Steel Manufacturing Process: Coal & Coke

Coal is a mineral consisting mainly of sedimentary fossilized carbon with smaller amounts of other elements, such as sulfur, hydrogen, oxygen, nitrogen and more. Coal is found under the earth crust as lignite, or brown coal — the lowest ranking coal, bituminous coals and anthracite. It is extracted either from underground by shaft mining or at ground level by open-pit mining.

Coal is the largest source of energy for the generation of electricity worldwide and is also used in the production of metallurgical coke as blast furnace fuel. Some smaller blast furnaces can utilize charcoal as a carbon source, but the larger blast furnaces require the strength and durability of coke.

Coke is produced by igniting bituminous coal under reduced oxygen conditions in oven batteries specially designed for this process. The coking process generates the following main volatiles as byproducts: coke oven gas, tar, ammonium sulfate, benzol, toluol and naphtha.

A coke battery is made up of multiple ovens. Coal is crushed and blended prior to being charged in a coke oven. A larry car charges the individual oven with the blended coal. In the coke oven, the coal is heated to 1,800°F for up to 18 hours. During that time, the volatiles of the coal are driven into the offgas and a pure carbon form called “coke” remains. The coke, when exposed to oxygen, will immediately ignite and begin to burn. When the coke is pushed from the oven into a railcar, it is quickly quenched to cool the coke and stop the burning process. The cooled coke is then dumped onto a coal wharf where it is taken to a facility to be screened and sized prior to being charged into the blast furnace.

From the Association for Iron & Steel Technology’s (AIST) Interactive Steel Manufacturing Process
The Making, Shaping & Treating of Steel Wheel
Produced in collaboration with Purdue University Northwest’s Center for Innovation through Visualization and Simulation and the Colorado School of Mines’ Advanced Steel Processing and Products Research Center
AIST.org
Copyright AIST, All Rights Reserved

[llll]

Thankyou for such a direct and comprehensive dialogue which explains exactly what is happening during the animation, so detailed and helpful, amazing

[slob]

I wasn't sure what was going to happen to the black things, but when they turned red I knew everything was going to be alright.

[calderarecords]

*IT'S A BIT TOO LOUD. COULD YOU TURN IT DOWN A NOTCH? Thank you!*

[relaxwithme]

This is a video of a battery in a coke oven plant.

The coke oven consists of multiple ovens each with 2 doors on either side of the battery.

The machine on top of the battery is called a larry car. It's job is to fill up the ovens as you can see. The product “cooks” for 24 hrs.

When it's done cooking it has to be taken out of the oven.

A pusher machine removes the door and their is a door machine on the other side that's not pictured that pulls off the door on the other side.

The pusher than pushes out the product to the other side into what's called a hot car.

That hot car then goes to the quench station to cool off the product.

After that the hot car drops the product off at the wharf

[TheGunslinger]

I like the animation...but I still don't really understand the process. Some text explanation or narration would be helpful.

[hehehihihoho]

What can you do with metallurgical coal besides for stell making? Ty

[ralphgreenjr.]

A coke battery is like working in hell, fumes, heat, smoke, tar, you name it. The by products are very toxic and the piping is made out of lead. I was apprenticed as a welder at Youngstown Sheet and Tube and pulled maintenance shifts in the battery. The workers on top of the battery wore wooden shoes!

[theepicone]

So this is how you make black cheetoose, i see

[ParamjitSingh-wjtw]

Sir mujhe ek question haa ???? The pure form of carbon which is manufacturing of steel

[brian]

After the coke is dumped onto a coal wharf how is it transported and what's the building called where it is taken to be screened and sized.

[Fcutdlady]

Heres what i see . I may not have the right technical terms, but this is the jist.
Coal is loaded into the coke oven and, for want if a beter word, cooked until it becomes coke . It is pushed out of the coke oven into a hot hopper and taken to the quenching tower where it's cooled by water . The hot hopper moves out of the quenching tower, and the coke is released for loading into a train to take it where it's needed .

[leventozsoy]

Dear Sir,


Can we download your video and use it for educational purpose?

[rocknroll]

What software do you use to create animation?

[army]

I don't understand whats going on and why...you heat it up then cool it down then throw it out ....ummm

[drewnamic]

Just got here after watching a reel from TATA Steel Industries. They are shutting down their operations. I feel sad about the workers.

[ULIEINTOME]

They dont show the humans that work it suffering and dying from all kinds of cancers when they retire... the nastiest job in the steel making industry...

[gunasri]

How to get the contact num for this i need carbon coke

[rezaghavimi]

Very good bout i dont give eny informatoin about nerdel cok