Petroleum Coke is a carbon-rich byproduct of oil refining. It is a solid material similar to coal but has different properties that make it more useful for industrial applications. It is the main source of heat in a steelmaking process called coke-ovens. Its low cost and high carbon content makes it a valuable fuel and feedstock.
The first step in refining crude oil is to separate the light and heavy fractions using a refinery. The heavier fractions are heated to high temperatures in a coking unit, which breaks down large hydrocarbon molecules into smaller ones. Some of the carbon and impurities are left behind as a solid residue, which is called petcoke.
This coke is usually characterized as either “fuel grade” or “anode grade.” The raw coke directly out of the coking plant is often referred to as green coke, and it can be further processed in a rotary kiln to produce calcined petroleum coke (also known as needle or shot coke) for use in aluminium and steel production. The calcining process increases the coke’s carbon content and reduces the impurities, such as sulfur and metals. The resulting calcined petroleum coke can be used in power plants, as an anode for aluminium electrolysis, and in the manufacture of graphite electrodes.
Fuel grade petroleum coke is burned in refinery boilers to produce steam and hot water. It has a higher calorific value than coal, making it an inexpensive alternative energy source. It is also used in cement kilns to provide the heat needed for the clinker formation process. However, its high sulfur concentrations can cause problems in cement kilns, and the vanadium and nickel contents of some petroleum cokes are less desirable for use as a boiler fuel.
Another important use for petroleum coke is to add it to the metallurgical coke that is made in the coke-ovens of iron and steelmaking plants. Adding petcoke reduces the reactivity of the coke and helps it to retain its strength. It also allows the steel industry to reduce its coking coal usage by up to 16 per cent, reducing its energy intensity and environmental impact.
In addition, a small amount of fuel grade petroleum coke is mixed with the metallurgical coke in order to reduce its sulphur content. This practice is used in a number of steel mills throughout the world. The use of petcoke can help the steel industry to meet government requirements for reducing its sulphur dioxide emissions by up to 95%. This can be an effective means to achieve lower sulphur dioxide levels without the need for a costly limestone scrubbing system. This will help to ensure the steel industry meets its environmental obligations and improve its operating efficiency at the same time. This will in turn benefit the global economy and will create more jobs.
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