860556374-10280271.pptx PETROLEUM COKE CALCINATION PLANT

Project description of petroleum coke calcination plant

1. Kuwait Petroleum Coke Calcination Plant Hu man & Technologies Corp. Change for the future, Value for the Customer

2. Contents 1.Project Outline 2.Calcination Process of PC 3.Product & Application 4.Plant Operation 5.Problem Noted in PCIC Project 7.Slip Form Construction Method for Silo 8.Construction Video 6.Construction Photograph

3. 1. Project Outline

4. 1. Project Outline NO. ITEM DESCRIPTION 1 Project Name Petroleum Coke Calcination Plant (1060 TPD) Project 2 Location Shuaiba , Kuwait 3 Client Petroleum Coke Industries Co.(PCIC) 4 Contractor Human & Technologies Corp. (H&TC) 5 Work Scope C (Main Process Equipment) E.P.C (Utility, Tie-in, Refractory, Fire fighting, HVAC) 6 Contract Amount 19,090,000 KD ( Excluding Main Process Equipment) 7 Construction Period 24 months (May 2006 ~ April 2008) 8 Major Material of Construction Con’c : 55,000 m3 (Incl. Silo(12,400 m3) x 3) Steel Str. : 4,000 Ton Equip. Erection : 3,700 Ton (Incl. Conveyor 1,600 Ton) Pipe Welding : 8,000 D/I

5. 2. Calcination Process of PC

6. 2. Calcinations Process of PC Petroleum Coke Calcining is converting the Petroleum Coke to Purity Carbon. The Calcined Coke is used to produce carbon anodes for the Aluminum Smelting Process. PC : Petroleum Coke(or Green Coke), Raw Material CPC : Calcined Petroleum Coke, Product Calcinations : Heat treatment that bring about chemical changes in raw materials PC CPC Calcin-ation Carbon Anode Aluminum Smelting Coke composition ratio and sintering temperature must be properly maintained. 1. Definition of Words 2. Calcination Process of PC

7. 1) Rotary Kiln Method. Most petroleum coke is calcined in a Rotary Kiln. Raw petroleum coke is sized to 50 to 100mm lump and fed to the rotary kiln at the high end. The kiln is sloped downward towards the discharge end at slope of 13 to 19mm per 300mm. Moisture is driven off the coke in the “Heat-Up Zone.” Devolatilization occurs mostly at 500 to 1,000 ºC in the “ Calcining Zone.” Further dehydrogenation, some desulfurization, and coke structure shrinkage (densification) take place in the “ Calcined Coke Zone” at 1,200 to 1,400 ºC The coke moves through the kiln in 40 to 60 minutes and drop off the discharge end of the kiln into a refractory-lined chute and into a rotary cooler. 2. Calcination Process of PC 3. Characteristic of Process 1) Humidity elimination 2) Volatile elimination 3) Densification 4) Increase physical strength 5) Increase electrical conductivity 4. System of Process

8. Boiler KNPC (Kuwait National Petroleum Company) Boiler Feed Water KOC (Kuwait Oil Company) Product Shipping Silo Day Bin Green Coke Shed Dump Hopper Station Fuel Gas Gas Burner 550℃ Air Cleaning System Cold Stack Coke Products Zone A : Raw material Loading (PC) K i l n Cooler Incinerator Zone B : Main Process Zone C : Storage / Product Shipment (CPC) 5. Process Diagram Coke 2. Calcination Process of PC Zone D : Auxiliary System Steam Hot Stack

9. Rotary Hearth Method ▶ System of Process ㆍ The rotary hearth consists of a large rotating disk-type furnace that slopes from outside toward the center. Raw coke is fed into the outer edge of the rotary hearth and is plowed inward with water cooled plows called rabbles that push the coke toward the center. ▶ Rotary Hearth Advantages Over Rotary Kiln ① Reduced Refractory Cost - Since the refractory on the hearth is covered with a layer of coke, there is very little wear. Refractory on the top of the kiln is stationary, eliminating problem with brick lock and rotating forces that are present in a rotary kiln. ② Lower Particulate Emissions - The coke fines are not entrained into the kiln exhaust. ③ Reduced Heat Losses and Less Fuel Consumption - Little or no extra fuel is required if combustion air is preheated. ④ Elimination of Extra Combustion Chamber for Incinerating Fines and Volatile Matter - Complete combustion occurs within the calciner . ⑤ Variable Operation - Varying the turntable speed and coke bed depth can change operating conditions and residence time over a wide range. 2. Calcination Process of PC 6. Other System of Process (For Reference)

10. 2. Calcination Process of PC ▶ Rotary Hearth Disadvantages Over Rotary Kiln ㆍ Some of the major problems with rotary hearth calciners has been with the rapid up-heat rate of the coke and calcined coke particle sizing. Rapid up-heat of the coke causes coke structure to become bloated, distorting the structure of the coke. This leads to poor bulk densities for the calcined product. 2) There are two primary methods of continuous calcination of petroleum coke. But to our knowledge, there is only one other method in use today for calcining coke. Located in Russia, it is a special type of heated wall vertical shaft calciner (sort of like a moving slot oven) that can produce a good density coke. The operating cost is higher than a rotary kiln or hearth, but the slower up-heat rates allow them to use higher volatile matter green coke to achieve similar calcined densities.

11. 3. Product(CPC) & Application

12. Product : Calcined Petroleum Coke (CPC) CPC are used as follows, ㆍ Raw material for Electrolysis Electrode of Aluminum Products (70%) ㆍ Raw material for Graphite Electronic Boards (10%) ㆍ Raw material for Titanium dioxide/Steel/Refractory materials (20%) Production Capacity : 350,000 ton/year Calcined Coke Coke + Impurity H 2 O S 2 3. Product(CPC) & Application

13. 4. Plant Operation

14. March 2008 April May Commissioning Production Product Shipping Incinerator Burning 3/12 Green Coke 2 Mt received 3/30 Kiln burning 4/10 Product Calcined Coke 4/15 First shipping 2Mt Of Calcined Coke 5/10 4 . P lant Operation

15. 5. Problem Noted in PCIC Project

16. 1. Phenomenon ▶ Improper Split of Scope of Work between H&TC and PCIC   ⇒ PCIC responsible for design/engineering and procurement of main process facilities.   ⇒ H&TC responsible for construction/installation of main process facilities, and for EPC for all other facilities (Utility, Tie-In, Refractory, Fire-Fighting, HVAC ) ▶ Improper Project Management   ⇒ PCIC manage the project by its own personnel (temporarily hired). - Project management group is in lack of expertise. 5 . Prob lem Noted in PCIC Project 2. Problem Noted ▶ Design Engineering ⇒ Drawings not issued on time.   ⇒ Insufficient descriptions given in drawings.   ⇒ No full details provided in drawings.   ⇒ Frequent revisions made.   ⇒ Drawings not fully and properly provided.(i.e., piecemeal provision)   ⇒ Delay in approving AFC drawings, etc. ▶ Supply of Equipment   ⇒ Delay in delivery of equipment.   ⇒ No delivery of full package of equipment.(partial delivery)   ⇒ Delivered equipment not matched with descriptions in drawings.   ⇒ Lack of constructability of the delivered equipment.   ⇒ Missing of parts, etc.  Having caused numerous Field Correction Activities.

17. 5 . Prob lem Noted in PCIC Project 3. Key Equipment ▶ Ovality noted in Incinerator (during installation)    ⇒ Seven (7) stiffener rings installed outside the Incinerator.    ⇒ Design failure. ▶ Severe ovality (approx. 0.87%) noted in Kiln, having caused fall-down of refractory bricks during commissioning.    ⇒ Cause : Too thin thickness (20mm) of Kiln Shell (Kiln shell Inner Dia 4.35M, Length 78M)  Thinnest thickness in the world.    ⇒ Five (5) stiffener rings installed outside the Kiln shells.    ⇒ Design failure (on the part of Designer) (probably in Designer’s intention to seek for cost reduction of materials, thus seducing clients’ attention)

18. 5 . Prob lem Noted in PCIC Project 4. Project Management ▶ PCIC manage the project by its own personnel (temporarily hired).      ⇒ Project management group is in lack of expertise.    ⇒ Project management group is in lack of capability to lead the project.    ⇒ Delay in approval of works, frequent change of instruction.    ⇒ Lack of responsibility, etc.   ▶ Consultant improperly exerted its right to review the project. ⇒ Not cooperative attitude.    ⇒ Lack of professional qualification.   ▶ Government approval (Power)     ⇒ Responsibility for getting permit (especially for permanent power) mixed between the parties.

19. 5 . Prob lem Noted in PCIC Project Solution  Require contractor to do whole project on EPC basis and take single line responsibility for the maximum efficiency in managing the project. Solution  Employment of qualified and experienced PMC (Project Management Company) working under independent authority. Solution  Full cooperation and support to be given to contractor for government permit.

20. 6. Construction Photograph

21. 1. Panoramic View (Site Location) 6 . Co nstruction Photograph Total Area : 330,000M 2 Location : Shuaiba Complex, Kuwait

22. 6 . Co nstruction Photograph (North View) (East View)

23. (Kiln) 2. Main Equipment 6 . Co nstruction Photograph Capacity : 40ton/hr Size : 4.35mDia. x 78mL

24. 6 . Co nstruction Photograph (Incinerator) Size : 7.33mDia. x 113mL Characteristic - Flue Gas Combustion (1,200 ºC) - Each shell supplied in segment and welded on site.

25. 6 . Co nstruction Photograph (Green Coke Shed & Reclaimer ) PEB Structure : 62.5mW x 242mL x 25mH (Storage 3,500ton) Reclaimer Capacity : 500ton/hr Erection Weight : 322ton

26. 6 . Co nstruction Photograph (Day Bin) Size : 11.5mDia. x 19mH x 4sets Storage : 800ton x 4sets = 3,200ton Characteristic : Total Three(3) Days Consumption

27. 6 . Co nstruction Photograph (Silo) Size : 22.7mDia. x 55mH x 3sets Storage : 10,00ton x 3sets = 30,000ton Characteristic - Total Thirty(30) Days Consumption - Applied “Slip Form Construction Method” - Construction Concrete Volume : 12,400m 3

28. 6 . Co nstruction Photograph Capacity : 135MTPH (Steam) Characteristic - Product 435 ºC Superheated Steam - Using Waste Heat from Incinerator (Waste Heat Boiler)

29. 6 . Co nstruction Photograph (Gas Suspension Absorber(GSA) & Gas Conditioning Tower(GCT)) Function : Desulfurization System GSA : Desulfurization Reaction GCT : Supply Water & Drop Temperature

30. 6 . Co nstruction Photograph (Fuel, BFW, Seam Piping) Fuel : 4 inch x 2.5km BFW(Boiler Feed Water) Line Fuel Line Steam : 16 inch 3.0km BFW : 8 inch x 1.9km Steam Line

31. 3. Kiln Erection 6 . Co nstruction Photograph (Pier Construction) (Shell Erection) (Shell Alignment & Fit-up) (Riding Ring Assembly) (Girth Gear Assembly) (Shell Welding)

32. 3. Kiln Erection 6 . Co nstruction Photograph (Burner Assembly) (Air Fan Assembly) (Refractory Erection) (Erection Complete & Rotation) (Driving Unit Assembly)

33. 7. Slip Form Construction Method for Silo

34. 7 . Slip Form Construction Meth od for Silo 1. Process Photograph (Excavation) (Placing Concrete) (Basic Formwork) (Tunnel Formwork) (Slip Form Installation) (Slip form Work)

35. 7 . Slip Form Construction Meth od for Silo (Slip Form Parallel) (Slip Form Work) (Roof Floor Work) (Roof Steel Frame Work) (Silo Top Gallery Installation)

36. HEIGHT (M) SLIPFORM TRADITIONAL 0.00 0.20 0.40 0.60 0.80 1.00 1.20 1.40 1.60 1.80 2.00 1 0.95 0.9 0.85 0.8 0.75 0.7 0.65 0.6 0.55 0.5 1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2 20 40 60 80 100 120 140 160 180 200 220 COST / M2 2. Form Work Comparison ( Slipform & Traditional) 7 . Slip Form Construction Meth od for Silo

37. 3. Slip Form System 7 . Slip Form Construction Meth od for Silo

38. Shuttering 7 . Slip Form Construction Meth od for Silo 3. Slip Form System

39. 7 . Slip Form Construction Meth od for Silo

40. 7 . Slip Form Construction Meth od for Silo

41. 7 . Slip Form Construction Meth od for Silo

42. 7 . Slip Form Construction Meth od for Silo

43. Slip form rig Target Lane of sight Auto plumb Slip formed wall Concrete base Ground level 7 . Slip Form Construction Meth od for Silo

44. 8. Construction Video

45. 8 . Construction Video

46. Thank You!