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See also:COKE (a See also:northern See also:English word, possibly connected with " colk," core) , the product obtained by strongly See also:heating See also:coal out of contact with the See also:air until the volatile constituents are driven off; it consists essentially of See also:carbon, the so-called " fixed carbon," together with the incombustible matters or ash contained in the coal from which it is derived . In addition to these it almost invariably contains small quantities of See also:hydrogen, See also:oxygen and See also:nitrogen, the whole, however, not exceeding 2 or 3% . It also contains See also:water, the amount of which may vary considerably according to the method of manufacture . When produced rapidly and at a See also:low See also:heat, as in See also:gas-making, it is of a dull See also:black See also:colour, and a loose spongy or See also:pumice-like texture, and ignites with See also:comparative ease, though less readily than bituminous coal, so that it may be burnt in open See also:fire-places; but when a See also:long-continued heat is used, as in the preparation of See also:coke for See also:iron and See also:steel melting, the 'product is hard and dense, is often prismatic in structure, has a brilliant semi-metallic lustre and silvery-See also:grey colour, is a conductor of heat and See also:electricity, and can only be burnt in furnaces provided with a strong See also:chimney See also:draught or an artificial blast . The strength and cohesive properties are also intimately related to the nature and See also:composition of the coals employed, which are said to be caking or non-caking according to the compact or fragmentary See also:character of the coke produced . Formerly coke was made from large coal piled in heaps with central chimneys like those of the See also:charcoal burner, or in open rectangular clamps or kilns with air flues in the enclosing walls; but these methods are now practically obsolete, closed See also:chambers or ovens being generally used . These vary considerably in construction, but may be classified into three See also:principal types:-(1) See also:direct heated ovens, (2) flue-heated ovens, (3) condensing See also:oven. circular hole at the See also:top . The See also:floor, made of refractory bricks or slabs, is laid with a slight slope towards an arched opening in the See also:ring See also:wall, which is stopped with See also:brickwork during the coking but opened for See also:drawing the finished See also:charge . The ovens are usually arranged in rows or See also:banks of 20 to 30 or more, with their doors outwards, two rows being often placed with a See also:longitudinal flue between them connected by uptakes with the individual ovens on either See also:side . A railway along the top of the See also:bank brings the coal from the screens or washery . The largest ovens take a charge of about 5 tons, which is introduced through the hole in the roof, the See also:brick-See also:work of the empty oven being still red hot from the preceding charge, and when levelled fills the cylindrical See also:part nearly to the springing of the roof . The gas fires as it is given off and fills the See also:dome with See also:flame, and the burning is regulated by air admitted through holes in the upper part of the See also:door stopping . The temperature being very high, a proportion of the volatile See also:hydrocarbons is decomposed, and a film of graphitic carbon is deposited on the coke, giving it a semi-metallic lustre and silvery grey colour . When the gas is burned off, the upper part of the door is opened and the glowing charge cooled by jets of water thrown directly upon it from a See also:hose, and it is subsequently See also:drawn out through the open door . The charge breaks up into prisms or columns whose length corresponds to the See also:depth of the charge, and as a See also:rule is See also:uniform in character and See also:free from dull black patches or " black ends." The See also:time of burning is either 48 or 72 See also:hours, the turns being so arranged as to avoid the See also:necessity of drawing the ovens on See also:Sunday . The longer the heat is continued the denser the product becomes, but the yield also diminishes, as a portion of the finished coke necessarily See also:burns to See also:waste when the gas is exhausted . For this See also:reason the yield on the coal charged is usually less than that obtained in See also:retort ovens, although the quality may be better . Coals containing at most about 35% of volatile See also:matter are best suited for the beehive oven . With less than 25% the gas is not sufficient to effect the coking completely, and when there is a higher percentage the coke is brittle and spongy and unsuited for blast See also:furnace or foundry use . The spent flame from the ovens passes to a range of See also:steam boilers before escaping by the chimney . The retort oven, which is now generally displacing the beehive See also:form in new installations, is made in a See also:great variety of forms, the Retort See also:differences being mainly in the arrangement of the heating flues, but all have the central feature, the coking oven. chamber, in See also:common . This is a tubular chamber with See also:vertical sides and cylindrical roof, about 30 ft. long, from 17 to 20 in. wide, and 6 or 7 ft. high, and closed at both ends by sliding doors which are raised by crab winches when the charge is to be drawn . The See also:general arrangements of such an oven are shown in fig. i, which represents one of the earliest and most popular forms, that of Evence See also:Coppee of See also:Brussels . The coking chambers A B connect by rectangular posts at the springing of the roof, where the gas given off from the top of the charge is fired by air introduced through c c . The flames pass downwards through the parallel flues f f along the bottom flue of one oven, and return in the opposite direction under the next to the chimney flue, a further part of the heat being intercepted by placing a range of steam boilers between the ovens and the chimney stack . The charging of the oven is done through the passages D D in the roof from small wagons on transverse lines of rails, the See also:surface being raked level before the doors are closed and luted up . The time of coking is much less than in the beehive ovens and may be from 24 to 36 hours, according to the proportion of volatile matter See also:present . When the gas is completely given off the doors are lifted and the charge is pushed out by the See also:ram—a See also:cast-iron See also:plate of the shape of the See also:cross See also:section of the oven, at the end of a long See also:horizontal See also:bar, which is driven by a See also:rack and pinion See also:movement and pushes the See also:block of coke out of the oven on to the See also:wharf or bank in front where it falls to pieces and is immediatelyquenched by jets of water from a hose See also:pipe . When sufficiently cooled it is loaded into railway wagons or other conveyances for removal . The ram, together with its motor, and See also:boiler when steam is used, is mounted upon a See also:carriage See also:running upon a See also:line of rails of about 2 ft. See also:gauge along the back of the range of ovens, so that it can be brought up to any one of them in See also:succession . In some cases, instead of the small coal being charged through the roof of the oven and levelled by See also:hand, it is formed into blocks by being stamped in a slightly moistened See also:condition in a See also:mould consisting of a bottom plate or See also:peel on a racked See also:rod like that of the ram, with movable sides and ends . This, when the ends are removed, is pushed forward into the oven, and the bottom plate is withdrawn by See also:reversing the rack See also:motion . The moulding See also:box is mounted on a carriage like that of the ram, the two being sometimes carried on the same framing . The moulding is done at a fixed station in the centre of the range of ovens by a See also:series of cast-iron stampers driven by an electric motor . This See also:system is useful for coals low in volatile matter, which do not give a coherent coke under See also:ordinary conditions . In the distilling or by-product ovens the gases, instead of being burned at the point of origin, pass by an uptake pipe in the roof about the centre of the oven into a water-sealed See also:collecting trough or See also:hydraulic See also:main, whence they are drawn by Condensexhausters through a series of air and water cooled See also:con- ingovens. densers and scrubbers . In the first or atmospheric condensers the See also:tar is removed, and in the second ammoniacal water, which is further enriched by a graduated system of scrubbing with weak ammoniacal liquor until it is sufficiently concentrated to be sent to the See also:ammonia stills . The first treatment by scrubbing with See also:creosote or heavy tar oil removes See also:benzene, after which the permanent gaseous See also:residue consisting chiefly of hydrogen and See also:marsh gas is returned to the ovens as See also:fuel . In the See also:Otto-See also:Hoffmann oven, one of the most generally used forms, vertical side flues like those of Coppee are adopted . The returned gas enters by a horizontal flue along the bottom of the coking chamber, divided into two parts by a See also:mid-See also:feather wall, and is fired by heated air from a See also:Siemens regenerator on the substructure at one end, and the flame rising through one See also:half of the side flues to a parallel See also:collector at the top returns downwards through the flues of the other half and passes out to the chimney through a similar regenerator at the other end . The course of the gases is reversed at intervals of about an See also:hour, as in the ordinary Siemens furnace. each end of the oven having its own gas See also:supply . In the later modification known as the Otto-Hilgenstock, the regenerators are abandoned, but See also:provision is made for more perfect See also:distribution of the heat by a line of sixteen See also:Bunsen burners in each wall; each of these serves two flues, the course of the flame being continuously upwards without reversal . In the newest Otto ovens the same system of burners is combined with regenerators . In the See also:Bauer system, another vertical flue oven, each flue has its own burner, which is of a simplified construction . In the Carves oven, the earliest of the by-product ovens, the heating flues are arranged horizontally in parallel series along the entire length of the side walls, the gas being introduced from both ends but at different levels . This system was further See also:developed by H . See also:Simon of See also:Manchester, who added a continuous air " recuperator " heated by the spent flame; this Simon-Carves system has been extensively adopted in Great See also:Britain . Another horizontal flue oven, the Semet-Solvay, is distinguished by the structure of the flues, which are See also:independent of the dividing walls of the ovens, so that the latter can be made with thinner sides than those of the earlier systems, and are more readily repaired . In the horizontal ovens it is sometimes difficult to maintain the heat when the flues are continuous along the whole length of the wall, especially when the heating value of the gas is reduced by the removal of the heavy hydrocarbons . This difficulty is met by dividing the flues in the See also:middle so as to shorten the length of travel of the flame, and working each end independently . The Hiissener and Koppers systems are two of the best-known examples of this modification . Coke from retort ovens is not so dense or brilliant as that made Longitudinal Seetion D Seeps, o•A ir~to rcwnsnaeaseae— figi:,..• a * yioniav000~ir mvimioc/~wan : sic \WM, Transverse Section C C C C c chimney t«e _ mve . /ahMM=1917AW .umi® iPmn f~\F1\'' .Val &ma& aro-eonau a ovens . In the first class the heating is done by direct contact or by burning the gases given off in coking within the oven, while in the other two the heating is indirect, the gas being burned in cellular passages or flues provided in the walls dividing the coking chambers, and the heat transmitted through the sides of the latter which are comparatively thin . The arrangement is somewhat similar to that of a gas-See also:works retort, whence the name of " retort ovens " is sometimes applied to them . The difference between the second and third classes is founded on the treatment of the gases . In the former the gas is fired in the side flues immediately upon issuing from the oven, while in the latter the gases are first subjected to a systematic treatment in condensers, similar to those used in gas-works, to remove tar, ammonia and condensable hydrocarbons, the incondensable gases being returned to the oven and burned in the heating flues . These are generally known as " by-product ovens." The simplest form of coke oven, and probably that still most largely used, is the so-called " beehive oven." This is circular in See also:plan, from 7 to 12 ft. in See also:diameter, with a cylindrical wall Beehive about 21 ft. high and a nearly hemispherical roof with a in beehive ovens, but the waste being less there is a decided saving, apart from the value of the condensed products . In one instance the coke was found to be about 5 % less efficient in the blast furnace, while the yield on the coal charged was increased 10 % . In the further treatment of the condensed products by See also:distillation the tar gives burning oil and See also:pitch, the benzene is separated from the creosote oil by steam-heated stills, and the ammoniacal liquor, after some See also:lime has been added to decompose fixed ammonium compounds, is heated to vaporize the ammonia, which is condensed in See also:lead or See also:copper-lined tanks containing strong sulphuric See also:acid to produce a crystalline See also:powder of ammonium sulphate, which accumulates in the See also:receiver and is fished out from time to time . The yield of by-products averages about i % of ammonium sulphate, about 31% of tar, and o•6 to 0.9 % of benzene, of the See also:weight of the coal carbonized . After the ovens have been heated and steam supplied for the machinery of the condensing plant and the coke ovens, there is usually a surplus of gas, which may be used for See also:lighting or See also:driving gas-engines . For the latter purpose, however, it is necessary to remove the last traces of tar, which acts very prejudicially in fouling the valves when the gas is not completely purified . The gas given off during the earlier part of the coking See also:process is richer in heavy hydrocarbons and of a higher See also:illuminating value than that of the later See also:period when the temperature is higher . This See also:property is utilized in several large coking See also:plants in See also:America, where the gas from the first ten hours' working is drawn off by a second hydraulic main and sent directly to See also:town gas-works, where it passes through the ordinary purifying treatment, the gas from the second period being alone used for heating the ovens . Coke is essentially a partially graphitized carbon, its See also:density being about midway between that of coal and See also:graphite, and it should therefore occupy less space than the See also:original coal; but owing to the softening of the charge a spongy structure is set up by the escaping gases, which acts in the other direction, so that for equal bulk coke is somewhat lighter than coal . It is this See also:combination of properties that gives it its See also:chief value in iron smelting, the substance being sufficiently dense to resist oxidation by carbon dioxide in the higher regions of the furnace, while the vesicular structure gives an extended surface for the See also:action of heated air and facilitates rapid See also:consumption at the tuyeres . Compact coke, such as that formed on the inner sides of gas retorts (retort carbon), can only be burned with great difficulty in small furnaces of See also:special construction, but it gives out a great amount of heat . The most deleterious constituents of coke are ash, See also:sulphur and volatile constituents including water . As the coke yield is only from two-thirds to three-quarters of that of the coal, the original proportion of ash is augmented by one-third or one-half in the product . For this reason it is now customary to crush and See also:wash the coal carefully to remove intermingled patches of shale and dirt before coking, so that the ash may not if possible exceed le% in the coke . About one-half of the sulphur in the coal is eliminated in coking, so that the percentage in the coke is about the same . It should not be much above 1 % . According to the researches of F . Wuest (Journ . Iron and Steel Inst., 1go6) the sulphur is retained in a complex carbon See also:compound which is not destroyed until the coke is actually consumed . The older methods of coking and the earlier forms of retort ovens are described in J . See also:Percy, Metallurgy, See also:Jordan, See also:Album du See also:tours de metallurgie . See also:Phillips and Bauerman, Handbook of Metallurgy, and other See also:text-books . A systematic series of articles on the newer forms will be found in The Engineer, vol . 82, pp . 205-303 and vol . 83, pp . 207-231; see also Durre, See also:Die neuern Koksofen (See also:Leipzig, 1892) ; D .
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