90%.

19. A coke product, comprising:

a Coke Reactivity Index (CRI) of at least 30%; and

an ash fusion temperature (AFT) between 982° C. and 1426° C.,

wherein the 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), and

wherein:

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;

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; and

the coke product is solid.

20. The coke product of claim 19 , wherein a fixed carbon content of the coke product is at least 80.0%.

21. A solid coke product, comprising:

a Coke Reactivity Index (CRI) of at least 30%;

an ash fusion temperature (AFT) no more than 1427° C.;

a fixed carbon content of at least 80.0%.

Assignments (2)

Continuity (4)

References Cited (400)