Detailed Project Report on calcined petroleum coke (cp coke) 50,000 tons/annum

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CALCINED PETROLEUM COKE (CP COKE) [3619]

We need to well note the fact that Calcined Petroleum Coke is a very important ingredient in aluminium production. It is produced by placing premium quality “green” petroleum coke and heating it to 1200-1350 degree celsius temperature in rotary kilns. It needs to be understood well that high temperature is required to eradicate excess of moisture and extract all hydrocarbons. This in turn modifies the crystalline structure of coke leading to a denser product. The coke that is produced is then handled safely and transported via trucks in shipping containers as well as railcars.

As far as structure is concerned, the calcined petroleum coke is known to have a sponge like structure which assists in the making of anodes. The binding material is known to penetrate through the coke particles forming a solid carbon block. At the moment, there is no viable substitute for calcined petroleum coke in utilization of aluminium smelter snodes as well as for fabrication.

The majority of calcined petroleum coke that is produced is used in the aluminium industry as well as in the steel industry. It is also used in the production of titanium oxide used as a pigment in sunscreens, paints, plastics, food coloring and various other agents. It needs to be understood well that calcined petroleum coke is used for production of carbon anodes in the aluminium smelting process as it has relatively low cost, low impurity levels and is readily available. The world has plentiful supply of green petroleum coke, but the next wave of aluminium smelting capacity growth puts much pressure on the supply of higher quality cokes traditionally favoured.

Calcined petroleum coke is being used since more than 120 years in the production of carbon anodes (which are mainly used in aluminium electrolysis process). When this coke is used, it is made sure that the right combination of impurity levels, cost and availability is checked. It is important to be regularly updated with the pricing of aluminium and coal markets to understand the supply side disruptions as well as the refinery production cuts. Research indicates that the green coke supply is running tighter as oil refineries reduce run rates due to consumption of jet fuel as well as gasoline amidst the COVID-19 pandemic.

The calcined petroleum coke is used well in the making of anodes for titanium, steel and aluminium industry. The green coke must have low metal content to be used as anode material. The green coke that has low metal content is also called the anode-grade coke. The calcined petroleum coke is made in 3 steps – which include – drying, devolatization and densification. To obtain the calcined form of coke, it is important that the coke is subjected to high temperatures of 1150-1350 degree celsius to achieve high conductivity and density. This type of coke is a very essential and valuable commercial product that has wide applications including aluminium manufacturing, fuels and various other products such as glass, steel, paint as well as fertilizers – and thus depicts commercial value.

COST ESTIMATION

Plant Capacity                           167 Ton/Day
Land & Building (35000 sq.mt)     Rs. 24.63 Cr
Plant & Machinery                    Rs. 7.23 Cr
Working Capital for 2 Months   Rs. 17.93 Cr
Total Capital Investment          Rs. 51.18 Cr
Rate of Return                         34%
Break Even Point                     58%

INTRODUCTION
COKE
PETROLEUM COKE
CLASSIFICATION
CALCINED PET COKE
PROPERTIES
SPECIFICATIONS
PHYSICAL PROPERTIES
CHEMICAL PROPERTIES
STANDARD SIZES (GRANULOMETRY)
TYPICAL PROPERTIES:
PHYSICAL: HD ND
CHEMICAL:
USES AND ITS APPLICATION
USES:
ANODES
FUEL
GRAPHITE ELECTRODES
APPLICATIONS
B.I.S. SPECIFICATION
PROCESS FLOW CHART
TECHNOLOGICAL DEVICES AND EQUIPMENT:
PRODUCTION PROCESS
MAIN STEPS ARE GIVEN BELOW
COKE CALCINING TECHNOLOGY
(A) ROTARY KILN TECHNOLOGY
BASIC CALCINING PROCESS
HOW IT WORKS
ROTARY KILN
COOLING:
AFTERBURNER:
FLEXIBILITY IN OPERATIONS
(B) ROTARY HEARTH CALCINER
SCHEMATIC OF ROTARY HEARTH CALCINER
(C) VERTICAL SHAFT TECHNOLOGY
VERTICAL SHAFT KILN
FIG: ZONAL SECTION OF VERTICAL KILN
KILN FIRING AND HEATING PROCESS
(D) EMISSION CONTROL TECHNOLOGY
(1) WET SCRUBBING SYSTEMS
(2) SEMI-DRY SCRUBBING SYSTEMS
(3) DRY SCRUBBING SYSTEMS
BAGHOUSE OPERATION
(F) STORAGE TECHNOLOGY
LOADING
UNLOADING
DUST AND FIRE PREVENTION
FIRE EXTINGUISHING
COKE BLENDING
MARKET POSITION
ADVANTAGES OF USING PETCOKE
CHALLENGES IN USING PET COKE
RECENT PROBLEMS
INDUSTRY TRENDS
PETCOKE MARKET, BY GRADE
PETCOKE MARKET, BY PHYSICAL FORM
PETCOKE MARKET, BY APPLICATION
PETCOKE MARKET, BY REGION
COMPETITIVE PETCOKE MARKET SHARE
PETCOKE INDUSTRY BACKGROUND
RAIN INDUSTRIES LTD MANAGEMENT DISCUSSIONS.
CAUTIONARY STATEMENT
OVERVIEW
INDUSTRY STRUCTURE
CARBON PRODUCTS
CALCINED PETROLEUM COKE ("CPC") & GREEN PETROLEUM COKE ("GPC")
COAL TAR PITCH ("CTP") AND OTHER CARBON PRODUCTS
THREATS & CHALLENGES
CO-GENERATED ENERGY
2. CHEMICALS
RESINS & MODIFIERS
SUPER PLASTICIZERS
AROMATIC CHEMICALS
THREATS & CHALLENGES
3. CEMENT
CURRENT POSITION
NEAR FUTURE
THREATS & CHALLENGES
2. DISCUSSION ON FINANCIAL PERFORMANCE
3. OVERALL BUSINESS AND GROWTH STRATEGIES
4. INTERNAL CONTROL SYSTEMS AND THEIR ADEQUACY
5. HUMAN RESOURCE DEVELOPMENT AND INDUSTRIAL RELATIONS
6. STATUTORY COMPLIANCE
CALCINED PETROLEUM COKE MARKET OVERVIEW
GROWING IN TANDEM WITH ALUMINIUM INDUSTRY
FIGURE 1: FOR EVERY TON OF ALUMINIUM, SMELTING
   PROCESS CONSUMES 0.4 TONS OF CPC
PLANT LAYOUT
MANUFACTURERS/SUPPLIERS OF CALCINED COKE
SUPPLIERS OF RAW MATERIALS
GREEN PET COKE
SUPPLIERS OF HDPE BAGS
SUPPLIERS OF PLANT AND MACHINERIES
CHINA SUPPLIERS OF ROTARY KILN
ROTARY KILNS
SUPPLIERS OF STEAM POWER PLANTS
CRUSHING PLANT
SUPPLIERS OF BALL MILL
EOT CRANE
SUPPLIERS OF POWER TRANSFORMER
SUPPLIERS OF ELECTRICAL PANEL
SUPPLIERS OF COOLING TOWER
EFFULENT 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

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)

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