Coke (fuel)
Coke is the solid carbonaceous material derived from destructive distillation of low-ash, low-sulfur bituminous coal. Cokes from coal are grey, hard, and porous.
Production
Coke is usually produced from coal; the process is called coking.
 | This article needs attention from an expert in chemistry. Please add a reason or a talk parameter to this template to explain the issue with the article. (March 2009) |
Volatile constituents of the coal—including water, coal-gas, and coal-tar—are driven off by baking in an airless furnace or oven at temperatures as high as 2,000 degrees Celsius. This fuses together the fixed carbon and residual ash. Most modern facilities have "by-product" coking ovens. Today, the hydrocarbons are considered by-products of coke-making, but many American steel companies capture and use them to create other products.[citation needed] Non by-product coking furnaces or coke furnaces (ovens) burn the hydrocarbon gases produced by the coke-making process to drive the carbonization process.
Bituminous coal must meet a set of criteria for use as coking coal, determined by particular coal assay techniques. These include moisture content, ash content, sulfur content, volatile content, tar, and plasticity.
The greater the volatile matter in coal, the more by-product can be produced, but too low or too high levels of volatile matter in the coal results in inferior coke produced in respect to coke quality properties. It is generally considered that levels of 26-29 % of volatile matter in the coal blend is good for coking purposes. Thus coal is blended in proportions among different types of coal to reach acceptable levels of volatility before the coking process begins.
Uses
Coke is used as a fuel and as a reducing agent in smelting iron ore in a blast furnace.
Since smoke-producing constituents are driven off during the coking of coal, coke forms a desirable fuel for stoves and furnaces in which conditions are not suitable for the complete burning of bituminous coal itself. Coke may be burned with little or no smoke under combustion conditions, while bituminous coal would produce much smoke.
Discovered by accident to have superior heat shielding properties when combined with other materials, coke was one of the materials used in the heat shielding on NASA's Apollo program space vehicles. In its final form, this material was called AVCOAT 5026-39. This material has been used most recently as the heat shielding on the Mars Pathfinder vehicle. Although not used for modern day space shuttles, NASA is utilizing coke and other materials for a new heat shield for its next generation space craft, named Orion, which is due to be completed in 2014.[citation needed]
Gas byproducts
Coke may be used to make fuel gases. These useful gases require careful handling because of the risk of carbon monoxide poisoning. It appears that the names have different meanings in the USA and the UK. The following are UK meanings:
- Water gas: a mixture of carbon monoxide and hydrogen, made by passing steam over red-hot coke (or any carbon based char)
- Producer gas, wood gas, generator gas, synthetic gas, suction gas: a mixture of carbon monoxide, hydrogen and nitrogen, made by passing air over red-hot coke (or any carbon based char)
History
The use of coke as a fuel was pioneered by the Chinese in the 11th century during the Song Dynasty (960–1279 AD). In Europe, it was introduced during the 17th century in England to replace wood which was becoming scarce and expensive due to deforestation. Coal's fumes, particularly smoke and sulfur compounds, disqualified it from many applications, including cooking and iron smelting.
In 1603, Sir Henry Platt suggested that coal might be charred in a manner analogous to the way charcoal is produced from wood. This process was not put into practice until 1642, when coke was used for roasting malt in Derbyshire. Coal cannot be used in brewing because its sulfurous fumes would impart a foul taste to the beer. In 1709, Abraham Darby I established a coke-fired blast furnace to produce cast iron. Coke's superior crushing strength allowed blast furnaces to become taller and larger. The ensuing availability of inexpensive iron was one of the factors leading to the Industrial Revolution.
In England in the first years of steam railway locomotives, coke was the normal fuel. This resulted from an early piece of environmental legislation; any proposed locomotive had to "consume its own smoke".[citation needed] This was not technically possible to achieve, but burning coke, with its low smoke emissions, was considered to meet the requirement. However, this rule was quietly dropped and cheaper coal became the normal fuel, as railways gained acceptance among the general public.
In the late 19th century, the coalfields of western Pennsylvania provided a rich source of raw material for coking. In 1885, the Rochester and Pittsburgh Coal and Iron Company[1] constructed the world's longest string of coke ovens in Walston, Pennsylvania, with 475 ovens over a length of one and a quarter miles. Their output reached 22,000 tons per month.
Properties
The bulk density of coke is typically around 0.77. It is highly porous.
The most important properties of coke are ash and sulfur content, which are linearly dependent on the coal used for production. Coke with less ash and sulfur content is highly priced on the market. Other important characteristics are the M10, M25, and M40 test crush indexes, which convey the strength of coke during transportation into the blast furnaces (BF); depending on BF size, finely crushed coke pieces must not be allowed into the BF because they would impede gas dynamics. A related characteristic is the Coke Strength After Reaction (CSR) index; it represents coke's ability to withstand the violent conditions inside the blast furnace before turning into fine particles.
The water content in coke is practically zero at the end of the coking process, but coke is often water quenched to reduce its temperature so that it can be transported inside the BF. The porous structure of coke absorbs some water, usually to 3-6 % of its mass. In modern coke plants an advanced method of coke cooling is by air quenching.
Bituminous coal must meet a set of criteria for use as coking coal, determined by particular coal assay techniques. See Section "Production".
The volatility of coke reaches minimum levels at the end of the coking process.
Other processes
The solid residue remaining from refinement of petroleum by the "cracking" process is also a form of coke. Petroleum coke has many uses besides being a fuel, such as the manufacture of dry cells and electrodes. Gas works manufacturing syngas also produce coke as an end product, called gas house coke.
Fluid coking is a process which converts heavy residual crude into lighter products such as naphtha, kerosene, heating oil, and hydrocarbon gases. The "fluid" term refers to the fact that coke particles are in a continuous system versus older batch-coking technology.
See also
References
- ^ A subsidiary of the Buffalo, Rochester and Pittsburgh Railway.