Green Coke Pelletization for Calcination Dust Reduction
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Solution Overview
Problem
The calcination of green petroleum coke faces challenges such as product dusting issues and inconsistent quality due to high contaminant levels and varying structural properties, which are exacerbated by the increasing demand and diminishing supply of suitable quality green petroleum coke, necessitating additional processing steps to enhance the value and recovery of calcined coke.
Innovation Solution
The method involves combining pelletization, agglomeration, or briquetting technologies with screening and milling/grinding to separate and process green petroleum coke into denser, spherical pellets or briquettes, which are then calcined in shaft or rotary kilns, reducing dusting problems and improving the quality and recovery of calcined coke.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If green petroleum coke is directly calcined without pelletization, then the processing steps are fewer and equipment complexity is lower, but product dusting problems occur and recovery is insufficient
Solution Approach 1:
The patent applies preliminary action by pelletizing green petroleum coke before calcination. The green coke is pelletized into dense spheres with binders (such as coal tar pitch, petroleum pitch, or lignin) to form compact pellets that reduce dusting during subsequent calcination and improve recovery rates. This preliminary formation of dense pellets prevents material loss during the calcination process.
2Productivity
If green petroleum coke with high contaminant levels is used, then the raw material utilization is higher, but calcined coke quality deteriorates
Solution Approach 1:
The patent applies parameter changes by controlling the calcination temperature profile and duration to optimize quality while utilizing lower quality raw materials. The process adjusts temperature parameters (heating rates, peak temperatures, holding times) to facilitate contaminant removal and structural transformation, enabling the production of high-quality calcined coke from green coke with higher contaminant levels such as sulfur, vanadium, and nickel.
Solution Approach 2:
The patent uses binders as intermediary substances during pelletization. Binders such as coal tar pitch, petroleum pitch, or lignin act as mediators that bind fine coke particles together to form dense pellets. These binders not only improve pellet strength but also facilitate uniform heating and contaminant removal during calcination, thereby improving final product quality while allowing broader raw material acceptance.
3Reliability
If pelletization is applied to green petroleum coke, then product dusting is reduced and recovery improves, but additional equipment and processing complexity are required
Solution Approach 1:
The patent applies segmentation by dividing the green petroleum coke into fine particles before pelletization. The green coke is ground or milled to create fine particles that can be effectively pelletized. This segmentation allows for better binder distribution and more uniform pellet formation, resulting in consistent product quality and reduced dusting during calcination while maintaining manageable equipment complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach allows for the use of a broader range of green petroleum coke materials, enhances the quality of calcined coke by producing denser, more consistent products, and significantly improves recovery rates, addressing dusting issues and quality inconsistencies in the calcination process.
Implementation Method 1
the undersized fraction is pelletized with a binder to form pelletized coke or briquetted to form briquettes
Implementation Method 2
which is thereafter calcined in a shaft calciner or a rotary kiln calciner
Data Source
AI summary
A method of calcining green petroleum coke which includes separating the green coke having a particle size of between 0.1 mm and 50 mm into undersized and oversized fractions, pelletizing the undersized fraction with a binder to form pelletized coke, combining the oversized fraction and the pelletized coke to form a feed mixture, and calcining the feed mixture to form calcined coke. The method includes the addition of a pulverization step wherein all the green coke is pulverized before pelletization and the pellets are then calcined to produce a pelletized calcined coke product.