Petroleum coke is a solid byproduct of oil refining and contains high levels of moisture and volatile matter. This moisture is removed by heating the coke in a "calcining process" which produces a highly pure carbon product known as calcined Petroleum Coke. Coke can be used for several different industries including steel production, aluminum manufacturing, cathodic protective coating, etc.
Fuel grade petcoke is a major source of energy for refineries, where it is burned to produce steam and hot water for various processes. The fuel grade petcoke is used as an alternative to coal and natural gases in many industrial applications. Aluminum smelters are the largest consumers of fuel grade coke, using it to make anodes for aluminum smelting. Demand for calcined coal is predicted to grow in line with the growth of aluminum.
During the calcination process, the green coke is pounded into small pieces and is then heated in a rotary kiln at temperatures up to 1000degC. This process reduces the moisture content and volatile matter by driving off these compounds through the counter current of hot combustion gasses. The coke is also heated, changing its chemical and physical composition. The result is a coke with low volatile matter and sulfur content, which is used in the aluminum industry for producing anodes for smelting aluminum.
Another major application of calcined coal is the production of activated carbon. This is widely used for wastewater treatment, water and air purification and in food processing. This is because the high surface area of activated carbon makes it highly effective at absorbing and holding water molecules. Activated carbon can be made from a variety of sources, including nutshells, corncobs, and water hyacinth, but green coke is the most common source because it has a higher carbon content than most agricultural wastes.
Calcined coke is also used in the steel industry as a reducing agent in the production of steel. It helps remove oxygen from iron ore, and lowers energy requirements for the smelting. The global steel industry is growing, which will also increase demand for calcined coke.
Another important consumer of calcined coke is the cement industry, which uses it as an alternative to natural gas in the clinker-making process. Construction and industrialization are driving the global demand for cement.
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