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BCHE317L
DIGITAL ASSIGNMENT 01
GROUP 10
Often crude oil is described to as "a useless combination of precious products," a complicated
hydrocarbon mixture. Petroleum coke, which takes up roughly 5-7 weight percent of each
barrel of oil, is essentially the carbon as in crude charge that is lost during typical refining
procedures. Carefully weighing refinery capabilities and product lines against crude attributes
is necessary. If the plant produces carbon appropriate for anodes, other consequences must be
considered. High-quality coke is produced by using consistently high-quality crudes. To
regulate the quality of the resident (Coker feed), proper distillation in the vacuum unit is
essential. To ensure sufficient hardness of the green coke generated by the Coker, the
quantity of vacuum gas oil sent to the Coker with the vacuum residuum (determined by the
effectiveness of the fractionation in the Vacuum tower itself) must be closely monitored and
controlled. The "optimal" reside yield for a refiner more focused on catalytic units
downstream may not always be the best for the ultimate properties of calcined coke . At
refineries, three distinct coking processes—delayed, hid, and flexi coking—are used to create
petroleum cokes. In forty-nine U.S. plants, the delayed Coker is primarily used for
processing. The other fluid cooker and flexi Coker are used less frequently and to a lesser
extent, respectively. Shot, sponge (occasionally honeycomb), and needle coke are the three
types of coke produced by a delayed coker, according to their molecular and physical
properties. Shot coke, which is almost always marketed as fuel, is made literally by
precipitating asphaltenes and is hard and spherical in shape; As a mixture of shot and needle
cokes, sponge coke is dull and black, with a porous, amorphous structure; needle coke, on the
other hand, is silver-grey, with a crystalline broken needle structure, and is made chemically
by cross-linking of shot and sponge coke. Flexi coke has never been used in the aluminium
smelting process, and the majority of fluid coke does not reach the anode pool. Various
hydrocarbon molecules can be found in crude oil, but there are only small amounts of
inorganic substances or metals. The two elements found in crude oil most frequently are
vanadium and nickel. The majority of the time, these metals is in solution in the oil, and any
leftover fuel oil during the purifying process condenses. Metals in petroleum have been
known to have negative impacts for some time. These metals not only taint the product but
also impair judgement, destroy catalysts, and cause machinery to corrode. In this research,
petroleum residues and heavy metal removal were looked into. Treatment procedures using
physical, chemical, and biological means are among these techniques.
PETROLEUM COKE
DESULPHURIZATION OF PETCOKE
of the organic sulphur affixed to the aromatic carbon skeleton as well as the general
desorption of the inorganic sulphur present in the coke pores or on the coke surface. The
desulphurization methods suggested usually fit into these categories. Petroleum coke is no
longer a by-product of refineries' "bottom-of-the-barrel" activities, .which are primarily
focused on producing other materials. Petcoke has grown in value on its own, and there is a
growing market for premium low-sulfur coke. However, more coke with a high sulphur
content is being created, and methods for reducing or eliminating this content are needed,
especially in light of the tightening regulations on sulphur oxide emissions for environmental
reasons. The desulphurization of petcoke entails the partitioning and removal.
PROCESS
Solvent extraction. - Chemical treatment. - Thermal desulphurization. - Desulphurization in
an oxidizing atmosphere. - Desulphurization in an atmosphere of sulphur-bearing gas. -
Desulphurization in an atmosphere of hydrocarbon gases. - Hydrodesulphurization.
ELECTRODE PRODUCTION
Coke can also be categorised as shot, sponge, or needle coke depending on its physical shape.
Shot coke is a product of high asphaltene precursors and appears as hard cylinders. Needle
coke is made from feedstocks that contain a lot of aromatic hydrocarbons and has the
appearance of silvery-grey brittle needles. Although it appears macroscopically amorphous
and is a drab black colour, sponge coke contains both shot and needle coke structural
elements. The green coke feed is heated to a high enough temperature during the calcining
process to burn any remaining hydrocarbons and force off any remaining moisture (the
combustion of the derived volatile materials generates the heat required for the calcination
process).
ROTARY KLINS
In contrast to tank calciners, which acquire heat indirectly, rotary kilns for Calcining
petroleum coke are heated directly by flame. The raw materials come From the kiln end of
the large kiln when the rotary kiln is being calcined. The raw materials steadily advance
towards the kiln head as the cylinder rotates as a result of the kiln body's tilt.
A high temperature calcination zone that is 5 to 10 metres long is created by spraying gas or
heavy oil into the air that is regulated by the kiln head. The calcination zone has an average
temperature of 1200–1350°C. The raw ingredients must remain in the process for 50 to 60
minutes. The final product is then cooled and recovered by being discharged through the
cooling kiln head. But when the needle coke is calcined, the temperature in the rotary kiln
Increases too quickly, and the calcined needle coke particles are too big to satisfy the
requirements for creating ultra-high-function electrodes.
Rotary kilns are commonly used in the calcination of petroleum coke, a material derived from
oil refining. Calcination is a thermal treatment process that involves heating a material to
high temperatures in the absence of air or oxygen. In the case of petroleum coke, calcination
is used to remove volatile components, such as moisture and hydrocarbons, and to transform
the material into a more stable and useful form.
The rotary kiln is a large, refractory-lined cylindrical vessel that is inclined slightly from the
horizontal and rotates slowly on its axis. The raw petroleum coke is fed into the upper end of
the kiln and is gradually heated as it moves down towards the lower end, where it is
discharged as calcined coke. The kiln is fired with a fuel, such as coal, natural gas, or oil,
which provides the heat necessary to drive the calcination reaction.
The rotary kiln process can be divided into three stages: drying, calcining, and cooling. In the
drying stage, the moisture and volatile components are driven off by the heat of the kiln. The
temperature in this section is typically around 100-200°C. In the calcining stage, the
temperature is increased to around 1200-1400°C, which causes the carbon and other solid
components in the coke to react with oxygen from the air and become oxidized. This reaction
produces heat, which helps to maintain the high temperatures required for calcination.
Finally, in the cooling stage, the calcined coke is cooled down to a safe temperature before
being discharged from the kiln.
The design of rotary kilns for petroleum coke calcination is complex, and many factors must
be considered, including the characteristics of the feed material, the desired product quality,
and the requirements of the downstream processes. The length and diameter of the kiln, the
slope of the kiln, the speed of rotation, and the fuel type and consumption rate are all
important parameters that must be optimized to ensure efficient and effective calcination.
In conclusion, the rotary kiln is a critical component in the calcination of petroleum coke. Its
unique design and operating characteristics enable the efficient removal of volatile
components and the transformation of the material into a more stable and useful form. The
use of rotary kilns for petroleum coke calcination is widespread in the oil refining industry,
and on-going research and development continue to refine and improve this important
process.
SHAFT KLINS
Petroleum coke is a by-product of the refining process of crude oil, and it is widely used as a
fuel and a raw material in various industries. Calcination is a process that involves heating the
petroleum coke to high temperatures to remove impurities and moisture, and to increase its
carbon content. This process is typically carried out in a rotary kiln or a shaft calciner.
A shaft calciner is a type of vertical calciner that is used for the calcination of petroleum
coke. It consists of a vertical cylinder or shaft that is lined with refractory material, and a
burner at the bottom that supplies heat to the calcining process. The coke is fed into the top of
the shaft and gradually moves downward as it is exposed to the high temperatures. The
process is typically carried out in batches, with each batch taking several hours to complete.
The shaft calciner offers several advantages over other types of calciners. One of the main
advantages is its ability to produce high-quality calcined petroleum coke with a low level of
impurities. This is due to the fact that the coke is heated in a relatively small space, which
allows for better control of the temperature and atmosphere. Additionally, the vertical design
of the shaft calciner means that the coke is exposed to the heat for a longer period of time,
which leads to more complete calcination.
Another advantage of the shaft calciner is its energy efficiency. The burner at the bottom of
the shaft is typically fuelled by natural gas or other fossil fuels, which provides a high-energy
input to the calcining process. However, the design of the shaft calciner also allows for the
use of waste heat from other processes, such as the exhaust gases from a cement kiln or a
power plant. This can significantly reduce the energy costs of the calcining process and make
it more environmentally friendly.
In summary, the shaft calciner is a type of vertical calciner that is used for the calcination of
petroleum coke. It offers several advantages over other types of calciners, including high-
quality product, energy efficiency, and the ability to use waste heat from other processes. The
shaft calciner is an important tool in the production of high-quality calcined petroleum coke,
which is widely used as a fuel and a raw material in various industries.
2.1 MATERIALS REQUIRED
S. MATERIALS DESCRIPTION REFERENCES
NO
The process of calcination of petroleum coke typically involves the following steps:
• Preheating: The petroleum coke is typically crushed and screened to remove any oversized
particles or impurities, and then preheated to a temperature of around 800-1000°C in a rotary
kiln.
• Calcination: The preheated petroleum coke is then fed into a kiln, where it is heated to
temperatures of around 1200-1400°C. This high temperature causes the volatile organic
compounds and moisture to evaporate, leaving behind a higher carbon content material.
• Cooling: Once the calcination process is complete, the material is then cooled down to
room temperature before it is either stored or further processed.
• Grinding: The calcined petroleum coke may be further processed by grinding into a fine
powder, which can be used in various industrial applications such as electrodes, anodes, and
carbon raisers.
The calcination process is typically carried out in a rotary kiln, which is a long cylindrical
furnace that rotates on its axis. The kiln may be fuelled by natural gas, coal, or other fuels,
depending on the specific requirements of the process. The length and diameter of the kiln
may vary depending on the amount of material being processed and the desired outcome.
2. Grind the petroleum coke into a fine powder using a pulverizer or mill.
7. Once the calcination process is complete, remove the tray or crucible from
the furnace and allow the petroleum coke to cool.
8. Analyse the calcined petroleum coke for various properties, such as ash
content, sulfur content, and particle size distribution.
9. Store the calcined petroleum coke in a suitable container until it is ready for
use.
3. EXPERIMENTAL TABLE
FLOW CHART
Simplified refinery flow sheet with delayed coker showing relative product values
DIAGRAM
Edwards, L. (2015). The history and future challenges of calcined petroleum coke production and
use in aluminum smelting. Jom, 67(2), 308-321.
Martins, M. A., Oliveira, L. S., & Franca, A. S. (2001). Modeling and simulation of petroleum coke
calcination in rotary kilns. Fuel, 80(11), 1611-1622.
Zheng, B., Liu, Y., Zou, L., & Li, R. (2016). Heat transfer characteristics of calcined petroleum
coke in waste heat recovery process. Mathematical Problems in Engineering, 2016.
Rohani, A., Sharifi, K., & Golpasha, R. (2014). Calcinations of Petroleum coke. In 3rd International
Conference on Chemical, Ecology and Environmental Sciences, Abu Dhabi.
Wikipedia contributors. (2023, January 19). Petroleum coke. In Wikipedia, The Free
Encyclopedia. Retrieved 16:55, March 2, 2023,
from https://en.wikipedia.org/w/index.php?title=Petroleum_coke&oldid=1134529534
https://www.sciencedirect.com/science/article/pii/S0016236101000321
https://doi.org/10.1016/S0016-2361(01)00032-1