公开(公告)号：US20240158709A1

公开(公告)日：2024-05-16

申请号：US18511621

申请日：2023-11-16

Applicant: SUNCOKE TECHNOLOGY AND DEVELOPMENT LLC

Inventor： John Francis Quanci ,  Jonathan Hale Perkins ,  John Michael Richardson

IPC: C10L5/36 ,  C10L5/04 ,  C10L5/10 ,  C10L5/14 ,  C10L5/44

CPC classification number: C10L5/363 ,  C10L5/04 ,  C10L5/105 ,  C10L5/14 ,  C10L5/447 ,  C10L2290/02 ,  C10L2290/06 ,  C10L2290/24 ,  C10L2290/28 ,  C10L2290/60

Abstract: Pellet products, and associated systems, devices and methods are disclosed herein. A production system can include a heat processing assembly comprising an oven configured to process an input material at a processing temperature of at least 1,000° F. for a processing period to produce processed materials, and a pelletization assembly configured to pelletize at least some of the processed materials and one or more additives to generate the pellets. In some embodiments, individual pellets include two or more of coke, coke breeze, char, biochar, charcoal fines, biochar fines, or carbon-containing materials, and at least one of a binder or a cross-linker. A production method can include receiving an input material, processing the input material at a processing temperature of at least 1400° F. in an oven for a processing period to produce processed materials, and pelletizing at least some of the processed materials with one or more additives to produce the pellets.

公开(公告)号：US20240150667A1

公开(公告)日：2024-05-09

申请号：US18501488

申请日：2023-11-03

Applicant: SUNCOKE TECHNOLOGY AND DEVELOPMENT LLC

Inventor： John Francis Quanci ,  John Michael Richardson ,  Jonathan Hale Perkins

IPC: C10L5/04 ,  C10B57/04 ,  C10L5/44 ,  C10L5/48 ,  G01N33/22

CPC classification number: C10L5/04 ,  C10B57/04 ,  C10L5/442 ,  C10L5/48 ,  G01N33/222 ,  C10L2290/24 ,  C10L2290/60

Abstract: Coal blends used to produce foundry coke products are disclosed herein. Coal blends can include first coals having a first volatile matter mass fraction less than or equal to a first threshold, and second coals having a second volatile mass fraction greater than or equal to a second threshold that is less than the second threshold. The coal blend can have an ash fusion temperature less than 2600° F. and an aggregated volatile matter mass fraction between 15% and 25%.

公开(公告)号：US20240229172A1

公开(公告)日：2024-07-11

申请号：US18506746

申请日：2023-11-10

Applicant: SUNCOKE TECHNOLOGY AND DEVELOPMENT LLC

Inventor： John Francis Quanci ,  John Michael Richardson ,  Jonathan Hale Perkins

IPC: C21B5/00

CPC classification number: C21B5/007

Abstract: A coke product configured to be used in foundry cupolas to melt iron and produce cast iron products is disclosed herein. In some embodiments, the coke product has a Coke Reactivity Index (CRI) of at least 30% and an ash fusion temperature (AFT) less than 1316° C. Additionally or alternatively, the coke product can comprise (i) an ash content of at least 8.0%, (ii) a volatile matter content of no more than 1.0%, (iii) a Coke Strength After Reaction (CSR) of no more than 40%, (iv) a 2-inch drop shatter of at least 90%, and/or (v) a fixed carbon content of at least 85%.

公开(公告)号：US11946108B2

公开(公告)日：2024-04-02

申请号：US18052739

申请日：2022-11-04

Applicant: SUNCOKE TECHNOLOGY AND DEVELOPMENT LLC

Inventor： John Francis Quanci ,  John Michael Richardson ,  Jonathan Hale Perkins

IPC: C21B5/00 ,  C01B32/40

CPC classification number: C21B5/007 ,  C01B32/40

Abstract: Foundry coke products, and associated methods and systems for melting iron in a cupola furnace with the coke products are disclosed herein. A representative method can include receiving a population of coke products and iron in a cupola furnace, and melting the iron in the cupola furnace to form molten iron having a carbon content higher than a carbon content of the received iron. The coke products can comprise (i) an elongate shape including a length:width dimension of at least 1.5:1, (ii) an ash fusion temperature of no more than 2400° F., and/or (iii) a coke reactivity index (CRI) of at least 30%.

公开(公告)号：US20240229173A1

公开(公告)日：2024-07-11

申请号：US18586236

申请日：2024-02-23

Applicant: SUNCOKE TECHNOLOGY AND DEVELOPMENT LLC

Inventor： John Francis Quanci ,  John Michael Richardson ,  Jonathan Hale Perkins

IPC: C21B5/00 ,  C01B32/40

CPC classification number: C21B5/007 ,  C01B32/40

Abstract: Foundry coke products, and associated methods and systems for melting iron in a cupola furnace with the coke products are disclosed herein. A representative method can include receiving a population of coke products and iron in a cupola furnace, and melting the iron in the cupola furnace to form molten iron having a carbon content higher than a carbon content of the received iron. The coke products can comprise (i) an elongate shape including a length:width dimension of at least 1.5:1, (ii) an ash fusion temperature of no more than 2400° F., and/or (iii) a coke reactivity index (CRI) of at least 30%.

公开(公告)号：US20230147916A1

公开(公告)日：2023-05-11

申请号：US18052760

申请日：2022-11-04

Applicant: SUNCOKE TECHNOLOGY AND DEVELOPMENT LLC

Inventor： John Francis Quanci ,  John Michael Richardson ,  Jonathan Hale Perkins

IPC: C21B5/00

CPC classification number: C21B5/007

Abstract: A coke product configured to be used in foundry cupolas to melt iron and produce cast iron products is disclosed herein. In some embodiments, the coke product has a Coke Reactivity Index (CRI) of at least 30% and an ash fusion temperature (AFT) less than 1316° C. Additionally or alternatively, the coke product can comprise (i) an ash content of at least 8.0%, (ii) a volatile matter content of no more than 1.0%, (iii) a Coke Strength After Reaction (CSR) of no more than 40%, (iv) a 2-inch drop shatter of at least 90%, and//or (v) a fixed carbon content of at least 85%.

公开(公告)号：US20230142380A1

公开(公告)日：2023-05-11

申请号：US18052739

申请日：2022-11-04

Applicant: SUNCOKE TECHNOLOGY AND DEVELOPMENT LLC

Inventor： John Francis Quanci ,  John Michael Richardson ,  Jonathan Hale Perkins

IPC: C21B5/00 ,  C01B32/40

CPC classification number: C21B5/007 ,  C01B32/40

Abstract: Foundry coke products, and associated methods and systems for melting iron in a cupola furnace with the coke products are disclosed herein. A representative method can include receiving a population of coke products and iron in a cupola furnace, and melting the iron in the cupola furnace to form molten iron having a carbon content higher than a carbon content of the received iron. The coke products can comprise (i) an elongate shape including a length:width dimension of at least 1.5:1, (ii) an ash fusion temperature of no more than 2400° F., and/or (iii) a coke reactivity index (CRI) of at least 30%.

公开(公告)号：US20250163339A1

公开(公告)日：2025-05-22

申请号：US18949426

申请日：2024-11-15

Applicant: SUNCOKE TECHNOLOGY AND DEVELOPMENT LLC

Inventor： John Francis Quanci ,  John Michael Richardson ,  Jonathan Hale Perkins

IPC: C10L5/36 ,  C10L5/14 ,  C10L5/22 ,  C10L5/44 ,  C10L9/02 ,  C10L9/08 ,  C10L9/10

Abstract: Production systems and methods for producing pellets or pellet products, which can be used, e.g., in an electric arc furnace (EAF) to produce metal alloys, are disclosed herein. In some embodiments, a method for forming coke pellets includes (i) blending biomass with a set of materials to form an input blend, (ii) preconditioning the input blend by hydrating the input blend to generate a first plurality of particles, (iii) charging the first plurality of particles into an oven to produce a second plurality of particles via pyrolysis, (iv) post-conditioning the second plurality of particles to produce a third plurality of particles by exposing the second plurality of particles to at least one of an amphipathic binder, a hydrophobic binder, or a hydrophilic binder, and (v) physically altering the third plurality of particles to form coke pellets. The biomass can have a first volatility and the set of materials can have a second volatility lower than the first volatility.

公开(公告)号：US12286591B2

公开(公告)日：2025-04-29

申请号：US18501795

申请日：2023-11-03

Applicant: SUNCOKE TECHNOLOGY AND DEVELOPMENT LLC

Inventor： John Francis Quanci ,  John Michael Richardson ,  Jonathan Hale Perkins

IPC: C10B15/02 ,  C10B5/02 ,  C10B21/10 ,  C10B41/00 ,  C10B53/00 ,  C10B57/04 ,  C10B57/06 ,  C10B57/16 ,  C10L5/04 ,  C10L5/44 ,  C10L5/48 ,  G01N33/22

Abstract: Methods and systems for coking coal blends to produce foundry coke products are disclosed herein. Methods for producing coke products can include charging a coal blend into a coke oven; and heating the charged coal blend such that a crown temperature of the coke oven is greater than a lower bound coking temperature. The pyrolysis duration begins when the crown temperature of the oven is greater than the lower bound coking temperature, and ends when the crown temperature of the oven is less than the lower bound coking temperature.

公开(公告)号：US12110458B2

公开(公告)日：2024-10-08

申请号：US18501488

申请日：2023-11-03

Applicant: SUNCOKE TECHNOLOGY AND DEVELOPMENT LLC

Inventor： John Francis Quanci ,  John Michael Richardson ,  Jonathan Hale Perkins

IPC: C10B57/06 ,  C10B5/02 ,  C10B21/10 ,  C10B41/00 ,  C10B53/00 ,  C10B57/04 ,  C10B57/16 ,  C10L5/04 ,  C10L5/44 ,  C10L5/48 ,  G01N33/22

CPC classification number: C10B57/06 ,  C10B5/02 ,  C10B21/10 ,  C10B41/00 ,  C10B53/00 ,  C10B57/04 ,  C10B57/16 ,  C10L5/04 ,  C10L5/442 ,  C10L5/48 ,  G01N33/222 ,  C10L2290/24 ,  C10L2290/60

Abstract: Coal blends used to produce foundry coke products are disclosed herein. Coal blends can include first coals having a first volatile matter mass fraction less than or equal to a first threshold, and second coals having a second volatile mass fraction greater than or equal to a second threshold that is less than the second threshold. The coal blend can have an ash fusion temperature less than 2600° F. and an aggregated volatile matter mass fraction between 15% and 25%.