Impact of heating rates on the vibrated bulk density of calcined petroleum

coke

Abstract

Calcined petroleum is one of the low and best commodity feedstock for anodes used in aluminum
smelters. In the current market Calcination of petroleum coke in rotary kiln is challenging in terms
of product quality, utilities required and facing environmental norms. Some of the promising ways
to optimize the calcining conditions in rotary kiln are increasing the thermal gradient across the
kiln, decreasing the bed axial velocity and reducing coke profile temperature. Present study
focusses the reduction of heating rate along the axial length of the kiln. It ensures the increase of
vibrated bulk density (VBD) of calcined petroleum coke (CPC). Three different grades of green
petroleum coke (GPC) is used for this study. These samples are categorized based on their volatile
matter (VM) and sulphur content in GPC. Muffle furnace is programmed at different heating rates
to reach calcination temperature. The suitable calcination temperature for GPC was found as
1250oC compared to 1400oC. Sample with moderate level of VM (12.04 wt.%) and Sulphur (3.19
wt.%) found to be suitable feed stock to give a good VBD of CPC. Heating rate of < 15oC/minute
for coke calcination gives an improvement in VBD from 0.85 to 0.877 g/cc. Estimated activation
energy at this heating rate ranges between 139 to 267 kJ/mol at the conversion rate of 40% under
nitrogen atmosphere. Off gas analysis of GPC using FTIR also ensures the gradual release of VM
at slower heating rate. An industrial calcination kiln is simulated using Metsim software reveals
the closer coke heating rate along the kiln length. It is ensured by the shift of exponential heating
rate of coke at the kiln mid zone towards its discharge end. The optimum parameter which controls
these actions are the onboard shell mounted fan flow quantity and reducing the kiln rotational
speed.