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PetCoke is a carbonaceous solid derived from oil refinery coker units or other cracking processes. Other coke has traditionally been derived from coal.

Petcoke is the coke that, in particular, derives from a final cracking process–a thermo-based chemical engineering process that splits long-chain hydrocarbons of petroleum into shorter chains that takes place in units termed coker units. Other types of coke are derived from coal. Stated succinctly, coke is the "carbonization product of high-boiling hydrocarbon fractions obtained in petroleum processing heavy residues. Petcoke is also produced in the production of synthetic crude oil.

Types of petcoke

There are at least four basic types of petroleum coke, namely, needle coke, honeycomb coke, sponge coke and shot coke. Different types of petroleum coke have different microstructures due to differences in operating variables and nature of feedstock. Significant differences are also to be observed in the properties of the different types of coke, particularly ash and volatile matter contents.

Fuel-grade coke

Fuel-grade coke is classified as either sponge coke or shot coke morphology. While oil refiners have been producing coke for well over 100 years, the mechanisms that cause sponge coke or shot coke to form are not well understood and cannot be accurately predicted. In general, lower temperatures and higher pressures promote sponge coke formation. Additionally, the amount of heptane insolubles present and the fraction of light components in the coker feed contribute

Desulfurization of petcoke

A high sulfur content in petcoke reduces its market value and may prevent its use as fuel due to restrictions on sulfur oxides emissions for environmental reasons. Methods have thus been proposed to reduce or eliminate the sulfur content of petcoke. Most of them involve the desorption of the inorganic sulfur present in the pores or surface of the coke, and the partition and removal of the organic sulfur attached to the aromatic carbon skeleton.

Calcined petroleum coke

Calcined petroleum coke (CPC) is the product from calcined petroleum coke. This coke is the product of the coker unit in a crude oil refinery. The calcined petroleum coke is used to make anodes for the aluminum, steel, and titanium smelting industry. The green coke must have sufficiently low metals content in order to be used as anode material. Green coke with this low metals content is referred to as anode-grade coke. The green coke with too high metals content will not be calcined and is used for burning. This green coke is called fuel-grade coke.
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