Simulation of the Coke Calcining Processes in Rotary Kilns

The objective of this study is to simulate the green petroleum coke calcining processes using the simulation program HYSYS and using actual industrial data. Because counter-current mass flow is not allowed in the HYSYS program, the kiln was described by using fictive streams and unit operations. By the simulation, it is possible to predict the operating conditions that control the contents of undesirable impurities in the calcined petroleum coke, namely, sulfur, volatile matter and moisture contents. It also gives the desirable calcined petroleum coke properties such as density. Apart from the metal contents, the simulation allows the coke calciner to utilize any type of green coke regardless of the undesirable impurities. This is done without resorting to the costly blend from different types of green cokes. Simulation is also effective in controlling and optimizing calcination processes' variables. From the simulation it was found that it is possible to process any type of green coke for varying sulfur, volatile matter and water content by adjusting the amount of tertiary air and/or fuel. Two simulation cases were studied for low and high volatile matter contents of 8.5 and 14.7 wt% in the feed. Mass flow rates of fuel and tertiary air were both increased in the first case, while no fuel was required in the second case. The benefit from this is to reduce the operating costs.