Coke dust problem

I’ve taken on this task myself; I’m considering investing in the construction of a coking plant. What would be the prospects for that? Currently, there’s an inversion in the prices of coal and coke, and I already don’t understand much about this area, so now I’m even more confused

Project Proposal for an Annual Production Capacity of 30,000 Tons of Coke Powder Pellets I. Necessity of Implementing the Project In China’s metallurgy, chemical fertilizer, and calcium carbide industries, coke or anthracite coal is widely used in production. Due to the low yield of mechanized extraction of anthracite coal, coupled with the closure of small coal mines and rising coal prices and transportation costs, the production costs of anthracite coal and coke continue to increase； Coke prices have risen from 700 yuan per ton to over 1,000 yuan per ton, with prices in the Shanghai market reaching as high as 1,300 yuan per ton. The price of anthracite coal has increased from 300 yuan per ton to over 500 yuan per ton. In our country, the amount of coke powder generated from coke crushing each year exceeds 40 million tons; due to the lack of effective shaping technologies, a large portion of this coke powder can only be used as low-grade fuel. Therefore, utilizing coke dust for shaping in order to accelerate the development of high-tech, high-value-added products derived from coal processing, and selecting suitable binder formulations as well as coke dust shaping technologies suitable for use in industries such as metallurgy, chemicals and fertilizers, and calcium carbide to replace part of the coke used in these industries, is one of the topics that has been under discussion in this industry for many years. To this end, building on my work with industrial briquettes, gasification briquettes, and metal ore powder briquettes, I have successfully resolved the key technical challenge of the extreme difficulty in shaping coke dust into blocks or balls. The molding technology using coke powder or pulverized coal remaining from coke or anthracite not only effectively solves the problem of waste molding and saves substantial costs associated with pollution control, but also transforms waste into a valuable resource, providing enterprises with large amounts of inexpensive and clean fuel; its social and economic benefits are extremely significant. It saves energy and protects the environment while also enabling value-added transformation; therefore, it is feasible to establish projects for shaping coke powder or coal powder into balls. II. Basic conditions for coke (coal) powder shaping. The construction of industrial coke plants involves technical fields such as civil engineering, mechanical automation, chemistry, and thermal engineering ； Adhesives and shaping agents relate to polymer chemistry, colloid chemistry, and crystallography ； Briquette combustion involves combustion science, thermodynamics, high-temperature thermochemistry, catalytic activation theory, and redox mechanisms. At present, the briquette factories already built in China often fail to achieve their intended production capacity and design scale due to issues such as inadequate equipment, inappropriate binders, a lack of theoretical foundations, and insufficient research on manufacturing processes. Using coke dust for processing and shaping is possible only if the produced coke is suitable for the user’s application conditions. Those in the industry are aware that different combustion devices and furnace types have varying requirements regarding the particle size, ash content, moisture, volatile matter, calorific value, reactivity, cinder properties, and other related technical parameters of coke or lump coal. Therefore, when using coke powder to produce shaped coke for applications in industries such as metallurgy, chemicals, and calcium carbide production, it is first necessary to determine the constraints imposed by different combustion devices and furnace types. Once these conditions are known, scientific formulation and advanced processing techniques must be employed to adjust the ash content, moisture, volatile matter, calorific value, reactivity, cinder properties, and particle size of the shaped coke to the optimal values suitable for industrial use. Only then can it be applied in industrial production. So, coke powder shaping: the raw material is the key factor ； Molding agent technology is key ； Molding equipment is the guarantee. III. The technology of binders is crucial. Only when coke (coal) powder, after being formed, meets the requirements for long-distance transportation and outdoor storage, and possesses properties equal to or better than those of lump coal, can it be truly commercialized. Therefore, when using coke (coal) powder for processing and shaping in industries such as metallurgy, chemicals, and calcium carbide production, the key is to select an appropriate bonding agent technology. At present, the molding of industrial coke (coal) powder in China generally relies on low-pressure cold molding, which requires high-quality binders. Although significant research has been conducted in China on industrial briquettes with considerable practical results, the existing technologies generally have various shortcomings, such as low strength in both cold and hot conditions, poor moisture and water resistance, high costs, limited sources of raw materials, and inadequate combustion performance. In light of this, I propose a high-strength, waterproof composite adhesive, based on the following principles: 1. This adhesive contains chemical components that enhance heat resistance, thereby improving the heat tolerance of briquettes ； 2. The adhesive contains low-cost waterproof components, meeting the requirements for easy transportation, handling, and storage in outdoor areas ； 3. Certain components of the binder can improve the combustion activity of briquettes ； 4. The preparation of this adhesive and the manufacturing process for the corresponding briquettes require simplicity. The cold pressing process is employed, along with the use of a composite binder; after mixing and cold pressing, the product (coke powder balls or briquettes) is obtained. It can be dried either by heating or through natural air drying (over 3-5 days). After drying, the cold strength is around 70 kilograms per ball. The material remains intact at temperatures of up to 1000°C without disintegrating or becoming powdery. It is waterproof and moisture-resistant, with minimal reduction in fixed carbon content. The additives contain no chemical elements such as magnesium, phosphorus, aluminum, or iron, resulting in good chemical stability. It can be suitable for use in industries such as metallurgy, chemical fertilizers, and calcium carbide to replace part of the coke. IV. The composite binder for coke powder molding has the following advantages: 1. It is suitable for producing gasified coal briquettes from anthracite and coke powder, as well as coke powder pellets, which can be used in industries such as metallurgy, chemicals and fertilizers, and calcium carbide production to replace part of the anthracite coals, graphite, and coke. 2. The cost per ton for self-production for internal use is 350–500 yuan (varies by region); 8–12 tons of semi-coke (coal) can be produced ； Moreover, the raw materials have a wide range of sources ； The cost per ton of gasified briquettes produced from smokeless coal is around 35 yuan, while the cost per ton of carbonized pellet balls is around 60 yuan. 3. It can be cured naturally or dried using residual heat ； 4. Cold strength greater than 70 kg per piece, thermal stability greater than 85% (resistance to high temperatures of over 1100°C without decomposition or powdering) ； Good chemical reactivity ； Excellent water resistance (does not break or disintegrate when submerged in water) ； 5. Used for fertilizer gas production: stable gas quality and volume, high steam decomposition rate ； 6. The reduction in fixed carbon is minimal, and it contains no chemical elements such as magnesium, phosphorus, aluminum, or iron. V. Types of adhesives suitable for use 1. Coke powder type: This technology not only provides a simple and practical method for recycling waste coke powder in industries such as metallurgy, chemicals, and calcium carbide production, but it also offers a viable solution for the shaping and granulation of various powdered materials used in related industries, such as manganese ore powder, chromium ore powder, and iron-containing dusts in smelting plants. It has shown good performance in applications by enterprises in the metallurgy, chemical industry, and calcium carbide sectors. 2. Gasified briquettes: In China, thousands of enterprises in the chemical and calcium carbide industries require gasification briquettes. Using these briquettes instead of coke or anthracite for gas production not only solves the problem of what to do with pulverized coal but also reduces raw material costs, **promoting the coordinated development of China’s energy, fertilizer, agriculture, and environmental protection industries. 3. Kiln-type coal: Industrial kilns that use coal are numerous, widespread, and come in a variety of types. According to the latest surveys, there are approximately 180,000 such kilns in China, operating across 12 industries including metallurgy, building materials, light industry, and chemicals. These kilns feature high energy consumption, low thermal efficiency, and are scattered across different locations; moreover, they emit exhaust gases at low heights. The use of kiln-type coal can reduce SO2 emissions by over 60%, cut dust emissions by around 70%, and save 15–20% in coal usage. VI. Site and Supply of Raw Coal 1. Site: Relatively flat and regular in shape. 2. Raw material supply: The supply of smokeless coal is stable. VII. Plant type, land area, working hours, and staffing 1. Plant type: One production line with a capacity of 30,000 tons per year, at a rate of 8 tons per hour. 2. Land area: 30m×10m (factory building) ； 40m×16m (plant area). 3. Working hours: ≥300 days/year, 16 hours/day (two-shift system). 4. Staffing: 6 people per shift, totaling 10 people (including management staff). VIII. Production Process of Pattern Coke 1. Characteristics of Coke Powder and Preparation of Raw Coal: The quality characteristics (composition parameters) of the coke powder meet the requirements. 2. Uses: Coking dust and pulverized coal are used in metallurgy as substitutes for coke, as well as in gasified coal and other fuels. 3. Briquette production process: Quantitative feeding of raw materials → Crushing → Quantification → Quantitative addition of binder → Kneading and mixing in a roller press → Shaping → Drying → Finished briquettes. 4. Equipment selection: (1) Meet the current production capacity and expansion requirements; components should be easy to maintain, and wear-prone parts should be easy to purchase and replace. ⑵Reliable quality, smooth operation, high efficiency with low consumption. ⑶The entire production line is well-matched, and the control and protection devices are reasonable and safe. ⑷Production line configuration: a. Main unit components: 1 homogenizer, 1 ultra-fine crusher, 2 roller mills, 1 molding machine, and 1 quantitative feeder for raw coal. b. Drying system: 1 set of vertical dryers (1 motor, 1 exhaust fan, etc.). c. Auxiliary equipment: 4 belt conveyors, 3 rotary dose feeders, 1 reaction kettle, 1 set of electrical control assemblies, 1 magnetizer, and 2 silos. IX. Water Supply and Drainage 1. Domestic water:

Report on the Project to Produce 10,000 tons per year of gas-producing coal briquettes using coke dust (anthracite dust) I. Analysis of raw material conditions Coke and anthracite briquettes are essential raw materials for the chemical, calcium carbide, and metallurgical industries. Due to their wide range of applications and high demand, coupled with the increasing degree of mechanization in coal mining, the closure of small coal mines, and rising transportation costs, coal prices have continued to rise, thereby increasing the production costs for enterprises that use it in their operations； However, the residual powder of coke and anthracite is a by-product used as raw material in the chemical, calcium carbide, and metallurgical industries. Due to its powdered form, it can only be used as fuel for domestic or industrial purposes. Its market price differs significantly from that of lump coal. Therefore, in an era of energy shortages, converting this residual powder of coke (or anthracite) into pellets for use in place of lump coal represents the best way for the electrochemical, calcium carbide, and metallurgical industries to reduce their consumption. II. Quality of shaped coke 1. Quality of coking coal and anthracite used in chemical applications: The key parameters include cold strength, hot strength, fixed carbon, volatile matter, and ash content. 2. Due to the properties and characteristics of coke and anthracite, they are raw materials that are difficult to shape, which implies higher requirements for binders and manufacturing processes. 3. The strength of coke and anthracite pellets is crucial; generally, a cold strength of 50–70 kg/pellet (50 mm×30 mm) is required. Such pellets can replace part of the coke and anthracite in industries such as metallurgy, chemicals, and calcium carbide production. 3. The adhesive technologies I offer come in various types to choose from, with the selection primarily based on the properties and characteristics of the raw materials; the adhesives do not contain elements such as P, Al, Mg, Fe, etc., which can be harmful to production ； It is suitable for use in industries such as metallurgy, foundry, chemicals, fertilizers, and calcium carbide to replace coke or anthracite. 4. Production costs: The processing cost for coke pellets is 80–90 yuan, while that for anthracite pellets is 60–70 yuan (including labor, electricity, and additives). If the price difference between pellets and lump coal is small, it’s better to produce them for internal use; if the difference is significant, it’s feasible to organize their production and sale, with a profit of over 100 yuan per ton. This figure depends on local conditions. III. Technical and economic indicators of pellets 1. Dry pellet strength: >60 kg/pellet ； 2. Thermal stability: remains intact at 800°C without crumbling or dispersing ； 3. Increased ash content: ≤4% ； 4. Drying conditions: Either drying in an oven or natural drying is acceptable ； 5. The main raw materials are readily available locally, facilitating digestion and absorption ； IV. Advantages of molding coal and coke residual powder 1. It is possible to make extensive use of the abundant coal dust resources; only a small amount of additives is required to initiate production ； 2. The produced products have uniform particle size, and this size can be adjusted according to customer requirements, which facilitates customer selection; the spherical shape is suitable for use in blast furnace smelting or in the calcium carbide, chemical, and gas industries ； The block form is suitable for casting. 3. The product has a high yield rate, with a production efficiency as high as 95%. And it has no impact on production requirements. 4. Due to the differences in the quality specifications of the raw materials used, meeting the production requirements necessitates proper selection of these raw materials; this decision should be made based on the local availability of resources and the production requirements. V. Production Process Technology: Clean coal technology is employed to process the residual powder from coke or anthracite into clean pellets through a series of processes and formulations, thereby achieving efficient use of resources and reducing environmental pollution. This can be achieved through the following process: in the production of coke and anthracite pellets, coke or anthracite powder is crushed, mixed with appropriate additives and binders, shaped using a cold pressing process, and then dried before it can be used. This method helps to alter the physical and chemical properties of the coal, thereby improving its combustion efficiency and achieving efficient and clean burning. V. Production process flow for industrial coke VI. Main production equipment and other requirements (designed for an annual output of 0.5–10,000 tons, for reference only) 1. Crusher: 1 unit, capacity 3–5 tons/h, price 0.89 million yuan per unit 2. Mixer: 1 unit, capacity 3–5 tons/h, price 1.85 million yuan per unit 3. Roller forming machine: 1 unit, capacity 3–5 tons/h, price 1.83 million yuan per unit 4. Belt conveyor: 30 meters, self-made 5. Power supply: 50 kw/h VII. Scope of technical services 1. Our institute provides composite bonding agents for coke and anthracite pellets, based on the properties of the raw materials (through optimization) ； 2. Provide, in accordance with the contract, the production process for coke and anthracite pellets (adhesive formula and processing methods) ； 3. As stipulated in the contract, personnel can be sent for technical guidance to train technicians so that the products meet production requirements ； 4. Provide complete pellet production lines as well as manufacturers of adhesive raw materials, ensuring that these raw materials are available everywhere ； 5. Provide customers with complete set of briquette production equipment; on-site training in Kaifeng is also available. To facilitate customers’ evaluation of a project before proceeding with it, I have powder molding machinery, various additives, and testing equipment available. Customers can bring coal ash, coking coke residue, and metal ore powder waste to process various molded samples, before deciding whether to move forward with the project. Unit: Kaifeng Clean Coal Chemical Engineering Research Institute
Address: No. 85, Bianjing Road, Kaifeng City (Science and Technology Bureau)
Contact person: Zhou Guangyu (Senior Engineer)
Phone: (0378)5968327, 13803780327
Email: zgykf@126.com
Website: http://www.kfzhl.com

GY coke powder briquette binder – 21 tons of coke can be produced from 1 ton of this binder. Utilizing the CY coke powder briquette forming dry powder binder, recently developed by the Kaifeng Clean Coal Chemical Engineering Research Institute, and combined with an advanced cold-pressure forming process, coke powder pellets are produced. This binder has the following advantages: 1. Easy to use: There is no need to dry coke powder with high moisture content; it can be directly mixed with the binder in the appropriate proportions to form pellets. 1 ton of this binder can be used to produce 20 tons of coke powder pellets； 2. Excellent performance: One-step molding with a molding rate of 95–98%; the pellets do not disintegrate when dropped from a height of 2 meters. They can be dried naturally or using heat, and after drying their strength is 100 kilograms per pellet. They can withstand temperatures up to 1000°C without disintegrating or losing their integrity. The additives contain no chemical elements such as magnesium, phosphorus, aluminum, or iron, resulting in good chemical stability and minimal reduction in fixed carbon content ； 3. Policy support and low investment: No asphalt or coal tar is needed as a binder; there is no need to build additional coke calcination furnaces, no need to dry coke dust, and no need to heat and mix raw materials. The entire production process is pollution-free, making it an **ideal project for energy conservation and emission reduction initiatives. 4. Wide range of applications: Pellets made from coke, petroleum coke, and residual carbon powder can be used in small blast furnaces for iron production. They serve as alternatives to coke in various industries such as metallurgical feedstocks, raw materials for chemical gas production, and raw materials for calcium carbide manufacturing. GY coke powder-type liquid binder for coke – 1 ton of this binder can be used to produce 6–10 tons of coke. The CY coke powder-type liquid binder for coke, recently developed by the Kaifeng Clean Coal Chemical Engineering Research Institute, is produced through polymerization reactions of various chemical raw materials in a reactor. It is used to manufacture cast coke: the binder is simply mixed in the appropriate proportions and then compressed into shapes, after which it can be dried naturally or using heat. One ton of liquid binder can produce 6–10 tons of large lumpy coke powder-type coke ； After drying, its cold strength is 300 kg per block; it can withstand temperatures of up to 1200°C. It is waterproof and moisture-resistant. It does not increase the ash content, nor is there a need to dry coke powder. There is no requirement to heat or mix the raw materials, and asphalt or coal tar is not used as a binder. There is no need to build additional furnaces for coke production. The entire production process is pollution-free, and the additives contain no chemical elements such as magnesium, phosphorus, aluminum, or iron, giving it good chemical stability. It is widely suitable for iron production in small blast furnaces, and can be used as a substitute for coke in industries such as metallurgical burden and casting. Process flow diagram of the industrial gas-producing coal briquette production line; Instruction manual for the series of coke powder shaping binders -------------------------------------------------------------------------------- Coke, semi-coke, petroleum coke, and lump coal are essential bulk raw materials for the chemical, calcium carbide, and metallurgical industries. Due to their wide range of applications and high demand, coupled with rising coal prices, these materials undoubtedly increase the production costs for enterprises that use them ； However, the residual powders of coke, semi-coke, and petroleum coke used in industrial applications are by-products of the production processes in the chemical, calcium carbide, and metallurgical industries. Due to their powdered form, they can only be used as fuel for domestic or industrial purposes. Their market price differs significantly from that of solid coke. Therefore, in an era of energy shortages, converting these residual powders of coke, petroleum coke, and semi-coke into pellets to replace some of the solid coke is the best way for the chemical, calcium carbide, and metallurgical industries to reduce consumption and save costs. To this end, my institute has made the coke powder molding adhesive project a key focus for research and development, and through years of relentless effort, has successfully developed a series of technologies for coke powder molding adhesives. Using coke, petroleum coke, and semi-coke as raw materials, this invention enables the production of industrial briquette and shaped coke products suitable for various industries, different applications, and specific technical requirements. A **patent was granted in May 2005. Won the Henan Province Science and Technology Progress Award in 2006. I. Types and Characteristics of Binders This series of binders is suitable for using in the production of coke (or pellets) from coke powder, graphite powder, petroleum coke powder, and lignite powder; they can be employed in industries such as metallurgy, foundry manufacturing, chemicals, lime production, and calcium carbide production as substitutes for coke. 1. GY-3-8 type dry powder binder: One ton of this binder can be used to produce 20–25 tons of product. It can be formed by cold pressing followed by drying; after drying, its cold strength is 100 kg per pellet, it can withstand temperatures up to 1100°C, and its ash content increases by 2%. Suitable for use in the chemical industry, gas production, calcium carbide manufacturing, ferroalloy production, small blast furnace ironmaking, and coke production ； 2. GY-3-9 type liquid binder: 6–10 tons can be produced from one ton, and it requires only cold pressing and drying. After drying, its cold strength is 200 kg per block; it can withstand temperatures up to 1200°C, is waterproof and moisture-resistant, and does not increase the ash content. Formed coke is suitable for use in industries such as calcium carbide production, ferroalloy manufacturing, and small blast furnace casting, as a substitute for part of the coke used there ； 3. The product specifications are diverse; it can be in block or spherical form, and the particle size and block size can be adjusted according to the user’s production needs, which facilitates selection for users. The spherical form is suitable for use in blast furnace smelting or in the calcium carbide, chemical, and gas industries ； The block form is suitable for casting. 4. High yield rate, with a product yield of up to 95%. And it has no impact on production requirements. The tonnage cost is reduced by 500-800 yuan compared to purchasing coke, anthracite, petroleum coke blocks, and lump coal, resulting in significant economic benefits. II. Production process flow of industrial coke: The production of coke and semi-coke pellets involves grinding coke powder, semi-coke powder, or anthracite powder, adding appropriate amounts of additives and binders, mixing them together, shaping them through a cold pressing process, and then drying them before they can be used. 1. Production process of coke powder pellets 2. Production process of coke powder-type coke (blocs) III. Main equipment for industrial coke production: 1. 1 crusher, 2. 1 mixing machine, 3. 1 pelletizing or compressing machine, 4. 1 dryer, etc. IV. Requirements for process equipment in coke production 1. Moisture content of raw materials – whether drying is necessary (high moisture content and large production volumes require drying facilities). 2. Whether the raw materials need to be crushed (the particle size of the raw materials should generally be less than 3 mm, with 80% falling within this range). 3. Use of binders and method of addition (using a metering feeder can help avoid uneven distribution of binders) ； 4. Mixing and stirring is a necessary homogenization process; therefore, the uniformity of the mixture of raw materials and binders must be considered ； 5. Full integration of the raw materials and binder (a mixer is used to improve the uniformity of the raw materials and binder) ； 6. A good quality of the molding machine and a high molding rate are essential conditions for mechanical integration; 7. Drying of the shaped coke provides suitable conditions for production and use. V. Ratio of raw coal to binder 1. Raw coke powder or coal powder: 95% (one or more types can be used as raw materials; the production process should be adjusted according to local resources and customer requirements) ； 2. Dry powder adhesive: 4-6% (suitable for raw materials with a moisture content of less than 8%). 3. Liquid curing agent: 8-15% (the amount added should be adjusted according to the moisture level of the raw materials). 4. Mixing method for the liquid adhesive: 85% coke powder or coal powder, plus 15% liquid adhesive. VI. Usage Method 1: Use a conveyor belt for transportation; first, install a dry powder dosing machine on the conveyor belt, so that the raw materials and adhesive are crushed together by a crusher ； 2. Then, the crushed raw material coke powder is conveyed to the mixer using a conveyor belt. A water tank is installed on the mixer, and the amount of water (or liquid adhesive) added is adjusted according to the humidity of the raw material (it should be in a consistency that allows it to form a ball when held in the hand). After the raw materials are mixed evenly, they are fed into the briquetting machine ； 3. Then, the evenly mixed material is conveyed by a conveyor belt to the molding machine for molding ； 4. Send the formed coke blocks (or pellets) to a dryer, where they can be dried for 2–3 hours. VII. Other Notes: Our facility is equipped with adhesives suitable for shaping various types of coal, coke, and mineral powders. We have ball pressing machines, disk granulators, as well as equipment for cylindrical shaping, rod manufacturing, and testing, allowing customers to bring in various powders for testing and processing into different types of pellets or blocks ； Then, based on the condition of the test samples, a decision is made as to whether to purchase an adhesive or a technology. Dry powder adhesives are available on a long-term basis at 2,800 yuan per ton; better prices for larger quantities. Shipping arrangements can also be handled. Unit: Kaifeng Clean Coal Chemical Engineering Research Institute
Address: No. 85, Bianjing Road, Kaifeng City (Science and Technology Bureau)
Contact person: Zhou Guangyu (Senior Engineer)
Phone: (0378)5968327, 13803780327
E-mail: zgykf@126.com
http://www.kfzhl.com
The above information is for reference only