This process transforms green petroleum coal (GPC), into the solid, carbon-based petcoke. It is an essential intermediate in the production of aluminum, carbon-based materials and energy. In order to meet the growing demand for GPC/calcined Petcoke, industry must strike a balance that is both economically viable and environmentally friendly.
It is vital to use calcined oil coke as a refractory material in order to produce high-quality aluminum anodes. They are anodes which conduct electricity to the pots in aluminum smelters. These materials must have low sulfur content, be refractory and durable. The porous structure allows binding materials to penetrate the anode, and keep it together throughout the melting process. For every 100 tonnes of aluminum, aluminum smelters use about 40 tons calcined coal.
Calcined coke is used by many industries. The refractory and steel industries use it as carbon additives to manufacture graphite and electrodes. In addition, the chemical industry uses it to make chemicals such as methanol and formaldehyde. Asphalts and bricks are also industrial uses of calcined coal.
Calcination involves heating the petroleum coke to remove the moisture and volatile material, thus reducing the sulfur level in the end product. In addition, this heating process alters the physical-chemical properties of raw carbonaceous materials. The calcined material can be significantly improved in terms of mechanical strength, electrical conductivity, and density. The coke can be enhanced in terms of its degree of graphitization and thermal stability.
It can also serve as a fuel alternative for power plants and cement kilns. The reason for this is that it has a much higher thermal value than lignite and coal. In many cases, its low ash and high carbon contents make it a great substitute for pulverized conventional coal. The hot gases produced by the combustion of petroleum coke in kilns are captured and used to generate energy. The heat generated is used to produce steam and electricity for the calcining procedure.
There are several types of calcination processes used to manufacture calcined petroleum coke. To calcine the coke, most electrolytic anode or commercial prebaked alumina production companies use either rotary kilns of tank calciners. The domestic pot calciner, however, has several advantages over other methods. These include low raw material requirements, stable product quality and low oxidation losses.
The three types of processes for producing coke are: semi-continuous, fluidized beds, and delayed coking. They can be differentiated by temperature, residence time, and pressure. The delayed coking method has multiple coking chambers, while the fluidized bed coke calcination process uses a continuous flow of feedstock. The final product of this process has lower sulfur and metal concentrations than that of the rotary kiln method, but it may also have a smaller production capacity.
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