petcoke

Petroleum coke, commonly known as petcoke, is a carbon-rich solid material derived from petroleum refining. It is produced in cokers from heavy residual oils and bitumen, through processes such as delayed coking or fluid coking, which thermally crack high-boiling point fractions into lighter hydrocarbons and a solid carbon-rich residue.

Two major grades are widely produced: fuel-grade petcoke, which has higher sulfur and metals content and is used primarily as a fuel in cement kilns, power plants, and some industrial furnaces; and anode-grade petcoke, which is lower in sulfur and tailored for use in aluminum smelting as a feedstock for carbon anodes.

Petroleum coke typically has a high carbon content, often 80-90 percent by weight, with ash and trace metals. Sulfur content varies by feedstock and processing, with fuel-grade petcoke commonly high in sulfur, while anode-grade is selected for lower sulfur. The material is abrasive and coarse, with variable calcination and microstructure affecting reactivity and porosity.

Uses include direct fuel in cement and power generation, as well as a feedstock for carbon anodes in aluminum production. Some specialty grades are used in electrode production, and it can be marketed as a supplementary fuel in cement and other kilns.

Environmental and health considerations center on emissions and dust: burning petcoke releases sulfur dioxide, nitrogen oxides, and fine particulate matter; handling can generate powders that pose respiratory risks. Regulations often restrict sulfur content and require dust control, with transport and storage managed to minimize spills and combustion risks.

Global trade involves bulk shipments by ship, rail, or barge. Major producers include the United States, Canada, Saudi Arabia, India, and China, with prices linked to crude oil refining margins and sulfur content, quoted as dollars per ton with regional differences.