Petroleum Coke Manufacturing and Markets

Petroleum Coke Manufacturing and Markets

Over the forecast period, the global petroleum coke market is expected to experience exponential demand from the cement and power generation industries. The expansion of the petroleum coke industry is directly related to the growth of the petroleum refining, cement, and power industries.  Growing power and cement industry in emerging economies such as India, China, and Vietnam are anticipated to drive the market over the forecast period. Approval to use petroleum coke in industrial applications by agencies such as EPA and CRS is anticipated to drive the market over the foreseeable future on account of its nontoxic nature.

Petroleum refineries separate useful products such as gasoline, jet fuel, diesel fuel, motor oils, and waxes from crude petroleum, leaving a heavy tar-like residue. This heavy residue can be processed at high temperatures and pressure to crack large molecules into smaller molecules, yielding more product. This process, known as coking, produces petroleum coke, a hard, coal-like substance. It is primarily composed of carbon, with minor amounts of hydrocarbons (oil), sulfur, and trace amounts of metals.

Petroleum coke and calcined coke are included in this category. Petroleum coke, also known as green coke, is primarily used as an industrial fuel. Green coke can be processed further at very high temperatures to produce calcined coke. This calcining process removes almost all of the residual oil, resulting in calcined coke that is mostly pure carbon with trace amounts of sulfur and metals. Because of its lower oil content, calcined coke is a dustier material than green coke. Calcined coke is used to make synthetic graphite and smelting furnace electrodes.

Green Coke has a heavier fraction when compared to gasoline. Due to the lower calorific value of between 7500-8500 Kcal/ Kg, but when compared with coal (Kcal/ 5000 to 6000 Kg), the calorific value higher green coke. Low ash content and high calorific value are some of the eminent characteristics fueling the product demand.

Because coke is primarily composed of carbon, and carbon is an inert substance, the potential for coke to cause acute toxicity (harm from large-scale exposure) is extremely low. As a result, health studies conducted by the petroleum industry have looked for potential chronic toxicity, or harm from repeated exposures to the dust over time. Due to its higher oil content, green coke was used in the majority of these studies; calcined coke would be expected to have a lower hazard because it is almost entirely carbon.

As the petroleum coke is a solid, relatively inert material, there has been little concern about its environmental impact. The typical battery of tests used to assess a chemical’s environmental impact, such as sunlight breakdown, water stability, soil breakdown, and volatility, cannot be performed on petroleum coke. Furthermore, the absence of significant adverse effects in animal studies suggests that the residual oil associated with petroleum coke either does not come off or is present in amounts too small to cause harm. Green coke samples will be tested in aquatic organisms, plants, and earthworms to assess environmental effects.

Calcined Petroleum Coke (CPC) is important industrial commodity linking the oil refining, metallurgical/chemical with solid material industries and an aluminum and titanium dioxide production. The application for Calcined Petroleum Coke (CPC) is used in this following industries:

  • The Aluminum industry

More than 70 percent of all CPC used to produce anodes for the smelting of alumina into aluminum.

  • Titanium Dioxide Industry

Calcined pet coke is used in the production of titanium dioxide (TiO2), a naturally occurring mineral that is used as a pigment for plastics, paints, sunscreen and food coloring. Two significant usefulness of titanium dioxide is as a replacement for lead in paint and as a bleach paper.

  • The Steel Industry

Calcined pet coke as recarburizer in the steel industry recarburizer used to adjust the carbon content.

Pet coke Market size in 2016 was valued over USD 11 billion and the annual capacity is set to exceed 190 thousand metric ton by 2024.

Rapid industrialization along with increasing demand for aluminum smelter anodes for fabrication purpose will drive the pet coke market size. For instance, as per the International Aluminum Institute, China primary aluminum production witnessed an increase from 2,085 thousand metric tons in April 2013 to 2,711 thousand metric tons in July 2015.

Surging investments toward expansion of refining capacities to cater the growing demand for petroleum products will boost the business growth. For instance, in 2019, ExxonMobil announced the expansion of Beaumont, Texas refinery by constructing a new unit to increase crude refining capacity by 250,000 barrels per day. The refinery is anticipated to start operation by 2022. Ongoing investments toward development of key industries including aluminum, cement and steel will drive the product demand over the forecast period.

The adoption of stringent government regulations aimed at reducing the carbon footprint will propel the global pet coke industry forward. The availability of mediocre quality crude, as well as the low economic costs of primary fuel sources, will enhance the business landscape. Furthermore, ongoing initiatives to boost productivity across multiple industries, combined with significant economic transformation as a result of rapid commercialization and industrialization, will have a positive impact on the industry outlook. Pet coke market was valued at 11 million USD in 2016. The worth of pet coke market is expected to reach a valuation of 25 billion USD by 2024.

The New Training course on Petroleum Coke Manufacturing added in PetroKnowledge will introduce to the participants the main process of the petroleum coke production, storage and handling of pet coke, the pet coke usage and application and the environmental and health classification of pet coke. This training course provides both theoretical and practical knowledge and skills.

This training course will highlight:

  • Method of pet coke production, Fuel-grade coke and Calcined petroleum coke.
  • Describe the refinery method of production of the petroleum coke
  • Pet coke properties and end uses
  • Pet coke safety and storage
  • Pet coke industry market analysis

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