Calcined Petroleum Coke from Green PET Coke (Cap: 50 Ton/Day)

CALCINED PETROLEUM COKE FROM GREEN PET COKE (CAP: 50 TON/DAY)

[EIRI/EDPR/4685] J.C.: 2902XL

Calcined Petroleum Coke (CPC) is manufactured from Raw Petroleum Coke (RPC) by the process known as high temperature pyrolysis. The process is carried out in a rotary or vertical kiln at temperatures exceeding 1300 deg C. Calcination of CPC is essentially a high temperature treatment in which the carbon to hydrogen ratio of RPC is increased from 20 to 1000 and above. Calcination is achieved by complete demoisturisation and dehydrogenation of RPC under controlled conditions. During the process molecular rearrangement takes place making the CPC electrically conductive, an essential property required for Aluminium smelting.

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.

Classification of Pet Coke

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 this 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            50 MT/Day

Land & Building (6000 sq.mt.)    Rs. 4.30 Cr

Plant & Machinery                    Rs. 4.70 Cr

Working Capital for 1 Month    Rs. 2.95 Cr

Total Capital Investment          Rs. 12.41 Cr

Rate of Return                          34%

Break Even Point                      54%

CONTENTS

INTRODUCTION

PETROLEUM COKE

CLASSIFICATIONS OF PET COKE

CALCINED PET COKE

PROPERTIES

SPECIFICATIONS

PHYSICAL PROPERTIES

CHEMICAL PROPERTIES

STANDARD SIZES (GRANULOMETRY)

TYPICAL PROPERTIES:

USES AND ITS APPLICATION

ANODES

FUEL

GRAPHITE ELECTRODES

APPLICATIONS

SPECIFICATION OF CPC

CALCINED PETROLEUM COKE - SPECIFICATION:

PACKAGING

B.I.S. SPECIFICATION

SEQUENCES IN CPC MANUFACTURE

BASIC CALCINING PROCESS

ROTARY KILN

COOLING

AFTERBURNER

MANUFACTURING DETAILS OF CALCINED PET COKE

PROCESS FLOW CHART

TECHNOLOGICAL DEVICES AND EQUIPMENT:

PRODUCTION PROCESS

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

STEP-8: TRANSPORTATION

TECHNOLOGY OF COKE CALCINING

(A) ROTARY KILN TECHNOLOGY

BASIC CALCINING PROCESS

HOW IT WORKS

ROTARY KILN

COOLING

AFTERBURNER

FLEXIBILITY IN OPERATIONS

(B) 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 OVERVIEW OF CALCINED PET COKE

PRODUCT DEFINITION AND SEGMENTATION

BY APPLICATION

BASIS OF THE GRADES CALCINED PET COKE

INCREASING PREFERENCE OF CALCINED PET COKE OVER THE COAL

GLOBAL CALCINED PET COKE MARKET: KEY PLAYERS

OPPORTUNITIES FOR MARKET PARTICIPANTS

ALUMINUM INDUSTRY A MAJOR CONSUMER OF CALCINED COKE

LIST OF MACHINERY & EQUIPMENTS

MANUFACTURERS/SUPPLIERS OF CALCINED COKE

ADDRESSES OF RAW MATERIAL SUPPLIERS

SUPPLIERS OF GREEN PET COKE

CHINA SUPPLIERS OF ROTARY KILN

ADDRESSES OF PLANT AND MACHINERY SUPPLIERS

SUPPLIERS OF ROTARY KILNS

SUPPLIERS OF STEAM POWER PLANTS

SUPPLIERS OF CRUSHING PLANT

SUPPLIERS OF BALL MILL

SUPPLIERS OF EOT CRANE

SUPPLIERS OF POWER TRANSFORMER

SUPPLIERS OF ELECTRICAL PANEL

SUPPLIERS OF COOLING TOWER

SUPPLIERS OF EFFLUENT TREATMENT PLANT

SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS

SUPPLIERS OF AIR CONDITIONING EQUIPMENTS

SUPPLIERS OF AIR COMPRESSORS

SUPPLIERS OF PLATFORM WEIGHING MACHINE

SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS

SUPPLIERS OF FIRE FIGHTING EQUIPMENTS

SUPPLIERS OF JIGS AND FIXTURE

SUPPLIERS OF 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)