Detailed Project Report on CALCINED PETROLEUM COKE (CPC) PRODUCTION RATE – 24,000 TPA

Coke is a fuel with few impurities and 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

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ENGINEERS INDIA RESEARCH INSTITUTE
4/54, Roop Nagar, Delhi-110007 (India)
Phone: [phone]
E-mail: [email protected]
Website: www.eiriindia.org




CALCINED PETROLEUM COKE (CPC)
PRODUCTION RATE – 24,000 TPA
[EIRI/EDPR/4742] J.C.: 2962XL

Coke

Coke is a fuel with few impurities and 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.

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.

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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 these 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).

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CONTENTS

ORGANISATION PROFILE

THE REGISTERED OFFICE OF THE COMPANY IS LOCATED AT

THE DIRECTORS OF THE COMPANY ARE

THE PROJECT

REASON FOR SELECTION OF THE PROPOSED SITE

INTRODUCTION

COKE

PETROLEUM COKE

CALCINED PETROLEUM COKE

USES & ITS APPLICATIONS

ANODES

FUEL

GRAPHITE ELECTRODES

APPLICATIONS

ALUMINIUM INDUSTRY:

FERRO ALLOYS INDUSTRY:

FERROUS METALLURGY:

PROPERTIES/SPECIFICATIONS

PHYSICAL PROPERTIES

CHEMICAL PROPERTIES

RAW MATERIAL SPECIFICATIONS

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RAW PETROLEUM COKE

BIS SPECIFICATION

RAW MATERIAL SUPPLIER

RAW PETROLEUM COKE

HDPE BAGS

MARKET OVERVIEW

DRIVERS OF THE MARKET

CHALLENGES OF THE MARKET

COVID-19 IMPACT ON THE MARKET

MANUFACTURERS/SUPPLIERS OF CALCINED COKE

INPUT/OUTPUT DATA

COKE CALCINING TECHNOLOGY

ROTARY KILN - BASIC CALCINING PROCESS

HOW IT WORKS

ROTARY KILN

COOLING:

AFTERBURNER:

FLEXIBILITY IN OPERATIONS

PRODUCT STORAGE REQUIREMENTS

LOADING

UNLOADING

DUST AND FIRE PREVENTION

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FIRE EXTINGUISHING

EMISSION CONTROL

WET SCRUBBING SYSTEMS

SEMI-DRY SCRUBBING SYSTEMS

DRY SCRUBBING SYSTEMS

BAGHOUSE OPERATION

PROCESSING STEPS

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:

MANUFACTURING PROCESS

TECHNOLOGICAL DEVICES AND EQUIPMENT:

PROCESS FLOW

FIRE PROTECTION

RAINWATER HARVESTING SYSTEM

ENVIRONMENT MANAGEMENT PLAN

THE AREAS, BROADLY, TO BE ADDRESSED ARE

PLANT & MACHINERY SUPPLIERS/TURNKEY

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COKE CALCINATION PLANT

ROTARY KILN

CRUSHING PLANT

BALL MILL

EOT CRANE

POWER TRANSFORMER

ELECTRICAL PANEL

COOLING TOWER

EFFLUENT TREATMENT PLANT

AIR POLLUTION CONTROL EQUIPMENTS

AIR CONDITIONING EQUIPMENTS

AIR COMPRESSORS

PLATFORM WEIGHING MACHINE

MATERIAL HANDLING EQUIPMENTS

FIRE FIGHTING EQUIPMENTS

JIGS AND FIXTURE

SUBMERSIBLE WATER PUMP

DCS SYSTEM

ENGINEERING DESIGN CONSIDERATIONS

ETP FACILITY

ETP FLOW DIAGRAM (TYPICAL)

STP FLOW DIAGRAM (TYPICAL)

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SEWAGE AND WASTE WATER EFFLUENT

UTILITIES REQUIREMENT (ESTIMATED - MONTH)

WASTE GENERATION & MANAGEMENT/GREEN BELT

GREEN BELT

PLANT & MACHINERY

PRINCIPLES OF PLANT LAYOUT

MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:

PLANT LOCATION FACTORS

PRIMARY FACTORS

RAW-MATERIAL SUPPLY:

MARKETS:

POWER AND FUEL SUPPLY:

WATER SUPPLY:

CLIMATE:

TRANSPORTATION:

WASTE DISPOSAL:

LABOR:

REGULATORY LAWS:

TAXES:

SITE CHARACTERISTICS:

COMMUNITY FACTORS:

FLOOD AND FIRE CONTROL:

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HEALTH SAFETY AND ENVIRONMENT

ANTICIPATED ENVIRONMENTAL IMPACTS

CONSTRUCTION PHASE

OPERATION PHASE

HSE REQUIREMENT

SAFETY DATA SHEETS

ENVIRONMENTAL/SAFETY LIABILITY AND ENVIRONMENT CLEARANCE
PROCESS

ENVIRONMENTAL IMPACT ASSESSMENT - TOR

A) LOCATIONAL DETAILS

B) PROJECT RELATED ACTIVITIES

A) ENVIRONMENTAL BASELINE DATA GENERATION

B) METEOROLOGY

C) AMBIENT ENVIRONMENT

D) NOISE ENVIRONMENT

E) WATER ENVIRONMENT

A) LAND ENVIRONMENT

THE FOLLOWING AREAS WILL BE COVERED PERTAINING TO LAND
ENVIRONMENT

B) SOCIO ECONOMY

C) IDENTIFICATION & QUANTIFICATION OF ENVIRONMENTAL IMPACTS

AIR ENVIRONMENT

NOISE ENVIRONMENT

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WATER, LAND, BIOLOGICAL AND SOCIO-ECONOMIC ENVIRONMENTS

WATER ENVIRONMENT

LAND ENVIRONMENT

SOCIO-ECONOMIC ENVIRONMENT

A) FORMULATION OF ENVIRONMENTAL MANAGEMENT PLAN

ENVIRONMENTAL MANAGEMENT PLAN DURING CONSTRUCTION PHASE

ENVIRONMENTAL MANAGEMENT PLANT – OPERATIONAL PHASE

A) DISASTER MANAGEMENT PLAN

B) ENTREPRENEUR SOCIAL COMMITMENT

C) SUMMARY &CONCLUSION

POTENTIAL RISKS

ONSITE EMERGENCY RESPONSE

SOCIO-ECONOMIC BENEFIT

PROPOSED IMPLEMENTATION SCHEDULE

ENGINEERING PACKAGE/DOCUMENTS

BASIS – PROJECT ECONOMICS

PROJECT FINANCIALS

BASIS & PRESUMPTIONS (FOR PROFITABILITY WORKINGS)

PRELIMINARY LAYOUT

CONCLUSIONS

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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)

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COST ESTIMATION

Plant Capacity 80 MT/Day

Land & Building (15,470 sq.mt.) Rs. 15.23 Cr

Plant & Machinery Rs. 12.49 Cr

Working Capital for 0.5 Month Rs. 2.78 Cr

Total Capital Investment Rs. 31.43 Cr

Rate of Return 28%

Break Even Point 70%