Use of CPC (Green Petroleum Coke) in Electric Arc Submerged Furnaces (SAF) – Challenges and Practical Solutions
Green petroleum coke is a viable alternative to reduce costs in submerged arc furnaces, but requires specific technical adjustments to maintain productivity and efficiency.
What makes GPC different from other reductants?
Green petroleum coke differs from metallurgical coke and charcoal in two main characteristics:
-
Low reactivity reacts more slowly in the reduction process;
-
High electrical conductivity conducts electrical current more effectively.
These properties, although advantageous in some contexts, can generate negative operational impacts when not controlled.
Main challenges of using GPC in SAF furnaces
The combination of low reactivity and high electrical conductivity tends to cause:
-
Inadequate electrode positioning – electrodes stay closer to the furnace surface, increasing energy loss through the top;
-
Electrode shortening – reduces heat transfer efficiency;
-
Difficulty in electrode penetration – leading to "cooling" of the furnace bottom, compromising productivity.
As a direct consequence, there is a drop in productivity, increased energy consumption, and higher operation and maintenance costs.
Practical solution: particle size adjustment
The main strategy to enable the use of GPC in SAF furnaces is strict particle size control.
While metallurgical coke is typically used in the 6 x 20 mm or 6 x 25 mm range, GPC should be applied in smaller particle sizes, around 6 x 15 mm.
This size reduction increases the available surface area for reaction, which:
-
Enhances GPC reactivity in the furnace;
-
Reduces the risk of unreacted material accumulation;
-
Improves burden distribution;
-
Contributes to operational stability.
Conclusion: is it worth using GPC?
Yes. Green petroleum coke is a technically and economically viable alternativeprovided that its application is preceded by careful planning.
The key to success lies in particle size control (~6 x 15 mm). This adjustment is essential to mitigate operational risks and ensure:
-
Energy efficiency;
-
Final product quality;
-
Production process competitiveness.
By mastering the use of GPC, the producer gains:
-
Flexibility to diversify inputs (metallurgical coke, GPC, and charcoal);
-
Economic gain by choosing the best material according to current market prices.
Enjoyed this content? Contact us by clicking hereSee you next time!
