Petroleum coke composition

Claim 1

Metallurgical grade carbonaceous material in the form of agglomerates not less than about 1/4 inch in diameter and suitable for use in metallurgical and calcining equipment for metal reduction, metal melting and calcining processes, said agglomerates consisting essentially of (a) a carbonaceous component, (b) an alkali metal silicate and (c) refractory component which is a metal oxide or a derivative of a metal oxide which on heating under conditions of use yields a metal oxide said carbonaceous component (a) containing petroleum coke as at least a major ingredient, being present in the agglomerates in the form of particles the major part of which by weight are greater than 200 mesh in size; said alkali metal silicate component (b) being selected from the class consisting of sodium silicate having an SiO 2 /Na 2 O weight ratio between about 2.4/1 and 3.75/1 and potassium silicate having an SiO 2 /K 2 O weight ratio between about 1.80/1 and 2.50/1; the proportions of components (a), (b) and (c) being as follows: the carbonaceous component (a) being present in major amount exceeding the combined weight of components (b) and (c) and such that the agglomerates, when ignited will continue to burn by forced or natural air draft and will serve as a reductant for ferrous metal oxides, to melt ferrous metal or to calcine linestone, the alkali metal silicate component (b) being present in an amount not less than about 4% by weight of the agglomerates and sufficient to act as a binder for the carbonaceous component (a); the refractory component (c) being selected and being present in an amount to increase the softening point of component (b) and to avoid softening of the agglomerates at service temperatures not less than about 2000° F. said agglomerates having a mechanical strength sufficient to pass the drop-shatter test of ASTM D141-48.

Claim 5

A method of producing a metallurgical grade of carbonaceous material suitable for use as a source of heat for at least one of the following operations: melting ferrous metal, reduction of ferrous metal oxides and to calcine limestone, said method comprising providing three components as follows: a. a coke component having petroleum coke as at least a major ingredient, such petroleum coke being in the form of particles the major part of which by weight is greater than 200 mesh in size; b. an alkali metal silicate selected from the class consisting of sodium silicate having an SiO 2 /Na 2 O weight ratio between about 2.4/1 and 3.75/1 and potassium silicate having an SiO 2 /K 2 O weight ratio between about 1.80/1 to 2.50/1; c. a refractory component which is a metal oxide or a derivative of a metal oxide which on heating under conditions of use yields a metal oxide, mixing components (a), (b) and (c) to provide a uniform blend together with sufficient water to form a paste, the components being employed in the following proportions; component (a) being employed in major amount exceeding the combined weight of components (b) and (c) such that the end product, when ignited, will continue to burn by forced or natural air draft and will serve as a reductant for ferrous metal oxide, to melt ferrous metal or to calcine limestone, component (b) being present in an amount not less than 4% by weight of the dry weight and sufficient to act as a binder for the carbonaceous component (a), The refractory component (c) being selected and being present in an amount to increase the softening point of component (b) and to avoid softening of the agglomerates at service temperatures not less than about 2000° F. said method also comprising subjecting the blend of components (a), (b) and (c) to pressure sufficient to consolidate the mixture into a self-sustaining mass.

Claim 6

A method of producing a metallurgical grade of carbonaceous material suitable for use as a source of heat for at least one of the following operations: melting ferrous metal, reduction of ferrous metal oxides and to calcine limestone, said method comprising providing three components as follows: a. a coke component having petroleum coke as at least a major ingredient, such petroleum coke being in the form of particles the major part of which by weight is greater than 200 mesh in size; b. an alkali metal silicate selected from the class consisting of sodium silicate having an SiO 2 /Na 2 O weight ratio between about 2.4/1 and 3.75/1 and potassium silicate having an SiO 2 /K 2 O weight ratio between about 1.80/1 to 2.50/1; c. a refractory component which is a metal oxide or a derivative of a metal oxide which on heating under conditions of use yields a metal oxide, mixing components (a), (b) and (c) to provide a uniform blend together with sufficient water to form a paste, the components being employed in the following proportions; component (a) being employed in major amount exceeding the combined weight of components (b) and (c) such that the end product, when ignited, will continue to burn by forced or natural air draft and will serve as a reductant for ferrous metal oxide, to melt ferrous metal or to calcine limestone, component (b) being present in an amount not less than 4% by weight of the dry weight and sufficient to act as a binder for the carbonaceous component (a), The refractory component (c) being selected and being present in an amount to increase the softening point of component (b) and to avoid softening of the agglomerates at service temperatures not less than about 2000° F. said method also comprising subjecting the blend of components (a), (b) and (c) to pressure sufficient to consolidate the mixture into a self-sustaining mass.