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Petroleum coke, abbreviated coke, pet coke or pet coke, is a final carbon-rich solid material that derives from oil refining, and is one type of the group of fuels referred to as cokes. Pet coke is the coke that, in particular, derives from a final cracking process a thermo-based chemical engineering process that splits long chain hydrocarbons of petroleum into shorter chains that takes place in units termed coker units. (Other types of coke are derived from coal.) Stated succinctly, coke is the "carbonization product of high-boiling hydrocarbon fractions obtained in petroleum processing (heavy residues.
In petroleum coker units, residual oils from other distillation processes used in petroleum refining are treated at a high temperature and pressure leaving the pet coke after driving off gases and volatiles, and separating off remaining light and heavy oils. These processes are termed "coking processes", and most typically employ chemical engineering plant operations for the specific process of delayed coking.
This coke can either be fuel grade (high in sulfur and metals) or anode grade (low in sulfur and metals). The raw coke directly out of the coker is often referred to as green coke. In this context, "green" means unprocessed. Pet coke, altered through the process of calcining which it is heated or refined raw coke eliminates much of the component of the resource. Usually pet coke when refined does not release the heavy metals as volatiles or emissions.
There are at least three basic types of petroleum coke: needle coke, sponge coke, and shot coke. Different types of petroleum coke have different microstructures due to differences in operating variables and nature of feedstock. Significant differences are also to be observed in the properties of the different types of coke, particularly ash and volatile matter contents.
There are at least three main types of petroleum coke: needle coke, sponge coke and crushed coke. Different types of petroleum coke have different microstructures due to differences in
operating parameters and nature of raw materials. Significant differences are also observed in the properties of different types of coke, in particular the content of ash and volatile substances.
Needle coke, also called acicular coke, is a highly crystalline petroleum coke used in the production of electrodes for the steel and aluminium industries and is particularly valuable because the electrodes must be replaced regularly. Needle coke is produced exclusively from either fluid catalytic cracking (FCC) decant oil or coal tar pitch.
SPONGE COKE
Sponge coke is a coherent, dull black porous delayed petroleum coke in which the individual spheres are not apparent and the coke has a continuum of structure. Sponge coke may also refer to an intermediate type of coke between this and shot coke. In physical appearance, sponge coke is very porous.
The pet coke formed under normal process and typical residue feed has a sponge structure, hence the name Sponge Coke. Depending on the impurity level, typically metals and Sulfur contents Sponge Coke is used for fuel or other industrial processes.
Is produced in a delayed Coker where residuum such as atmospheric reduced crude or vacuum residue is rapidly heated in a furnace and confined in a reaction zone or coke drum under specific operating temperature and coked drum pressure condition until the feed is converted into gas, oil stream and Pet coke.
Is produced in a delayed Coker where residuum such as atmospheric reduced crude or vacuum residue is rapidly heated in a furnace and confined in a reaction zone or coke drum under specific operating temperature and coked drum pressure condition until the feed is converted into gas, oil stream and Pet coke.
In the delayed coker the feed enters the bottom of the fractionator where it mixes with recycle liquid condensed from the coke drum effluent. It is pumped through the coking heater then to one of two coke drums through a switch valve. It is 480° to 500°C. Cracking and polymerization take place in the coke drum in a nominal 24-hour period. Coking is a batch operation carried out in two coke drums. Coking takes place in one drum in 24 hours while decoking is carried out in the other drum. A complete cycle is 48 hours. Coke is cut from the drum using high pressure water. Large drums are 27' in diameter and 114' flange to flange.
GREEN PETROLEUM COKE
Green petroleum coke is a refined byproduct of petroleum refining and is used as an energy source. It comprises nearly pure carbon, with small amounts of sulfur, metals, and non-volatile organic compounds. And it is commonly used as a fuel in many industries, including cement manufacturing, power plants, and steel production. Its market is expanded globally based on rising demand in the cement, ceramic, and electronic industries. It is insoluble in water, and its quality mainly depends on the quality of crude oil.
The physical properties of green petroleum coke vary depending on the source and grade of the material. But generally, it has a high heating value, low ash content, and low sulfur content. Its high heating value makes it an ideal fuel for applications such as boilers, furnaces, and other energy-intensive processes. Additionally, the low ash and sulfur content allows for its use in manufacturing processes where high quality is necessary.
It is often used as a fuel source but has other applications. In some cases, it can be used as a raw material in producing electrodes and carbon anodes for aluminum smelting. Other uses include sulfuric acid production, manufacturing activated carbon and other industrial chemicals, and the production of graphite electrodes.
Overall, green petroleum coke is a valuable commodity with various uses. Its physical properties, including its high heating value and low ash and sulfur content, make it ideal for multiple industrial applications.
