Petroleum Coke Research Articles

Sensitivity analysis and optimization of the whole process of continuous catalytic reforming for Persian gulf star oil company using an optimized data-driven model with tuned parameters

Abstract This paper applies an existing advanced model to improve key outputs in the continuous catalytic reforming (CCR) process for Persian Gulf Star Oil Company. Using tools like Aspen Custom Modeler and Aspen Plus, we focus on optimizing two main results: Research Octane Number (RON) and yield. A design of experiments was conducted to examine the effects of key input variables, including reactor temperatures and the hydrogen-to-hydrocarbon (H₂/HC) ratio, through 256 simulations. Various data fitting methods, including Response Surface Methodology (RSM), Radial Basis Function Network (RNLOOCV), and Artificial Neural Networks (ANN), were applied to describe process behavior. The Akaike Information Criterion (AIC)-optimized ANN model demonstrated the best performance, offering a balanced approach between accuracy and complexity. A sensitivity analysis revealed that increasing reactor temperatures improves RON but reduces yield due to enhanced cracking reactions. The H₂/HC ratio had a minimal impact on RON and yield, primarily serving to limit catalyst coke formation. Optimization using a genetic algorithm confirmed that optimal RON and yield can be achieved within specific temperature ranges. The results provide insights for enhancing CCR efficiency and refinery profitability.

Photocatalytic Decolorization of Waste Water Using ZnS Catalyst Synthesized from Petroleum Coke

Photocatalytic Decolorization of Waste Water Using ZnS Catalyst Synthesized from Petroleum Coke

Sustainable CO2 Capture: N,S-Codoped Porous Carbons Derived from Petroleum Coke with High Selectivity and Stability.

CO2 capture from the flue gas is a promising approach to mitigate global warming. However, regulating the carbon-based adsorbent in terms of textural and surface modification is still a challenge. To overcome this issue, the present study depicts the development of cost-effective and high-performance CO2 adsorbents derived from petroleum coke, an industrial by-product, using a two-step process involving thiourea modification and KOH activation. A series of N,S-codoped porous carbons was synthesized by varying activation temperatures and KOH quantity. The optimized sample exhibited a high specific surface area of 1088 m2/g, a narrow micropore volume of 0.52 cm3/g, and considerable heteroatom doping (1.57 at.% nitrogen and 0.19 at.% sulfur). The as-prepared adsorbent achieved a CO2 adsorption capacity of 3.69 and 5.08 mmol/g at 1 bar, 25 °C and 0 °C, respectively, along with a CO2/N2 selectivity of 17. Adsorption kinetics showed 90% of equilibrium uptake was achieved within 5 min, while cyclic studies revealed excellent stability with 97% capacity retention after five cycles. Thermodynamic analysis indicated moderate isosteric heat of adsorption (Qst) values ranging from 18 to 47 kJ/mol, ensuring both strong adsorption and efficient desorption. These findings highlight the potential of petroleum coke-derived porous carbons for sustainable and efficient CO2 capture applications.

Facile Surface Chemical Tailoring of Industrial Carbon Waste for Improved Sodium Storage

Sodium‐ion batteries (SIBs) have emerged as promising supplementary for energy storage devices. Among various anode materials, carbon‐based materials have been considered ideal for SIBs due to their excellent electronic conductivity, great mechanical strength, and large surface area. However, the small interlayer distance and slower reaction kinetics significantly limit their practical application in SIBs. The study of carbon materials in SIBs found that heteroatom doping could help enlarge interlayer distance and adsorb more Na+ simultaneously. Hence, petroleum coke (PC), an industrial waste, is chosen as a precursor. A straightforward oxidation and carbonization process is employed to introduce oxygen atoms into the carbon skeleton (OPC). The heteroatom‐doped OPC exhibits a unique microcrystalline structure comprising both graphitic and disordered regions. This structure improves rate performance and enhances initial columbic efficiency (ICE) for sodium storage. Consequently, it can deliver a better cycling capacity of 209 mAh g−1 at 0.1 A g−1 and a high ICE of 51.3% (vs 66.9 mAh g−1 with ICE of PC 12.6%). This study shows that heteroatom doping and microstructural tailoring of materials derived from petroleum coke provide a viable approach for enhancing the electrochemical performance of SIBs, paving the way for sustainable and efficient sodium storage.

Poly-(2-aminothiophenol) Functionalized Petroleum Coke for Fast Simultaneous Sequestration of Cd(II) and Pb(II) Ions from Industrial Effluents

Background: Nowadays, the challenge between clean water production and promoting an eco-friendly sorbent for the simultaneous fast and efficient removal of heavy metal ions is a hot topic and has attracted much attention. Objective: The objective of this study was to fabricate a novel material (PATP@PET) by incorporating poly-(2-amino thiophenol; PATP) into the matrix of Saudi Arabian petroleum coke (PET) for simultaneous fast and efficient removal of heavy metal ions. objective: The fabrication of a novel material (PATP@PET) by incorporating poly-(2-amino thiophenol; PATP) into the matrix of Saudi Arabian petroleum coke (PET) for simultaneous fast and efficient removal of heavy metal ions Method: The FTIR, EDX, SEM, and XRD techniques assessed the chemical structure and surface morphology of the thio-functionalized petcoke. The effects of medium pH, mass dosage of sorbent, metal ion concentration, and coexisting ions were investigated and optimized using batch sorption. Result: The excellent sorption capacity of PATP@PET sorbent towards the divalent lead and cadmium ions (98.44% and 312.5 mg.g-1 for Pb(II) and 90.15% and 217.4 mg.g-1 for Cd(II)) was realized by strong complex formation with the sulfur atoms of green petcoke and the thiol groups of poly-2- aminothiophenol moieties. The adsorption equilibrium data was best fitted to the pseudo-secondorder kinetic model and Langmuir adsorption isotherm. The reusability performance was tested for 10 cycles, and the simultaneous removal of Pb(II) and Cd(II) ions from industrial effluents was accomplished in 30 minutes with 100% removal efficiency at pH 6-7. Conclusion: PTAP-PET also demonstrated amazing performance for Cd(II) and Pb(II) removal in industrial wastewater samples. Subsequently, PTAP-PET contributes to developing fast, efficient, low-cost water remediation solutions for heavy metal ions that can potentially be translated into industrial- scale applications.

Coke deposition mechanisms of propane dehydrogenation on different sites of Al2O3 supported PtSn catalysts

Propane dehydrogenation (PDH) Pt-based catalysts are facing the serious challenge of coke deactivation. The locations would greatly influence the coke formation, while the detailed mechanism is not fully explored. Herein, the coke mechanisms on different locations including Al2O3, Sn, Pt, and Pt-Sn sites were deeply investigated via in situ Fourier transform infrared spectroscopy (FTIR) technology, and the key factors triggering catalyst coke deactivation were proposed. Excessive dehydrogenation of propyl species is a crucial initial step in the formation of coke, whether at metal sites or supports. These propyl species on Al2O3 supports then cyclize to form monocyclic aromatic and bicyclic aromatic species, while those on SnOx sites cyclize to form monocyclic aromatic species. As for the Al2O3 supported PtSn catalysts, the strong dehydrogenation function and the interaction between Pt and Al2O3 supports trigger the complex coke formation mechanism. The surface Pt sites with saturated coordination are prone to coke deposition, leading to rapid deactivation at the initial stage of the reaction. However, the low-coordination Pt sites with ultra-small size are found to be highly resistant to coke formation in the PDH reaction, which selectively catalytic the PDH. Owing to the metal-support interaction, the extensive active hydrogen species generated from Pt can regulate the formation of coke precursors on the Al2O3 supports. Furthermore, the effect of hydrogen co-feed on coke deposition is also explored. The hydrogen co-feed inhibits the coke formation and results in a higher H/C ratio (3.96) for aromatic coke precursors. This study can enhance the understanding of the coke formation in PDH, which is important to designing efficient PDH Pt-based catalysts.

Tin, silver, and copper sulfate compound extraction from lead-free solder dross by reduction with petroleum coke, electrorefining, cementation, and crystallization process

Solder dross, a waste by-product from the electronic component dipping bath, contains significant quantities of valuable metals. This study presents a four-step process for recovering tin, silver, and copper from lead-free Sn-Ag-Cu solder dross. The process involves the initial reduction of the dross using petroleum coke to produce an anode plate, followed by electrorefining to extract tin from the anode plate. Selective leaching of silver and copper from the residual anode slime and cementation techniques are employed to recover silver powder. The rest of the copper solution was used to synthesize copper sulfate crystals. Experimental results demonstrate optimal conditions for the reduction process, resulting in a high tin recovery rate of 92.88%. The electrorefining step yields tin with a purity of 99.94%. Silver and copper are successfully recovered from the anode slime, achieving purities of 99.60% for recovered silver powder and 99.90% for crystallized copper sulfate compounds. This comprehensive study offers insight into the efficient extraction and recovery of tin and other valuable metals from lead-free solder dross.

Surface Oxygen Engineering Catalytic Pore Tailoring of Coal-Based Needle Coke toward Capacitive Porous Carbon.

Coal-based needle coke (CNC) is an ideal carbon precursor for capacitive materials due to its layered graphitic structure and high electrical conductivity. However, the pore-rich engineering and graphitic structural inheriting of CNC-derived carbon during the conventional activation process present challenges. Herein, a surface oxygen engineering catalytic pore tailoring strategy is developed to manipulate the porous structures of CNC-derived porous carbon. This synthesis uses air oxidation to form oxygen-rich microregions on the CNC surface, which can effectively tear the graphite protective shell, accelerate the bonding of KOH with oxygen groups, and catalyze the etching reaction between potassium compounds and carbon atoms. Thanks to the low activation temperature of 600 °C and alkali-to-carbon ratio of 1:1, the obtained porous carbon (PC) inherits the long-range graphitic structure from CNC, and its specific surface areas can be adjusted from 182.6 to 855.4 m2 g-1 by adjusting the oxidation temperature, which is far more than that of PC (7.6 m2 g-1) derived from CNC direct activation. The optimized PC shows a high specific capacitance of 308.3 F g-1 at 0.5 A g-1 and a capacitive retention of 212.2 F g-1 at 20 A g-1 with a capacitive retention of 68.8%. The assembled supercapacitor delivers an energy density of 8.12 Wh kg-1 at a power density of 50.0 W kg-1 and ultralong cycle stability with capacitance retention of 99% and Coulombic efficiency of 100% after 50,000 cycles. This study validates the feasibility of pore tailoring by surface oxygen engineering catalysis in soft carbon for enhancing capacitance.

Impact of micro-cracking and self-healing on electromagnetic interference shielding of ultra-lightweight engineered cementitious composites

The explosion of wireless devices and electronic equipment has escalated electromagnetic pollution, sparking health concerns and demand for building shielding materials. Ultra-lightweight engineered cementitious composites (ULW-ECCs) incorporating carbon fibres (CF) and calcined petroleum coke (CPC) were proposed for electromagnetic interference (EMI) shielding. The effects of microcracking and self-healing, common in real-world applications, on EMI shielding effectiveness (SE) were examined. Two levels of microcracking (low and high) were induced, each followed by a self-healing process in a natural environment. Various lengths and contents of CFs, along with different CPC contents, were tested. Damage evolution throughout the cracking–self-healing cycle was monitored by measuring resonant frequency, while microstructural variations were observed via optical microscopy and SEM-EDS. Results show hybrid CF with polyethylene fibre enhanced cracking resistance but reduced strain-hardening capacity. CF was proved more effective than CPC in enhancing both EMI SE and cracking resistance. EMI SE was influenced by the length and content of conductive filler. Microcracking reduced EMI SE by up to 24.8% at 1.0GHz, depending on severity and conductive fillers. Higher conductivity based on contact conductive pathways enhanced EMI SE but led to greater SE loss after cracking. Self-healing restored EMI SE to its original levels after low-degree cracking and recovered SE to low-cracking levels even after severe damage. The multiple microcracking of ULW-ECCs promotes the nucleation of healing products and crack closure. These findings provide insights into EMI shielding of ULW-ECCs under microcracking and self-healing, highlighting practical applications.

A new soft-hard carbon composite derived from petroleum coke and glucose for high-performance sodium storage

A new soft-hard carbon composite derived from petroleum coke and glucose for high-performance sodium storage

Study on desulfurization and modification of high-sulfur petroleum coke via reduced iron powder catalytic roasting

Sulfur in petroleum coke poses significant environmental risks and damages equipment and carbon products, making its removal essential. This study presents a method for the desulfurization and modification of high-sulfur petroleum coke through catalytic roasting with reduced iron powder. The experimental results indicated that with a petroleum coke particle size of 75–58 μm, an iron powder-to-petroleum coke mass ratio of 50%, and roasting at 1400 °C for 1h, the desulfurization rate reached 87.93%, reducing the sulfur content to 0.91wt%, with a product recovery rate of 80.82%. A series of characterizations of petroleum coke products before and after desulfurization were conducted, revealing that both the desulfurization efficiency and the graphitization performance of petroleum coke were significantly enhanced by the addition of iron powder. Additionally, density functional theory calculations for the pyrolysis of benzothiophene showed that the energy barrier for the pyrolysis process was reduced in the presence of Fe catalysis, theoretically confirming the desulfurization mechanism. The resulting low-sulfur petroleum coke products can serve as raw materials for graphite preparation.

Mechanochemical driven oxidative desulfurization of high-sulfur petroleum coke over [Bpy]PMoVn coupled with amide-based binary deep eutectic solvents

Herein, a novel strategy combining heteropoly acid with deep eutectic solvent was developed to remove the sulfur from HSPC to produce low-sulphur petroleum coke (LSPC) with higher economic value, in which, phosphomolybdenum vanadium pyridine ionic liquid [Bpy]PMoVn (n = 1, 2, 3) and air was used as catalyst and oxidant, and amide-based dibasic deep eutectic solvent (DES) as the extractant and solvent, respectively. The experimental results confirmed that the sulfur content of HSPC can be remarkably decreased from 4.46 wt% to 1.54 wt% under the optimal reaction temperature of 110 °C, reaction time of 8 h, catalyst dosage of 0.20 g, and air flow rate of 100 mL/min, due to the coupling effect between [Bpy]PMoVn and DES. The results of reaction mechanism revealed that peroxyl radicals (O2−) were the key active species in catalyzing the ODS of HSPC in the presence of the [Bpy]PMoV2 catalyst.

Improving the process of calcination of petroleum coke in a tubular rotary kiln using thermal imaging scanning of its body

Improving the process of calcination of petroleum coke in a tubular rotary kiln using thermal imaging scanning of its body

Multifunctional ultra-lightweight engineered cementitious composites (ECC) for electromagnetic interference shielding

This study developed the multifunctional ultra-lightweight engineered cementitious composite (ULW-ECC) by integrating conductive fillers to achieve effective electromagnetic interference (EMI) shielding capabilities, outstanding mechanical properties and thermal insulation. The mechanical performance, electrical conductivity, EMI shielding effectiveness (SE), and microstructure were analysed. Initially, the effects of the carbon fibre (CF) content and the pre-heating temperature of CF on EMI SE of the matrix (named: ULW-CC) without polyethylene (PE) fibre were tested. Then, CFs (0.5 and 1.0 vol%) with seven lengths (1–20 mm) were respectively incorporated into ULW-ECC to study EMI SE. The EMI SE of ULW-ECC incorporating powder calcined petroleum coke (CPC) was compared with that of CF. Experimental results demonstrated that the incorporation of conductive fillers improved the strength, conductivity, and EMI SE. Both the conductivity and EMI SE of ULW-CC and ULW-ECC increased with the dosage of conductive filler. EMI SE was enhanced with increased electrical conductivity, and pre-heating CF at 300 °C further improved the EMI SE. In ULW-ECC, 9-mm CF showed the highest EMI SE and conductivity. The conductivity and EMI SE of ULW-ECC were lower than those of ULW-CC at the same CF dosage due to the negative impact of PE fibre dispersion on the conductive network of CFs. The mixing method of CF in ULW-ECC affected the EMI SE. The EMI SE of ULW-ECC incorporating powder CPC was much lower than that incorporating CF, but hybridization of CPC and CF significantly enhanced EMI SE.

Decoding the acidity effect of Pt‐based dehydrogenation catalysts on their dehydrogenation performance

AbstractPropane dehydrogenation (PDH) has become a significant method for propylene production. However, the systematic effects of catalyst acidity on dehydrogenation performance remain unclear. In this study, Pt‐based dehydrogenation catalysts with different acidities were prepared using n‐nonane modification, and their dehydrogenation performance was evaluated and compared. The synergistic interactions between the catalyst's acidity and its metallic functionality were thoroughly investigated. The results demonstrate that the relationship between the acidity of the PDH catalyst, the selectivity for propylene, and catalyst coke deposition follows a volcano‐shaped curve. An optimal acidity exists that allows Pt‐based dehydrogenation catalysts to achieve efficient performance. Specifically, the desorption of the target product, propylene, necessitates the combined action of acidic and metallic sites. Excessive acidic sites affect the desorption of propylene on acidic sites, while insufficient acidic sites affect the desorption of propylene on metallic sites. This study provides theoretical guidance for the design of PDH catalyst systems.

Preparation of heteroatom-doped hyper-crosslinked polymers via waste utilization of sulfur-containing petroleum coke: A promising adsorbent for CO2 capture

To overcome the worldwide environmental crisis related to the continuous emission of CO2, the use of porous organic polymers, which are excellent absorbents and conversion materials, to reduce CO2 emission is of great significance. Among them, hyper-crosslinked polymers (HCPs) are porous materials with a high pore density that are synthesized using a simple one-pot method that is economical and can realized at a low temperature, hence they have good application prospects as adsorbents for CO2. In this study, a batch of petroleum coke-based HCPs with different sulfur contents was prepared via the one-pot Friedel-Crafts alkylation reaction using inexpensive and abundant petroleum coke as raw material. Thereafter, the use of the prepared materials for CO2 adsorption revealed that the HCPs with a high sulfur content had a larger specific surface area (825 m2/g) and showed a higher CO2 adsorption capacity (2.1603 mmol/g at 1 bar 298 K) than its counterpart with a lower sulfur content. Thus, the presence of sulfur significantly enhanced the CO2 adsorption performance of the material. Further, the simulation of the heat of adsorption of HCPs with and without sulfur using Material Studio also confirmed the higher CO2 capture efficacy of HCPs with a higher sulfur content.

A Green Synthesis of Battery-Level Carbon Anode from PetCoke Carbon Waste

Petroleum coke (PetCoke) is a byproduct of oil refining that is commonly used as a heating resource and contributing to carbon emissions. Additionally, the presence of heavy metals and sulfur in PetCoke has also raised significant environmental concerns. Moreover, traditional high-temperature PetCoke treatment methods exacerbate greenhouse gas emissions. This study introduces an energy-efficient approach for converting PetCoke into carbon anode materials for solid-state batteries. Utilizing a custom-built laser-based vapor deposition setup, comprising a tube furnace and a nanosecond-pulsed infrared laser (1064 nm), we explored the PetCoke transfer process. Subjecting PetCoke to high power density laser irradiation generates localized high temperatures (~3000°C), initiating sample evaporation. By modulating the local conditions within the tube furnace, e.g., temperature, pressure, and argon flow rate, we can precisely control the kinetic gradient between the PetCoke and the plating substrate. This control is crucial for transforming PetCoke into various carbon forms with tailored microstructure and morphology, while selectively removing sulfur and heavy metals due to their differing nucleation rates on copper foil.One outcome of this process is the production of high-purity carbon black (C65) with a specific surface area of 400 m2/g, as verified by Brunauer-Emmett-Teller (BET) analysis. The exceptional surface area of C65 facilitates its use in creating a mixed-ionic-electronic conductor (MIEC) layer within all-solid-state batteries, enhancing lithium plating and stripping efficiency during cycling. Our battery design, incorporating C65/Ag/Solid Electrolyte/NMC811 and electrolyte composite, leverages laser-induced evaporation for C65 deposition on copper foil and employs Li6PS5Cl as the solid electrolyte. The resulting solid-state cell exhibits remarkable electrochemical performance, maintaining operation at an impressive current density of 2.4 mA/cm2 and achieving an average coulombic efficiency of 99.5% over 200 cycles.

Syngas from Reforming Methane and Carbon Dioxide on Ni@M(SiO2 and CeO2).

The accumulation of greenhouse gasses (CH4 and CO2) results in an increase in the temperature of the atmosphere. The conversion of greenhouse gasses into chemicals and fuels with high added value benefits not only the environment but also energy development. A promising and well-studied process is the reforming of methane, where CH4 and CO2 are converted into syngas (CO and H2). However, catalysts hinder the development of the process. In this paper, we investigate the conversion of CH4 and CO2 into syngas using a thermal conversion method. The catalysis performance was evaluated by reforming methane. Ni-based catalysts were prepared by different methods. All prepared catalysts were characterized (XRD, HRTEM et al.), and the process of reforming carbon dioxide-methane was carried out in a fixed bed reactor under atmospheric pressure and a high temperature. Ni(M) @CeO2 is one of the most popular options due to the role of CeO2. The deposition of coke in Ni-based catalysts was investigated.

Optimization of the Carbonization Process for the Preparation of High-Grade Needle Coke Based on the Response Surface Method and Microstructure Analysis.

Refined coal tar pitch (RCTP) with a quinoline insoluble (QI) content less than 0.01% was obtained from Wuhai coal tar pitch (CTP), which was used as a raw material to prepare needle coke by carbonization and calcination experiments. In this work, the effects of carbonization time, carbonization temperature, and carbonization pressure on the optical structure of green coke and the microstructure of needle coke were investigated. Meanwhile, the microstructure changes of products were characterized by polarizing microscopy, XRD analysis, Raman analysis, and SEM. The reliable transfer functions between the green coke mesophase content and the investigated factors, as well as the graphitization degree of needle coke, were established based on the response surface analysis method. Furthermore, we provide an operable window for carbonization temperature, time, and pressure, guaranteeing that the content of the green coke mesophase is greater than 90% and the graphitization degree of needle coke is greater than 80%. It can be found that the carbonization temperature has the most significant effect on the mesophase content and graphitization degree of coke. Prolongation of carbonization time is helpful for mesophase molecules to fully grow up, and the directional arrangement, which results in the structure of the coke, is regular. The appropriate carbonization pressure not only ensures that the carbonization reaction system has a certain viscosity but also provides hydrogen free radicals, which is conducive to the formation of drainage optical structure.

Heat transfer characteristics of petroleum coke particle packed bed: An experimental and CFD simulation study

AbstractDue to the complexity of the internal pore structure of petroleum coke loose particle‐packed beds, measuring their thermal conductivity has always been a challenging problem. This work independently developed an experimental apparatus for testing the thermal conductivity of petroleum coke particle‐packed beds and constructed a forward calculation model for the heat transfer process, which was based on one‐dimensional unsteady heat transfer. Using the Sparse Nonlinear OPTimizer (SNOPT) algorithm, a mathematical relationship between the thermal conductivity λ of the coke bed, temperature T, and equivalent particle diameter dp was established through inverse modeling. Concurrently, a digital model of the petroleum coke particle packed bed was derived utilizing three‐dimensional computed tomography (CT) scanning technology, and a pore‐scale gas–solid radiation heat transfer model was formulated based on CFD simulation technology, thereby further elucidating the heat transfer mechanism within the petroleum coke particle packed bed. The research results indicate that the temperature predicted by the established thermal conductivity model aligns well with experimental data. Further CFD simulation studies demonstrate that a smaller particle size leads to a larger temperature difference between the wall and the center of the packed bed, while a higher gas velocity results in a smaller temperature difference, with a linear correlation observed between these two factors. At high temperatures, thermal radiation between particles in the porous petroleum coke‐packed bed plays a dominant role. The research outcomes can offer significant theoretical support for a profound analysis of the heat transfer behavior of petroleum coke‐packed beds within a vertical shaft calciner.