Detailed Project Report on CALCINED PETROLEUM COKE (CP COKE) (PRODUCTION CAPACITY: 36,000 MT/YEAR)

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.

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ENGINEERS INDIA RESEARCH INSTITUTE
4/54, Roop Nagar, Delhi-110007 (India)
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Website: www.eiriindia.org



CALCINED PETROLEUM COKE (CP COKE)
(PRODUCTION CAPACITY: 36,000 MT/YEAR)
[EIRI/EDPR/4729] J.C.: 2949INR, 2949US$

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.

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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.

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CONTENTS

INTRODUCTION

PETROLEUM COKE

CLASSIFICATION OF PET COKE

CALCINED PET COKE

SPECIFICATION OF CALCINED PETROLEUM COKE

SPECIFICATION

PROPERTIES

SPECIFICATIONS

PHYSICAL PROPERTIES

CHEMICAL PROPERTIES

STANDARD SIZES (GRANULOMETRY)

TYPICAL PROPERTIES:

USES AND ITS APPLICATION

ALUMINUM INDUSTRY:

STEEL PRODUCTION:

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FOUNDRY INDUSTRY:

GRAPHITE ELECTRODE PRODUCTION:

CARBON PRODUCTS MANUFACTURING:

ANODES

FUEL

GRAPHITE ELECTRODES

APPLICATIONS

B.I.S. SPECIFICATION

PRUDUCTION PROCESS OF CALCINED PET COKE

SEQUENCES IN CPC MANUFACTURE

BASIC CALCINING PROCESS

ROTARY KILN

COOLING

AFTERBURNER

MANUFACTURING DETAILS OF CALCINED PET COKE

PROCESS FLOW CHART

TECHNOLOGICAL DEVICES AND EQUIPMENT:

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STEPS IN PET COKE CALCINATION

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

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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

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MARKET OVERVIEW OF CAL CINED PET COKE

INDIA'S GROWTH STORY

CHINA'S REAL-ESTATE SLOWDOWN

DEMAND OF PET COKE IN INDIA

TURNKEY SUPPLIERTS OF PET COKE CALCINATION

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

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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

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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)

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COST ESTIMATION

Plant Capacity 100 MT/Day

Land & Building (16,000 sq.mt.) Rs. 11.20 Cr

Plant & Machinery Rs. 9.00 Cr

Working Capital for 1 Month Rs. 3.87 Cr

Total Capital Investment Rs. 24.53 Cr

Rate of Return 48%

Break Even Point 38%