Steelmakers need some kind of carbon purified to create iron from molten ore a blast-furnace (not for use as an alloying component). It was previously coal coke that was produced by partial combustion of coal but now it is often petroleum coke (petcoke) as the solid byproduct from oil refining.
The grade of petcoke depends on how it's produced and the crude oil that it was derived from. The "coke ovens" are used to heat coal in order to make metallurgical coke. It transforms from a soft brownish-black powder into a tough carbon-shaped, black material that is used to fuel the blast furnace. This is also known as delayed or fluidized coaling.
After calcination, premium coke is distinguished by an acicular texture. This makes it suitable for the manufacture of high-power electrodes from graphite used in the steel industry. It has low sulfur and nitrogen levels, as well as ash and high conductivity, thermal stability, and purity. It is produced from specific raw materials and techniques which means it comes at an extremely high cost and is strictly regulated according to the required specifications for electrode production. Fuel-grade coke is a byproduct of refinement that is a lot less expensive. It is employed in industrial boilers and cement kilns. It is a fuel with a low ash and high energy content. It also contains more metals than coke needed to make carbon anodes or graphite electrodes.
In the United States, more than 1.5 million tons of fuel-grade petroleum coke is consumed annually by major utilities, mostly as a replacement for coal used to generate electricity. It's a superior alternative to coal as it has a higher calorific content.
Since the need for electricity in a variety of countries continues to grow, it is expected that the demand for petcoke made from fuel will grow too. To ensure that it is ready for these demanding industrial applications, petroleum coke must undergo numerous processing steps in a plant such as the one below.
The coke is pulverized or crushed. This improves the energy density of the coke by compressing the particles together. This step is usually followed by a process of densification that further increases the energy density and improves the flowability of the product. These processes may produce an item with more energy, but they can also pollute.
Testing petcoke before its end-use is a crucial element of the production and distribution. Ensuring the metal, sulfur and carbon contents of the petroleum coke are in safe levels protects industrial equipment from damage while reducing the emissions of greenhouse gases.
A petcoke pulverizer could assist in ensuring that volatiles in coke are removed before it's used as a blend fuel. This can reduce the emissions of harmful substances like vanadium and nickel and also reduce contaminant levels in the boiler water.
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