Download - THE WORLD’S
Oxbow Calcining LLC
THE WORLD’S LEADING SUPPLIER OFCALCINED PETROLEUM COKE (CPC)
GREAT LAKES CARBON LLCINDUSTRIAL PRODUCTS
Oxbow Calcining LLCOxbow Calcining, LLC• Nick Lyons – Project Engineer at Oxbow Midwest Calcining
• Chemical Engineer • University of Illinois at Urbana-Champaign
• Oxbow Corporation - 400 Employees Worldwide• 5 Calcining Plant Locations• 15 Rotary Kilns
• 2.5 Million Metric Ton (MT) Capacity• Products Sold or Used in 28 Countries
• Annual Purchase 3+ Million MT Green Coke• Greater than 35 Refinery Sources• Green Coke from 10 Different Countries
Oxbow Calcining LLCHow Much is 2.5 Million Metric Tons?
• 1 Metric Ton = 2,204 lbs.• 2,500,000 Metric Tons = 5,511,557,000 lbs.• Density of Coke = 125 lbs/ft3
• 5,511,557,000 lbs. ÷ 125 lbs/ft3 = 44,092,456 ft3
In one year, Oxbow can process enough coke to cover a whole football field with a 980’ high pile!
Oxbow Calcining LLCOxbow Midwest Calcining, LLC.
Oxbow Calcining LLCOxbow Calcining Locations
Baton Rouge, Louisiana
Port Arthur, Texas
Enid, OklahomaLa Plata, Argentina
Lemont, Illinois
Oxbow Calcining LLCQuiz # 1 – Your Daily Routine
• In your new Oxbow notebooks, make a list of everyday things that you use.• What bathroom products did you use?• What’s in your lunch?• What do you keep in your backpack? Locker?
• Nick, why are you making me do this??
Oxbow Calcining LLCWhat is Petroleum Coke? A By-Product!
• By-Product from the Refining of Crude Oil (Solid Carbon)
• Produced in a Refinery Coker Unit• Thermal Cracking Process• Uses Heat to Break Apart• Converts Low Value Long-Chain
Hydrocarbons to Valuable Products (Gasoline, Diesel, etc.)
• Petroleum Coke is a By-Product of the Coking Process
• Coke is the Lowest Value Product Produced in a Refinery
Oxbow Calcining LLCTypes of Petroleum Coke
Needle Coke Sponge Coke Shot Coke
Oxbow Calcining LLCRefinery Coking Process
Reaction inside of the Coke Drum takes place at 900oF & 80 PSIA!
Oxbow Calcining LLCHow Is Petroleum Coke Made?
Long Chain Hydrocarbon+
Heat & Pressure
Petroleum Coke(Low Value By-Product)
(Valuable Products)
Oxbow Calcining LLC
Calcined Petroleum Coke
(CPC)
Process Flow
Oil RefineriesRaw
Petroleum Coke (RPC)
Created Process Over 65 Years Ago
Calcining
Oxbow Calcining LLCPetroleum Coke Calcining
• Roasting Petroleum Coke at High Temperatures (2,500 oF)
• Removes Moisture and Remaining Hydrocarbons
• Increases Density, Physical Strength and Electrical Conductivity
• Product is Hard, Dense Carbon – Calcined Petroleum Coke
Oxbow Calcining LLC
• 55 m (180')
1200 -1400 C
500 - 1000 C25 - 400 C
Moisture Release"Heat Up Zone"
Devolatilization"Calcining Zone"
Some Desulfurization& Densification
Burning of C & Gas"Calcined Coke Zone"
Key Control Parameters - Consistent Feed - Feed Sizing - Air Velocity / Draft - Temperature Profiles
Raw CokeFeed
Kiln Exhaust
Natural Gas
Air
Calcined Coke
Rotary Kiln Heating Zones
Oxbow Calcining LLC
PYROSCRUBBER
HOTSTACK
COOLER
KILN
RAW “GREEN” COKE
• GAS LINE
AIR
WATER SPRAY
WATER LINE
• RAW COKE
COKE
Calcining Process
COOLER EXHAUST
CALCINED COKE to Storage/Screening/Shipment Mode
KILN EXHAUST
Oxbow Calcining LLCLemont Plant – Process/Material Flow
Oxbow Calcining LLCGreen Coke vs. Calcined Coke
Calcined Petroleum Coke Composition
Component Range
Moisture 0.0 %
Hydrocarbon 0.2 – 0.5 %
Sulfur 0.5 – 5.0 %
Ash 0.2 – 1.0 %
Carbon 93.5 – 99.1 %
Component Range
Moisture 5.0 – 10.0 %
Hydrocarbon 7.0 – 12.0 %
Sulfur 0.5 – 6.0 %
Ash 0.1 – 1.0 %
Carbon 71.1 – 87.3 %
Green Petroleum Coke Composition
Oxbow Calcining LLCCritical Calcined Coke Properties
• Density• Sulfur• Particle Sizing• Coefficient of Thermal Expansion• Ash (V, Ni, Fe, Si, Na, K, etc.)• CO2 Reactivity
• Air Reactivity
Helium Real Density
(RD)• Fills all pores with He• Density of Coke Particles Only
~2.070 g/cc
Hg Apparent Density (AD)• Fills outer pores & void spaces
between particles with Hg• Density of Coke Particles &
Inner Pores
~1.07 g/cc
Vibrated Bulk Density (VBD)• Density of Coke Particles with
Inner Pores & Void Spaces
~0.86 g/cc
Oxbow Calcining LLCProducts that Require Petroleum Coke
Aluminum
Steel
Pigments
Batteries
Graphite
Chemicals
Oxbow Calcining LLCWorldwide Petroleum Coke Picture
Raw Coke Production91 Million MTons
Fuel Coke(Power & Cement)68 Million MTons
Graphite/Steel1 Million MTons
Calcinable Coke23 Million MTons
Calcined CokeProduction
18 Million MTons
Aluminum14 Million MTons
OtherPigment, Steel, Etc.
3 Million MTons
Oxbow Calcining LLCFlexible Shipping Options
• Ocean-going Vessels
• Barges
• Railcars
• Trucks
Oxbow Calcining LLCSynergistic Relationship with CITGO
Green Petroleum Coke
Water (Boiler / Utility / Potable / Fire)
Air (Instrument / Utility)
Fuel Gas
Steam
Transportation & Barge Loading Services
Waste Water
Oxbow Calcining LLCEnergy, Efficiency, Sustainability
• Our plant produces 1.4 Trillion BTUs/year from calcining pet coke.• By capturing 1,800-2,000 oF waste heat, the steam and power
produced have no associated emissions.• 825,000,000 lb/yr steam to CITGO (450 psig & 460 oF)• 315,000,000 lb/yr steam to CITGO (600 psig & 680 oF)• 0.5 MW power used internally
• This offsets approximately 70 tons/yr NOx and 100,000 tons/yr CO2 emissions that would otherwise be emitted to the atmosphere in supplying this energy.
• Once a waste stream for refinery, pet coke serves as a major component in other industries worldwide.
Oxbow Calcining LLC
Questions & Discussion
Oxbow Calcining, LLC