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)
