Calcined Petroleum Coke (CPC) Production Rate – 24,000 TPA

CALCINED PETROLEUM COKE (CPC) PRODUCTION RATE – 24,000 TPA

[EIRI/EDPR/4742] J.C.: 2962XL

INTRODUCTION

Coke

Coke is a fuel with few impurities and high carbon content, usually made from coal. It is the solid carbonaceous material derived from destructive distillation of low-ash, low-sulphur bituminous coal. Cokes made from coal are grey, hard, and porous. While coke can be formed naturally, the commonly used form is synthetic. The form known as petroleum coke, or pet coke, is derived from oil refinery coker units or other cracking processes.

Coke is used in preparation of producer gas which is a mixture of carbon monoxide (CO) and nitrogen (N2). Producer gas is produced by passing air over red-hot coke. Coke is also used to manufacture water gas.

Petroleum Coke

Petroleum coke (often abbreviated pet coke or petcoke) is a carbonaceous solid delivered from oil refinery coker units or other cracking processes. Coking processes that can be employed for making petcoke include contact coking, fluid coking, flexicoking and delayed coking. Other coke has traditionally been delivered from coal.

This coke can either be fuel grade (high in sulfur and metals) or anode grade (low in sulfur and metals). The raw coke directly out of the coker is often referred to as green coke. In this context, “green” means unprocessed. The further processing of green coke by calcining in a rotary kiln removes residual volatile hydrocarbons from the coke. The calcined petroleum coke can be further processed in an anode baking oven in order to produce anode coke of the desired shape and physical properties. The anodes are mainly used in the aluminium and steel industry.

The Petroleum Coke category consists of two substances; green coke and calcined coke. These two substances are grouped together in a category based on their similarity of manufacturing processes which results in similar physical chemical characteristics and chemical composition. The principal difference is the amount of residual hydrocarbon (also termed volatile matter) in the two products. Petroleum coke (both green and calcined) is a black-colored solid produced by the high-pressure thermal decomposition of heavy (high boiling) petroleum process streams and residues. 

Green coke is the initial product from the cracking and carbonization of the feedstocks to produce a substance with a high carbon-to-hydrogen ratio. Green coke undergoes additional thermal processing to produce calcined coke. The additional processing removes volatile matter and increases the percentage of elemental carbon, which results in a lower potential for toxicity for calcined coke.

The green coke must have sufficiently low metals content in order to be used as anode material. Green coke with these low metals content is referred to as anode grade coke. The green coke with too high metals content will not be calcined and is used for burning. This green coke is called fuel grade coke

Petcoke is over 90 percent carbon and emits 5 to 10 percent more carbon dioxide (CO2) than coal on a per-unit-of-energy basis when it is burned. As petcoke has a higher energy content, petcoke emits between 30 and 80 percent more CO2 than coal per unit of weight. The difference between coal and coke in CO2 production per unit energy produced depends upon the moisture in the coal (increases the CO2 per unit energy — heat of combustion) and volatile hydrocarbon in coal and coke (decrease the CO2 per unit energy).

COST ESTIMATION

Plant Capacity            80 MT/Day

Land & Building (15,470 sq.mt.)    Rs. 15.23 Cr

Plant & Machinery                    Rs. 12.49 Cr

Working Capital for 0.5 Month    Rs. 2.78 Cr

Total Capital Investment          Rs. 31.43 Cr

Rate of Return                          28%

Break Even Point                      70%

CONTENTS

ORGANISATION PROFILE

THE REGISTERED OFFICE OF THE COMPANY IS LOCATED AT

THE DIRECTORS OF THE COMPANY ARE 

THE PROJECT

REASON FOR SELECTION OF THE PROPOSED SITE

INTRODUCTION

COKE

PETROLEUM COKE

CALCINED PETROLEUM COKE

USES & ITS APPLICATIONS

ANODES

FUEL

GRAPHITE ELECTRODES

APPLICATIONS

ALUMINIUM INDUSTRY:

FERRO ALLOYS INDUSTRY:

FERROUS METALLURGY:

PROPERTIES/SPECIFICATIONS

PHYSICAL PROPERTIES

CHEMICAL PROPERTIES

RAW MATERIAL SPECIFICATIONS

RAW PETROLEUM COKE

BIS SPECIFICATION

RAW MATERIAL SUPPLIER

RAW PETROLEUM COKE

HDPE BAGS

MARKET OVERVIEW 

DRIVERS OF THE MARKET

CHALLENGES OF THE MARKET

COVID-19 IMPACT ON THE MARKET

MANUFACTURERS/SUPPLIERS OF CALCINED COKE

INPUT/OUTPUT DATA

COKE CALCINING TECHNOLOGY

ROTARY KILN - BASIC CALCINING PROCESS

HOW IT WORKS

ROTARY KILN

COOLING:

AFTERBURNER:

FLEXIBILITY IN OPERATIONS

PRODUCT STORAGE REQUIREMENTS

LOADING

UNLOADING

DUST AND FIRE PREVENTION

FIRE EXTINGUISHING

EMISSION CONTROL 

WET SCRUBBING SYSTEMS 

SEMI-DRY SCRUBBING SYSTEMS

DRY SCRUBBING SYSTEMS

BAGHOUSE OPERATION

PROCESSING STEPS

STEP-1: RAW MATERIAL SOURCING: 

STEP-2: STORAGE: 

STEP-3: MIXING: 

STEP-4: CALCINATION: 

STEP-5: OPERATION CONTROL AND REVIEW: 

STEP-6: STORAGE OF CPC: 

STEP-7: PACKAGING: 

MANUFACTURING PROCESS

TECHNOLOGICAL DEVICES AND EQUIPMENT:

PROCESS FLOW

FIRE PROTECTION

RAINWATER HARVESTING SYSTEM

ENVIRONMENT MANAGEMENT PLAN

THE AREAS, BROADLY, TO BE ADDRESSED ARE 

PLANT & MACHINERY SUPPLIERS/TURNKEY

COKE CALCINATION PLANT

ROTARY KILN

CRUSHING PLANT

BALL MILL

EOT CRANE

POWER TRANSFORMER

ELECTRICAL PANEL

COOLING TOWER

EFFLUENT TREATMENT PLANT

AIR POLLUTION CONTROL EQUIPMENTS

AIR CONDITIONING EQUIPMENTS

AIR COMPRESSORS

PLATFORM WEIGHING MACHINE

MATERIAL HANDLING EQUIPMENTS

FIRE FIGHTING EQUIPMENTS

JIGS AND FIXTURE

SUBMERSIBLE WATER PUMP

DCS SYSTEM

ENGINEERING DESIGN CONSIDERATIONS

ETP FACILITY

ETP FLOW DIAGRAM (TYPICAL)

STP FLOW DIAGRAM (TYPICAL)

SEWAGE AND WASTE WATER EFFLUENT 

UTILITIES REQUIREMENT (ESTIMATED - MONTH)

WASTE GENERATION & MANAGEMENT/GREEN BELT

GREEN BELT

PLANT & MACHINERY

PRINCIPLES OF PLANT LAYOUT

MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:

PLANT LOCATION FACTORS

PRIMARY FACTORS

RAW-MATERIAL SUPPLY:

MARKETS:

POWER AND FUEL SUPPLY:

WATER SUPPLY:

CLIMATE:

TRANSPORTATION:

WASTE DISPOSAL:

LABOR:

REGULATORY LAWS:

TAXES:

SITE CHARACTERISTICS:

COMMUNITY FACTORS:

FLOOD AND FIRE CONTROL:

HEALTH SAFETY AND ENVIRONMENT

ANTICIPATED ENVIRONMENTAL IMPACTS 

CONSTRUCTION PHASE 

OPERATION PHASE 

HSE REQUIREMENT

SAFETY DATA SHEETS 

ENVIRONMENTAL/SAFETY LIABILITY AND ENVIRONMENT CLEARANCE PROCESS 

ENVIRONMENTAL IMPACT ASSESSMENT - TOR

A) LOCATIONAL DETAILS

B) PROJECT RELATED ACTIVITIES

A) ENVIRONMENTAL BASELINE DATA GENERATION

B) METEOROLOGY

C) AMBIENT ENVIRONMENT

D) NOISE ENVIRONMENT

E) WATER ENVIRONMENT

A) LAND ENVIRONMENT

THE FOLLOWING AREAS WILL BE COVERED PERTAINING TO LAND ENVIRONMENT 

B) SOCIO ECONOMY

C) IDENTIFICATION & QUANTIFICATION OF ENVIRONMENTAL IMPACTS

AIR ENVIRONMENT

NOISE ENVIRONMENT

WATER, LAND, BIOLOGICAL AND SOCIO-ECONOMIC ENVIRONMENTS

WATER ENVIRONMENT

LAND ENVIRONMENT

SOCIO-ECONOMIC ENVIRONMENT

A) FORMULATION OF ENVIRONMENTAL MANAGEMENT PLAN

ENVIRONMENTAL MANAGEMENT PLAN DURING CONSTRUCTION PHASE

ENVIRONMENTAL MANAGEMENT PLANT – OPERATIONAL PHASE

A) DISASTER MANAGEMENT PLAN

B) ENTREPRENEUR SOCIAL COMMITMENT

C) SUMMARY &CONCLUSION

POTENTIAL RISKS

ONSITE EMERGENCY RESPONSE

SOCIO-ECONOMIC BENEFIT

PROPOSED IMPLEMENTATION SCHEDULE

ENGINEERING PACKAGE/DOCUMENTS 

BASIS – PROJECT ECONOMICS

PROJECT FINANCIALS

BASIS & PRESUMPTIONS (FOR PROFITABILITY WORKINGS)

PRELIMINARY LAYOUT

CONCLUSIONS

APPENDIX – A:

01. PLANT ECONOMICS

02. LAND & BUILDING

03. PLANT AND MACHINERY

04. OTHER FIXED ASSESTS

05. FIXED CAPITAL

06. RAW MATERIAL

07. SALARY AND WAGES

08. UTILITIES AND OVERHEADS

09. TOTAL WORKING CAPITAL

10. TOTAL CAPITAL INVESTMENT

11. COST OF PRODUCTION

12. TURN OVER/ANNUM

13. BREAK EVEN POINT

14. RESOURCES FOR FINANCE

15. INSTALMENT PAYABLE IN 5 YEARS

16. DEPRECIATION CHART FOR 5 YEARS

17. PROFIT ANALYSIS FOR 5 YEARS

18. PROJECTED BALANCE SHEET FOR (5 YEARS)