Study Reveals How Cooling Gas Composition Impacts Industrial Coke Quality in Dry Quenching Systems

Cooling Gas Composition’s Critical Role in Coke Quality

Recent scientific research has revealed that the specific composition of cooling gases used in coke dry quenching processes significantly impacts the final quality parameters of industrial coke, according to reports published in Scientific Reports. The study provides comprehensive analysis of how different gas mixtures affect coke reactivity, strength, and overall quality metrics that are crucial for steel production and other industrial applications.

Cooling Gas Composition’s Critical Role in Coke Quality
Two Competing Industrial Approaches
Comprehensive Testing Methodology
Quality Assessment Protocols
Industrial Implications and Future Applications

Two Competing Industrial Approaches

Sources indicate that the research compared two fundamentally different concepts currently employed in Coke Dry Quenching Systems (CDQS) worldwide. The first approach, reportedly used in designs by SE “GIPROKOKS” with system capacities up to 70 tons per hour, maintains a high content of combustible components in the circulating gas mixture. Analysis shows this traditional method utilizes gases containing 10-12% CO, 2-3% H₂, and 0.2-0.6% CH₄.

The report states that an alternative approach, employed by major international companies including Nippon Steel, ACRE, and Paul Wurth for systems handling 100 tons per hour and above, utilizes circulating gas with minimal combustible components. This modern configuration reportedly maintains gas compositions with significantly reduced hydrogen (0.1-0.71%) and carbon monoxide (0.3-1.42%) levels while increasing nitrogen content to approximately 74%.

Comprehensive Testing Methodology

Researchers developed an extensive laboratory methodology to simulate industrial conditions, maintaining close alignment with actual CDQS operational parameters. The study involved preparing coal blends from Ukrainian coal grades including K (coking coal), DG (long-flame gas coal), GZhP (fat gas coal with platy structure), and G (gas coal), according to the published methodology.

Laboratory coking was conducted in electrically heated ovens reaching final temperatures of 950-1000°C over approximately 2.5 hours. The resulting coke was then subjected to dry quenching using precisely controlled gas mixtures, with researchers monitoring gas composition changes throughout the cooling process using chromatographic analysis.

Quality Assessment Protocols

The cooled coke underwent rigorous quality testing following international standards, including determination of Coke Reactivity Index (CRI) and Coke Strength after Reaction (CSR). Mechanical strength parameters were evaluated through multiple dropping tests from heights of 1-1.8 meters onto metal plates, followed by drum testing at 45±1 rpm for 300 revolutions., according to recent developments

Technical analysis included comprehensive assessment of moisture content, ash composition, volatile matter, and granulometric properties. The research methodology ensured that differences between multiple coke samples did not exceed 5% for strength indicators and 1% for abrasion values, maintaining statistical reliability throughout the experimental process.

Industrial Implications and Future Applications

Analysts suggest these findings could have significant implications for coke production efficiency and environmental performance. The detailed comparison between high-combustible and low-combustible gas systems provides valuable data for operations considering upgrades to existing CDQS infrastructure or planning new installations.

The research demonstrates that maintaining specific gas composition parameters during dry quenching directly influences critical coke quality metrics that affect downstream steel production processes. This comprehensive analysis of gas-coke interactions under controlled laboratory conditions provides a foundation for optimizing industrial coke production worldwide, according to the published report.

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