Foundry Coke

What is Foundry Coke?

Foundry coke is used exclusively in the iron and steel industries to cast metals. As an essential component of the metal manufacturing process, it is made from bituminous coal and serves as both a reducing agent and high-energy fuel. Whereas ordinary coal contains a lot of impurities, foundry coke is extremely well-suited for high-temperature industrial processes because it is almost pure carbon.

Foundry Coke Production

Crushing: Coal is crushed to obtain coal powder, which is then screened and impurities are removed.
Coal gasification: The processed coal powder is placed in a gasifier and heated to produce coal gas.
Coking: The coal gas is placed in a coke oven, where the volatiles of the coal gas evaporate in a closed environment of high temperature and pressure to form coke.
Coke processing: The coke is cooled and screened into different grades and specifications.

Foundry Coke Specification

Uses of Foundry Coke

Iron Casting

Foundry coke is vital for iron casting. It is also used in cupola furnaces commonly found in foundries that manufacture cast iron products. The coke serves to supply heat energy as a fuel and a reducing gas; it helps to melt the iron and maintain casting temperature.

Steel Production

Foundry coke is used even lesser in steel production as compared to metallurgical coke; however, it may be suitable for some processes for steel manufacturing, specifically where heating of iron at high temperatures is required.

Foundry Work

Foundries use foundry coke to melt metals, especially when casting parts for machinery, automotive components, and even sculptures. Its ability to achieve extreme heat as well as maintain the burn is critical to many industrial foundry operations.

Avantages de l'utilisation

High Efficiency

In fact, it is quite efficient because it has a low moisture and a low volatile matter. High flame, reliable energy, it is a guaranteed fuel for high-temperature industrial processes.

Durabilité

This coke is sturdier and does not wear off during long-term usages. It retains its strength and structure, even when exposed to very high heat, so it can be used in furnaces for long periods of time without breaking down.

Rentabilité

Foundry coke is cheaper in the long run, considering its high efficiency and low maintenance needs despite the high price as compared to regular coal. It has a high energy content so less is needed to produce the same output, making it more efficient and therefore reducing fuel usage.

Foundry Coke Vs Metallurgical Coke

The real world fuel choice for industrial use tends to be foundry vs metallurgical coke. The two products are similar, but different. Foundry coke is designed specifically for the iron casting market. Less heterogeneous size and reduced ash content. But steelmaking requires metallurgical coke, which has different size requirements and is stronger. Both used for heating but foundry coke is more focused on uniformity and low impurities needed for quality casting. However, total carbone content and structure is slightly different in metallurgical coke for blast furnaces.

Foundry Coke for Sale

Teneur en carbone

Find coke with a high carbon content for foundry use. Higher carbon = better heat output and reducing power for the coke. As a general rule, you’ll want a product with at least 85 percent carbon content.

Size and Shape

The coke can influence performance due to this size and shape. If coke size is too small, coke will burn too quickly, and if coke size is too large, it will not provide enough surface area for efficient combustion. Select coke suitable for the requirements of your four.

Ash Content

Foundry coke usually preferred lower ash content. Too much ash can contaminate the metal, which can create impurities and defects in the end product. Use the least ashy coke available.

Sulfur Content

Because sulfur can pollute molten metal and influence the grade of the castings, pick foundry coke with low sulfur level. A useful quality is 1% maximum sulphur content.