CALCINED PETROLEUM COKE
[CODE NO.3440]
COKE
Coke is a fuel with few impurities and a 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.
PETROLIUM 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
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 : 666.66 Ton./day
land & Building (85000 Sq.mt) : Rs. 55.46 cr
Plant & Machinery : Rs. 21.26 Cr
Working Capital for 2 Month : Rs. 75.83 Cr
Total Capital Investment : Rs. 154.83 Cr
Rate of Return : 11%
Break Even Point : 66%
INTRODUCTION
COKE
PETROLIUM COKE
CLASSIFICATION
CALCINED PET COKE
PROPERTIES
PHYSICAL PROPERTIES
CHEMICAL PROPERTIES
STANDARD SIZES (GRANULOMETRY)
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:
TECHNOLOGICAL DEVICES AND EQUIPMENT:
(B) ROTARY HEARTH CALCINER
(C) VERTICAL SHAFT TECHNOLOGY
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 SURVEY
ADVANTAGES OF USING PET COKE
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
WHAT INFORMATION DOES THIS REPORT CONTAIN?
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
CHEMICALS
RESINS & MODIFIERS
SUPERPLASTICIZERS
AROMATIC CHEMICALS
THREATS & CHALLENGES
CEMENT
CURRENT POSITION
NEAR FUTURE
THREATS & CHALLENGES
DISCUSSION ON FINANCIAL PERFORMANCE
OVERALL BUSINESS AND GROWTH STRATEGIES
INTERNAL CONTROL SYSTEMS AND THEIR ADEQUACY
HUMAN RESOURCE DEVELOPMENT AND INDUSTRIAL RELATIONS
STATUTORY COMPLIANCE
CALCINED PETROLEUM COKE MARKET OVERVIEW
GROWING IN TANDEM WITH ALUMINIUM
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 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:
1. COST OF PLANT ECONOMICS
2. LAND & BUILDING
3. PLANT AND MACHINERY
4. FIXED CAPITAL INVESTMENT
5. RAW MATERIAL
6. SALARY AND WAGES
7. UTILITIES AND OVERHEADS
8. TOTAL WORKING CAPITAL
9. COST OF PRODUCTION
10. PROFITABILITY ANALYSIS
11. BREAK EVEN POINT
12. RESOURCES OF FINANCE
13. INTEREST CHART
14. DEPRECIATION CHART
15. CASH FLOW STATEMENT
16. PROJECTED BALANCE SHEET
