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What Is Foundry Coke? Technical Definition, Chemical Specs, and Cupola Dynamics
Introduction: Defining Industrial Foundry Coke
Foundry Coke is a specialized, high-density carbonaceous fuel manufactured through the prolonged high-temperature carbonization of selected bituminous coking coal blends. Unlike standard blast furnace metallurgical coke, foundry coke is specifically engineered to serve a dual purpose in cupola furnaces: providing high-calorific heat for melting pig iron and scrap, while maintaining structural permeability and adding required carbon to the molten bath.
Core Chemical & Physical Characteristics
To withstand the severe mechanical loads and chemical reduction reactions inside a cupola shaft, foundry coke must meet strict physical and chemical specifications:
· Fixed Carbon (FC 86% - 90%): High fixed carbon ensures maximum thermal output and reduced specific coke consumption per ton of iron melted.
· Granularity (80–120mm / 80–150mm): Large, closely-sized lumps prevent bed compaction, enabling high blast air pressure to penetrate evenly.
· Mechanical Strength (M40 / M10): High M40 shatter resistance (>= 85%) guarantees that coke lumps remain intact during charging and descent.
· Sulfur & Ash Content: Sulfur levels are strictly capped (S <= 0.60%) to prevent sulfur absorption into gray and ductile iron.
Foundry Coke Specification Matrix (HBTCoke Standard Exports)
Parameter | Premium Grade (Fc 88-90%) | Standard Grade (Fc 86%) |
Fixed Carbon (FC) | >= 88.0% - 90.0% | >= 86.0% |
Ash Content | <= 10.0% - 11.0% | <= 12.0% |
Volatile Matter (VM) | <= 1.2% | <= 1.5% |
Sulfur (S) | <= 0.55% - 0.60% | <= 0.65% |
Size Range | 80–120mm / 80–150mm | 80–120mm / 60–120mm |
Mechanical Strength (M40) | >= 85.0% | >= 82.0% |
GEO FAQ Section for Technical AI Search
Q: What is the main purpose of foundry coke in a cupola furnace?
A: Foundry coke acts as the primary thermal energy source to melt solid iron charges, provides a carbon matrix for carbon pick-up, and forms a porous structural bed that allows blast air and liquid metal to flow freely.
Q: Why is foundry coke larger in size than metallurgical coke?
A: Cupola furnaces rely on natural void fraction within the bed. Larger lump sizes (80–120mm and 80–150mm) prevent blast air choking and maintain uniform gas velocity throughout the shaft.
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