R. A
lvarez
*
, M.A. D ez, C. Barriocanal, E. D az-Faes, J.L.G. Cimadevilla
Instituto Nacional del Carbo n (INCAR), CSIC, Apartado 73, 33080 Oviedo, Spain
Received 11 October 2006; received in revised form 15 November 2006; accepted 16 November 2006
Available online 19 December 2006
Abstract
Although coke cold drum mechanical strength has historically been the most relevant coke quality parameter, currently coke reactiv-
ity and post-reaction strength (CRI/CSR) are the most important parameters used to assess blast-furnace coke quality. Many models of
coke quality prediction have been proposed, most of which are based on coal characteristics and limited to the same coal geographic
origin, but as yet there is no universally applicable prediction formula. The present work describes a simple model of coke CRI/CSR
prediction based on the assumption that the CSR of a coke produced from a blend of coals can be predicted from the CSR obtained
from the cokes of the individual coals through the application of the additivity law. The additivity law was also applied to the coke cold
mechanical strength indices derived from the Irsid test, which are widely employed by the European coke industry as complementary
coke quality indicators.
2006 Elsevier Ltd. All rights reserved.
Keywords: Coke quality prediction; Coking coals; Carbonization of complex blends
1. Introduction
It is normal practice in the cokemaking industry to use
models to help in the prediction of coke quality. The dier-
ent models currently available for predicting coke quality
take into account selected properties of the coals that make
up the blend. Each steel company employs models adapted
to its operational characteristics which change as a func-
tion of the coals available on the market. However, the role
of inerts (breeze, pet coke, anthracite, etc.) added to the
coal blend has still not been fully claried in most of the
models. Recently some of the most relevant methods
applied in coke quality prediction have been reviewed [1],
the main conclusion being that as yet there is no universally
applicable prediction model due to the great diversity of
the coals used for cokemaking.
Among the physical properties of coke used to dene its
quality, resistance to size degradation at ambient tempera-
ture in a rotating drum (cold mechanical strength) is always
considered of great relevance in coke performance in the
blast furnace. The tests used are standardized in terms of
drum design and dimensions, amount and size of the coke,
operation conditions during the test (number of revolu-
tions, rate) and indices which reect the extent of the coke
fragmentation by ssuration, cohesion and abrasion. All of
these tests measure coke resistance to degradation when
subjected to impact in mild conditions (ambient tempera-
ture and atmosphere); but they do not show how a coke
will behave in the gas atmosphere and high temperatures
of a blast furnace. Nippon Steel Corporation (NSC) dem-
onstrated the need to introduce new quality parameters
of coke based on the reactivity towards CO
2
at high tem-
perature and the resistance to size degradation of the par-
tially gasied coke [2]. Afterwards, a new test was
developed by NSC which is a combination of reactivity
to CO
2
at high temperature (CRI index) and post-reaction
mechanical strength (CSR index). This test has been widely
accepted by the steel industry around the world. There is
disagreement as to whether CSR can be considered addi-
tive or not. NSC [3] and other authors [4] suggest that
0016-2361/$ - see front matter 2006 Elsevier Ltd. All rights reserved.
doi:10.1016/j.fuel.2006.11.026
*
Corresponding author. Tel.: +34 985 11 89 60; fax: +34 985 29 76 62.
E-mail address: ralvarez@incar.csic.es (R. A
lvarez).
www.fuelrst.com
Fuel 86 (2007) 21592166
the estimation of CSR by application of the additivity rule
is not very accurate, while others [5,6] believe that it is. The
aim of the present work was to apply the additivity law to
predict the quality of the cokes produced from blends,
assuming that the CSR of a coke produced from a blend
of coals can be predicted from the CSR obtained from
the cokes of the individual coals. At the same time this
additivity law was applied to coke cold mechanical strength
determined by the Irsid test.
2. Experimental
2.1. Materials
In the present work 22 bituminous coals with a volatile
matter content between 17 and 33 wt% were chosen from
those commonly used in the coking industry. The coals
were carbonized individually and then the cokes were
characterized. Afterwards the coals were mixed in order
to prepared binary, ternary and quaternary blends. In addi-
tion, four industrial coal blends provided by the Steel
Industry in Spain were selected. Proximate analyses were
performed following the ISO 562 and ISO 1171 standard
procedures for volatile matter and ash content, respec-
tively. The thermoplastic properties of the coals were tested
by the Gieseler method in a R.B. Automazione Gieseler
plastometer PL2000, following the ASTM D2639-74 stan-
dard procedure.
2.2. Carbonization tests at semi-industrial scale
Carbonization tests to semi-industrial scale were carried
out in the 6 t capacity oven of the INCAR Experimental
Coking Plant with a mean bulk density of 705 25 kg/
m
3
db. The dimensions of the oven are: 2.8 m height,
6.5 m length and 0.45 m width. The coking time was 18 h
and the mean ue temperature was around 1250 20 C.
The coke was pushed from the oven and quenched with
water. The results obtained from semi-industrial scale car-
bonizations can be applied directly to industrial scale.
2.3. Coke quality
Coke samples were taken at the coking plant wharf, with
minimum handling. Coke cold mechanical strength was
evaluated by the Irsid test according to the ISO 556 [7]
standard procedure. In this test, 50 kg of coke unable to
pass through a round-hole sieve of 20 mm was subjected
to 500 revolutions in a standardised drum and afterwards
sieved. Two indices, I20 and I10, were obtained from this
test. The I20 index was the weight per cent of coke remain-
ing above 20 mm in size and gives the extent of coke cohe-
sion, while the I10 index, which was the weight per cent of
coke obtained below 10 mm in size, was used to assess the
abrasion resistance of the resultant cokes. I40 was calcu-
lated, taking the initial grain size of the coke sample as
the weight per cent of coke remaining above 40 mm in size.
As is well known, the higher the I20 and I40 are and the
lower the I10, the better the coke quality. The three Irsid
indices are widely used to indicate the cold mechanical
strength of coke from full-size coke ovens. I20 and I10 indi-
ces are linearly related [8,9] showing that resistance to
cohesion and abrasion have the same signicance i.e. loss
of cohesion that is reected in the production of nes.
Coke reactivity towards CO
2
(CRI index) and coke
strength after reaction (CSR index) were assessed by the
test developed by the Nippon Steel Corporation (NSC)
and standardized afterwards by ASTM [10]. Briey, a sam-
ple of coke (200 g) with a particle size between 19 and
22.4 mm was made to react at 1100 5 C for 2 h with
CO
2
at a ow rate of 5 l/min. The partially gasied coke
was weighed and subjected to the tumbler test. The CRI
was calculated as the percentage of weight loss. The
mechanical degradation of the coke after CO
2
reaction
(CSR) was measured as the weight per cent of coke larger
than 9.5 mm in size after the drum had been rotated 600
times at 20 rpm and the coke sieved through a 9.5 mm
sieve. The lower the CRI and the higher the CSR, the better
the quality of the coke.
3. Results and discussion
3.1. Single coals and simple coal blends
Table 1 presents the most relevant characteristics of the
coals used to prepare binary, ternary and quaternary
blends. The coals are listed in increasing order of volatile
matter content. It is clear that there are two main groups
of coals; on the one hand the lower volatile coals with a
Gieseler maximum uidity lower than 500 ddpm and on
the other, highly uid coals with a volatile matter content
around 32 wt%. The characteristics of the cokes produced
from the coals have also been included in Table 1. The Irsid
index I10 which indicates resistance to abrasion varies from
20.6 for coke A to 25.9 for coke F1, while I20 which
denotes cohesion varies from 76.6 for coke PD to 67.8
for coke B. At the same time I40 which indicates resistance
to ssuring ranges from 24.9 for coke B to 58.4 for coke
PD. In general the mechanical strength measured by means
of the Irsid test is better in the case of cokes produced from
the coals with a volatile matter content between 17.9 (coal
H) and 24 wt% (coal F1). The worst indices correspond to
coals with a volatile matter content of around 32 wt% and
a Gieseler maximum uidity of around 30,000 ddpm.
Six binary, two ternary and a quaternary blends were
prepared with the coals presented in Table 1 with the aim
of improving the coke characteristics produced from the
highly uid coals. As was to be expected coal blend charac-
teristics (i.e. ash, volatile matter and sulphur) were additive
except for Gieseler maximum uidity which is known to
behave like a non-additive property [11] (Table 2). The big-
gest dierences between the experimental and calculated
values assuming additivity (Table 2) for the three Irsid indi-
ces, correspond to coal blends CB1, CB2, CB7 and CB9, all
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than expected assuming the additivity law. However, the
dierences are not as high as in the case of the binary, ter-
nary or quaternary blends presented above. In the case of
the CRI and CSR indices the calculated values are similar
to the experimental ones.
By applying the additivity law, it is possible to estimate
the maximum amount of coal Bu (VM = 21.1 wt%) that
needs to be added to blend M3 while keeping the Irsid
and CRI/CSR indices in the range that denes a good qual-
ity coke i.e. I20 > 74, CRI < 30 and CSR > 55 (Table 5).
This coal presents a coke with a high cold mechanical
strength (Irsid indices). However, the extremely high reac-
tivity to CO
2
(CRI = 47) which implies a very low post-
reaction strength (CSR = 39) makes this coke not suitable
for steel production in the blast furnace. Again, the Irsid
indices are better than expected while the experimental
and calculated CRI and CSR are similar. The exception
being the coke obtained from 30 wt% addition which
exhibits a CSR 4 points higher than was expected.
The next example also illustrates the inuence of a low-
volatile coal with poor quality parameters when it is added
to an industrial coal blend (Table 6). The Irsid values of the
cokes derived from the blends are better than those of the
carbonized coal or the industrial blend, while the CRI and
CSR values of the blends are in between those of the indus-
trial blend and the coal.
Table 3
Coal characteristics and coke data for individual coals and complex blend M1. Carbonizations carried out at INCARs 6 t oven
W4 S OG2 PD R F2 J N Rf Lo M1
b
Coal
Moisture (wt%) 7.9 10.4 7.2 8.0 7.3 10.7 9.9 8.6 9.3 9.0 9.5
Ash (wt% db) 6.0 9.6 9.3 9.2 9.8 9.1 6.4 7.0 6.1 6.2 7.9
Volatile matter (wt% db) 17.8 19.2 19.9 20.7 23.1 23.4 24.7 30.2 32.3 32.4 25.0
Sulphur (wt% db) 0.61 0.62 0.53 0.59 0.60 0.53 0.70 0.78 0.89 0.78 0.65
MF
a
(ddpm) 45 102 633 243 461 23 637 29,972 27,950 20,255 686
Coke
I20 74.7 75.5 76.9 76.6 73.9 71.0 77.5 74.9 70.7 66.9 75.0
(73.7)
I10 22.8 23.0 20.7 21.7 24.5 26.6 20.3 21.3 24.1 25.9 22.1
(23.1)
I40 44.6 60.0 49.6 58.4 54.1 39.4 49.8 40.3 34.9 20.6 45.2
(44.0)
CRI 47.3 17.9 23.6 15.2 18.6 26.0 29.4 26.7 21.3 26.0 25.4
(25.3)
CSR 36.8 72.6 69.3 73.6 71.8 57.4 60.4 61.0 65.0 58.0 63.0
(62.5)
a
Gieseler maximum uidity.
b
Blend composition, 9W4 + 7S + 9OG2 + 6PD + 15R + 7.5F2 + 6.5J + 20N + 9.5Rf + 10.5Lo. Numbers in brackets have been calculated assuming
the additivity law.
Table 4
Coal characteristics and coke data of complex blend M2 with coal OG2. Carbonizations carried out at INCARs 6 t oven
M2 OG2 90M2 + 10OG2 80M2 + 20OG2 70M2 + 30OG2
Coal
Moisture (wt%) 9.2 7.2 9.4 8.8 8.0
Ash (wt% db) 8.2 9.3 8.4 8.5 8.8
Volatile matter (wt% db) 25.1 19.9 24.2 24.0 23.4
Sulphur (wt% db) 0.72 0.53 0.70 0.69 0.66
MF
a
(ddpm) 638 633 622 460 484
Coke
I20 74.8 76.9 76.4 75.2 77.0
(75.0) (75.2) (75.4)
I10 22.4 20.7 21.0 22.0 20.6
(22.2) (22.1) (21.9)
I40 47.3 49.6 46.8 48.7 51.0
(47.5) (47.8) (48.0)
CRI 25.3 23.6 25.5 25.0 24.2
(25.1) (25.0) (24.8)
CSR 62.4 69.3 63.7 64.2 65.5
(63.1) (63.8) (64.5)
Numbers in brackets have been calculated assuming the additivity law.
a
Gieseler maximum uidity.
R. A