Petroleum Coke is the by-product produced during oil refining. It is almost pure carbon. It's produced in the final stages, also known as "coking units", of oil refinery operations where residual heavy crude oils are thermally broken to make lighter product. The three coking technologies -- fluid, delayed and flexi -- are used to produce petroleum coke. But the vast majority is produced by delayed technology in the United States.
It is a thermochemical process in which hydrocarbons are heated under high pressure and without oxygen in order to break down the molecules into smaller ones, resulting in petroleum coke. It is by far the most important product of oil refinement. With a very low amount of ash, and a high value in terms calorific, it can be used as fuel.
Petroleum coke is also cheaper than coal and contains less sulfur. It is suitable to blend with other fuels for electric power generation boilers. The volatile nature of petroleum coke requires that it be handled with care.
To ensure a safe and reliable operation, all petroleum coke must be stored in a covered area with adequate ventilation. It is also necessary to monitor and control the moisture content of the petroleum coke. Overly moist coke can lead to the formation of slag and have a negative impact on the quality.
Sulfur content is an important factor to consider when choosing the correct petroleum coke for ironmaking. Sulfur, which is an enemy to steel, must be removed from metallurgical or coke in order to produce a quality product.
The most common and effective way to reduce sulfur content in Petroleum Coke, is to heat it. This can be done either in a fluidized-bed reactor or in a gasifier, with a part of the reduction gas being carried out as flue gases.
Petroleum Coke can be purified by increasing the temperature at which it is calcined. Temperatures of between 1500 and 2000degC are the norm for calcining.
A second way to reduce sulfur is by using Petroleum Coke as a raw materials to manufacture carbon-black. This can be accomplished by heating the Petroleum Coke at high temperatures to remove sulfur and to dehydrate it.
Moreover, the high content of carbon in petroleum coke makes it useful for the production of chemical products such as urea and melanin. The products made are used in construction, food, medicine and the pharmaceutical industries.
Petroleum Coke has become more popular in the production process of arc furnace iron due to its lower price, lower emissions, and lower sulfur content. This type requires that the coke be low in ash, and contain no more than 2% of sulfur. In addition, the ash must be free of contaminants such as silica and gypsum. The ashes as well as other byproducts can be separated from the process and used in fertilizer.
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