A CRUCIAL BYPRODUCT OF OIL REFINING
Petroleum Coke (PETCOKE), a final carbon-rich solid, is a vital byproduct of oil refining. It undergoes a thermo-based chemical engineering process known as cracking, typically in Coker units, to split long-chain hydrocarbons into shorter chains. Unlike coke derived from coal, PETCOKE plays a pivotal role in various industrial applications due to its unique properties and composition.

PRODUCTION PROCESS AND TYPES
In petroleum Coker units, residual oils from distillation processes are subjected to high temperature and pressure, resulting in the production of PETCOK.

There are at least four basic types of PETCOKE:

NEEDLE COKE
Highly crystalline, needle coke finds applications in electrode production for steel and aluminum industries.

HONEYCOMB COKE
This intermediate coke possesses ellipsoidal pores that are uniformly distributed. It exhibits lower coefficient of thermal expansion and electrical conductivity compared to needle coke.

SPONGE COKE
Classified under fuel-grade coke, sponge coke morphology is influenced by lower temperatures and higher pressures during formation.

SHOT COKE
Another type of fuel-grade coke, shot coke morphology forms under specific operating conditions, with factors like heptane insoluble and light components contributing to its development.

These variations arise from differences in operating variables and feedstock nature, leading to distinct microstructures and properties.

GRADES AND PROCESSING
PETCOKE can be classified as fuel grade or anode grade based on sulfur and metal content. The raw coke, known as green coke, undergoes further processing through calcination to remove volatile hydrocarbons. The resulting calcined petroleum coke is utilized in anode baking ovens to produce anode coke with desired shape and physical properties, primarily for the aluminum and steel industries.

ENIRONMENTAL IMPACT
Despite its industrial significance, Petcoke emits more carbon dioxide (CO2) than coal when burned, posing environmental concerns. Its higher energy content results in increased CO2 emissions per unit of weight compared to coal, influenced by factors such as moisture content and volatile hydrocarbons present.

APPLICATION AND CHALLENGES
Petroleum coke, with its diverse types and applications, remains integral to industrial processes despite environmental considerations, driving innovation and sustainable solutions in its utilization. Technologies like fluidized bed combustion and gasification are employed to address environmental and technical issues associated with Petcoke combustion.

CALCINED PETROLEUM COKE (CPC)
CPC, a product of calcining petroleum coke, serves as a crucial material in various industries, including aluminum, steel, and titanium smelting. Anode-grade CPC requires low metal content for optimal performance, while excess metal content designates fuel-grade coke for furnace use.