Industry Overview
Coke is a carbon-rich solid fuel with a low level of impurities, primarily produced through the destructive distillation of low-ash, low-sulphur bituminous coal. It is typically grey, hard, and porous, making it an important industrial material for high-temperature applications. Coke is widely used in the production of producer gas, a mixture of carbon monoxide and nitrogen generated by passing air over red-hot coke, and in the manufacture of water gas.
Petroleum coke (petcoke) is a carbonaceous solid produced in oil refineries through coking and other heavy oil cracking processes, including delayed coking, fluid coking, flexicoking, and contact coking. It is classified into fuel-grade and anode-grade products based on sulphur and metal content. The initial product, known as green coke, contains residual volatile hydrocarbons. Through calcination in a rotary kiln, these volatile compounds are removed, producing calcined petroleum coke with higher elemental carbon content and improved physical properties.
Anode-grade calcined petroleum coke is used extensively in the aluminium and steel industries for manufacturing carbon anodes, while fuel-grade coke is primarily used as an industrial fuel. Calcined petroleum coke also serves as a key raw material for graphite electrodes and various metallurgical applications. Petroleum coke generally contains more than 90 percent carbon and has a higher energy content than coal. However, it also produces higher carbon dioxide emissions during combustion on both energy and weight bases, with actual emissions depending on factors such as coal moisture and volatile hydrocarbon content.
Cost Estimation
| Particular | Value |
|---|---|
| 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% |
Content Index
- 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
- 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
- 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
- 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)
- 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:
- 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
- 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
Appendix
- 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)
Frequently Asked Questions
Petroleum coke is a carbon-rich solid produced during the refining of heavy petroleum feedstocks. It is generated through coking processes such as delayed coking, fluid coking, flexicoking, or contact coking, where heavy hydrocarbon residues are thermally cracked. The initial product, called green coke, may be further calcined to remove volatile matter and increase carbon content, producing calcined petroleum coke for metallurgical and industrial applications.
Green petroleum coke is the unprocessed product obtained directly from the coking unit, while calcined petroleum coke is produced after high-temperature heat treatment. Calcination removes volatile hydrocarbons, increases the percentage of elemental carbon, and improves the material's physical properties. These characteristics make calcined petroleum coke suitable for manufacturing carbon anodes, graphite electrodes, and other high-performance industrial products.
Petroleum coke is widely used in metallurgical and energy-related industries. Depending on its grade, it serves as a fuel, a raw material for carbon anodes in aluminium production, an ingredient in graphite electrode manufacturing, and a reducing agent in several metallurgical processes. Fuel-grade coke is generally used for combustion, while anode-grade coke is processed into high-value industrial products.
Calcination is essential because it improves the quality of petroleum coke for industrial applications. The process removes residual volatile matter, increases carbon purity, enhances density and conductivity, and stabilizes the material's physical characteristics. These improvements are necessary for producing reliable carbon products used in aluminium smelting, steelmaking, and electrode manufacturing.
Petroleum coke processing requires effective environmental management to control emissions, dust, wastewater, and fire risks. Industrial facilities commonly incorporate emission control systems, effluent treatment, dust collection, safe material storage, and environmental management plans. Compliance with applicable environmental regulations and health and safety requirements is an important part of plant design and operation.
Calcined petroleum coke is primarily used by the aluminium, steel, ferro-alloy, and ferrous metallurgy industries. It is also an important raw material for manufacturing graphite electrodes and carbon anodes. Its high carbon content, low volatile matter, and enhanced physical properties make it suitable for demanding industrial and metallurgical processes.
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