Detailed Project Report on calcined petroleum coke

CALCINED PETROLEUM COKE [3595]

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. Coke 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 (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. 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 desired shape and physical properties. The anodes are mainly used in the aluminium industry. The Petroleum Coke consists of two categories- green coke and calcined coke. These two categories 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 feed-stocks 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 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 higher energy content, 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). The basic raw material, Green Petroleum Coke (GPC), is calcined into the end product called Calcined Petroleum Coke (CPC). Rotary Calcination Technology is being adopted for the Plant as this process shall produce good quality of CPC. The calcined coke industry is considered part of the pyro-processing industry. Its profitability is usually controlled by the aluminium industry’s performance, blending quality, cost of feed stocks and transportation costs. Calcined Petroleum Coke (CPC) is a form of highly electrically conductive, dense Carbon with very low specific Electrical Resistance, and having fixed Carbon of approximately 99.5%. CPC is used extensively as Anode in Alumina Smelters, as Soderberg Electrode for Ferroalloy Industries, and in the manufacturing of Graphite/ Graphite Electrodes, and Thermal Paste for Ferro Alloys & allied industries in Submerged Arc Furnaces. CPC is also used in various Steel Industries- Melting of Steel, Re-caburisation and for making Special Steels & Alloys. Calcined petroleum coke (CPC) is the product from calcining petroleum coke. This coke is the product of the coker unit in a crude oil refinery. The calcined petroleum coke is used to make anodes for the aluminium, steel and titanium smelting industry. CPC is also used in various Steel Industries- Melting of Steel, carburization and for making Special Steels. The feedstock for the project is the Green Petroleum Coke which is a byproduct of the oil refining industry. The quality and impurities of the product comes from the crude oil and depends mainly on the refining process parameters. The calcined petroleum cokes are used in production of aluminum anode-grade, graphite electrode, needle-grade, titanium dioxide pigments.

COST ESTIMATION

Plant Capacity                           1167 Ton/Day  
Land & Building (100000 sq.mt)     US$ 79 Lac
Plant & Machinery                    US$ 43 Lac
Working Capital for 2 Months   US$ 2.90 Cr
Total Capital Investment          US$ 4.20 Cr
Rate of Return                         34%
Break Even Point                     38%



INTRODUCTION- THE CPC PROJECT    
COKE    
PETROLIUM COKE    
CALCINED PETROLEUM COKE    
PROPERTIES (AS PER IS: 8502:1994)    
PHYSICAL PROPERTIES    
CHEMICAL PROPERTIES    
STANDARD SIZES (GRANULOMETRY)    
USES/APPLICATIONS    
USES    
APPLICATIONS    
PROCESS FLOW CHART    
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:    
TECHNOLOGICAL DEVICES AND EQUIPMENT:    
(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    
(E) STORAGE TECHNOLOGY    
LOADING    
UNLOADING    
DUST AND FIRE PREVENTION    
FIRE EXTINGUISHING    
COKE BLENDING    
MARKET OVERVIEW    
PETCOKE MARKET, BY GRADE    
PETCOKE MARKET, BY PHYSICAL FORM    
PETCOKE MARKET, BY APPLICATION    
PETCOKE MARKET, BY REGION    
COMPETITIVE PETCOKE MARKET SHARE    
PETCOKE INDUSTRY BACKGROUND    
WHAT INFORMATION DOES THIS REPORT CONTAIN?    
RAIN INDUSTRIES LTD MANAGEMENT DISCUSSIONS.    
CAUTIONARY STATEMENT    
OVERVIEW    
I. INDUSTRY STRUCTURE    
1. CARBON PRODUCTS    
1.1. CALCINED PETROLEUM COKE ("CPC") AND GREEN
    PETROLEUM COKE ("GPC")    
1.2. COAL TAR PITCH ("CTP") AND OTHER CARBON PRODUCTS    
THREATS & CHALLENGES    
1.3. CO-GENERATED ENERGY    
2. CHEMICALS    
2.1. RESINS & MODIFIERS    
2.2. SUPERPLASTICIZERS    
2.3. 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 PET COKE    
SUPPLIERS OF RAW MATERIALS    
GREEN PET COKE    
SUPPLIERS OF HDPE BAGS    
SUPPLIERS OF PLANT AND MACHINERIES    
SUPPLIERS OF PET COKE CRUSHING PLANT    
SUPPLIERS OF ROTARY KILN    
JAW CRUSHERS    
ROTARY KILNS (INDIAN)    
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 (ETP 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)