Petroleum coke, commonly referred to as Petcoke, is carbon-rich solid material derived from oil refining. It is produced when crude oil undergoes a process known as coking, in which high temperatures break down heavy hydrocarbons and transform them into lighter products. It is a byproduct of this operation, and it can be used for different purposes based on its characteristics. High-grade petcoke has low sulfur and heavy metal concentrations, making it an excellent choice for producing graphite electrodes for electric steel furnaces. It is also used as fuel in power plants and industrial heating applications.
According to the report, the global Steelmaking with high grade Petroleum Coke market is set to grow at a CAGR of 7.7 percent during the forecast period (2017–2021). This growth can be attributed to a rapidly growing construction and energy sector, as well as increasing demand for aluminum. Steelmakers use petcoke as a substitute for coal, as it has a higher calorific value, lower ash content and less sulfur and heavy metal concentrations. Additionally, petcoke is cheaper and more abundant than coal.
The global production of petroleum coke is around 1.6 billion tonnes per year. A large portion of this is produced in the U.S, with the rest coming from China, India and Russia. The majority of coke is used as a fuel in power plants and for cement kilns. Approximately 80% of the global production is used for thermal power generation. Other uses include making recarburizer for the aluminum smelting industry, and supplying carbon in electric steel furnaces.
There are several types of petroleum coke. The coke that comes directly from the coker is called green coke, and it can be either fuel-grade or anode-grade. The latter is further processed to produce calcined petroleum coke (CPC), which has a high carbon content and low volatiles, making it useful in the steelmaking industry. CPC can also be used to make a fuel that is suitable for use in automobiles and generators.
Other petroleum coke grades include sponge coke and spherical coke. Sponge coke, which forms from fluid catalytic cracking decant oil or coal tar pitch, is less dense than other petroleum coke grades and more porous, allowing it to absorb gases and liquids more efficiently. It is used in the aluminum smelting and steel industries, as well as in the manufacture of graphite electrodes for electric arc furnaces. Spherical coke, which forms from delayed coking, is less dense than needle coke and has a more compact, irregular shape.
A new technology that turns petroleum coke into a useful graphite product is under development at the National Energy Technology Laboratory (NETL). This method uses iron-based catalysts and heat to change the structure of the carbon in the petcoke so that it has low sulfur and heavy metal concentrations. This makes it an ideal fuel for processes that utilize melter gasifiers to make molten iron or steel preproducts. It is believed that this technology could reduce the amount of coal used in these processes while improving their efficiency.
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