Clean production of coke
AssigneeCombustion Resources, L.L.C.
InventorsCraig N. Eatough, Jon S. Heaton, Steven R. Eatough
Life of this patent
Estimating the term…
Abstract
Closed apparatus and processes by which carbon feedstock is composed of a mixture of non-coking coal fines and another carbonaceous material, such as waste coke fines, are described. The coal and coke fines are mixed together and may be formed into solid pieces. The mixture alone or as solid pieces is fired through pyrolyzation into solid pieces of coke, with solid and gaseous by-products of pyrolyzation being recycled for use within the coke-producing closed system, thereby reducing or eliminating release of undesirable substances to the environment. A char-forming binder may or may not be added to the carbon mixture prior to pyrolyzation.
Claims47
A method of continuously producing high-grade coke from low-grade material without causing a pollution problem, comprising:
- introducing a first mixture of low-grade non-coking, inexpensive coal fines and another type of inexpensive, carbonaceous fines comprised of waste coke fines, as a feedstock influent into a pyrolyzer;
- pyrolyzing the displaced mixture in the pyrolyzer to produce a high-grade coke;
- discharging said coke and pyrolytic by-products as effluents from the pyrolyzer;
- separating tar effluent from said pyrolytic by-products;
- continuously introducing mixtures of low grade non-coking inexpensive coal fines and another type of inexpensive, carbonaceous fines comprised of waste coke fines, as a feed stock into said pyrolyzer;
- continuously introducing said tar effluent into said pyrolyzer;
- wherein quantities of said low-grade non-coking inexpensive coal fines and said another type of inexpensive carbonaceous fines introduced into said pyrolyzer are adjusted such that said tar effluent, produced by a pyrolyzation of said fines does not exceed a quantity of tar effluent required to continuously maintain said production of coke.
A method of producing coke from a mixture of non-prime coal fines and waste coke fines comprising the acts of:
- introducing a mixture of low-grade coal fines and another type of carbonaceous material comprising waste coke fines as a feedstock influent into a pyrolyzer;
- pyrolyzing the mixture in the pyrolyzer;
- discharging segregated coke and pyrolytic by-products as effluents from the pyrolyzer;
- wherein quantities of said low-grade coal fines and said another type of carbonaceous material is adjusted such that said pyrolytic by-products do not exceed a quantity of pyrolytic by-products required to continuously maintain said method.
A method of continuously producing coke from low-grade coal and coke fines, comprising the acts of:
- obtaining and mixing low-grade coal fines and coke fines;
- introducing the mixture of low grade coal fines and coke fines as an influent into a pyrolyzer;
- pyrolyzing the mixture in the pyrolyzer;
- discharging segregated coke and pyrolytic by-products comprising combustible off-gas and tar as effluents from the pyrolyzer;
- separating the pyrolytic by-products into segregated tar and combustible off-gas;
- adding the segregated tar as a binder to the coal and coke fines mixture;
- and
- returning the segregated combustible off-gas to the pyrolyzer as a source of fuel;
- wherein quantities of said low-grade coal fines and said coke fines is adjusted such that said pyrolytic by-products do not exceed a quantity of pyrolytic by-products required to continuously maintain said method.
A method of producing coke from low-grade coal and coke fines, comprising the acts of:
- obtaining and mixing low-grade coal fines and coke fines;
- introducing the mixture of lower grade coal fines and waste coke fines as an influent into a pyrolyzer;
- pyrolyzing the mixture in the pyrolyzer;
- discharging segregated coke and pyrolytic by-products comprising combustible off-gas and tar;
- as effluents from the pyrolyzer;
- separating the pyrolytic by-products into segregated tar and combustible off-gas;
- adding the segregated tar as a binder to the coal and coke fines mixture;
- and
- returning the segregated combustible off-gas to the pyrolyzer as a source of fuel;
- wherein the coke fines comprise coke breeze fines which comprise 5-10% by weight of the coal and coke mixture.
A method of continuously producing high-quality coke from a mixture of low-grade and/or waste carbonaceous materials at a much lower cost, comprising the acts of:
- introducing a mixture of low-grade coal fines and waste coke fines as an influent into a pyrolyzer;
- pyrolyzing the mixture of fines in the pyrolyzer;
- and
- discharging the coke, and pyrolytic by-products from the pyrolyzer;
- wherein quantities of said low-grade coal fines and said waste coke fines is adjusted such that said pyrolytic by-products do not exceed a quantity of by-products required to continuously maintain said method.
A continuous method of producing coke from non-traditional carbonaceous materials comprising the acts of:
- introducing a mixture of waste coke fines and non-coking grade coal fines as an influent into a pyrolyzer;
- pyrolyzing the mixture in the pyrolyzer;
- discharging the coke and pyrolytic by-products comprising combustible off-gas and tar as effluents from the pyrolyzer;
- reintroducing said tar into said pyrolyzer;
- utilizing said combustible off-gas as a fuel to heat said pyrolyzer;
- wherein said mixture is formulated such that said pyrolytic by-products do not exceed the quantity of pyrolytic by-products required to maintain said continuous method.
A method of cost effectively producing high-quality coke from a mixture of non-traditional carbonaceous materials comprising the acts of:
- introducing into a pyrolyzer a mixture comprising low-grade coal fines and coke fines as salvage from prior production of coke;
- pyrolyzing the mixture and obtaining segregated coke and by-products.
A continuous method of producing coke, comprising the acts of:
- mixing a binder, low-grade non-prime coal fines selected from the group consisting of waste non-coking coal fines and non-coking coal fines and salvage coke fines selected from the group consisting of waste petroleum fines, waste char fines and waste coke breeze;
- introducing the mixture into a pyrolyzer;
- and
- pyrolyzing the mixture to derive coke, tar and combustible off-gas;
- wherein the mixture is adjusted during mixing such that upon said pyrolyzing of said mixture, an amount of said tar and combustible off-gas derived from said pyrolyzing does not exceed a required amount of said tar and combustible off-gas necessary to maintain said continuous method of producing coke.
A method of continuously producing high-grade coke comprising:
- forming a mixture of low-grade non-coking coal fines and waste coke fines, as a feedstock influent into a pyrolyzer;
- pyrolyzing the mixture in the pyrolyzer;
- discharging coke and pyrolytic by-products as effluents from the pyrolyzer;
- and
- introducing said by-products back into said pyrolyzer;
- wherein the relative amounts of said coal fines and said waste coke fines are adjusted during the forming of said mixture such that the pyrolytic by-products produced by said pyrolyzing of said mixture are amounts of said by-products required to maintain a continuous operation of said process and said amounts of said by-products do not exceed said amounts required to maintain said continuous operation.
Dependencies are inferred from the claim text.