Improving Stamped Coal Cake Strength Using Chemical Binders: Implications for Resource Efficiency in Coke-Making Technology
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1
Institute of Energy and Fuel Processing Technology, ul. Zamkowa 1, 41-803 Zabrze, Poland
2
Jastrzębska Spółka Węglowa S.A., Al. Jana Pawła II 4, 44-330 Jastrzębie-Zdrój, Poland
3
JSW KOKS S.A., ul. Pawliczka 1, 41-800 Zabrze, Poland
Corresponding author
Agata Czardybon
Institute of Energy and Fuel Processing Technology, ul. Zamkowa 1, 41-803 Zabrze, Poland
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ABSTRACT
Stamp-charging technology has gained increasing importance in the coke-making industry, owing to its ability to utilize lower-cost coals with inferior coking properties while maintaining the required coke quality. This contributes to more efficient utilization of coal resources and improved economic performance of the coking process. However, the successful application of this technology depends on the mechanical integrity of the stamped coal cake during handling and charging into coke oven chambers. Insufficient cake strength may result in its disintegration, causing operational disturbances and fugitive emissions of raw coke oven gas to the atmosphere.
This study investigates the potential of selected chemical binders to improve the mechanical strength of stamped coal cakes without adversely affecting the coking behaviour of the coal blend and the quality of the produced coke. Laboratory investigations were carried out to evaluate the influence of binder additions on the mechanical strength of stamped coal cakes, selected coking properties of the coal blend, including the Roga Index (RI), Free Swelling Index (FSI), maximum fluidity (Fmax), contraction (a), and dilatation (b), as well as the Coke Reactivity Index (CRI) and Coke Strength after Reaction (CSR) of the resulting coke.
The maximum binder dosage was limited to 1 wt.% to identify the minimum effective dosage capable of improving stamped coal cake strength while ensuring industrial applicability, minimizing material consumption in accordance with the principles of resource efficiency, and avoiding potential adverse effects of higher binder contents on the coking process and the quality of the produced coke.
The results demonstrated that chemical binders at dosages of up to 1 wt.% significantly improved the mechanical strength of stamped coal cakes without adversely affecting the coking properties of the coal blend or the key quality parameters (CRI and CSR) of the produced coke. These findings indicate that appropriately selected binders can enhance the operational reliability of stamp-charging technology while enabling more efficient utilization of lower-quality coking coals, thereby supporting resource efficiency and reducing the environmental impacts of coke production.