Manufacture of metallurgical

coke
By Group 8:
Aro Bibi Chrismi A
Pranav M Bhat
Praveen HP
Rishab Gopal Patil
Sriram B
Subhashree Hema S
 COAL
• Coal is an important primary solid fossil fuel
• It is a black or brown colour sedimentary rock which can be
used as afuel.
• It is composed mostly of carbon and hydrocarbons, which
contain energy that can be released through combustion
(burning).
• The process of conversion of vegetable matter to anthracite is
called coalification or metamorphism of coal
 CLASSIFICATION OF COAL

C% H% O% CALORIFI
C VALUE
WOOD
50 7 43 4000-
4500
PEAT
57 6 35 4125-
5400
LIGNITE 67 5 26 6500-
7100

SUB- BITUMINOUS COAL 77 5 16 7000-

7500
83 5 10 8000-
BITUMINOUS COAL 8500
90 4.5 4 8350-
SEMI BITUMINOUS COAL 8500
93 3 3 8650-
8700
ANTHRACITE
PROXIMATE ANALYSIS OF COAL
MOISTURTE CONTENT:
About 1gm of powered air dried coal sample is taken in a crusible and it
is heated at 100 – 105◦C in an electric hot air oven for 1 hour. The loss
in weight of the sample is found outand the percentage of moisture is
calculated as
%Of Moisture in coal = loss in weight of the coal X 100
weight of air dried coal

VOLATILE MATTER:
After the analysis of moisture content the crusible with residual coal
sample is covered with a lid and it is heated at 950+_20◦C for 7 minutes
in a muffle furnance. The loss in the weight of the sample is found out.
%of volatile matter in coal = loss in weight of the coal X100
weight of the moisture free coal
• ASH CONTENT:
After the analysis of volatile matter the crusible with residual
coal sample is heated without a lid at 700+_50 C for ½ an hour
in a muffle furnance. The loss in weight of the sample is found
out.
%of ash content in coal = weight of ash formed X 100
weight of dried coal
• FIXED CARBON:
It is determined by subtracting the sum total of moisture,
volatile matter and ash contents from 100.
%of fixed carbon in coal = 100 - % of (moisture content +
volatile matter + ash content )
 SIGNIFICANCE OF PROXIMATE
ANALYSIS
• Moisture content reduces the calorific value and increases the
transport cost.
• Higher the % of volatile matter reduces the calorific value and
it burns with a long flame with high smokes.
• Higher the % of ash reduces the calorific value and ash causes
hindrance to heat flow as well as producers clinkers which
blocks the supply of air.
• Higher the percentage of carbon greater is the calorific value.
ULTIMATE ANALYSIS
 NITROGEN
• This is done by using kjeldahl’s method. A known amount of
powered coal is heated with conc. H2SO4 in the presence of
K2SO4 as catalyst

% of Nitrogen = 1.4 X volume of acid consumed X Normality X100

weight of coal sample
 SULPHUR
• A known amount of the coal sample is burnt completely in a
bomb calorimeter. During this process sulphur is converted
into sulphate, which is extracted with water. The extract is
then treated with BaCl2 solution so that sulphates are
precipitated as BaS04.
% of sulphur in coal = 32 X weight of BaSO4 obtained X 100
233 X weight of coal sample
• ASH:
The determination of ash is done by proximate analysis method.

• OXYGEN:
% of oxygen in coal = 100 - % of (C + H + N + S + Ash)

SIGNIFICANCE OF ULTIMATE ANALYSIS:

 Higher is the %of C better is the quality of coal, higher is the quality
of coal.
 The good quality coal should contain lower % of N2.
 The presence of sulphur is undesirable, as it produces harmful by
products and it affects the properties of metals.
 Lower the % of oxygen higher is the calorific value.
 CARBONISATION
• When a coal is heated strongly in the absence of air
(destructive distillation) it is converted into lustrous, dense,
porous and coherent mass known as coke.

CAKING • Soft, plastic, fusses to give a

coherent mass
COALS
COKING •
•
Hard, porous, and strong
Lower volatile matter

COALS • Used for manufacture of

metallurgical coke
MANUFACTURE OF METALLURGICAL COKE
BEEHIVE OVEN
 The oven is a dome shaped structure made up of refractory
bricks (2.5m height, 4m wide). It has two openings one at the
top for charging the coal, the other at the side for coke
discharging as well as air supply.
 Coal is charged into the oven through the top opening and air is
supplied through the side opening and the coal is ignited.
 The volatile matter present in coal escapes and burns inside.
 Carbonisation takes place slowly from top to bottom layer.
 Time taken for complete carbonisation - 3-4 days.
 Yield of coke – 60%
 DEMERITS OF BEEHIVE OVEN:
 Lack of recovery of valuable by products.
 Combustion is not effective.
 It is time consuming and yield is low.
OTTO-HOFFMANS BY-PRODUCT
OVEN
 It consist of a number of silica chambers (each 10-12m long, 3-4m
height,0.4-0.45m wide) which are provided with a charging hole at
the top, gas take of valve, iron door at each end for discharging
coke.
 Coal is introduced into the silica chambers and closed. The
chambers are heated at 1200◦C by burning the preheated air and
the producer gas mixture in the interspaces between the chambers.
 Hot flue gas produced during combustion are allowed to pass
through 1st and 4th regenerators until the temperature has been
raised to 1000◦C.The 2nd and 3rd regenerators are used for heating
the incoming gas mixture.
 For economical heating the direction of the direction of the inlet
gas and the flue are changed frequently. This system is known as
the regenerative system of heat economy.
 Time taken for complete combustion – 12 – 20 hours
 Yield of coke – 70%
 • Liquor Ammonia is sprayed
TAR • Tar dissolves &collected in a tank below,
heated to recover the ammonia sprayed

AMMONIA
• Water is sprayed
• Ammonia is converted to NH4OH

NAPTHALENE
• Cooled water is sprayed
• Napthalene gets condensed

BENZENE
• Petroleum is sprayed
• Benzene gets condensed to liquid

• gas pass through a purifier packed with

HYDROGEN SULPHIDE moist Fe2O3
• H2S is retained
• ADVANTAGES :
• Valuable by products like ammonia, coal gas, napthalene,
benzene, hydrogen sulphide, tar, are recovered.
• The carbonisation time is less.
• Heating is done externally by producer gas.
THANK YOU