Coking processes costs

Coking processes have the virtue of eliminating the residue fraction of the feed, at the cost of forming a solid carbonaceous product. The yield of coke in a given coking process tends to be proportional to the carbon residue content of the feed (measured as the Conradson carbon residue see Chapter 2). The data (Table 7-11) illustrate how the yield of coke from delayed and fluid coking varies with Conradson carbon residue of the feed. 

It cannot be denied that the processing cost of the NSC system is a little higher, because of its need for coke and limestone. Despite that, the pyrolysis and melting system is economical when advantages (2) and (3) are desired or when underirable combustible refuse have to be processed. 

Coal-coking process cuts costs and emissions ... 

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. 

Processes for hydrogen gasification, hydrogen pyrolysis, or coking of coal usually produce Hquid co-products. The Hygas process produces about 6% Hquids as benzene, toluene, and xylene. Substitution of petroleum residuum for the coal-derived process oil has been used in studies of coal Hquefaction and offers promise as a lower cost technology (104). 

The fluohmic process is a third process for manufacturing hydrogen cyanide, which is being appHed in Spain and AustraUa. This process involves the reaction of ammonia with a hydrocarbon, usually propane or butane, in a fluidized bed of coke particles. The endothermic heat of reaction is suppHed electrically through electrodes immersed in the fluid bed. Yields from propane and ammonia are reportedly above 85% and the waste gas is essentially hydrogen, but the costs for electricity are high. Thus this process is appHcable only when there is an inexpensive source of power. 

These three steps all produce significant amounts of waste. First, as discussed earlier, the nitration process results in the production of spent sulfuric acid. In the past the company had been able to sell much of this material to the coke and steel industries but declining demand meant that the acid now required disposing of, at additional cost. At the time green catalytic nitration technology was becoming available with clay, zeolite and lanthanide catalysts all providing possible alternatives to the use of sulfuric acid (see below). Improved selectivity to the desired para-isomer is an added benefit of some of these catalytic systems. However on the... 

Produces strong, blocky coke having good reactivity. Involves low capital and running costs. Production process delinks with availability of markets for byproducts. Allows shut down without any detrimental effects to refractory. Produces hard coke for foundry. The process is characterized by simplicity. There involves no requirements of extra fuel for heating as in by-product oven practice. 

The ODH of ethylbenzene to styrene is a highly promising alternative to the industrial process of non-oxidative dehydrogenation (DH). The main advantages are lower reaction temperatures of only 300 500 °C and the absence of a thermodynamic equilibrium. Coke formation is effectively reduced by working in an oxidative atmosphere, thus the presence of excess steam, which is the most expensive factor in industrial styrene synthesis, can be avoided. However, this process is still not commercialized so far due to insufficient styrene yields on the cost of unwanted hydrocarbon combustion to CO and C02, as well as the formation of styrene oxide, which is difficult to remove from the raw product. 

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