Description

The present invention relates to an integrated process containing the fol lowing steps (i) py rolysis of hyd rocarbons to carbon and hyd rogen, (iia) removal of at least a part of the pro duced carbon in step (i) and at least partly fu rther processing of said carbon into a carbon containing electrode, (iib) removal of the hydrogen produced in step (i) and at least partly use said hydrogen for providing energy, preferably electric energy or heat, for the electrode production in step (iia). I n addition, the present invention relates to a joint plant containing (a) at least one reactor for a pyrolysis process, (b) at least one reactor for production of electrodes for an aluminu m process, (c) a power plant and/or at least one gas-fired burner and optional ly (d) at least one reactor for the electrolysis for producing alu minu m.

Reduction of C02-emissions is an on-going task for any country in the world. I m portant sou rces of C02 emissions are not only power generation, but also the manufactu re of our everyday consu mer goods; among these the use of energy-intensive materials such as alu minum. Whether beverage cans, packaging, New Year's Eve rockets, toothpaste, car parts, machine parts, airplanes or even food - alu minu m is contained everywhere.

The production of aluminiu m is carried out in electrolytic cel ls or pots (known as Hal l-He- rou lt process) . Electrolysis of AI203 occurs in a molten bath of cryolite (Na3AI F6) layered between the carbon anodes and the molten metal. Aluminiu m ions within AI203 are reduced to form molten alu miniu m. The molten alu miniu m is col lected at the bottom of the cel l.

Smelters have high power demand, the energy costs accou nt for nearly 40% of the total alu minu m cost. Aluminu m oxide is chemical ly very stable and requires a large amou nt of elec trical energy to reduce, also to keep the cryolite molten, heated by electrical heating from resistance across the cel l, which com bined have very high electricity consum ption - on the order of 13-14kWh/kg Al. Energy is also required to preheat the electrodes before putting into service, which is done using electrical resistance or preheating with a gas burner.

Additional ly, inconsistent power disru pts production and constant power is required to keep the process molten, blackouts can cause significant downtime. I n reverse, potline trips may also cause sudden drops in demand from power com panies which the power supplier must be able to cope with.

For this reason, alu minum plants benefit from large scale, and are often located near sou rces of cheap and available electric power or even employ their own power generation plants (captive power plants from nuclear, hydrothermal, or coal) . For exam ple, the new Emirate Aluminu m plant in Al Taweelah has a connected 3000MW natural gas bu rning power plant supplying power for just the smelting operations, and Santiago Hydroelectric project aims to build an alu minu m smelter run directly from its own hyd roelectric power sou rce.

The needed carbon electrodes for the aluminu m production may be Soderberg anodes, a continuous self-baking type, or much more commonly pre-baked, which are made in-house and periodical ly exchanged in the smelting cel ls as they are consumed.

For the production of the prebaked anodes, calcined coke, a byproduct from petrochemical refining (petcoke) is crushed and blended with material from spent electrodes (butts) , mixed with pitch and formed into green anodes, then baked in large gas-fired fu rnaces at 1000-1250C. Reclaimed material from the butts can make u p 15-25% of the total cel l and represents significant cost and waste reduction.

I n the alu minum production from AI203, the carbon anode serves as a reducing agent in the electrolysis process according to the fol lowing scheme, with stoichiometrical ly 334 kg of carbon being required per tonne of raw aluminu m, but actual ly about 400 kgC / tAI are re quired by carbon deposition:

2 AI203 + 3 C - 4 AI + 3 C02

Various reactions in the cel l contribute to the consu mption of the anode carbon. Those that do not resu lt in metal reduction contribute to excess carbon consum ption like airburn (02 + C ® C02, with 02 from ambient air), carboxy attack (C02 t C e CO, with C02 as product of the Aluminiu m-producing redox reaction) and selective oxidation (dusting) . Dusting oc curs as a secondary effect of C02 attack due to reactivity imbalance between the different coke phases al lowing fragments of solid C to fal l out.

I n this process, the carbon impurities, which consist mainly of metal lic trace elements and u p to 3% by weight of su lfu r, resu lt in either faster bu rnu p of the electrodes, contamination of the aluminum or S02 emissions.

The cost of carbon anode accou nts for 15-20% of the total cost of alu minu m electrolysis production. Hence, the quality of the carbon anode is of crucial im portance and significantly influences the energy consu mption and environmental effects of aluminu m electrolysis.

The needed petcoke is pu rchased, usual ly after calcination directly from refineries. Because of the size and high th rough put of anodes and need to recycle a significant fraction of butts, smelters maintain the anode production and baking in-house, with dedicated equipment and cranes etc for moving the large anodes between forming, baking and smelting steps. Keeping the baking in-house also al lows smelters to maintain control of the baking condi tions, which affect cel l performance. The anode production for the aluminum process is described for example in“Anode Manu facture, Raw Materials Formulation and Processing Parameters” by Kristine L. Hulse, R&D Carbon.

The continued increase of the demand for aluminium metal combined with the decrease and fluctuations in the quality of aluminium grade coke with both the density and the purity of the cokes affected makes it more challenging for the anode manufacturing plants to de liver steady quality anodes. The low-quality grade coke has higher reactivity resulting in higher carbon consumption in the smelter.

Approximately 95% of the S02 emissions generated by a smelter can be attributed to sulfur found in the incoming petroleum coke used in anode production. Thus, environmental regu lations are aiming at reducing sulfur emissions, while the coke suppliers are offering higher sulfur material. The low sulfur coke material is becoming less available on the market and the price is steadily increasing. In addition, the sulfur level of many traditional“high sulfur” anode grade green cokes is increasing. Five years ago, a high sulfur anode grade green coke was regarded as one with a sulfur level of 3-4%. Today, a more typical level is 4-6%.

The difference in price between a barrel of low sulfur sweet crude oil and high sulfur sour crude, the“sweet-sour spread”, is causing more refineries to process cheaper, higher sulfur crude oil. These higher sulfur crudes produce cokes with higher sulfur and metal impurity levels (particularly vanadium and nickel). Calciners are using more of these cokes to satisfy the increasing demand from the aluminum industry.

As the aluminum smelters have not changed coke sulfur specifications significantly due to the smelter environmental constraints the high coke sulfur levels must be offset by blending with lower sulfur cokes. As a result, the difference in sulfur level of cokes used in typical anode blends is increasing - where cokes with a sulfur level of 1-2% may be blended with cokes with sulfur levels up to 4-6% to achieve a smelter anode coke specification of 1.0- 3.5%.

With the growth rates projected in primary aluminum production, the industry will have no other choice than using these higher sulfur blend cokes. The sulfur level of high sulfur cokes used in blends is increasing and will likely continue to increase.

Beside the requirements on sulfur, the primary aluminum industry is faced with the task of reducing the C02 emission.

The use of pyrolysis of hydrocarbons to carbon and hydrogen is already disclosed as a pos sibility to obtain hydrogen with less or even without C02 emission; see for example WO 2013/004398. In addition, the pyrolysis is described for example in DE1266273B, US 2002/0007594, WO 2014/090914 and PCT/EP2019/051466. It is described that the pro duced carbon cou ld be used in the alu minu m industry (see EP 18184459.8, filed on J uly 19, 2018) or for power generation (see EP 2987769) and that the hyd rogen cou ld be used in the chemical industry or for any power generation. U p to now, no joint plant concept is dis closed in view of an integrated aluminu m production.

If using the pyrolytic hydrogen in the chemical industry, the hydrogen must be pu rified to >99% and even higher pu rity is required to use in fuel cel l applications. Typical ly, the pyro lytic hydrogen offgas may only contain 30-90% hydrogen with the remainder mostly uncon verted methane. Pu rification cou ld be done by Pressu re Swing Absorption which requires significant construction and operating costs for the pyrolyser.

I n a nutshel l, the u nderlying chal lenges are: (i) ensuring a sufficiently pure carbon sou rce and a stable su pply, (ii) reducing C02 and S02 emissions during electrode production and the aluminu m production process, driven by political incentives for C02 and S02 reduction, (iii) ensu ring a stable, economical supply of electrical energy, especial ly in view of an in creased proportion of regenerative, fluctuating energy sou rces.

The present invention relates to an integrated process containing the fol lowing steps: (i) py rolysis of hyd rocarbons to carbon and hyd rogen, (iia) removal of at least a part of the pro duced carbon in step (i) and at least partly fu rther processing of said carbon into a carbon containing electrode and optional ly using the produced carbon containing electrode for pro ducing alu minu m in step (iii) , (iib) removal of the hyd rogen produced in step (i) and at least partly use said hyd rogen for generation and providing energy, preferably electric energy or heat, for the anode production in step (iia) and/or for the aluminu m production in step (iii).

Preferably, the present invention relates to an integrated process containing the fol lowing steps: (i) pyrolysis of hyd rocarbons to carbon and hyd rogen, (iia) removal of at least a part of the produced carbon in step (i) and at least partly fu rther processing of said carbon into a carbon containing electrode, (iii) use of the electrode produced in step (iia) for producing aluminu m, especial ly in a Hal l-Herou lt-Electrolysis, (iib) removal of the hydrogen produced in step (i) and at least partly use said hydrogen for generation and providing energy, prefer ably electric energy or heat, for the anode production in step (iia) , for the alu minu m produc tion in step (iii) and/or for the pyrolysis process in step (i) .

The main featu res of the underlying invention are that both, the produced carbon and the by-product hydrogen, can be used in the electrode and/or aluminu m production beneficial ly. Thus, the underlying invention is a material and energetic integration of the pyrolysis and the electrode and/or aluminu m production while solving both the S02 and C02 reduction requirements. The pyrolysis of step (i) can be conducted as described in the literatu re and known to the skil led person in the art (see for exam ple Mu radov, Nazim. "Low to near-zero C02 produc tion of hydrogen from fossil fuels: Status and perspectives." I nternational Jou rnal of Hyd ro gen Energy 42.20 (2017) : 14058-14088). Typical ly, gaseous hyd rocarbon compounds are de com posed at tem peratures ranging from 1000 to 2500 K and at pressures ranging from 0,5 - 5000 kPa (abs) . Typical ly, a su bstrate is used; the su bstrate can either be porous or non- porous and can either be a support substrate in the reactor (a pre-installed part) or a gran u lar and powderish material. The latter can either be realized as fixed bed, moving bed, flu idized bed or entrained flow. The pyrolysis is not limited to a specific energy su pply; fossil- fired, electrical ly heated and/or plasma-d riven production reactors are possible.

The su bstrates are advantageously thermal ly stable within the range from 500 to 2000° C, preferably 1000 to 1800° C, further preferably 1300 to 1800° C, more preferably 1500 to 1800° C, especial ly 1600 to 1800° C.

The su bstrates are advantageously electrical ly conductive within the range between 10 S/cm and 10 ⁵ S/cm.

Usefu l thermal ly stable su bstrates advantageously include carbonaceous materials, e.g. coke, silicon carbide and boron carbide. Optional ly, the su bstrates have been coated with catalytic materials. These heat su bstrate materials may have a different expandability com pared with the carbon deposited thereon.

The granu le particles have a regu lar and/or irregular geometric shape. Regular-shaped par ticles are advantageously spherical or cylind rical.

The granu les advantageously have a grain size, i.e. an equivalent diameter determinable by sieving with a particu lar mesh size, of 0.05 to 100 mm, preferably 0.1 to 50 m m, fu rther pref erably 0.2 to 10 m m, especial ly 0.5 to 5 m m.

Also advantageous is the use of carbonaceous material, for exam ple in granular form. A car bonaceous granu lar material in the present invention is u nderstood to mean a material that advantageously consists of solid grains having at least 50% by weight, preferably at least 80% by weight, fu rther preferably at least 90% by weight, of carbon, especial ly at least 90% by weight of carbon.

It is possible to use a multitude of different carbonaceous granular materials in the process of the invention. A granu lar material of this kind may, for example, consist predominantly of charcoal, coke, coke breeze and/or mixtures thereof. I n addition, the carbonaceous granu lar material may com prise 0% to 15% by weight, based on the total mass of the granu lar mate rial, preferably 0% to 5% by weight, of metal, metal oxide and/or ceramic. The word“pyrolytic carbon” covers solid carbon produced from pyrolysis of light hyd rocar bons in absence of oxygen. The preferred pyrolytic carbon for electrodes, preferably anode, is a high density solid elemental carbon produced by deposition on carbon granules. This is preferred to thermal black produced by thermal/plasma processes or nanostructured car bon grown on metal/oxide catalysts.

A wide range of microstructu res, e.g. isotropic, lamel lar, su bstrate-nucleated and a varied content of remaining hydrogen, can occu r in pyrolytic carbons, depending on the deposition conditions (temperatu re, type, concentration and flow rate of the sou rce gas, su rface area of the u nderlying su bstrate, etc.) .

Typical ly, the density of the pyrolytic carbon is in the range of 1.6 to 2.3 g/cc, preferably 1.8 to 2.2 (real density in xylene, ISO 8004) .

Typical ly, the im pu rities of the pyrolytic carbon are: S in the range of 0 to 1%, preferably 0 to 0.5%, more preferable 0 to 0.1%. Fe in the range of 0 to 1000 ppm, preferably 0 to 500 ppm, Ni in the range of 0 to 250 ppm, preferably 0 to 100 ppm, V in the range of 0 to 450 ppm, preferably 0 to 250 ppm, more preferable 0 to 100 ppm. Na in the range of 0 to 200 ppm, preferably 0 to 100 ppm.

Typical ly, the particle size of the pyrolytic carbon after pyrolysis has at least 5 % by weight > 1 mm, preferably 50 % by weight > 0.5mm.

Typical ly, the crystal size (XRD) of the pyrolytic carbon is in the range of 20 to 60 A, prefera bly 30 to 50 A, (XRD, ISO 20203)

Typical ly, the porosity of the pyrolytic carbon granu le is under 15%, preferably < 10%, most preferably below 5% (Hg porosimetry, DI N66133) .

Typical ly, the specific su rface area of the pyrolytic carbon measu red by Hg porosimetry (DI N66133) is in the range of 0.001 to 5 m2/g, preferably 0.01 to 2 m2/g.

I n step (iia) at least a part of the produced pyrolytic carbon in step (i) is removed from the pyrolysis reactor. The removed carbon is at least partly fu rther processed into a carbon con taining electrode, preferably anode. The process of producing an electrode, preferably an odes for the alu minu m production, is wel l known in the art (see for example“Anode Manu factu re, Raw Materials Formu lation and Processing Parameters, Kristine L. Hu lse, R&D Car bon”) . The use of pyrolytic carbon as blend material in anodes is described in the EP patent application EP 18184459.8, filed on J uly 19, 2018.

Typical ly, 35 to 95 weight-% of the total weight of the anode recipe is a blend composition of carbon material, especial ly petroleum cokes, preferably 50 to 80 weight-%. Typical ly, 0 to 40 weight-% of the total weight of the anode recipe are butts and/or scraps, preferably 15 to 30 weight-%. Typically, 5 to 25 weight-% of the total weight of the anode recipe is a binder, preferably 10 to 20 weight-%, even more preferably 13 to 18 weight-%.

Preferably the carbon electrode includes a blend composition comprises a mixture whereas (i) the content of petroleum coke is in the range of 30 to 98 weight-%, more preferably in the range 50 to 95 weight-%, more preferably in the range 70 to 95 weight-%, more prefera bly in the range 85 to 95 weight-%, even more preferably in the range of 90 to 95 weight-% in view of the total weight of the blend composition and (ii) the content of pyrolytic carbon is in the range of 2 to 70 weight-%, more preferably in the range 5 to 50 weight-%, more preferably in the range 5 to 30 weight-%, more preferably in the range 5 to 15 weight-%, even more preferably in the range of 5 to 10 weight-% in view of the total weight of the blend composition.

Preferably, calcined petroleum coke (CPC) is used as petroleum coke (Predel, H. (2000). Petroleum coke. Ullmann's Encyclopedia of Industrial Chemistry). Preferably, the sulfur con tent of the petroleum coke is in the range of 0 to 10 weight-%, more preferably in the range of 0.5 to 8.5 weight-%, more preferably in the range of 1.5 to 7.0 weight% in view of the total weight of the petroleum coke. Petroleum coke is often abbreviated as petcoke.

Preferably, the blend composition contains as least two particle size fractions (i) granular above 0.5 mm and (ii) fines below 0.5 mm. Typically, the granular size fraction ranges from 0.5 to 16 mm, preferably 0.5 to 8 mm. Typically, the fines size fraction ranges from 0.005 to 0.5 mm.

In view of the total pyrolytic carbon: Preferably 30 to 100 weight-% of the total pyrolytic car bon of the blend composition is in the granular fraction, even more preferably 50 to 100 weight-%, more preferably 70 to 100 weight-%, more preferably 90 to 100 weight-%, even more preferably 95 to 100 weight-%, even more preferably all pyrolytic carbon is in the gran ular size fraction.

Preferably 30 to 80 weight-%, more preferably 40 to 70 weight-%, even more preferably 50 to 65 weight-% of the particles have a granular particle size, and 20 to 70 weight-%, more preferably 30 to 60 weight-%, even more preferably 35 to 50 weight-% of the particles have a fine particle size.

The pyrolytic carbon could be added to the petroleum coke either before crushing, screen ing and sizing the fractions or by adding the pyrolytic carbon directly in the already crushed, screened and sized aggregate of petroleum coke. Preferably, the pyrolytic carbon can be added directly into the existing anode raw material streams. d

The blend composition of pyrolytic carbon and petroleu m coke and the butts and/or scraps are preferably preheated, preferably to a tem perature (to melt the binder) of 100 and 175 C, and mixed with binder, typically coal tar pitch, that has preferably also been preheated to melt. The preheated anode recipe is preferably pressed to the final shape, ensu ring the com pacted anode block maintains its structural form. The green compact is preferably su b sequently heated at an elevated tem perature, for exam ple 1000 to 1250 ° C, to form a baked anode before it is suitable for consum ption in the electrolysis cel l.

Preferably, the carbon anode produced according to this invention provides one or more of the fol lowing performance properties, preferably al l mentioned parameters:

The green density is preferably at least as high as 1.50 g/cm3. Established ranges for CPC anodes are 1.54 to 1.66 g/cm3 (ISO 12985-1) .

The baked density is preferably at least as high as 1.50 g/cm3 (ISO 12985-1) . The estab lished ranges for CPC anodes are 1.50 to 1.58 g/cm3 (ISO 12985-1) .

The thermoshock and mechanical resistance is preferably higher than 6 M Pa (ISO 12986-1) , whereas 6 - 11 M Pa are typical for CPC-based anodes.

The com pressive strength is preferably higher than 25 M Pa (ISO 18515).

The electric resistance is preferably below 80 pQm. 55-80 pQm is a typical industry range. The so-cal led air residue after test reaction with air is preferably lower than 85 wt.-%, more preferably 70 wt.-%, in case of air reactivity (70-85 are typical, ISO 12989-1). The so-cal led C02 residue after test reaction with C02 is preferably lower than 95 wt.-%, more preferably 80 wt.-% for the C02 reactivity (where 80-95 are conventional, ISO 12988-1) .

Preferably, 80 to 100 weight-% of the produced carbon in step (i) is fu rther processed into a carbon containing electrode; more preferred 90 to 100 weight-% of the produced carbon in step (i) is fu rther processed into a carbon containing electrode; even more preferred al l of the produced carbon in step (i) is further processed into a carbon containing electrode. The capacity of the pyrolysis reaction can easily be adapted to the carbon demand of the elec trode production.

Additional ly, another part of the removed pyrolytic carbon produced in step (i) cou ld be combusted to heat other parts of the integrated process as gas-fired burners can ru n on carbon dust.

I n addition, another part of the removed pyrolytic carbon cou ld be sold for other applications like the use in steels or for electrode production on another industrial site.

I n step (iii) the electrode, preferably anode, produced in step (iia) is used in an al uminum production, especial ly in a Hal l-Herou lt-Electrolysis. The Hal l-Herou lt-Electrolysis is wel l known in the art (see for exam ple [Grjotheim K, Kvande H, eds. I ntroduction to Alu minium Electrolysis— U nderstanding the Hal I— Herou It Process. 2nd ed. Ddsseldorf, Germany: Alu- miniu m-Verlag; 1993:199-217.]) . I n step (iib) the hyd rogen produced in step (i) is removed from the pyrolysis reactor. At least a part of said hydrogen is used for the generation of energy, preferably for the generation of electric energy or heat both wel l known in the state of the art. The generated energy is pro vided for the electrode production in step (iia) , for the aluminu m production in step (iii) and/or for the pyrolysis process in step (i) .

The regulation whether hyd rogen is used to generate heat or electric power may be su bject to the availability of external regenerative excess electricity capacities (see for example WO 2014/090914) . I n addition, the regu lation whether hydrogen is used to generate heat or electric power depends on the energy portfolio of the smelter, the aluminu m production.

The hyd rogen generated in step (i) can preferably be used as fuel or as a blend to the tradi tional fuel, mainly natu ral gas, for any heating step in the process of aluminu m production, electrode production and/or in the pyrolysis process. Preferably, at least a part of the hy d rogen produced in step (i) is used to enrich natu ral gas in bu rners for heating the electrode production in step (iia) .

Preferably 5 to 50 volume %, even more preferably 10 to 40 %, even more preferably 20 to 30 % of the natu ral gas, used as fuel, can be replaced by the hydrogen produced in step (i).

Preferably up to 30% by volu me of natu ral gas can be replaced with hydrogen produced in step (i) . Typical ly, the existing bu rner does not need to be modified. Hydrogen can improve the combustion and reduce the emissions if blended into existing natural gas bu rners. A re placing of 30% of natu ral gas with hyd rogen in power generators or gas-fired bu rned would al ready cut C02 emissions by up to 18%. Natural gas, en riched with hydrogen, is al ready used in Germany and the Netherlands. Maughan et al. discloses that natu ral gas with 10-20 volu me percent H2 wil l also have lower NOx emissions (Maughan, J.R., J.H. Bowen, D.H. Cooke and J .J. Tuzson, "Reducing Gas Turbine Emissions th rough Hyd rogen-En hanced, Steam-I njected Combustion," Proceedings of ASM E Cogen-Turbo Conference, pp. 381-390, 1994) .

The fuel en riched with hyd rogen is preferably used for the burners in the baking step of the electrode in step (iia) and/or the electrode pre-heating in step (iii) . The modification of ex isting bu rners based on natu ral gas to a fuel based on hyd rogen and/or natu ral gas is known in the art.

Alternatively, a part of the hyd rogen produced in step (i) is used to heat the pyrolysis; either as fuel for a bu rner or via generating electricity.

Alternatively, a part of the hydrogen produced in step (i) is used for generating electricity to heat smelting cel ls of the alu minu m production (iii) . I n addition, a part of the hydrogen produced in step (i) is used for generating electricity to heat the baking step of the electrode in step (iia) . The com mon known facilities for pre heating and baking the electrode can easily be adapted to be heated by electricity.

The hyd rogen produced in step (i), that means the pyrolytic hydrogen offgas, contains about 30 to 90 vol ume% hyd rogen and the remainder mostly u nconverted methane. If this pyrolytic hyd rogen offgas is used to blend natu ral gas in a burner system, such as for power genera tion or in gas-fired bu rners, it wou ld not be required to remove the excess methane from the hyd rogen and stil l provides the benefits to C02 reduction of hydrogen-enriched natu ral gas.

Preferably, the hyd rogen produced in step (i) is used to blend natu ral gas in a bu rner sys tem without any pu rification.

I n addition, part of the hyd rogen produced in step (i) cou ld be exported, for example to a neigh boring industrial plant or site like a site manufacturing iron, especial ly for the direct reduction of iron ore, or for other chemical processes needing hydrogen as a reducing agent.

I n addition, part of the hyd rogen produced in step (i) cou ld be fed into the national gas grid.

The th ree plants can be easily connected by a skil led person in the art. Preferably, the pyro lytic carbon can be added directly into the existing electrode, preferably anode, raw material streams. Preferably the hydrogen produced in step (i) can be easily blended with the natu ral gas lines.

I n addition, the present invention relates to a joint plant containing (a) a reactor for a pyrol ysis process, (b) a reactor for production of electrodes, preferably anodes, for an aluminum process, (c) a power plant and/or at least one gas-fired bu rner and optional ly (d) a reactor for the electrolysis for producing alu minu m.

Preferably, a power plant is integrated in the joint plant. The power plant for electricity gen eration is preferably a gas tu rbine, a boiler or a hyd rogen fuel cel l. The tu rbine and/or boiler can preferably be used without any treatment and/or separation of the feed gas.

The benefit of the joint plan stil l exists if the plants are located in a radius about 50 to 100 km.

Advantage:

An advantage of this process is that methane (natu ral gas) is a carbon sou rce that can more easily be transported than petcoke. Natu re gas can be transported by pipeline, readily avail able in locations where petcoke may not be. Petcoke is supplied primarily from refineries and shipped by boats to smelters located near cheap electric power such as from hydroe lectricity that may not be near sea ports.

An additional advantage is that the pyrolysis coke is very clean and that the integrated py rolysis process results in a constant carbon supply. The carbon does not suffer from fluctu ations in cost, pu rity and properties which are experienced in the petcoke market. This sta bility has significant operational benefit for smelters.

I n addition, smelters produce a lot of C02 by their process and wil l benefit from reducing emissions, H2 could be used for the baking instead of traditional gas-fired burners. Hyd ro gen cou ld also be used for C02-free power generation.

For exam ple, Australia gives smelters cheaper power if they’re using higher % renewables energy („Energy efficiency best practice in the Australian aluminu m industry“, Department of I ndustry, Science and Resou rces - Australian Government. Ju ly 2000) .

As smelters al ready blend in a portion of butts, smelters are al ready able to handle mixed streams, internal and external carbon supply.

I n addition, when generating H2 from pyrolysis, the hydrogen must be pu rified to >99 vol- u me% for use in chemical processes, and even higher purity is required to use in fuel cel l applications. Typical ly, the offgas may on ly be 30-90% hyd rogen with the remainder mostly u nconverted methane. Pu rification is done typical ly by Pressu re Swing Absorption which re quires significant construction and operating costs for the pyrolyser. I nstead, using the off gas from pyrolysis blended into natu ral gas in a bu rner system, such as for power genera tion or in gas-fired bu rners, would not require removal of excess methane from the hydro gen and stil l provides the benefits to C02 reduction of Hyd rogen-enriched natu ral gas.

I n su m mary, the present inventions offers the fol lowing economic and technological ad vantages: (i) integrated production and use of pyrolysis carbon for electrode production with potential ly advantageous properties in aluminu m production, e.g. lower electricity and car bon consu mption and a reduction in C02 and S02 emissions; (ii) lower petroleu m coke re quirement and increased tolerance of lower grade petcoke; (iii) integrated su pply and use of electrical energy and thus reduction of electricity costs; (iv) integrated use of hyd rogen by firing and thus reduction of methane / natu ral gas combustion and C02 emissions; (v) no third party, e.g. customers for co-products such as synthesis gas, required.

I n view of (v), the integration within the joint plant is completed and no additional cou pling or decou pling of material and energy flows is required. That means, that the integration of a pyrolysis in the electrode production is not dependent on the demand of any co-product streams by third parties.

Figu re 1 shows the sketch of the joint plant: [1] is the anode baking step, [2] is the Hal l-Herout smelting process, [3] is the com bined methane pyrolysis and power generation plant, [4] is the methane pyrolysis reactor, [5] is the offgas from power tu rbine, [6] is a combined cycle natural gas/H2 tu rbine, [7-11] are the steps in anode manufactu re/baking where [7] is heating, [8] mixing, [9] forming, [10] green anodes, [11] the anode baking step. [12] is the natu ral gas from grid for the anode baking step and [13] the natural gas to the pyrolysis reactor. Pyrolitic carbon from the reac tor [14] com bines with [15] fresh petcoke from refineries and [16] recycled electrode butts.

[17] is pitch. [18] is the C02 and emissions from anode baking step and [19] is the com bined emissions including C02/S02 from electrolysis. [20] H2-rich product gas from pyroly- sis reactor which [21] is added to the natu ral gas to anode baking [12] and the remainder [22] used to generate electrical power. [23] is electrical power used in the pyrolysis and [24] is electrical power to the smelter. [25] is the com bined grid and captive generated elec tricity and [26] is power used in anode manufactu re and baking.

Examples Exam ple 1:

An alu minum smelter which historical ly averages 1.36 kWh/kg Al product on the anode bak ing step, supplied by direct combustion of natural gas, replaces 50% of its anode carbon with pyrolytic carbon. This gives direct reduction of 50% of the sulfu r emissions from the smelting step. The methane pyrolysis produces an additional 0.07 kg of H2 and requires 0.88 kWh energy to perform the pyrolysis per kg of final Al production. Direct combustion of the Hyd rogen byproduct is used to heat the pyrolysis step. Because the byproduct gasses with the hydrogen wil l be mostly methane, pu rification is not required if the hyd rogen is used in com bustion burners. The residual H2 after heating the pyrolysis reactor is used to heat the anode baking step, com pletely displacing the natural gas demand in baking and re su lting in net reduction of 500kg CDE (Carbon dioxide emissions) per metric ton of Al. The remaining excess 0.12 N m3 of H2 per kg of Al and can sold or flared or used elsewhere in the system.

Exam ple 2:

As in Exam ple 1, an alu minu m smelter which historical ly averages 1.36 kWh/kg Al product on the anode baking step, supplied by direct com bustion of natu ral gas, replaces 50% of its anode carbon with pyrolytic carbon. This gives direct reduction of 50% of the sulfu r emis sions from the smelting step. The methane pyrolysis produces an additional 0.07 kg of H2 and requires 0.88 kWh energy to perform the pyrolysis per kg of final Al production. Direct com bustion of the Hydrogen byproduct is used to heat the pyrolysis step, and residual H2 is blended with natu ral gas for direct use in existing combined cycle power generation tu r bines. The resu ltant power is used to provide electrical power to the smelters. The total generated pyrolysis hyd rogen displaces 15% by volu me of the total natu ral gas. Hydrogen enrich ment to 30% can be used with little or no modification to existing burners. This resu lts in a direct reduction of 350kg/ metric ton Al CDE (C02 emissions) .

Exam ple 3:

As in Exam ple 2, an alu minum smelter which historical ly averages 1.36 kWh/kg Al product on the anode baking step, su pplied by direct com bustion of natu ral gas, replaces 50% of its anode carbon with pyrolytic carbon. This gives direct reduction of 50% of the sulfu r emis sions from the smelting step. The methane pyrolysis produces an additional 0.07 kg of H2 and requires 0.88 kWh energy to perform the pyrolysis per kg of final Al production. The Hy d rogen byproduct is blended with natu ral gas for direct use in existing com bined cycle power generation tu rbines. The resu ltant power is used to provide electrical power to the pyrolysis reactor and the smelters. The total generated pyrolysis hyd rogen displaces 20% by volu me of the total natu ral gas. This results in a direct reduction of 170kg/ metric ton Al CDE (C02 emissions) .