Recent shortages of high-grade coking-coals and other undetermined factors have led to changes in the quality of coke available to foundries. As a result, foundries use more coke with reduced melt rates or tolerate lower iron temperatures and poorer carbon pick-up, making it more difficult to compete in the casting market. Foundry coke properties affect cupola melt rate, iron temperature, iron/coke ratio, carbon pickup, slag formation, CO emissions, and SO₂ emissions. This project was initiated by the AFS 8K Melting Methods & Materials Research Committee and funded by the project participants.

Purposes of project:

• To characterize current cokes and compare their properties to cokes produced a decade ago, prior to current quality and performance issues;
• Based on the results of the characterization work, make recommendations regarding how foundries can maximize the performance of coke in cupola melting;
• Based on the results of the characterization work, suggest how coke producers may be able to provide cokes with improved performance.