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Influence of coal blending structure on pushing current of coke oven

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Influence of coal blending structure on pushing current

of coke oven
Minmin Sun1, Jianliang Zhang1,2, Kejiang Li1,*,a, and Chunhui Hu3
1
School of Metallurgical and Ecological Engineering, University of Science and Technology Beijing, Beijing 100083, PR China
2
School of Chemical Engineering, The University of Queensland, St Lucia, QLD 4072 Brisbane, Australia
3
Coking Plant of Shaoguan Iron and Steel Co., Ltd., Shaoguan 512000, Guangzhou, PR China

Received: 18 December 2018 / Accepted: 9 April 2019

Abstract. The difficulty of pushing coke directly affects the quality and output of coke, which disturbs the
normal production, causes damage, and shortens the service life of coke oven and other ancillary equipment. The
relationship between coal blending structure and pushing current is studied through industrial test in this paper,
including the influence of coal moisture, caking, volatile matter content and fineness. The results indicate that
the pushing current has a complex relationship with coal blending structure. The increase of moisture increases
the average pushing current Iav, and the dry and wet coal blending technology can reduce the times N of large
pushing current without changing the Iav. Iav and N first decrease and then increase with the increase of caking
index. A small increase of volatiles plays an important role in reducing Iav and N. While the effect of blending coal
fineness on the pushing current shows an opposite trend. Therefore, appropriate coal structure parameters are
very important for economical and efficient coking.
Keywords: coal blending structure / pushing current / coking

1 Introduction The pushing current is an important indicator to reflect

At present, the development of iron and steel industry is
facing severe tests, and energy savings and CO2 emission
reduction are the key question. Reducing costs and
increasing efficiency become the main direction of effort
at the same time [1]. Coke is an important raw material of
modern industry for blast furnace smelting, casting and
gasification. In order to improve the competitiveness of
coking enterprises, coke production is gradually developing
towards a large scale for saving energy and protecting
environment [2]. Six meters (6 m) coke oven is the main
equipment used in production. The difficulty of pushing
coke directly affects the quality and output of coke during
the production process of coke oven, which disturbs the
normal production, causes damage and shortens the service
life of coke oven and equipment. What’s more, it brings
challenges to the safety production and increases the labor
intensity of workers, imperceptibly [3].
* e-mail: likejiang@ustb.edu.cn
a
Present address: 30 Xueyuan Road, Haidian District, Beijing,
100083, PR China
the force of coke oven during pushing coke, and then
indicate the stability of production situation. Therefore,
the influence factors of coke pushing current and the
interaction of various factors should be explored to prevent
incidents, control the coke yield and quality and prolong
the oven life [4–7]. The factors causing the fluctuation of
coke pushing current mainly include unreasonable coal
blending structure, excessive thickness of graphite on
furnace wall, unstable heating system and deformation of
furnace wall or coke push rod, etc. [8]. High-quality coking
coal is running out, so the flexible coal blending is crucial to
reduce production cost. The pushing current is affected by
the properties of coal, mainly for caking, shrinkage,
moisture, etc. The influence of coal moisture control
(CMC) on carbon deposition in the coke oven chamber has
been described by Atsushi et al. [9], which found volatile
matter has a bigger impact on the carbon deposits in CMC
operation than in wet coal operation.
Nomura et al. [10] studied the permeability of the
plastic coal layer and coking pressure for blended coal,
discovered the addition of high volatile matter coking coal
increases plastic coal layer permeability. Liu et al. [11]
studied the coal blend properties and evaluation on the
coke quality from weakly coking blends. When the
percentage of weakly coking coal in blend is obviously
2 M. Sun et al.: Metall. Res. Technol. 116, 506 (2019)

Table 1. The design and production parameters of two different 6 m coke oven.

Project JN60-6A (1 #) JN43-99 (2 #)

Length of carbonization chamber/mm 15980 14080
Height of carbonization chamber/mm 6000 4300
Average width of carbonization chamber/mm 450 450
Center distance of carbonization chamber/mm 1300 1143
Quantity of dry coal per hole/t 32 23.8
Effective volume per hole/m3 38.5 21.7
Center distance of vertical fire path/m 480 480
Turnaround time/h 19 22

increased, Y index and G index of blend are decreased.

Nomura et al. and Krishnan et al. [12,13] studied the caking
and fineness on coal caking property and coke strength,
found that dilatation differs greatly with coal types and
particle size fractions. When the specific dilatation volume
of fine coal is equal to that of coarse coal, the coke structure
becomes more homogeneous.
In conclusion, the existing research is mainly aimed at
reducing the cost and stabilizing coke quality. The
systematic research on the influence of coal blending
structure on the pushing current of coke oven is rare.
Therefore, this paper focuses on studying the influence of coal
moisture, volatile matter, fineness and caking on coke
pushing current through industrial tests. It is to lay a
foundation for preventing the occurrence of coke pushing
incidents, improving coke output and quality, prolonging
furnace life and stabilizing coke production.

2 Experimental details Fig. 1. The changes of current in the coking process.

2.1 The research object

The coke oven studied in this paper is the JN60-6A and
JN43-99 dual-fire channel reheating coking furnace, which
were designed and constructed by Anshan coking institute,
and they were officially put into operation in 2008 and
2003, respectively. The design and production parameters
of the coke oven are shown in Table 1.
2.2 The data collection
The data in this paper comes from the field production record
and the MES data automatic acquisition system. Data
collection plays an important role in the completion of this
paper, which needs to be paid enough attention to.
Meanwhile, the abnormal data should be analyzed to
summarize the reasons affecting the large current. The
changes of current in the coking process are shown in
Figure 1.
Coke cake shrinkage rate is the ratio of the coke height
to the coal height, as expressed by:
ðcoal height H 2 coke height H 1 Þ
shrinkage rate ¼
coke height H 1
 100%:
The height measurement of coal cake can be carried out
after the operation of smoothing coal surface at the time of
coal loading. When the thickness of coke oven roof is
known, the height of coal cake can be calculated by
measuring the distance between the top surface of coal and
the top surface of coke oven in the carbonization chamber.
Similarly, the height of coke cake can be obtained by
measuring the distance between the top surface of coke
cake and the top surface of coke oven. Figure 2 shows the
detailed schematic diagram of coking equipment and coke
cake changes.
3 Results and discussion
3.1 Influence of coal moisture on pushing current
Moisture content in blending coal is of great importance to
stabilize operation of coke oven, improve quality of coke
and reduce energy consumption [14]. At present, the coking
plant adopts scientific coal blending management and dry-
wet base blending technology according to coal character-
istics, which has achieved good results. Moisture content
will mainly affect the accuracy of coking time and coal
charging quantity. The shrinkage of coke cake reduces with
 M. Sun et al.: Metall. Res. Technol. 116, 506 (2019) 3

Fig. 3. Influence of different coal moisture content on coke

pushing current.

moisture affects the maintenance of furnace equipment

Fig. 2. The schematic diagram of coking equipment and coke
during the heating process. Bao et al. [16] found that after
cake changes.
coking with wet coal containing 12% moisture, the coke
quality become poor due to the gap of coal increases caused
by the high temperature diffusion of water vapor. According
Table 2. The coke cake shrinkage under different coal to Minkova et al. [17] two effects are responsible for these
moisture content. modifications. One is a physical effect in which water plays
the role of a vehicle for the volatiles by penetrating the porous
Blending coal moisture (Mav)/% structure of the coal and accelerating the desorption of low-
molecular-weight compounds trapped within the macro-
Project 11.4 10.2 9.3 7.5
molecular network. The other effect is a chemical one, the
Average of coal 474 485 499 482 water partially depolymerizing the coal network to release
line/mm low-molecular-weight components with similar sizes but
Average of coke 785 792 761 710 different compositions. In order to explore the relationship
line/mm between the blending coal moisture and the coke pushing
Mean shrinkage/mm 311 307 262 228 current, the data were counted and analyzed in a short
period, as shown in Figure 3.
Height shrinkage 5.63 5.57 4.76 4.13 Without the CMC system, the fluctuation of blending
rate/% coal moisture content Mav is obvious in 6 m coke oven, and
it maintains in 11–12.5%. The max pushing current Imax
keeps up with the average moisture content. When Mav is
the decrease of coal moisture content, leading to a greater more than 12%, Imax is more than 150 A. The fluctuation of
resistance in the process of coke pushing. Secondary coking Iav is small, but a similar change trend still exists, which
incidents appear when there is sharp increase of the indicates that a larger Mav in blending coal increases the
pushing current signals. The relationship between blending pushing current.
coal moisture and the coke cake shrinkage is shown in Yin et al. [18] found that when the Mav in blending coal
Table 2. is on the high side, water evaporates and continues to
As can be seen in Table 2, when blending coal moisture condense at the top of the carbonization chamber, and
changed from 11.4 to 7.5%, the mean coke cake shrinkage eventually form a cycle. The evaporation of water and
reduces 83 mm and the shrinkage rate in height direction overheating of coal will take away a lot of heat, causing a
reduces 1.50%. Mean shrinkage reduces mainly due to the certain temperature gradient between bottom and top of
increase of dry base composition in coal. The problem of carbonization chamber. In this case, raw coke exists on top
insufficient amount of coke oven has been improved by the of the coke oven. Lower coke shrinkage results in the large
lower shrinkage, which decreases the heat consumption pushing current. Studies have shown that Mav should be
and heat loss of coke oven. Kebs et al. [15] believed that if maintained at 9.0–9.5% for the smoothly pushing.
the blending coal moisture is less than 4%, difficult coal Affected by mining, transportation and storage, the
charging will occur; if higher than 12%, the coking energy moisture content in coal fluctuates greatly. The current dry
consumption will increase. What’s more, the increase of and wet base coal blending technology play an important
4 M. Sun et al.: Metall. Res. Technol. 116, 506 (2019)

Table 3. Wet and dry base conversion of coal blending.

Coal Ratio of dry basis/% Single coal moisture/% Ratio of wet basis/% Wet base conversion/%
C1 7.00 12.76 8.02 7.10
C2 13.00 12.66 14.88 13.10
C3 28.00 14.24 32.65 28.70
C4 0.00 12.51 0.00 0.00
C5 0.00 7.60 0.00 0.00
C6 14.00 3.64 14.53 12.80
C7 14.00 11.12 15.75 13.80
C8 11.00 10.41 12.28 10.80
C9 13.00 17.11 15.68 13.80
Total 100.00 11.30 113.80 100.00

Table 4. The effect of dry and wet base blending coal on the pushing current.

Average pushing current (Iav) /A Count of large pushing current (N)

Project 1# 2# 1# 2#
Normal coal blending 125 123 35 31
Dry and wet coal blending 121 123 24 26

role in coking. Firstly, the moisture of each single coal is
measured, and then converts it into dry base for coal
blending, so as to eliminate the influence of water
fluctuation on coal blending ratio. The conversion of dry
and wet base blending ratio is shown in Table 3.
The effect of dry and wet base blending coal on the
pushing current is shown in Table 4. After the application
of dry and wet coal blending technology, Iav of 1# coke
oven reduced 4 A, while that of 2# did not change, showing
the dry and wet base blending coal has little impact on Iav.
The times of large pushing current N reduced from 35 to 24
for 1#, it reduced from 31 to 26 for 2#, which indicates that
dry and wet base blending coal can prevent the large
pushing current. The phenomenon of lack filling angle and
uneven top temperature due to the low coal line no longer
occur, which is advantageous to the coke mature and
contraction. The higher Mav is not conducive to the
maintenance of coke oven thermal system, and thus has an
impact on the uniform maturity of coke.
3.2 The effect of coal caking on pushing current
Caking refers to the property that coal particles can bond
to each other in the process of pyrolysis due to the
decomposition and melting of organic matter in coal. The
effect of coal caking on pushing current of different coke
oven is shown in Figure 4.
As can be seen in Figure 4a, with the increase of caking
index from 82 to 90, the Iav first decreases and then
increases for both ovens. When the caking index is close to
86, the Iav reaches the minimum, which suggests that the
large pushing current appear when larger or smaller caking
index. When the caking index is 89, Iav increases
significantly to 130 A. In Figure 4b, N shows the same
trend, which indicates that the caking index of blending
coal must be maintained in an appropriate range to reduce
the probability of coking incidents.
During coking process, a large number of colloids are
formed by softening and melting of coal. The gas produced
by pyrolysis diffuses out through the colloids to form
expansion pressure. The distortion of the macropores
occurs in the thermoplastic phase during the carbonization
of coals in a coke oven [19,20]. Various coals differ in
colloids thickness, gas generation and swelling pressure.
The content of coking coal and fat coal has great influence
on the swelling pressure, especially. Studies have shown
that if the ratio of strongly caking coal increased, the caking
index is bigger resulting in an increase of swelling pressure.
In the coke prepared from coal of high swelling pressure
in the test oven, the macropore distortion was less than
that for a medium-swelling coal, whereas the macro-
porosity was much reduced in the regions where the
swelling pressure were greatest and the gas pressure in the
plastic layer. As the oven centre, where the gas pressure
was extremely high, was approached, the macroporosity
and the mean macropore diameter decreased, while the
microporosity increased [19]. Coke strength is improved
when using high caking coal; however, the fragility of coke
causes pushing difficulties. The macroporosity and the
microporosity along the oven width are modified by the gas
pressure in the plastic layer and the resulting swelling
pressure developed during carbonization in the coke oven.
If the caking index is low, the coke made is loose in
structure which also brings difficulties to coke pushing.
 M. Sun et al.: Metall. Res. Technol. 116, 506 (2019) 5

Fig. 4. The effect of coal caking property on pushing current. (a) average pushing current; (b) count of large pushing current.

increases to 27.45% when the proportion of gas coal and fat

Table 5. Two different schemes for coal blending. coal increased. When volatiles in blending coal increased,
the Iav decreased from 124 to 121 A. The main reason is that
Coal Plan 1 (%) Plan 2 (%) Difference (%) the increase of volatile is advantageous to the coke
shrinkage, thus reducing friction resistance between coke
C1 7 11 4
and oven wall.
C2 10 12 2 As can be seen in Figure 5a, when the volatiles are low,
C3 7 0 7 there is a downward trend of Iav with the increase of
C4 13 11 2 volatile, indicating that Iav increases when volatile is lower.
C5 26 26 0 However, the Iav shows a rising trend with the increase of
C6 18 19 1 volatile when it is higher, shown in Figure 5b. Therefore, a
reasonable range is needed for the normal coke pushing of
C7 4 4 0
coke oven. An increase in macerals in coal fraction
C8 7 9 2 enhances the reactive content that help in producing
C9 8 8 0 porous [22]. High volatile matter coking coal act as an
“inert” (pressure modifier) to help the gas to escape from the
plastic layer, which decreases coking pressure and increases
Sun et al. [21] found that when the caking index increased plastic coal layer permeability [10]. N decreases from 2 to 1,
from 63 to 67, the shrinkage of coke cake decreased by which generally shows a trend of decrease with the increase
4 mm, which was the main reason for the reduce of coke of coal volatiles. More volatiles weak coking properties,
pushing current. In order to guarantee the quality of coke, decrease coke strength, resulting in the decrease of average
the proportion of coking coal and fat coal in blending coal lumpiness. When the volatiles are less, the proportion of
cannot change much. coal with high degree carbonization increase, which will
eventually lead to a smaller shrinkage. As a result, the
3.3 The influence of coal volatile matter on pushing separation between oven wall and coke cake is not
current complete, which will eventually have an impact on coke
pushing current.
The technology of controlling coal moisture has become an For other coals, the scheme with small difference of
important method to reduce energy consumption in coking shrinkage should be selected for coal blending. The high
process. The adding amount of gas coal and fat coal has porosity and crack of coke caused by bigger shrinkage can
obvious influence on the volatile matter in blending coal. In lead to fragile coke. The smaller shrinkage leads to the
order to explore the relationship between the coke incomplete separation between oven wall and coke cake.
shrinkage, degree of crack and volatile matter of coal, Qiu et al. [23] believed that the lean coal entering the oven
two different coal blending schemes were designed in this is the main cause of difficult coke pushing, and the volatiles
paper, as shown in Table 5. and caking index of blending coal should be appropriately
Compared with Plan 1, Plan 2 has less coking coal and increased to improve the shrinkage of the mixed coal. Yin
more gas coal and fat coal, in order to increase the volatile et al. [18] believed that the colloids formed in the pyrolysis
matter content of blending coal. Fifteen sets of samples process filled the gap between the coal particles especially
were mixed under each scheme. Figure 5 shows the when the bulk density of coal is high, so that the coke cake
variation of pushing current under different schemes. The could not shrink at the contraction stage. Sun et al. [21]
average volatile component of Plan 1 is 26.76%, and it studied the influence of coal blending ratio on the pushing
6 M. Sun et al.: Metall. Res. Technol. 116, 506 (2019)

Fig. 5. The influence of coal volatiles on the pushing current. (a) Plan 1; (b) Plan 2.

Table 6. The influence of coal fineness on the pushing current.

Project Speed of crusher/min Blending coal fineness/% M10 M40 Iav/A N

1 460 80 5.69 86.03 129 35
2 450 79 5.42 86.87 126 36
3 440 78 5.38 87.34 125 31
4 435 77 5.21 88.12 123 30
5 430 76 5.22 88.64 119 28
6 425 75 5.36 87.96 122 29
7 420 74 5.48 87.02 126 34

current, and found that the pushing current remains
relatively stable when the volatile component  26.1%,
caking index ≥ 66.9 and the shrinkage of coal cake ≥ 7 mm.
3.4 The influence of coal fineness on the pushing
current
Blending coal is composed of coals with different size,
which has a great influence on coke quality. Coal must be
broken to the appropriate fineness before being charged.
The fineness of coking coal is expressed as the quality
percentage of 0–3 mm particles in total coal. The
granularity of different coal is related to the degree of
coal deterioration. In general, 0–3 mm particles are
controlled at 75 and 85% for blending coal [24]. In this
paper, the speed of crusher was changed to obtain different
coal blending fineness. The influence of coal fineness on
pushing current is shown in Table 6.
Figure 6 shows the influence of coal fineness on the cold
strength of coke M10 and M40. As can be seen in Figure 6a,
M10 decreases first and then increases with the reduction of
blending coal fineness. It gets the minimum value when the
coal blending fineness is between 76 and 77%. While M40
shows the opposite trend in Figure 6b, which indicates that
the blending coal fineness has influence on the cold strength
of coke. Determining the appropriate fineness is of great
significance for improving coke quality and stabilizing coke
oven operation. When the content of 0–3 mm particles is
more, weak caking coal with large size and mineral particles
leads to the decrease of the caking properties and the
increase of coke crack. At the same time, the amount of
graphite attached on coke oven increased, which worsen
the operation and adjustment of coke oven. On the
contrary, low fineness will deteriorate the caking property
and bulk density, making it more difficult to charge coal. In
the process of blending operation, the weak caking coal
should be kept at a relatively fine particle size, while the
strong caking coal granularity can be coarse. Therefore,
determining the appropriate range of fineness is of great
significance for improving coke quality and stabilizing coke
oven operation.
It can also be seen in Table 6 that with the gradual
reduction of blending coal fineness, the Iav and N also present
a trend of first decrease and then increase. When blending
coal fineness is 76%, the Iav is 119 A and the N reduced up to
28. That is to say, 76% is the most suitable blending coal
fineness, under which circumstance coke quality is relatively
stable and coking operation problems become fewer.
 M. Sun et al.: Metall. Res. Technol. 116, 506 (2019)
Fig. 6. The influence of coal fineness on the cold strength of coke: (a) M10; (b) M40.
4 Conclusion
In this paper, the relationship between coal blending
structure and pushing current is studied, including the
influence of coal moisture, caking, volatile matter content
and fineness on pushing current. The conclusions are as
follows:
– when the moisture content of coal Mav is more than 12%,
the average coke pushing current Iav is basically increase
up to 150 A, and the average shrinkage of coke cake
increases. The dry and wet coal blending technology have
little effect on the Iav, but it can reduce the frequency of
the large pushing current;
– with the increase of caking index from 82 to 90, Iav and
Nmax first decrease and then increase for different coke
oven. When the caking index is 86, Iav and Nmax reach the
lowest, indicating that the large or small caking index will
cause unstable of coke pushing current and then affect
coking operation;
– the increase of volatiles reduces the Iav and Nmax, which is
conducive to the shrinkage of coke, thus reducing the
friction resistance of coke against the oven wall. However,
both higher and lower volatiles increase Iav, causing
disadvantageous to coke production;
– when the coal fineness is 76%, the minimum Iav is 119 A
and N decreases to 28. With the gradual decrease of
blending coal fineness, cold strength of coke show the
phenomenon of first decreasing and then increasing,
indicating that the coal blending fineness must be strictly
controlled to reduce the pushing current.
Acknowledgments. This work was supported by the National Key
Research and Development Program of China [2017YFB0304300
& 2017YFB0304303]; the National Science Foundation of China
[51774032]; the Chinese Fundamental Research Funds for the
Central Universities [FRF-TP-17-086A1].
7
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current of coke oven, Metall. Res. Technol. 116, 506 (2019)
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