Detailed Project Report (DPR) on calcined petroleum coke

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