Calcined coke benefits include being a critical ingredient in the production of aluminum. It also serves as fuel in cement kilns and blast furnaces, as well as a key component for brick and glass manufacturing.
Most rotary coke kilns have waste heat energy recovery systems that capture the steam from the hot flue gas and use it to make electricity. This is known as coke-to-energy.
Despite its lower energy content, calcined coke offers an attractive calorific value and high yield when compared to coal. This leads to increasing preference of end-users for this fuel as a substitute for traditional energy sources.
GPC is an electrical nonconductor and calcining transforms its structure into a more ordered, electrically conductive form. This improves its quality for use in the manufacture of anodes.
A rotary kiln is the most commonly used type of calcination plant for petroleum coke (CPC). It offers benefits such as simple structure, large production capacity, improved energy efficiency, and good adaptability to raw materials. In addition, it allows for faster start-up and shutdown times. These advantages are key to efficient aluminum smelter operations. It also enables manufacturers to meet increasingly stringent SO2 emissions limits.
The demand for calcined petroleum coke is growing globally due to the growth in steel industry, development in the cement and power generation industries, supply of heavy oils and favorable government initiatives regarding sustainable and green environment. Anode grade coke is used in the aluminum smelting process as a carburizer and for making graphite electrodes.
Calcined coke can also be used to produce carbon products such as activated carbon, which is useful in water treatment and air purification. The material is also being researched as a fuel source for fuel cells.
As the COVID-19 pandemic impacted manufacturing and supply chain operations, businesses implemented digital transformation strategies to improve operational efficiency and agility in response to changing market conditions. This study provides a comprehensive analysis of the global Calcined Petroleum Coke market by manufacturers, region and country, type and application, enabling businesses to identify opportunities and develop effective strategies to maximize their success in this rapidly evolving marketplace.
The sulfur content of calcined coke is significantly lower than that of coal. This makes it an attractive alternative fuel. The market for calcined coke is expected to grow rapidly, driven by the steel industry and aluminum production. Additionally, increasing infrastructure development in developing countries is expected to boost demand for this product.
A delayed coker converts heavy crude oil into petcoke by thermal "cracking" the hydrocarbon molecules. Approximately 75% of the petcoke produced from this process is utilized as a combustible fuel in electric power plants and cement kilns. The rest is calcined in a rotary or shaft kiln to produce calcined petroleum coke (CPC). The higher grade, called needle coke due to its needle-like crystals, is used in the manufacture of graphite electrodes for aluminum smelting.
The reactivity of calcined coke makes it an excellent fuel for the Hall-Heroult aluminum smelting process. Low impurity levels and ready availability have made it a popular substitute for coal for this application.
It is also used as a fuel in cement kilns and for power generation. Rising iron and steel production in Asia Pacific and developing countries has been driving demand for calcined petroleum coke.
Reactivity is measured by measuring the ability of coke to absorb oxygen under specific conditions. Reactivity is a function of both porosity and bulk density. Blending of different quality coke to control supply risks is common in smelters. This practice is expected to increase with increasing sulfur levels in CPC and tightening emissions limits. The ability to use a combination of rotary and shaft coke will help to maximize cost benefits.
Using calcined coke in the aluminum smelting process is an efficient way to reduce energy costs. It is a low-sulfur, low-ash fuel with high thermal conductivity, so it can be used to replace more expensive natural gas or coal in the smelter’s furnace.
Calcined coke can also be used to make carbon fiber, which is an extremely versatile material. It is used in a variety of applications, including aerospace technology and automotive parts. The carbon atoms in calcined coke have a higher bond strength than those in raw petroleum coke, so they can be arranged more easily into stronger structures.
The market is dominated by Asia Pacific due to the growing manufacturing and construction activities in countries like India, China, Singapore, etc. This is primarily attributed to government initiatives such as 100 smart cities and Housing for All by 2022.
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