Coal to Make Coke and Steel

Metallurgical coal (also called "met" coal) is an important raw material used in the steel-making
process, although very small amounts of coal (relative to the amount used for electricity) are
needed. The coal used to make steel is heated without air in an oven at temperatures of as much
as 2,060°F (1,125°F), until most of its volatile matter is released. During this process, it softens,
then liquefies, and re-solidifies into a hard porous material called "coke". This is not the cola soft
drink. Coke is a porous, carbon-rich material used to make steel. The coke is mixed with iron ore
and limestone to make molten iron, which is then further treated and heated to make steel.
Generalized diagram showing how steel is made.

In the steel-making process, coke is used in the blast furnace as a (1) fuel to produce added heat;
(2) chemical-reducing agent for the reduction of iron oxides; and (3) as a permeable support in
the molten material in the furnace. By-products from coke ovens are used in the chemical
industry (see Coal for chemicals and specialty products).

Not all coals can be used as metallurgical coals to make coke. Met coals must have low sulfur
content (<1%), low ash yield (<7%), low volatile matter (15 to 40%) and low phosphorous-, low
chlorine-, and low alkali content. Ideally, they are medium-volatile bituminous in rank, although
other coal ranks can be used and blended to make a suitable met coal. Because of the relative
rarity of met coals, they are more expensive than coals used for heating or electricity.

Both the coals and subsequent cokes are tested for their quality. Another important quality of the
coke, which is tested, is its strength. Coals and cokes are also microscopically analyzed (called
petrography) to determine the relative proportions of "reactive" components (vitrinite and
liptinite macerals) vs. "inert" components (inertinite macerals and mineral matter), which
influence coking properties.
The production of steel in the United States has declined in recent years because of the increased
use of imported and recycled steel. Not surprisingly, the amount of coal mined in Kentucky to
make coke has also declined. In 2014, in the United States, approximately 22,000 tons of coal
was sold in the met market, which was less than three percent of the total mined coal that year
(EIA, 2016 data).

Other Uses of Coal:

 Coal for Electricity Generation

 Coal for Industry and Residential Markets
 Coal for Specialty Products and Chemicals
 Rare Earth Elements from Coal


References for Coal for Coke and Steel

 Ammosov, I.I., Eremin, I.V., Sukhenko, S.F., Oshurkova, L.S., 1957, Calculation of
coking changes on basis of petrographic characteristics of coals: Coke Chem. U.S.S.R.,
v.2, p. 9– 12.
 Benedict, L.G., Thompson, R.R., Wenger, R.O., 1968, Relationship between coal
petrographic composition and coke stability: Blast Furnace and Steel Plant, v.56 (3),
p.217–224.
 Dıez, M.A., Alvarez, R., Barriocanal, C., 2002, Coal for metallurgical coke production:
predictions of coke quality and future requirements for coke making: International
Journal of Coal Geology, v. 50, p. 389– 412.
 Dutcher, L.A.F., Crelling, J.C., 2000, History of applied coal petrology in the United
States: I. Early history of the application of coal petrology in the steel industry:
International Journal of Coal Geology, v.42, p. 93– 101.
 Gray, R.J., 1978, Selection of coals for coke making, in Meissner, C.R., Jr., Cecil, C.B.,
and Stricker, G.D. (eds.), Coal Geology and the Future Symposium Abstracts and
Selected References: U.S. Geological Survey, Circular 757, p. 15-16.
 Karr, C. (ed.), 2013, Analytical methods for coal and coal products: Academic Press, v.2,
669 p.
 Nakamura, N., Togino, Y., Tateoka, T., 1977, Behaviour of coke in large blast furnace.
Coal, Coke and Blast Furnace: London, The Metals Society, p. 1-18.
 Schapiro, N., and Gray, R.J., 1964, The use of coal petrography in coke making: Journal
of the Institute of Fuel, v. 43, p. 234–242.
 Thompson, R.R., 2000, History of applied coal petrology in the United States: III.
Contributions to applied coal and coke petrology at the Bethlehem Steel Corporation:
International Journal of Coal Geology, v. 42, p. 115–128.
 Thompson, R.R., and Benedict, L.G., 1976, Coal composition and its influence on coke
making. Ironmaking Proceedings, v.3 (2), p. 21– 31.
 U.S. Environmental Protection Agency (EPA), 1995, Coke production: U.S. EPA
Emissions Factors and AP 42, Compilation of Air Pollutant Emission Factors, Chapter
12, Metallurgical Industry, varied pagination.
 Zimmerman, R.E., 1979, Evaluating and testing the coking properties of coal: San
Francisco, Miller Freeman Publications, San Francisco, California, 144 p.