Petroleum coke, instead of coal, is used to maintain the flame temperature required at the melter dome. Its high carbon content and low ash content, also provides the necessary thermal stability to prevent cracking of tar and hydrocarbons during combustion. Calcined petroleum coal also has a high yield volatile matter. This results in a superior performance for EAF injection carbon.
The heavy fractions of crude oil that are left after it has been refined into different fuels are then further processed in a petcoke unit. High temperatures during the coking process are used to break down large hydrocarbon molecule into smaller ones. The resultant coke, a grey solid with a lot of fixed carbon, can be microscopically examined to determine the quality and especially its strength.
The high content of carbon in petroleum coke makes this a desirable feedstock for many industrial processes. It can be used as anodes in aluminum production, and reduces the carbon dioxide produced during steelmaking. The petroleum coke has to be calcined so that it can meet the specifications of these applications. Calcination increases the fixed carbon content of the product and improves adsorption.
Coke is produced in a large variety of forms during the coking of oil. One of these is needle coke. It's a petcoke premium with a narrow form and good conductivity. Its low sulfur content and thermal expansion also make it an ideal forming agent for graphite electrodes and electric steel furnaces. Sponge coke, which is produced from delayed coking and lower-quality raw materials, is less dense than needle coke and more porous. It's cheaper than needle coal, and it absorbs gases and liquids. This makes it a useful material for ceramic, glass, cement, and glass kilns.
The high calorific content of petroleum coke allows it to be burned as fuel in conventional boilers. However, it must be conditioned to remove sulfur before it is burnt. The flue gas desulfurization process (FGD) or fluidized bed combustion can remove sulfur. It can also be gasified within a refinery in a gasification plant to produce liquid petroleum gases, which are then fed to a steam generator to create electricity. This alternative energy source to fossil fuels is a great way to reduce both emissions and power costs. It can also provide a cost-effective replacement for imported natural gas. This is a crucial consideration, especially in light of the rising cost of energy and concerns over global warming.
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