ISSN 1068-364X, Coke and Chemistry, 2007, Vol. 50, No. 5, pp. 124–130. © Allerton Press, Inc., 2007.

Original Russian Text © V.M. Strakhov, I.V. Surovtseva, A.V. D’yachenko, V.M. Men’shenin, 2007, published in Koks i Khimiya, 2007, No. 5, pp. 17–24.

COKE

Semicoke Production and Quality

at Chinese Vertical SJ Furnaces
V. M. Strakhova, I. V. Surovtsevaa, A. V. D’yachenkob, and V. M. Men’sheninc
a Kuznetsk Center, Eastern Coal-Chemistry Institute
b OOO Gruppa NITOL
c Eurasian Industrial Association

DOI: 10.3103/S1068364X07050031

In Russia, for some reason, there has been little is synchronous with the discharge of semicoke. Gas to
interest in the thermal processing of nonsintering coal. heat the charge is injected through tuyeres in the fur-
Even today, no projects based on such technology are nace walls. By partial combustion of the volatile com-
underway. However, it may be used to obtain many spe- ponents of the coal released on heating into the furnace,
cial types of coke and semicoke that are necessary for the gas uniformly heats the coal charge. Furnace cham-
processes (other than blast-furnace smelting) employ- ber 3 may be divided into three zones: an upper zone,
ing small metallurgical-coke fractions that do not meet where the coal is dried; an intermediate zone, character-
the relevant quality requirements [1]. ized by semicoking; and a lower zone, where the semi-
In Russia, there is only one semicoking plant, fitted coke is cooled and discharged. In the semicoking zone,
with old and slow Pinch furnaces; it requires recon- the temperature reaches 750 ± 20°C; in the cooling
struction. There have been a few industrial tests of zone, it is no less than 80–100°C.
semicoking methods for coal of rank D, DG, and SS: For cooling, the semicoke is charged in a water
for example, in vertical furnaces, in the gas generators trough. A scraper conveyer collects the semicoke from
of the Slanets plant, and in Karbonika-F self-heating the floor of the trough. Then it is sent to a belt conveyer 4,
reactors [2–12]. However, these methods have yet to be where hot gas is supplied under the conveyer covering.
industrially implemented. Moreover, the powerful The semicoke is dried to a moisture content of 8–
existing three-zone Lurgi furnaces at Angarsk and the 12%. Then the semicoke is sent by means of a conveyer
prototype annular furnaces at Nizhnii Tagil Metallurgi- system for sorting into classes, mm: >28, 28–15, 15–5,
cal Works and Moscow Coke and Gas Plant have been and <5.
shut down, with no prospect of repair.
However, China has recently made great progress in
developing the thermal processing of coal (primarily
energy coal), to obtain a highly effective product, semi-
coke. It is primarily used in metallurgy and in adsorp-
tion processes.
Industrial semicoking in China is of undoubted
interest. In the present work, we consider the operation
of a Chinese semicoking plant equipped with vertical
SJ furnaces. The plant is in the Shenmu district of
Shanxi province (Inner Mongolia). The enterprise
includes two furnaces of total output ~100000 t/yr
semicoke.
The semicoking furnace is shown in Fig. 1, and the
process in Fig. 2.
The SJ furnace is square and vertical and consists of
four chambers. Its dimensions are as follows: length ×
width × height = 7.16 m × 4.26 m × 6.96 m. Coal of the
20–80 mm fraction is charged from car 1 into bunker 2
at the top of the furnace (Fig. 2). There are four such
bunkers (one for each chamber). Direct charging of the
coal into the furnace occurs periodically (~5–6 t/h) and Fig. 1. Chinese vertical SJ semicoking furnace.

124
 SEMICOKE PRODUCTION AND QUALITY AT CHINESE VERTICAL SJ FURNACES 125

The gas leaving the furnace chamber consists of the 1

gas drying the coal and some volatile products; the
combustion products of a mixture of the gas with the air
sent to the lower part of the furnace and from combus-
tion of the volatiles; and steam from the slaking of the
semicoke. The gas from the furnace is evacuated
through a vertical pipe and an intermediate pipe and is
then cleaned in a venturi scrubber 5 and an eddy-flow
column 6. The technological gas mixed with air is
returned to the furnace by means of a centrifugal air
pump 7 and then burns in the coal charge. The remain-
ing (excess) gas is burned in a flame.
Semicoking is accompanied by the formation of tar,
which is sent to settling tank 8 for dehydration, and then
delivered to 1500-m3 tar store 10 by means of pump 9.
After secondary dehydration, the tar is ready for use.
The yield of tar from the coal is ~7–10%. According to
plant data, the characteristics of the tar are as follows:
moisture content 4.0%; ash content 0.1%; density 1.05–
1.07 g/cm3; viscosity (E80) at the 3.0 level; content of
toluene-insoluble components 0.5%; content of frac-
tions, ≤4% of the fraction up to 210°C and ≥60% up to
360°C.
To ensure safe furnace operation, a centrifugal fan is
employed, which permits sealing of the furnace and the
elimination of gas emission.
In the technological process, the gas, tar, and water
are completely separated. After cooling of the semicoke
in the water bath, it is sent to the recycling system.
The tar is used as a chemical raw material or for
combustion and, to some extent, for the production of
fuel (low-quality diesel fuel for agricultural use). The
gas (heat of combustion 1900 kcal/m3) is used as fuel
for various industrial furnaces: for example, for the pro-
2
3 5 6
7
12
4
11
10 9 8
Fig. 2. Semicoke production at the Shenmu plant: (1) car for
coal supply; (2) charging bunker for coal; (3) semicoking
furnace; (4) belt conveyer for semicoke; (5) venturi scrub-
ber; (6) eddy-flow column; (7) centrifugal air pump; (8) set-
tling tank for tar and ammoniacal liquor; (9) pump for tar
extraction; (10) tar store; (11) pump for extracting hot
ammoniacal liquor; (12) pipe for hot-gas supply to furnace.
duction of lime, brick, refractory components, soda,
and tile.
According to data from the Sanzuan coal company
and the Shenmu plant, the requirements on coal for
semicoking are relatively strict (Table 1), especially for
the ash content (Ad ≤ 6%) and phosphorus content (Pd ≤
0.015%). Nonsintering coal with a high yield of vola-
tiles (Vdaf = 37–41%) is employed. The requirements on

Table 1
Quality standards for semicoke
Quality
Characteristic standards Shenmu Ministry of Metallurgy, UV/T 134–92
for coal plant high grade first grade second grade
Size class, mm 20–80 – – – –
Technical analysis, %
Wt
r
≤10 ≤8 ≤8 ≤8 ≤8
Ad ≤6 <7 ≤10 ≤13 ≤16
Vdaf 37–41 ≤8 ≤4 ≤4 ≤4
Sd <0.4 ≤0.25 ≤0.8 ≤0.9 ≤1.3
Pd <0.015 ≤0.005 ≤0.025 ≤0.035 ≤0.045
Carbon content (Cfix), % 55–59 >85 ≥86 ≥83 ≥80
Al2O3 content, % – ≤1.5 ≤2.0 ≤3.0 ≤5.0
Electrical resistivity (950°C), 10–6 Ω cm – ≥3100 ≥2200 ≥2000 ≥1000
Reactivity (1100°C), % – ≥98 – – –

COKE AND CHEMISTRY Vol. 50 No. 5 2007

126 STRAKHOV et al.

Table 2 semicoke (Table 1) at the Shenmu plant agree with the

DKO coal
quality of the initial coke (Ad ≤ 7%; Pd = 0.005%, on
Chinese
from Ego- average) and the heat-treatment conditions (Vdaf ≤ 8%).
coal, The carbon content (Cfix) must be 85–86% here.
Characteristic zovskaya
Shenmu
mine (Kuz- Since the semicoke obtained by this means is used
deposit
netsk Basin)
in various processes, the Chinese Ministry of Metal-
Technical analysis, % lurgy has developed requirements on its quality for var-
Wr 8.8 9.0 ious purposes. In particular, the semicoke produced at
Ad 4.2 5.0 the Shenmu plant is widely used in electric-heating pro-
Vdaf 38.0 41.0 cesses: the production of ferroalloys such as ferrosili-
Sd 0.23 0.35 con and ferromanganese, phosphorus (in the 5–15 mm
class), and calcium carbide (8–20 mm). Accordingly,
Pd 0.001 0.023
additional requirements are imposed on characteristics
Carbon content (Cfix), % 59.4 56.1 such as the electrical resistance at 950°C (≥3100 ×
Elementary composition in 10−6 Ω cm) and the reactivity at 1100°C (≥98%). How-
organic mass, %:
ever, it is difficult to compare these requirements on
Cdaf 82.38 79.35 semicoke with the Russian characteristics, since the
Hdaf 6.37 5.57 methods by which they are determined are not indi-
Ndaf 1.00 2.40 cated.
Odaf 9.99 12.30
In existing operating conditions at the Shenmu
Sdaf 0.26 0.38 plant, representative samples of coal and semicoke
Heat of combustion, kcal/kg have been taken. At the Kuznetsk Center of the Eastern
maximum ( Q s
daf
) 7821 7780 Coal-Chemistry Institute, the quality of these samples
r
has been thoroughly investigated.1
minimum ( Q i ) 6379 6500
Table 2 presents the characteristics of coal used at
Petrographic composition, %: the Shenmu plant, in comparison with the characteris-
Vt 50 86 tics of commercial DKO long-flame coal (class 25–
Sv 9 2 100 mm) from the Egozovskaya mine (Kuznetsk
I 38 7 Basin) used at the Leninsk–Kuznetsk semicoking plant
L – 2 (LKSP).
Me 3 3 The Shenmu coal has a relatively low ash content
Sum of lean components ΣLC, % 45 9 (Ad = 4.2%), with a low overall sulfur content (Sd =
Reflection coefficient of vitrinite 0.63 0.57 0.23%) and an especially low phosphorus content
Ro, % (0.001%, on average). The yield of volatiles is high
Reflection diagram: (38.0%, on average), which permits their use as a heat
standard deviation Sr 0.038 0.046 source in industrial semicoking. In this case, the coal
number of discontinuities 0 0 has a relatively low fixed-carbon content (59.4%). The
Plastometric indices, mm: elementary composition for the organic mass includes
x 34 35 a relatively low carbon content (Cdaf = 82.38%), and
high contents of hydrogen (6.37%) and oxygen
y 0-det. 0
(~10%). Correspondingly, the heat of coal combustion
Roga index (RI) 1.1 3 is not very high (between 7821 and 6379 kcal/kg).
Oxidation (Wsf), % 6.0 4.8
Density, g/cm3: Comparison of the characteristics of Chinese coal
and Kuznetsk Basin coal shows that they are similar,
actual 1.439 1.404
except for the larger phosphorus content of Kuznetsk
apparent 1.263 1.215 coal: 0.023%, as against 0.001%.
Porosity, % 12.2 13.5
Total pore volume, cm3/g 0.097 0.110 The chemical composition of the ash in the coal
used at the Shenmu plant (Table 3) is characterized by
Reactivity of the solid residue 3.00 4.35
for CO2 at 1000°C, cm2/g s a somewhat elevated content of alkaline-earth oxides
(CaO + MgO = 15.53%) and alkali oxides (K2O + Na2O =
Structural strength, % 69.8 68.4
3.18%) and a low content of phosphorus pentoxide
Thermal stability at 900°C, % 81.7 87.9 (P2O5 = 0.08%). The quantity of other common oxides
Classification of coal (SiO2, Fe2O3, and Al2O3) is practically the same in the
(State Standard 25543–88):
rank D D 1 Withthe participation of A.S. Stankevich, N.I. Podchishchaeva,
subgroup DF DV N.V. Osipova, L.A. Nadtoka, and T.D. Nedesheva.

COKE AND CHEMISTRY Vol. 50 No. 5 2007

 SEMICOKE PRODUCTION AND QUALITY AT CHINESE VERTICAL SJ FURNACES 127

Table 3
Coal Semicoke
Parameter
Shenmu Egozovskaya mine Shenmu plant LKSP
Solid-carbon content Cso, % 59.4 56.1 81.1 74.5
Content of mineral impurities per 7.1 8.9 12.2 13.4
100 kg of carbon (Cso), kg
Chemical composition of ash, %:
SiO2 49.30 44.53 45.53 34.26
Al2O3 18.57 21.86 13.16 26.05
Fe2O3 4.51 9.76 17.88 20.11
CaO 14.82 7.65 12.18 8.95
MgO 0.71 3.16 1.39 4.11
TiO2 1.00 0.91 0.56 0.95
P2O5 0.08 1.58 0.12 1.22
SO3 7.11 5.33 5.74 2.70
K2O 1.26 0.33 1.26 0.51
Na2O 1.92 0.48 1.31 0.53
Mn3O4 0.09 – 0.36 –
Oxide content per 100 kg
of carbon, %:
SiO2 3.50 3.96 5.55 4.59
Al2O3 1.32 1.95 1.60 3.49
Fe2O3 0.32 0.87 2.18 2.69
CaO 1.05 0.68 1.49 1.20
MgO 0.05 0.28 0.17 0.55
TiO2 0.07 0.08 0.07 0.13
P2O5 0.06 0.14 0.015 0.16
SO3 0.50 0.47 0.70 0.36
K2O 0.09 0.029 0.15 0.068
Na2O 0.14 0.043 0.16 0.071
Mn3O4 0.006 – 0.044 –

Shenmu and Egozovskaya coal (72.4% and 76.12%,
respectively).
Since the ash content of the Chinese coal is rela-
tively low (Ad = 4.2%), the content of the mineral impu-
rities per unit carbon content (100 kg) is 7.1 kg, on
average. For the Kuznetsk coal, this figure is higher:
8.9 kg (Table 3).
Petrographic data show that Shenmu coal has a high
content of inertinite-group microcomponents (I = 38%)
and a correspondingly reduced vitrinite content (Vt =
50%). The sum of lean components (ΣLC) is 45%. The
reflectivity of the vitrinite is low (Ro = 0.63%), indicat-
ing a low metamorphic stage. The reflection diagrams
of the coal indicate relatively high uniformity (Fig. 3).
The coal does not sinter: the plastic-layer thickness
y varies from 0 to just detectable; the Roga index RI =
1.1. The oxidation capacity of the coal is low (Wsf =
r daf
6.0%). In terms of Vdaf, Ro, Cdaf, O i , Q s , RI, and y, the
coal corresponds to an early metamorphic stage.
According to the Russian genetic and technological
classification (State Standard GOST 25543–88),
Shenmu coal belongs to long-flame group D and sub-
group DF (fusinized). The Kuznetsk Basin coal chosen
for comparison is also of rank D but subgroup DV, since
it contains more vitrinite (Vt = 86%). In other respects,
it is comparable to Shenmu coal: low vitrinite reflectiv-
ity (Ro = 0.57%), no sintering (y = 0, RI = 3), and no
oxidation.
Data on the semicoking products corresponding to
State Standard GOST 3168–93 (550°C) show that the
yields of semicoke and tar from Shenmu coal are rela-
tively high: 78.1% and 11.6%, respectively (Table 4).
For Kuznetsk coal, the tar yield is considerably lower
(5.0%), and the semicoke yield is higher (80.0%).

COKE AND CHEMISTRY Vol. 50 No. 5 2007

128 STRAKHOV et al.

Frequency, % netsk semicoke (10.0%). The yield of volatiles Vdaf is

60 8.6–11.8%, indicating greater readiness of the Chinese
semicoke relative to the Kuznetsk semicoke (with Vdaf =
17.2%). With decrease in size class of the semicoke,
50 both Ad and Vdaf increase (Table 5).
The semicoke is characterized by a low content of
harmful mineral impurities: 0.23% total sulfur content
40
(Sd), as against 0.28% for Kuznetsk semicoke, and
0.001–0.006% phosphorus, as against 0.031% for Kuz-
netsk semicoke. The fixed-carbon content is relatively
high (78.9–83.6%), and increases with increase in size
30 class of the semicoke.
The best technical composition for electrothermal
application is observed for semicoke of the large size
20 class >28 mm (Table 5).
The elementary composition of the semicoke in
terms of the organic mass is typical for such products of
coal pyrolysis, with a high carbon content (92.55–
10
93.72%), elevated hydrogen (1.68–2.32%) and oxygen
(2.83–3.81%) contents, and a low nitrogen content
(0.99–1.10%).
0 The following comments may be made regarding
0.475 0.525 0.575 0.625 0.675 0.725 the physicochemical properties of Shenmu semicoke
Ro, %
for use as a reducing agent in electrothermal processes.
Fig. 3. Reflection diagram of Shenmu coal. The chemical activity of the semicoke is high. Its
reactivity ( R CO2 ), determined from the rate constant of
the C + CO2 reaction, is relatively high: 3.26–
Table 5 presents the characteristics of the Chinese 3.67 cm3/(g s), with an average value of 3.43 cm3/(g s).
semicoke, in comparison with those of LKSP semicoke These values are somewhat lower than for Kuznetsk
obtained from long-flame Kuznetsk coal in vertical semicoke (4.35 cm3/g s), but an order of magnitude
Pinch furnaces, according to classical semicoking tech-
nology. Data on semicoke at the Khaiti (Ukhai) plant higher than for coke nuts (0.36 cm3/g s).
specializing in calcium-carbide production are also Another benefit of Shenmu semicoke is its high
shown. The carbide furnaces operate using up to 100% electrical resistivity: 122.4–829.8 Ω cm (395.9 Ω cm,
semicoke as the carbon-based reducing agent. on average). For Kuznetsk semicoke, the resistivity is
considerably higher (1.6 × 106 Ω cm), on account of the
According to the technical analysis, Shenmu semi- low final temperature in its production (Vdaf = 17.2, as
coke is characterized by an ash content (Ad) of 8.5– against 8.64–11.82% for Chinese semicoke). Attempts
10.6%, which agrees with that of the Leninsk–Kuz- to obtain such high resistivity are sometimes associated
with the appearance of tar vapor in the volatile products
of the semicoke, which may have a negative influence
Table 4
on the conditions at the electrofurnace charge hole.
Shenmu
Egozo- The pore structure of Shenmu semicoke is suffi-
Characteristic vskaya ciently developed for heterogeneous gas reactions with
coal
coal [13] the carbon surface: porosity 32.3–36.2%; total pore
Technical analysis, % volume 0.289–0.331 cm3/(g s). These figures are some-
what higher for Kuznetsk semicoke: 45.9% and
analytical moisture content Wa 6.4 3.8
0.530 cm3/(g s), respectively.
ash content Ad 4.9 4.9
The structural strength of the semicoke meets the
Yield of semicoking products, % requirements of electrothermal processes in low-shaft
pyrogenetic water W sc
daf
3.03 7.42 furnaces with low mechanical loads. The thermal
strength of the semicoke is also satisfactory: the ther-
anhydrous tar T sc
daf
11.61 5.00 mal strength (PTS) at 900°C is 89.6%, which is compa-
rable with that of Kuznetsk semicoke (90.5%).
semicoke (sc)daf 78.07 80.03 Thus, the semicoke produced at the Shenmu plant
gas
daf
G sc 7.29 6.47 may regarded as a satisfactory carbon-based reducing
agent in terms of composition (minimal sulfur and

COKE AND CHEMISTRY Vol. 50 No. 5 2007

 SEMICOKE PRODUCTION AND QUALITY AT CHINESE VERTICAL SJ FURNACES 129

Table 5
Shenmu semicoke of size class (mm) Khaiti
LKSP
Characteristic (Ukhai)
>28 28–15 15–5 mean semicoke
semicoke
Technical analysis, %:
Wr – – – – – 13.8
Wa 2.41 9.46 7.89 6.59 3.86 –
Ad 8.53 10.58 10.55 9.89 7.07 10.0
Vdaf 8.64 9.53 11.82 10.00 6.15 17.2
Sd 0.24 0.23 0.23 0.23 0.19 0.18
Pd 0.001 0.006 0.003 0.003 0.004 0.031
Fixed-carbon content (Cfix), % 83.6 80.9 78.9 81.1 87.2 74.5
Elementary analysis, %:
Cdaf 93.72 93.44 92.55 93.24 94.36 88.83
Hdaf 2.20 1.68 2.32 2.07 2.40 2.97
Ndaf 0.99 1.10 1.07 1.05 1.00 2.76
Odaf 2.83 3.52 3.81 3.38 2.03 5.24
Sdaf 0.26 0.26 0.25 0.26 0.21 0.20
Reactivity (for CO2) at 1000°C, cm3/g s 3.26 3.36 3.67 3.43 2.67 4.35
Electrical resistivity, Ω cm 122.4 235.5 829.8 395.9 151.7 1.6 × 106
Density, g/cm3:
actual 1.667 1.698 1.657 1.674 1.698 1.606
apparent 1.064 1.087 1.121 1.091 1.092 0.869
Porosity, % 36.2 36.0 32.3 34.8 35.7 45.9
Total pore volume, cm3/g 0.327 0.331 0.289 0.319 0.327 0.530
Structural strength, % 70.8 79.2 73.9 74.6 79.6 64.7
Thermal strength (PTS), % 89.6 – – – – 90.5

phosphorus content and high carbon content) and phys-
icomechanical properties (high reactivity and electrical
resistivity and satisfactory porosity and strength).
In terms of its composition and physicochemical
properties, the semicoke used at the Khaiti plant is also
a good reducing agent for calcium-carbide production.
These properties evidently permit the complete
replacement of coke with semicoke.
On the basis of the foregoing, we may note the ben-
efits of semicoking in vertical SJ furnaces:
the compactness of the equipment;
the use of nonsintering coal;
the high productivity;
simplicity of maintenance and ease of control;
low environmental impact (no toxic emissions;
complete separation of the gas, tar, and water);
thorough utilization of the products (semicoke, tar,
and gas);
high quality of the semicoke (with the appropriate
quality of the initial coal and technological parameters)
as a carbon-based reducing agent, for example, for
electrothermal processes;
low capital costs (mainly the refractories and partly
the metal).
In China, large-scale high-speed semicoke produc-
tion has been organized using SJ furnaces. Existing
designs permit the output of 30000, 50000, and
100000 t/yr of semicoke per furnace.
Development work on semicoking in SJ furnaces is
underway in Kazakhstan. Six furnaces with a total
semicoke output of 300000 t/yr were constructed at the
edge of the Shubarkol’sk pit in 2006.
CONCLUSIONS
1. Semicoke from SJ furnaces in China has very
good characteristics as a carbon-based reducing agent
for electrothermal processes. Along with the low ash
content (Ad ≤ 8%), the high carbon content (>85%), and
the very low phosphorus content (Pd < 0.005%), semi-
coke is characterized by very high reactivity with
respect to CO2 and high electrical resistivity. Semicoke
is used in the production of ferroalloys, calcium car-
bide, and phosphorus.

COKE AND CHEMISTRY Vol. 50 No. 5 2007

130 STRAKHOV et al.
2. Research shows that long-flame coal analogous to
Shenmu coal from China is available in the Kuznetsk
Basin. Regrettably, however, semicoke production still
awaits development in Russia.
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COKE AND CHEMISTRY Vol. 50 No. 5 2007