Petroleum Coke, a product with high carbon content, is an important component of the iron/steel manufacturing process. It has several functions, including providing heat and energy to blast furnace operations, as well as other metallurgical processing. It is also used in direct reduction, where it can produce nearly pure iron.
In blast ovens, metallurgical slag (often known as slag) is reduced to metallic steel by burning metallurgical slag. Metallurgical coke performs four key functions in the furnace: it provides a concentrated source of heat; it reacts with the air to form carbon monoxide, which lowers the melting point of iron; it maintains permeability in the blast furnace by preventing agglomeration of the sinter; and it supports the burden in the furnace.
In order to improve the performance of coke as a fuel in blast furnaces, certain coals are converted into it using a 'battery oven. Coke has a high carbon content, a porous structure, and a resistance to crushing that make it an important fuel for blast furnaces. It serves other purposes as well: it helps remove impurities from the iron/steel mixture, and it provides necessary heat.
Blast furnaces use a lot of energy. Reducing their energy needs is possible by increasing the quality and/or using scrap metal. However, the effect of such energy conservation is limited as it doesn't reduce raw material requirements for producing steel.
Moreover, considerable energy is expended in the extraction and preparation of ores, which cannot be considered as part of the steelmaking process. Reducing the amount of raw materials used in the steelmaking will improve the energy efficiency.
A large percentage of the total energy expenditure in a blast furnace is consumed by the heating of raw materials and coke. In order to improve energy efficiency in blast furnaces, increasing the coke efficiency is a key goal. The coke efficiency is a measure of how much energy it takes to melt the raw materials into a cohesive mass.
Coke Efficiency of a Blast Furnace is defined as a ratio between the vapor-pressure at normal temperature, the Coke Bond Index(CBI), and the Coking Pressure Index(RI). CBI and RI are used to determine the quality and stability of coke. The oxygen analyzer on a gas-chromatograph is used for this. The Coke Stability Diagram is used to plot the data. The peaks of the graph represent the maximum values of CBI and RRI for each coal sample.
Alternatively, a number of steelmakers are utilizing an energy-saving technology known as the "melter gasifier." This method uses a high-pressure fluidized bed to achieve the desired melting point of raw materials and to create a reaction zone that can be heated to the desired temperature without the need for a blast furnace. The melter gases are almost completely free of heavy and sulfur metals.
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