Formed Coke Process Plant for Iron Manufacturing

1. Overview

The formed coke process (FCP) utilizes noncaking coal as the main raw material. Next, a binder is used to allow the coal to be shaped, and then it is carbonized in formed shapes in a vertical furnace to obtain coke.

2. Features

A series of steps are employed in FCP, including raw material processing, shaping, carbonizing the formed coal, and cooling the carbonized coke. In particular, the carbonizing and cooling steps are conducted in a vertical furnace within an enclosed system, providing many superior features in terms of work environment, work productivity, ease of system starts and stops. Relative to conventional chamber ovens, FCP systems are compact, meaning less installation space is required.

3. Results of the prococess

1. Production of formed coke from 100% noncaking coal The pilot plant was normally operated with a blend of 70% noncaking coal and 30% caking coal; however, 100% noncaking coal operation was also attained. 2. Establishing stable operating technology and engineering technology The pilot plant was operated for an extended period at the facility capacity of 200 tons/day. Production of 300 tons/day, or 1.5 times the designed capacity, was also achieved. Regarding the unit requirement of heat, 320 Mcal/t-formed coal was achieved. 3. Extended period of operation and continuous use of 20% formed coke in large blast furnace In a large blast furnace, a long and continuous operating test was carried out for 74 days with standard 20% formed coke and a maximum blend of 30% formed coke to confirm that the formed coke can be used in a similar way as chamber oven coke.