Formed Coke
Your Professional Formed Coke Supplier
Hebei Hangba International Trade Co., Ltd. has thrived in the coke industry for over 11 years. Our extensive export experience makes us a reliable global partner, with a strong reputation built on expertise and long - term commitment.We offer a wide range of high - quality products, including metallurgical coke, foundry coke, semi - coke, graphite petroleum coke, calcined petroleum coke, and calcined anthracite coal. These products are essential for industries where energy matters and cost - effectiveness is key.
Why choose us
Quality Assurance
Quality is our top priority. Every production step is strictly controlled to meet international standards. To further assure our clients of the superior quality of our products, we support third - party inspection.
Quality Service
We support port inspections. Our team is available 24/7, 7 days a week for any inquiries or assistance.
Our Market
Our Market include Indonesia, Malaysia, India, Pakistan, Japan, Vietnam, also North America, etc.
Customized Services
Arrange production according to the customer's product specifications. Customizable granularity and packaging.
Formed Coke
Shaped coke is made from non-coking coal pulverization or carbonaceous powder (such as semi-coke, coke, petroleum coke, charcoal, etc.) by pressurizing the coal into briquettes, followed by post-processing such as carbonization. The production process primarily involves two stages: pulverized coal shaping (briquette preparation) and briquette post-processing. The goal is to produce a product with a defined shape, strength, and uniform mass, designed to replace coke.
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Formed Coke Grade |
Technical Parameters |
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|
Fixed Carton |
Calorific Value |
Ash |
V.M |
Sulphur |
Phosphorus |
Moisture |
|
|
Min |
Max |
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Special Grade Standard |
90% |
7200Kcal/kg |
8% |
1.50% |
0.50% |
0.03% |
7% |
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First Grade Standard |
88% |
7200Ka/kg |
10% |
1.50% |
0.50% |
0.03% |
8% |
|
Second Grade Standard |
86% |
7000Kcal/kg |
12% |
1.50% |
0.60% |
0.03% |
8% |
|
Size |
130mm*130mm, 30- 60mm (or as customer's request) |
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Advantages of Formed Coke
Expanding Coking Coal Sources: Formed coke technology can rationally utilize non-coking coal resources or expand coal-coking coal resources, effectively alleviating the shortage of coking coal resources.
Regular Shape and Uniform Size: Formed coke can be customized to meet the needs of various industrial sectors.
High Mechanical Strength: High-quality formed coke has a crushing strength similar to that of qualified conventional coke and high compressive strength, meeting the requirements of industrial processes such as blast furnace ironmaking.
Environmental Advantages: Formed coke is made from powdered coke or weakly bonded coal generated during coke production and transportation. These raw materials are difficult to reuse directly and can easily cause environmental pollution. Converting coke or coal into formed coke not only reuses resources but also reduces environmental pollution.
Conserving high-quality prime coking coal: Expanding coking coal resources and utilizing low-cost non-coking coal.
Utilizing fines and waste: Effectively utilizing the large amount of coke fines (approximately 10% of coke output) generated during coke production, transportation, and use, as well as other industrial waste (such as dust removal fines and lean coal), to achieve resource recycling.
Reducing environmental pollution: Traditional coke oven coking produces significant amounts of waste gas and wastewater, while some coke forming processes (particularly non-recycling or clean processes) can mitigate environmental pollution.
Controllable product performance: Through coal blending and process adjustments, coke forming with specific chemical composition and physical properties (such as reactivity and strength) can be produced to meet the needs of different users (such as blast furnaces, ferroalloy furnaces, and gasifiers).
Type of Formed Coke
Coal-Based Formed Coke
Using various types of coal as the primary raw materials, exclusively non-coking coal is used. Non-coking coal is blended with a small amount of coking coal or coke fines to improve performance.
Coke Fines Formed Coke
Recycles waste and achieves a resource-saving recycling process. Coke fines themselves have no binding properties and rely entirely on binders.
Waste-Incorporated Formed Coke
Other carbon-containing waste materials, such as biomass (sawdust, straw), waste plastics, and sludge, are blended into coal or coke fines. This allows for resource-saving and harmless treatment of solid waste.
Applications of Formed Coke
Blast furnace ironmaking:
Especially in small and medium-sized blast furnaces, it can partially or completely replace traditional metallurgical coke.
Ferroalloy production
Used as a reducing agent in the production of ferroalloys such as ferrosilicon and ferromanganese.
Calcium carbide production
Used as a raw material for the production of calcium carbide (calcium carbide).
Gasification
Used as a raw material to produce synthesis gas (CO + H₂), which is used in the synthesis of ammonia, methanol, etc.
Foundry
Used as a fuel and carburizing agent for metal smelting.
Household fuel
Made into clean briquettes/coke for heating and cooking, it is more efficient and environmentally friendly than loose coal.
Production Process of Formed Coke
Raw Material Preparation: The core raw materials are non-coking coal (gas coal, lean coal, long flame coal, etc.) and coke fines.
Binder: This is the core of the forming process. Common binders include: Coal tar pitch or petroleum pitch: The most commonly used, providing good bonding and coking properties. Other binders include starch, humic acid, pulp waste liquor, clay, etc.
Forming: Pressing the coke into shape under high pressure in a mold to give it its initial shape and strength. Subsequent processing (determines the type of coke)
Cold-pressed coke process: After pressing and forming, the binder polymerizes and hardens, primarily through oxidative curing, resulting in cold-pressed coke. This type of coke has lower strength and is generally used in chemical gasification, casting, etc.
Hot-pressed coke process: The coal is rapidly heated to its plastic temperature (~450°C) and immediately pressed into shape. It is then carbonized (calcined at high temperature to drive out volatiles, similar to coking). This process produces a denser, stronger coke suitable for blast furnace ironmaking.
Production Considerations
Raw Material Selection and Proportioning
Raw Material Stability
Ensure the chemical composition (ash, sulfur, volatile matter) and physical properties (particle size, hardness) of the raw coal (especially non-coking coal) and coke fines are relatively stable. Frequent changes in raw materials can lead to fluctuations in molded coke quality.
Particle Size Grading
The raw material particle size distribution (grading) is crucial. A proper ratio of coarse to fine particles increases the bulk density of the preform, thereby producing stronger molded coke.
Impurity Removal
Carefully remove foreign matter such as metal and stone from the raw materials to avoid damage to expensive rollers and molds.
Binder Selection and Dosage
Compatibility
The binder must have good compatibility and wettability with the raw materials. Different types of coal fines have different adsorption capacities for binders.
Precise Dosage Control
Too little binder will result in substandard molded coke strength. Too much binder will not only increase costs but also make the molded coke sticky and prone to sticking, and produce black smoke and an unpleasant odor during combustion.
Environmental and Health
If asphalt-based organic binders are used, the emission of asphalt fumes must be strictly controlled, as they are harmful to operator health and the environment.
Process Parameter Control
Moisture Control: The moisture content of the mixture directly affects the molding effect and initial strength. Excessive moisture can easily cause deformation or cracking of the preform; too low a moisture content makes compaction difficult.
Temperature Control (for hot pressing): The heating temperature must be precisely controlled within the plastic temperature range of the coal (approximately 400-500°C). Too low a temperature will result in a lack of binding properties; too high a temperature will cause the coal to solidify prematurely or even burn, losing its binding capacity.
Pressure Control: The molding pressure must be high enough to ensure the preform density, but excessive pressure should be avoided, leading to "overpressure" and elastic aftereffects that can cause cracking.
Curing/Carbonization System: For cold pressing, the temperature and time of the oxidative curing process must be strictly controlled to ensure sufficient oxidation and crosslinking of the binder. The heating rate during the carbonization process must be controlled to prevent cracking.