The aluminum industry has depended on calcined petroleum coke (CPC) as the preferred fuel for carbon anode production since the invention of the Hall-Heroult process in 1929. Coke is a superior fuel for carbon anodes due to its excellent electrical properties, physical characteristics, and ability to resist degradation. The coke is also cheaper and has a lower sulfur content.
However, the smelting industry has been faced with challenges in CPC production due to changes in crude oil quality and refining economics over the last decade, which have had significant impacts on the coke quality and availability. Smelters have responded to this by mixing different coke feedstocks.
The higher-quality, calcined petcoke market has been characterized by rapid growth, driven by the need for a more sustainable alternative to coal. By 2025, the calcined petcoke market will reach $10 billion.
Calcined petroleum coke is used in a wide range of ways by the aluminum industry. It is used in the Hall-Heroult aluminium smelting processes to make anode-grade carbon because it has low levels of impurities and is readily available. Due to its high electrical conductivity, it is used for the production of graphite electrodes in electric arc furnaces and induction ovens.
Calcined petroleum coke is also used to make alumina bricks and glass as well as paints and coatings. The substance can also be gassed into titanium dioxide which is then used in plastics and paints. It is a vital raw material in the manufacturing of steel and aluminum because it has a high calorific value and low sulfur content.
CPC can be produced by heating green petroleum coke at temperatures higher than 800degC. GPC is a byproduct of the delayed coking process in petroleum refineries. In rotary kilns or shaft calciners, the coke is heated and calcined. The calcination process removes most of the sulfur and heavy metals contained in GPC, leaving a solid product called petroleum coke.
A key challenge for the calcined petroleum coke industry is the growing global demand for natural resources such as wood, fossil fuels, and minerals. As a result, the supply of crude oil will be constrained and prices for coke are expected to rise. This is especially true for the higher-quality, calcined coke, which is used to make anodes for the aluminum industry.
Aminco has developed a calciner that uses waste heat as well as alternative fuels, such coke gas. This reduces energy consumption and environmental impact, while at the same time improving smelter performance. By listening to and understanding the operating challenges of smelters and offering flexible blend options, Aminco will continue to provide the highest-quality calcined petroleum coke on the market. Whether a smelter is best served by a blend of high and low-sulfur coke, or by coke from traditional rotary or shaft calciners, Aminco will provide the right feedstock to meet a smelter's needs. This approach ultimately will help smelters meet their emission goals.
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