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Foundry coke without coal: more
than half a century of production
in Argentina
Jorge Madias
Mariano de Cordova
San Nicolas, Argentina
Content
• Introduction
• Raw materials
• Blend design
• Coke plant operations
• Coke quality
• Conclusions
Introduction
• Foundry coke is produced in Argentina using
domestic raw materials, with any coal at all
• This way to produce coke was developed as a
substitute for coke imports, in the sixties
• Reasons
– Availability of domestic low S petroleum coke
– Availability of domestic coal tar pitch
– Lack of domestic coking coals
• Produced in non-recovery coke ovens
Raw materials
• Petroleum coke
– Production in four oil refineries
• YPF Lujan de Cuyo (Mendoza) and La Plata (Buenos
Aires): 0.93 Mt/year
• Esso Campana (Buenos Aires): 0.35 Mt/y
• Shell Avellaneda (Buenos Aires): 0.2 Mt/year
• Annual production in the order of 1.5 Mt
• Due to the crude oil quality, pet coke sulfur content is
in between 0.5 and 1%
Raw materials
• Petroleum coke
• Foundry coke producers must compete with other
industries for the supply
– the conventional slot oven batteries at Ternium Siderar, San
Nicolas, Buenos Aires, using up to 40% petroleum coke in the coal
blend
– Copetro, a coke calciner for the production of anodes for the
aluminum industry
– Ferroalloys producers, for use as a reductant at submerged arc
furnaces
– Other smaller markets
Raw materials
• Coal tar pitch
– Produced in Carboquimica del Parana, Ramallo,
Buenos Aires, departing from coal tar supplied by
Ternium Siderar steel plant
– Tar is heated to temperatures up to 400 oC in
specially designed distillation stills
– This removes moisture, naphtalene, light creosote
oil and heavy creosote oil from the coal tar
– The resultant product is the coal tar pitch
Raw materials
– Pitch substitutes (when domestic pitch is scarce)
• Imported pitch (Colombia, 200 l drums)
• Oxidized asphalt 120/5
– produced in batch reactors where hot liquid asphalt is air
injected and then dumped to a pool
– cut in big pieces after solidification.
– cut into small pieces in a special cutting machine
– incorporated to the blend, before grinding
• Asphaltite
– Mined in Mendoza and Neuquen states
Raw materials
• Coke fines
– Recycled to the coking blend to improve coke size
by acting on the fissuring network structure
• Additions for higher ash (for low
recarburization in cupolas)
– Imported coking coals (in the past)
– Domestic high-ash Rio Turbio steam coal
– Sand
– Soil
Blend design
• Typical
– 80% petroleum coke
– 17% coal tar pitch
– 3% coke breeze
• The lower the pitch content, the lower the
coke cost
• Compared with coal-based coking blends, ash
is much lower, fixed carbon is higher and
volatile matter is more or less the same
Blend design
• Alternative design (to replace pitch)
– with oxidized asphalt: 27%
• Careful oven control to avoid fast fissuring bringing
about too small coke size)
– with asphaltite
• Limited to 5% due to high Sulfur content
• For SAFs producing CaC2, 30-35% asphaltite, 5-10% coal
tar pitch, balance pet coke have been used
Blend design
• Coking mechanism differs somewhat from
coal-based blends
• Pitch softens at much lower temperature than
coking coals
• Grinding and mixing are key to coke quality, as
inert and active components are not
intimately mixed as in coking coal
Coke plant operations
• Six sites belonging to
five companies
– Las Palmas S.R.L.
– MECAF Argentina
S.R.L.
– SIDYMETAL S.A.
– Minera Lujan S.R.L.
– PROCAMET S.A.
Coke plant operations
• Typical process flow
Coke plant operations
• Non-recovery coke
ovens
– Rectangular plant
view
– Arched roof
– Low alumina
refractories
Coke plant operations
Coke plant operations
• The total number of ovens could be estimated
in 120
• Just four of them are of the heat-recovery
type, with sole heating by off gas
• Supposing continuous four-day operation and
four metric tons of coke per oven, annual
capacity would be around 40,000 t
• Some production is exported to Chile,
Uruguay and Brazil
Coke quality
• Typical specifications
Product Volatile
matter (%)
Ash (%) Moisture
(%)
Sulfur (%) Fixed
carbon (%)
Size >70
mm (%)
High
recarb./
Low S
1.7 1.5 4 0.6 96 min 95
Medium
recarb./
Low S
2.5 5 4 0.6 93 min 95
Low
recarb.
2.5 9 4 0.7 89 min 95
Medium
recarb./
Medium S
2.5 5 4 1.0 93 min 95
Coke quality
• Control at coke plant
– size, moisture, proximate analysis, sulfur and in
some cases, ASTM tumbler test
– Occasionally, MICUM tests and reactivity
determinations have been carried out by third
parties
Coke quality
• Most foundries evaluate this coke based on
visual aspect at arrival and behavior during
cupola operation; some of them request
proximate analysis to commercial labs
• Just the larger ones, dedicated to the
automotive industry, carry out some testing
(moisture, proximate analysis, sulfur)
• In operation, the low ash content must be
taken into account
Conclusions
• Due to lack of coking coals and availability of
low S pet coke and coal tar pitch, the foundry
coke industry opted for a coal-less coke
production in Argentina more than 50 years
ago
• Coke plant operations has to adapt to the
particular raw material base
• A low-ash high quality coke is obtained
Thank you for your attention!
Contact:
jorge.madias@metallon.com.ar

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Foundry coke without coal - more than half a century of production in Argentina

  • 1. Foundry coke without coal: more than half a century of production in Argentina Jorge Madias Mariano de Cordova San Nicolas, Argentina
  • 2. Content • Introduction • Raw materials • Blend design • Coke plant operations • Coke quality • Conclusions
  • 3. Introduction • Foundry coke is produced in Argentina using domestic raw materials, with any coal at all • This way to produce coke was developed as a substitute for coke imports, in the sixties • Reasons – Availability of domestic low S petroleum coke – Availability of domestic coal tar pitch – Lack of domestic coking coals • Produced in non-recovery coke ovens
  • 4. Raw materials • Petroleum coke – Production in four oil refineries • YPF Lujan de Cuyo (Mendoza) and La Plata (Buenos Aires): 0.93 Mt/year • Esso Campana (Buenos Aires): 0.35 Mt/y • Shell Avellaneda (Buenos Aires): 0.2 Mt/year • Annual production in the order of 1.5 Mt • Due to the crude oil quality, pet coke sulfur content is in between 0.5 and 1%
  • 5. Raw materials • Petroleum coke • Foundry coke producers must compete with other industries for the supply – the conventional slot oven batteries at Ternium Siderar, San Nicolas, Buenos Aires, using up to 40% petroleum coke in the coal blend – Copetro, a coke calciner for the production of anodes for the aluminum industry – Ferroalloys producers, for use as a reductant at submerged arc furnaces – Other smaller markets
  • 6. Raw materials • Coal tar pitch – Produced in Carboquimica del Parana, Ramallo, Buenos Aires, departing from coal tar supplied by Ternium Siderar steel plant – Tar is heated to temperatures up to 400 oC in specially designed distillation stills – This removes moisture, naphtalene, light creosote oil and heavy creosote oil from the coal tar – The resultant product is the coal tar pitch
  • 7. Raw materials – Pitch substitutes (when domestic pitch is scarce) • Imported pitch (Colombia, 200 l drums) • Oxidized asphalt 120/5 – produced in batch reactors where hot liquid asphalt is air injected and then dumped to a pool – cut in big pieces after solidification. – cut into small pieces in a special cutting machine – incorporated to the blend, before grinding • Asphaltite – Mined in Mendoza and Neuquen states
  • 8. Raw materials • Coke fines – Recycled to the coking blend to improve coke size by acting on the fissuring network structure • Additions for higher ash (for low recarburization in cupolas) – Imported coking coals (in the past) – Domestic high-ash Rio Turbio steam coal – Sand – Soil
  • 9. Blend design • Typical – 80% petroleum coke – 17% coal tar pitch – 3% coke breeze • The lower the pitch content, the lower the coke cost • Compared with coal-based coking blends, ash is much lower, fixed carbon is higher and volatile matter is more or less the same
  • 10. Blend design • Alternative design (to replace pitch) – with oxidized asphalt: 27% • Careful oven control to avoid fast fissuring bringing about too small coke size) – with asphaltite • Limited to 5% due to high Sulfur content • For SAFs producing CaC2, 30-35% asphaltite, 5-10% coal tar pitch, balance pet coke have been used
  • 11. Blend design • Coking mechanism differs somewhat from coal-based blends • Pitch softens at much lower temperature than coking coals • Grinding and mixing are key to coke quality, as inert and active components are not intimately mixed as in coking coal
  • 12. Coke plant operations • Six sites belonging to five companies – Las Palmas S.R.L. – MECAF Argentina S.R.L. – SIDYMETAL S.A. – Minera Lujan S.R.L. – PROCAMET S.A.
  • 13. Coke plant operations • Typical process flow
  • 14. Coke plant operations • Non-recovery coke ovens – Rectangular plant view – Arched roof – Low alumina refractories
  • 16. Coke plant operations • The total number of ovens could be estimated in 120 • Just four of them are of the heat-recovery type, with sole heating by off gas • Supposing continuous four-day operation and four metric tons of coke per oven, annual capacity would be around 40,000 t • Some production is exported to Chile, Uruguay and Brazil
  • 17. Coke quality • Typical specifications Product Volatile matter (%) Ash (%) Moisture (%) Sulfur (%) Fixed carbon (%) Size >70 mm (%) High recarb./ Low S 1.7 1.5 4 0.6 96 min 95 Medium recarb./ Low S 2.5 5 4 0.6 93 min 95 Low recarb. 2.5 9 4 0.7 89 min 95 Medium recarb./ Medium S 2.5 5 4 1.0 93 min 95
  • 18. Coke quality • Control at coke plant – size, moisture, proximate analysis, sulfur and in some cases, ASTM tumbler test – Occasionally, MICUM tests and reactivity determinations have been carried out by third parties
  • 19. Coke quality • Most foundries evaluate this coke based on visual aspect at arrival and behavior during cupola operation; some of them request proximate analysis to commercial labs • Just the larger ones, dedicated to the automotive industry, carry out some testing (moisture, proximate analysis, sulfur) • In operation, the low ash content must be taken into account
  • 20. Conclusions • Due to lack of coking coals and availability of low S pet coke and coal tar pitch, the foundry coke industry opted for a coal-less coke production in Argentina more than 50 years ago • Coke plant operations has to adapt to the particular raw material base • A low-ash high quality coke is obtained
  • 21. Thank you for your attention! Contact: jorge.madias@metallon.com.ar