Steel production has become a necessity for the modern industry. This depends on various critical raw materials. Petcoke, also known as petroleum coke, is one of the most important raw materials. This carbon rich material is a waste product of oil refining. It has similar properties to that of coal. Petcoke has a low sulfur and heavy metal content, but unlike coal it is non-combustible. It's a good feedstock for a variety of industries.
The invention described is an improved method for the manufacture iron and stainless steel by using high quality Petroleum Coke. The present invention was based on the realization that petroleum coke could be a good alternative to coal or metallurgical kiln coke for iron-making in a melting gasifier, since it's free from sulfur and other heavy elements. The use of Petroleum Coke also provides a superior reduction gas with a large proportion of carbon monoxide, which is especially beneficial for COREX ironmaking or steelmaking in an oxygen converter or electric arc furnace because it increases carburization.
In the method invented, crude oil feedstocks are fed into a refinery to be processed through a delayed unit. This produces sponge petroleum coal that is fed to the melter-gasifier in the ironmaking process. The invention discloses that a high-quality calcined petroleum coke is produced in the melter gasifier by heating it to temperatures ranging from 1400 to 1500degC. The calcination removes volatile hydrocarbons, and other volatile impurities. The resultant coke meets the industry requirements and is suitable for ironmaking.
After the calcination, the coke will be further dried to remove moisture. It is important to dry the coke thoroughly, because excessive moisture can ruin the product and make it unusable in industrial processes. This drying process is carried out by gently heating coke in order to avoid further reaction.
The coke that is produced after the drying and calcination processes is ready to be used. Coke is used to generate electricity in places where coal is scarce. It can also be used to make aluminum. It's also used to make graphite electrodes for an electric arc-furnace and improve the quality and strength in final steel products.
Petroleum coke is also a good alternative source of carbon that can be used for other industrial uses, including the manufacture of various chemicals and certain types of fertilisers. This fuel is a better alternative for coal than any other because it produces fewer pollutants. The high concentration of carbon in the coke can also be used to make more effective anodes for use in the aluminum smelting process.
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