Multi-modal beds of coking material

Patent metadata

Field	Value
Publication number	US-10975310-B2
Application number	US-201514984489-A
Country	US
Kind code	B2
Filing date	Dec 30, 2015
Priority date	Dec 31, 2014
Publication date	Apr 13, 2021
Grant date	Apr 13, 2021

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.

First claim

We claim:

1. A method of preparing a multi-modal bed of two or more materials to charge a coking oven in the process of manufacturing coke, the method comprising:
providing a quantity of first particulate material having a first particulate size and a first moisture content;
providing a quantity of second particulate material having a second particulate size, wherein the second particulate size is smaller than the first particulate size and a second moisture content; a moisture content differential existing between the first moisture content and the second moisture content that increases an adhesion strength between the first particulate material and second particulate material;
combining the first particulate material with the second particulate material to define the multi-modal bed of material; such that the first particulate material is distributed in a manner that defines a plurality of void spaces between individual particulate within the first particulate material and the voids are at least partially filled with the second particulate material, to define the multi-modal bed of material having a generally uniform distribution of first particulate material and second particulate material from a bottom portion of the bed of material to an upper portion of the bed of material, wherein the quantity of second particulate material approximates less than 10% by weight of the multi-modal bed of material; and
processing the multi-modal bed of material in the coking oven.

2. The method of claim 1 wherein the first particulate material is a carbon containing material having a first particulate size of between 50% passing through a ⅛ inch screen and 99% passing through a ⅛ inch screen.

3. The method of claim 1 wherein the first particulate material is a carbon containing material having a first particulate size of between size 8 mesh and size 16 mesh.

4. The method of claim 1 wherein the second particulate material is a carbon containing material having a second particulate size that is smaller than 30 mesh.

5. The method of claim 1 wherein the second particulate material is a carbon containing material having a second particulate size that is smaller than 60 mesh.

6. The method of claim 1 wherein the second particulate material is a carbon containing material having a second particulate size that is smaller than 100 mesh.

7. The method of claim 1 further comprising:
drying the second particulate material prior to combining the first particulate material with the second particulate material to define the multi-modal bed of material.

8. The method of claim 1 further comprising:
adding a suspension agent to the first particulate material prior to combining the first particulate material with the second particulate material to define the multi-modal bed of material.

9. The method of claim 8 further comprising:
drying the second particulate material prior to combining the first particulate material with the second particulate material to define the multi-modal bed of material.

10. The method of claim 8 wherein the suspension agent is comprised of a fluid hydrocarbon.

11. The method of claim 10 wherein the suspension agent is comprised of at least one of oil, tar, pitch and diesel.

12. The method of claim 1 wherein the first particulate material is comprised substantially of coal and the second particulate material is comprised substantially of breeze.

13. The method of claim 1 wherein the quantity of second particulate material approximates between 5% and 10% by weight of the multi-modal bed of material.

14. The method of claim 1 wherein the quantity of second particulate material approximates less than 5% by weight of the multi-modal bed of material.

15. The method of claim 1 wherein the first particulate material is comprised substantially of a carbon containing material and the second particulate material is chosen from a group of materials including: anthracite; breeze; petcoke; biochar; biomaterials; lignite; met coals; thermal coal; coke; pad coal; and pad coke.

16. The method of claim 1 wherein the second particulate material is comprised of a non-carbon containing inert material.

17. The method of claim 1 wherein the second particulate material is comprised of a carbon containing inert material.

18. The method of claim 1 wherein the first particulate material has a first bulk density, the second particulate material has a second bulk density, and the multi-modal bed of material has a third bulk density which is higher than the first bulk density.

19. The method of claim 1 wherein the quantity of second particulate material includes less than 10% moisture.

20. The method of claim 19 wherein the quantity of first particulate material includes less than 15% moisture.

21. The method of claim 1 wherein the quantity of second particulate material includes less than 5% moisture.

22. The method of claim 21 wherein the quantity of first particulate material includes less than 10% moisture.

23. The method of claim 1 wherein the quantity of second particulate material includes less than 1% moisture.

24. The method of claim 23 wherein the quantity of first particulate material includes less than 5% moisture.

25. The method of claim 1 wherein the quantity of first particulate material includes a first moisture content, the quantity of second particulate material includes a second moisture content, and the difference between the first moisture content and the second moisture content is less than 14%.

26. The method of claim 1 wherein the multi-modal bed of material has a charge weight that exceeds a charge weight of a similarly sized traditional bed formed from only the first particulate material, whereby the step of processing the multi-modal bed of material in the coking oven exhibits a mass/ton processing rate greater than an expected mass/ton processing rate for the similarly sized traditional bed formed from only the first particulate material.

27. The method of claim 1 wherein the quantity of second particulate material is comprised of recycled fines produced, at least in part, during a previous processing of a bed of material in the coking oven.

28. The method of claim 1 wherein the quantity of second particulate material is comprised of a portion of the quantity of first particulate material that has been ground to the second particulate size.

29. The method of claim 1 wherein the quantity of second particulate material is comprised of a portion of the quantity of first particulate material, which is smaller than the first particulate size, has been screened from the first particulate material, and has been ground to the second particulate size.

30. The method of claim 1 further comprising:
stamp charging the multi-modal bed of material to a density of between 0.85 sg to 1.2 sg.

31. The method of claim 1 further comprising:
stamp charging the multi-modal bed of material to a density above 1.2 sg.

32. A method of preparing a multi-modal bed of material to charge a coking oven in the process of manufacturing coke, the method comprising:
combining a first particulate material having a first particulate size distribution and a second particulate material having a second particulate size distribution, which is smaller than the first particulate size distri

Assignees

• Suncoke Tech & Development Llc

Inventors

• Quanci John Francis
• Ahmed Syed
• Sarpen Jake
• Perkins Jonathan
• Wozek Jeff

Classifications

• Y02P20/129

  Energy recovery, e.g. by cogeneration, H2recovery or pressure recovery turbines · CPC title

• C10L5/36

  Shape · CPC title

• C10L5/04

  Raw material {of mineral origin} to be used; Pretreatment thereof {(pretreatment of fuels of non-mineral origin C10L5/40)} · CPC title

• C10B57/06 Primary

  containing additives · CPC title

• C10B57/04 Primary

  using charges of special composition · CPC title