Patel Corporation

Graphitized Petroleum Coke (GPC) is a high-quality carbon material produced by heating petroleum coke to high temperatures (>2500°C) in the absence of oxygen. This process, called graphitization, results in the formation of graphite crystals within the coke structure, transforming it into a highly ordered carbon material with excellent properties. Here's a detailed description of Graphitized Petroleum Coke:

Composition:

• Carbon Content: Graphitized Petroleum Coke typically contains over 98% carbon by weight, with low levels of impurities such as sulfur, nitrogen, and ash. The high carbon content makes GPC an excellent carbon additive for various industrial applications.
• Graphitic Structure: Through the graphitization process, the carbon atoms in petroleum coke rearrange into a highly ordered graphitic structure, characterized by hexagonal lattice arrangements of carbon atoms. This structure imparts unique properties to GPC, including high thermal conductivity, electrical conductivity, and mechanical strength.

Properties:

• High Thermal Conductivity: Graphitized Petroleum Coke exhibits high thermal conductivity due to its graphitic structure, making it an excellent heat transfer medium in applications such as steelmaking and aluminum smelting.
• Low Electrical Resistivity: GPC has low electrical resistivity, making it suitable for use as a carbon electrode in electric arc furnaces and other electrical applications requiring high conductivity.
• High Mechanical Strength: The graphitic structure of GPC provides excellent mechanical strength and stability, enabling it to withstand mechanical stresses and abrasion in harsh industrial environments.
• Chemical Stability: Graphitized Petroleum Coke is chemically stable and resistant to oxidation, corrosion, and chemical attack, even at high temperatures. This property ensures long-term durability and performance in demanding applications.
• Low Volatile Content: GPC typically has low volatile content, reducing emissions and environmental impact during processing and use.
• Consistent Particle Size: GPC is available in various particle sizes, ranging from fine powder to granules, allowing for precise control over its application and performance characteristics.

Applications:

• Steelmaking: Graphitized Petroleum Coke is used as a carbon additive in the production of steel and iron alloys to improve carbon content, enhance melt fluidity, and reduce sulfur and nitrogen impurities. It is commonly added to the molten metal in electric arc furnaces and ladle furnaces.
• Aluminum Smelting: GPC serves as a carbon electrode material in the production of aluminum through the Hall-Héroult process. It provides electrical conductivity and facilitates the reduction of alumina to aluminum metal in electrolytic cells.
• Foundry and Casting: GPC is used as a recarburizer in foundry and casting applications to adjust carbon content and improve the quality of castings by reducing defects such as porosity and shrinkage.
• Friction Materials: GPC is employed in the production of friction materials such as brake pads and clutch linings due to its high thermal conductivity, low coefficient of friction, and wear resistance.
• Graphite Products: GPC serves as a precursor material for the production of various graphite products, including graphite electrodes, graphite crucibles, and graphite lubricants.

Calcined Petroleum Coke (CPC) is a critical carbon material used in foundry and steelmaking applications due to its high carbon content, low impurities, and excellent performance characteristics. Here's how Calcined Petroleum Coke is utilized in foundries and steel plants:

1. Carbon Additive in Steelmaking: In steelmaking processes such as electric arc furnaces (EAF) and basic oxygen furnaces (BOF), Calcined Petroleum Coke is added to the molten metal as a carbonaceous additive. It serves several purposes:

   • Carbon Content Adjustment: CPC increases the carbon content of the molten metal to achieve the desired composition for the steel grade being produced.
   • Deoxidation: CPC aids in the removal of oxygen and other impurities from the molten metal, improving steel quality and cleanliness.
   • Temperature Control: CPC helps regulate the temperature of the molten metal, promoting uniform heating and facilitating the refining process.

2. Reinforcement in Foundry Casting: In foundry casting processes, Calcined Petroleum Coke is used as a carbon additive in molding sand mixtures. It serves various functions:

   • Enhanced Carbon Content: CPC increases the carbon content of the molding sand, improving its ability to absorb heat and reduce the risk of defects such as gas porosity.
   • Improved Surface Finish: The addition of CPC can enhance the surface finish of castings, reducing surface roughness and improving dimensional accuracy.
   • Reduced Metal Penetration: CPC helps prevent excessive penetration of molten metal into the mold cavity, reducing the risk of defects such as sand burn-in and metal penetration.

Carbon raiser, also known as carbon additive or recarburizer, is a material used in foundry and metallurgical processes to increase the carbon content of molten metal, particularly in steelmaking. It is primarily composed of carbonaceous materials such as petroleum coke, coal tar pitch, anthracite coal, or graphite. Here's an overview of carbon raiser and its role in foundry applications:

1. Composition:

   • Carbonaceous Materials: The main component of carbon raiser is carbon, typically derived from petroleum coke, coal tar pitch, anthracite coal, or graphite. These materials provide the carbon content necessary for adjusting the composition of the molten metal.
   • Volatile Matter: Carbon raiser may contain volatile matter, such as hydrogen, oxygen, and sulfur, which can affect the reactivity and combustion characteristics of the material.
   • Ash Content: Depending on the source of carbonaceous materials, carbon raiser may contain varying amounts of ash, minerals, and impurities. Low ash content is desirable to minimize slag formation and impurities in the molten metal.

2. Function:

   • Carbon Adjustment: Carbon raiser is added to the molten metal to adjust its carbon content to the desired level. Controlling the carbon content is essential for achieving the desired mechanical properties, such as hardness, strength, and ductility, in the final castings.
   • Deoxidation: Carbon raiser helps deoxidize the molten metal by reacting with oxygen and other impurities present in the metal, forming stable oxides that can be removed as slag.
   • Graphitization: In cast iron production, carbon raiser promotes the formation of graphite in the metal matrix, improving its machinability, thermal conductivity, and damping properties.
   • Reducing Agent: Carbon raiser acts as a reducing agent in metallurgical processes, facilitating the removal of oxygen and sulfur from the molten metal and reducing the risk of defects such as porosity and inclusions in the final castings.

3. Types:

   • Graphite: Graphite-based carbon raisers are preferred for their high carbon content, low ash content, and consistent performance. They are particularly suitable for applications requiring high-quality carbon additives.
   • Petroleum Coke: Petroleum coke-based carbon raisers are widely used in steelmaking and foundry applications due to their availability, cost-effectiveness, and acceptable performance characteristics.
   • Coal-Based: Coal-based carbon raisers, such as anthracite coal or metallurgical coal, are also used in certain applications, although they may have higher ash content and lower carbon purity compared to graphite or petroleum coke.

4. Application:

   • Steelmaking: Carbon raiser is added to the molten metal in steelmaking processes, such as electric arc furnaces (EAF) or basic oxygen furnaces (BOF), to adjust the carbon content and improve the quality of the steel.
   • Cast Iron Production: In foundries producing cast iron, carbon raiser is used to enhance the carbon content of the molten metal and promote the formation of graphite, resulting in improved mechanical properties and machinability.
   • Alloy Production: Carbon raiser may be added to alloying processes to modify the composition and properties of metal alloys, such as nodularizing agents in ductile iron production or inoculants in aluminum alloy castings