Patent ID: 8906336

Claim:
A process to produce a metallurgical coal substitute from feed material for use in a pulverized coal injection (PCI) process for blast furnace production of iron from iron ore, comprising: selecting a non-metallurgical coal carbon containing feed source as a carbon base for the metallurgical coal substitute to be produced; pulverizing the feed source carbonaceous material; controlling ash content of the feed source by measurement and adjustment to a low ash content wherein controlling ash content comprises reducing and modifying ash content of the feed source, and wherein the reducing and modifying ash content of the feed source results in an ash content within a range of about 1-4%; partially pyrolizing the feed source by heating the feed source to a temperature below the melting point of carbon in an oxygen free atmosphere to drive off moisture and volatiles, and to increase the surface area and the internal void volume of the feed source material; and collecting resulting carbon material as a metallurgical coal substitute product suitable for pulverized coal injection into a blast furnace.