Anode coke

Petroleum cokes, on the other hand, represent the second largest source of consumable industrial carbon in the United States. In 1992, about 2 million tons of anode coke and 250,000 tons of needle coke were used in the United States. 

Backfill the soil replaced over the pipe in the trench (general connotation). In cathodic protection, special backfills are packed around the anodes. These backfills are selected to lower circuit resistance of the anode for sacrificial anodes a gypsum/bentonite mixture is used, and for impressed-current anodes, coke breeze. 

The presence of oxygen in a gas mixture containing hydrocarbons prevents the formation of carbon deposits on the anode— coking (see Section... 

The physical and chemical properties of fuel coke, anode coke, and needle coke vary substantially, and determine the end use of the material that can be burned as fuel, calcined for use in the aluminum, chemical, or steel industries, or gasified to produce steam, electricity, or gas feedstocks for the petrochemicals industry. Petroleum coke can be successfully employed for the production of synthesis gas via gasification route. Since the main objective in a coking-based refinery is to maximize liquid product yield, any value added by selling the fuel grade coke is a bonus for the refiners (Jacob, 1971 Dymond, 1991). 

Delayed or retarded coking, which can produce shot coke (a type of fuel coke), sponge coke (used to produce anode coke or as a fuel coke), or needle coke. This process accounts for the majority of the coke produced in the world today. 

Naphthalene, anthracene, carbazole [86-74-8] phenol [108-95-2] and cresyUc acids are found in the tar. Phenol and cresyUc acids are useful as chemical and resin intermediates. The aromatic chemicals are useful in the manufacture of pharmaceuticals, dyes, fragrances, and pesticides. Various grades of pitch are made from residues of tar refining. Coal-tar pitch is used for roofing and road tar, and as a binder mixed with petroleum coke to produce anodes for the aluminum industry. 

Piebaked anodes aie produced by molding petroleum coke and coal tar pitch binder into blocks typically 70 cm x 125 cm x 50 cm, and baking to 1000—1200°C. Petroleum coke is used because of its low impurity (ash) content. The more noble impurities, such as iron and siUcon, deposit in the aluminum whereas less noble ones such as calcium and magnesium, accumulate as fluorides in the bath. Coal-based coke could be used, but extensive and expensive prepurification would be required. Steel stubs seated in the anode using cast iron support the anodes (via anode rods) in the electrolyte and conduct electric current into the anodes (Fig. 3). Electrical resistivity of prebaked anodes ranges from 5-6 Hm anode current density ranges from 0.65 to 1.3 A/crn. ... 

Alternative Processes for Aluminum Production. In spite of its industrial dominance, the HaH-HAroult process has several inherent disadvantages. The most serious is the large capital investment requited resulting from the multiplicity of units (250 —1000 cells in a typical plant), the cost of the Bayer aluniina-puriftcation plant, and the cost of the carbon—anode plant (or paste plant for Soderberg anodes). Additionally, HaH-HAroult cells requite expensive electrical power rather than thermal energy, most producing countries must import alumina or bauxite, and petroleum coke for anodes is in limited supply. 

Property Aluminum anode-grade coke Graphite electrode-grade needle coke... 

Production of one metric ton of molten aluminum requites about 500 kg of anode carbon and 7.5—10 kg of cathode blocks which is the largest industry usage of carbon materials. Aluminum smelters generally have an on-site carbon plant for anode production. Anode technology is focused on taw materials (petroleum coke and coal-tar pitch), processing techniques, and todding practices (74). 

Galvanic anodes must not be backfilled with coke as with impressed current anodes. A strong corrosion cell would arise from the potential difference between the anode and the coke, which would lead to rapid destruction of the anode. In addition, the driving voltage would immediately collapse and finally the protected object would be seriously damaged by corrosion through the formation of a cell between it and the coke. 

Fig. 7-1 Material consumption from impressed current anodes. graphite anode without coke backfill, O graphite anode with coke backfill, FeSi anode without coke backfill, A FeSi anode with coke backfill.

Table 7-2 Composition and properties of solid impressed current anodes (without coke backfill)...

Polymer cable anodes are made of a conducting, stabilized and modified plastic in which graphite is incorporated as the conducting material. A copper cable core serves as the means of current lead. The anode formed by the cable is flexible, mechanically resistant and chemically stable. The cable anodes have an external diameter of 12.7 mm. The cross-section of the internal copper cable is 11.4 mm and its resistance per unit length R is consequently 2 mQ m l The maximum current delivery per meter of cable is about 20 mA for a service life of 10 years. This corresponds to a current density of about 0.7 A m. Using petroleum coke as a backfill material allows a higher current density of up to a factor of four. 

Without coke backfill, the anode reactions proceed according to Eqs. (7-1) and (7-2) with the subsequent reactions (7-3) and (7-4) exclusively at the cable anode. As a result, the graphite is consumed in the course of time and the cable anode resistance becomes high at these points. The process is dependent on the local current density and therefore on the soil resistivity. The life of the cable anode is determined, not by its mechanical stability, but by its electrical effectiveness. 

Where there is available ground and the specific resistivity of soil in the upper layers is low, the anodes are laid horizontally [3]. A trench 0.3 to 0.5 m wide and 1.5 to 1.8 m deep is dug with, for example, an excavator or trench digger (see Fig. 9-2). A layer of coke 0.2-m thick is laid on the bottom of the trench. The impressed current anodes are placed on this and covered with a 0.2-m layer of coke. Finally the trench is filled with the excavated soil. No. IV coke with a particle size of 5 to 15 mm and specific gravity of 0.6 t m" is backfilled at a rate of 50 kg per meter of trench. The anodes are connected in parallel and every three to four anode cables are connected to the anode header cable by a mechanical cable crimp encapsulated in an epoxy splice kit to give an economical service life at high current output. 

Fig. 9-3 Grounding resistance of anodes in a continuous coke bed with a covering of earth t = 1 m and a diameter d = 0.3 m for a specific soil resistivity of p = 10 Q m. Horizontal anodes from Eq. (24-23), see line 9 in Table 24-1 vertical anodes R ...

For installations with continuous coke backfill, the anodes can be installed at double the spacing of the anode bed extension. The lower the ratio p /p (i e., the higher the specific soil resistivity), the further apart the anodes can be placed. 

Fig. 9-4 Effective anode lengthening by coke backfill with Eq. (9-3) with Pc = 1 G m and C = 0.31.

Centering equipment is used to ensure that the impressed current anode is centrally situated in the borehole. The anode with the centering device can be inserted in the borehole by use of, for example, plastic-insulated wire ropes (see Fig. 9-11). After each of the anodes is inserted, the free space is filled with No. IV coke up to the level of the next anode about 50 kg of coke are necessary per meter of anode bed. The wire rope is fixed to a support above the borehole and provides offloading to the anode cable. The anode cables are laid to a junction box so that the... 

The installation costs for a single impressed current anode of high-silicon iron can be taken as Kj = DM 975 (S550). This involves about 5 m of cable trench between anodes so that the costs for horizontal or vertical anodes or for anodes in a common continuous coke bed are almost the same. To calculate the total costs, the annuity factor for a trouble-free service life of 20 years (a = 0.11, given in Fig. 22-2) should be used. For the cost of current, an industrial power tariff of 0.188 DM/kWh should be assumed for t = 8750 hours of use per year, and for the rectifier an efficiency of w = 0.5. The annual basic charge of about DM 152 for 0.5 kW gives about 0.0174 DM/kWh for the calculated hours of use, so that the total current cost comes to... 

The wattage is directly proportional to the grounding resistance of the whole anode bed and therefore to the specific soil resistivity. Equation (9-5) gives the grounding resistance of the anode installation which either consists of n horizontal or vertical single anodes or of anodes with a horizontal continuous coke bed of total length I = ns. The total cost function is given by [1] ... 

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