Carbon Anode Production Plant PDF

EMHNN CORPORATION
CHAPTER I
INTRODUCTION
Once discovered, drilled and brought to the earths surface, crude oil is
transported to a refinery by pipelines or ships. Crude oil is separated into its
natural components through distillation. It incorporates the principle of physical
separation through differences in boiling points that will yield different
products. One of these products is the petroleum coke. The raw coke directly out
of the coker is often referred to as green coke that means unprocessed.
Petroleum coke can either be fuel grade (high in sulfur and metals) or anode
grade (low in sulfur and metals).
Impurity levels in petroleum coke have been progressively increasing in
recent years as the refineries have been obliges to accept higher proportion of
sour crude oil. These changes in refinery practice dictated by the economics of
the petroleum market aimed at maximizing the yield of lighter high value
products, resulting in an increase in the sulfur content of the petroleum coke that
made it more of a waste than a useful by-product and making its disposal as a
challenge. To reduce the environmental hazard and as well as to utilize the
carbon rich properties of petroleum coke, it can be processed further and
upgraded, be cleaned and be more useful.
Petroleum coke is sometimes considered as a waste or residue from the
refinery and sold to other markets for industrial purposes. Some of the industrial
uses of petroleum coke includes carbon anode making for aluminum smelting,
production of titanium oxide as lead substitute in paints and colorings,
replacement for coal as feedstock in furnaces, production of ammonia and urea
ammonium nitrate for pulp and paper and fertilizers and used by brick and glass
manufacturers as fuel.
The production of carbon anode is similar to the production of carbon and
graphite electrodes and shapes, but having significant differences in percentage
of coal tar pitch, other process parameters and baking temperature and gradient.
The plant will import green petroleum coke from refineries, and then convert it
into a calcined coke. This calcined petroleum coke or CPC will be the feedstock
Petroleum related Production Plant
EMHNN CORPORATION
for the creation of carbon anode considering its physical properties which is vital
for the production of aluminum and other possible products.
In the proposed Carbon Anode plant where the feed is green petroleum coke, the
process starts with calcination. It is a process where the raw petroleum coke is
thermally upgraded in order to clean and remove the volatile combustion
material and moisture of petroleum coke. Calcination also improves the physical
properties of petroleum coke like real density, electrical conductivity and
oxidation characteristics. Thus, making the coke suitable for the production of
high quality carbon anode. Crushing and grinding is used in the process to
squeeze the calcined petroleum coke and break large particles into smaller
pieces. The calcined petcoke is further screened and milled to convert it into
smaller pieces usually into powdered form. Then the calcined petroleum coke
and coal tar pitch are mixed to form a paste. The paste will be cooled through
water quenching. The cooled paste is heated in a burner or furnace where it
transformed into a hard anode block, the pitch is partially carbonised and
evaporated. The anode which doesnt pass the quality are recycled back and
further baked.
In the realm of further development most especially in our basic human
necessities and commodities such as transportation, communication and the
power sector, aluminum did a great job of being the metal of choice. Not only
did it serve as a lightweight and strong component for each product, it also
provides a more economic and environmentally friendly approach towards the
world's growth. The demand for aluminum will surely rise and the world needs
to keep up with its pace. To have a cheaper cost in the production of aluminum,
the pre baked anodes play a vital and key role. The problem for some aluminum
smelters is their insufficient and substandard carbon anode supply which is a
very important component in the harnessing of the aluminum's full potential as a
metal. Having this type of plant having to run from the feed petroleum coke and
calcinized which is considered the most viable and economic way of producing
anodes and aluminum, the world's demand for aluminum in the next years will
be sufficed and the world will continue to go forward.
EMHNN CORPORATION
Carbon Anode production consists of the following processes:
Calcination
Calcinations is a process where raw petroleum coke is
thermally upgraded in order to clean and remove the
volatile combustion material and moisture of petroleum
coke. Calcination also improves the physical properties of
petroleum coke like real density, electrical conductivity and
oxidation characteristics.
Crushing and Grinding

Crushing and grinding is used in the process to squeeze the
petroleum and break large particles into smaller pieces.
Screening and Classifying
Milling
Milling is used in the process to convert smaller pieces
petroleum coke into powdered form.
Mixing
Mixing is a process were in a petroleum coke is mixed with
liquid pitch to form a paste.
Cooling
Cooling occurs when cooling water gets into contact with
hot paste and evaporates.
Anode Baking
Baking is used in the process were the petroleum coke and
pitch is form and converted it to a hard anode block. During
this process, liquid pitch is partially carbonised and
evaporated.
EMHNN CORPORATION
1. AMOUNT OF LAND REQUIRED
The Carbon Anode Plant will be located at the Nellore District, Andhra
Pradesh State, India. Taking into consideration all the units and equipment
necessary for the production plant including the raw material storage,
processing areas and expansion areas, the amount of land required is 250
hectares. The plant is strategically situated near a port to allow transportation
of raw materials. Railways are also within reach. Refineries are easily
accessible as they are also nearby the shore and are abundant within the
district. Jetties allow receiving of raw materials and other supplies from
external sources mostly coming from India. Coal industry is very much
abundant in India, thus it is easy get the needed amount of Coal Tar Pitch.
The district is also home to aluminum smelters which are the primary and
target customers.
2. TRANSPORTATION FACILITIES
A plant must be strategically positioned in a location that is easily
accessible by all modes of transportation. The accessibility of a plant is a key
factor in determining a plants overall success. Having a stable and easy
transportation of goods, services, products and other necessary plants needs
make the production smoother and continuous, lessen the costs and ensure
that the logistics are made appropriately. Time is also a critical element,
adequate transportation facilities will help avoid delays, shortcomings which
in return will mean additional income.
The state of Andhra Pradesh in India is situated in between other state.
Road and railways are the primary means of transportation. Roads consist of
state highways and national highways, some of which comes under the Asian
Highway Network. The state also has a railway network of 5,046 kilometer
and has significantly boosted the economy of the state. Accessing there
railway networks allow the industrial and tourism sector to develop.
Specifically, the Vijayawada railway station is one of the busiest railway
network in India and ranks as the highest grosser in the SCR zone.
EMHNN CORPORATION
Seaports and airways also connect the state to other countries. Many
ports for sea trade lay along the Bay of Bengal. One of the countrys largest
port in terms of cargo handling. Visakhapatnam is situated within the state of
Andhra Pradesh. Other ports include Gangavaram Port, Kakinada Port and
Krishnapatnam Port (Nellore).
In terms of the airports, the state has five domestic airports, 1 small air
strips and the Visakhapatnam Airport, the only airport having international
connectivity.
3. PROXIMITY TO MARKETS AND RAW MATERIAL SOURCES

Carbon anodes are primarily used in the smelting process of
Aluminum. Smelting is a very vital process to harness and utilize the metal
Aluminum. Green petroleum coke from the delayed coking units of refineries
serve as the raw material for the Carbon Anode Plant. Thus, the primary
market for the production of carbon anodes would be the Aluminum
manufacturers and smelters. For this main reason, the plant is located in India
where the aluminum business is a major and a booming industry.
India ranked 5th in the worldwide production of Aluminum, thus
making it a stable market compared to China (largest producer of Aluminum)
where the production is too massive for the producers and even the economy
to handle. The local demand for Aluminum in India is rising again due to the
increase in construction, infrastructure and even in the automotive and
transportation sector where Aluminum is mostly and preferably used. Being
situated in between thermal plants, urban cities and manufacturing zones, the
carbon anode plant can easily penetrate its desired market. Aside from the
local demand, imports are now the next big thing in the Aluminum business.
Countries like Germany and Japan import Aluminum primarily for the fastrising automotive industry where lightweight metals with high strength are
needed. With its good relation with the European Union, easy access to
imports to Germany is at hand and since the plant is nearby the Indian
Ocean, shipping and logistics of the imported products will be much easier.
EMHNN CORPORATION
One of the main reason why the Indian government is supporting and
promoting the development of the Aluminum Industry is because of its rich
bauxite deposits, which is the primary source of Aluminum. Almost 5% of the
worlds high quality bauxite ore deposits amounting to 3 billion tons is found
in India. At an expected aluminum production capacity of 5.3 million tons by
2015, the reserves are likely to last for a century indicating a long term and
stable market.
Setting up a manufacturing/production unit in India attracts many
types of licenses from Indian Government. One of such license is for the
Pollution Licenses. Any industry, which discharge sewage or effluent into
the environment or emit any pollution in air will have to obtain consent of the
State Pollution Control Board. Similarly any industry / process generating,
storing, transporting, disposing or handling hazardous waste are required to
obtain authorization from MPC Board.
Also before a plant or activity is done within the vicinity of Indian
land, two consents or permit are required; consent to establish and consent to
operate.
Consent to Establish
All the industries and activities needing consent must obtain consent
to establish before actual commencement of the works for establishing the
industry/activity. Compliance with the requirements are essential to obtain a
consent to establish. Documents needed are: site plan/index, topographical
map, detailed plant layout of different processes and point sources of effluent
discharge/emissions, details of Water Pollution Control/ Air Pollution
Control devices proposed, ambient air quality report, SSI Certificate/NOC
from Directorate of Industries Government of Maharashtra, details of
chemical reactions with mass balance, consent fees, local body NOC and
undertaking on Rs.20 stamp paper or Chartered Accountant certificate about
proposed Capital Investment.
Consent to Operate
This consent needs to be taken before actual commencement of
production including trial production. This consent is valid for certain
EMHNN CORPORATION
duration and fixed term of 5 years. Permit expiration terminates the sources
right to operate unless a timely and complete renewal has been submitted.
The permittee shall allow authority representatives upon presentation of legal
papers to at all reasonable times enter the premises specifically where
emissions related activity is conducted. Records should be accessible. Prior to
the application for a consent to operate, certain documents are required
including: a detailed plant layout of different processes and point sources of
effluent discharge/emissions, process flow sheet, latest analysis report of
effluent, fuel gases, solid waste & hazardous wastes, details of Water
Pollution Control/Air Pollution Control devices, ambient air quality report,
SSI Certificate/NOC from Directorate of Industries Government of
Maharashtra, details of chemical reactions with mass balance, consent fees,
Xerox copy of previous consent (for renewal only)
Plant License
The plant owners are required to notify and also register their
premises with the local governing authority before the beginning of
operations. This helps in facilitating the risk management at workplace and
the total implementation of Safety and Health Management Systems in
factory premises.
Documents required are: application form for the consent, statutory
fees, copy of the lease agreement, Grampanchayat NOC copy in name of
company, final drawing copy of factory and layout, declaration for the
investment and Project profile by Chartered accountant, water budget (input
water, uses, applications, losses, recycled, effluent), manufacturing process of
each product with flow diagram, process flow diagram, list of raw material
with monthly or annual consumption, list of manufacturing products with
monthly or annual consumption, details of the generators or boilers, details of
the stack and the chimney, details of hazardous and non- hazardous waste,
treatment and disposal and ETP/STP scheme, process and diagram.
Along with these permits, primary emphasis and focus will be on the
Environmental certificates, pollution licenses and adherence to the Clean
Water Act and Clean Air Act.
EMHNN CORPORATION
Petroleum Coke is a by-product of crude oil refining. It serves as the
raw material for the plant. India is home to 22 crude oil refineries with
sufficient and stable production and refining capacities. Furthermore, the
largest refinery in the world, Jamnagar Refinery having a refining capacity of
668,000 barrels per day by Reliance Industries limited can be found in India
and will pose a greater and an easier sourcing of the plants raw materials
which is petroleum coke. Also Jamnagar is also termed as the Refinery Hub
housing the worlds largest refining complex with an aggregate refining
capacity of 1.24 million barrels of oil per day, more than any other single
location in the world. Having the plant strategically placed in between of
these refineries make it more accessible to the cokers and allows the plant to
have sufficient amount of raw materials and save huge transportation costs
through imports.
The proposed plant will have a production capacity of 300,000
tons/year of baked carbon anodes to adequately supply the anode needs of
the major and minor aluminum smelters within Andhra Pradesh and its
nearby district. This capacity will require 255,000 tons/year of Calcined
Petroleum Coke and 45,000 tons/year Coal Tar Pitch. The remaining feed
inlet would come from the recycled clean butts from the baking process.
EMHNN CORPORATION
Figure 1: Map of Refineries in India

Source: (http://appscgroup.blogspot.com/2010/04/map-oil-refineries-of-indiaupsc-appsc.html)
4. AVAILABILITY OF SERVICE AND POWER FACILITIES
The plant needs sufficient and reliable power and service facilities to
operate. Strategically, the plant is situated out of the main city to decrease
pollution and other hazards but is also close to available utility systems like
power, transportation and water.
EMHNN CORPORATION
The state of Andhra Pradesh is home to huge manufacturing business
in mining and mineral processing. Andhra Pradesh boasts a large coastline
that permits easier transport of processed and unprocessed products to or
from the plant. Also, having the second largest coastline in India makes the
supply at sea cooling water within reach. In terms of supply of fresh water for
cleaning and processing, dams can be easily tapped on.
Since the state is highly urbanized and home to huge and
international manufacturing firms, stable power supply is a basic utility in the
area. Coal-powered plants, thermal plants, diesel plants, etc. surround the
state of Andhra Pradesh and supply the needed energy consumption of each
plant. Coal-powered plants provide the majority of the power requirement of
the state but as the state progresses, alternate sources line natural gas and
some petcoke-driven power plants also give a significant share on the
production of power. The map below shows the location of some of the
power plants in India.
Due to the fuel capabilities of petroleum coke, the Carbon Anode
Plant will harness the heat power from the plants raw material upon
calcination and the residue after the production of carbon anodes amounting
to almost 34.25 MW of power from the rate of 1MWh/ton of anode. But in
case of power shortage, the plant can easily tap on the electrical lines of the
big power plants nearby to continue production.
10
EMHNN CORPORATION
Figure 2: Map of Thermal Power Plant in India

Source: (http://www.mapsofindia.com/maps/india/thermalpowerplants.html)
11
EMHNN CORPORATION
5. AVAILABILITY OF LABOR
A plant will not be able to perform its function of producing goods or
providing services without any personnel or staff to operate it. India, being
the second most populous country have too much to offer in terms of labor
and work force. The younger generation now dominates the population, thus
having a combination of junior and senior professionals, Indias young
workforce is expected to rise to almost 67% of the total population in the year
2020. A young workforce corresponds to more dynamic and innovative
minds, physically fit and less cost on the wage front. Two hundred and fifty
million people are set to join Indias work force in the next 5 to 10 years.
Comparing minimum wages within some of the main Asian
manufacturing countries showed that the Indian labors average minimum
salary is just 22% of their Chinese counterparts. But in the case of senior
executives, the Indian salary tops the charts, showing the internationalized
education and expertise of educated Indians.
With the Indians Government advocacy of being a global workshop
highlighting the Made in India labels, availability of labor in India is
sufficient and in good quality.
6. CLIMATE
Andhra Pradesh offers a tropical climate conditions. No extremities of
weather will be experienced throughout the state. Typically from March to
June, or the summer season temperature within the state range from 20C to
41C and above. July to September is the time for tropical rains, some heavy
rainfall brought about by the northeast monsoon. Tropical cyclones form in
the Bay of Bengal usually on the months of October and November. There is
also a winter season in Andhra Pradesh during the months of November to
February. During this season, temperature ranges from 12C to 30C. India is
situated near the equator and near a large body of water. Thus adequate
sunlight and some rainfalls will always be part of the weather cycle. This
balance will be of great help to the personnel and the plant as well.
12
EMHNN CORPORATION
7. LEGAL RESTRICTIONS AND TAXES
A country has its specific set of laws and regulations for a specific type
of business/investment operating within a sector or industry which may be
privately owned or by the government. Increase in the number of
investments both foreign and local will mean a growth in the economy no
matter how small or big it is. Under the Indian Law specifically under its
taxation, a company which is defined as a juristic person having an
independent and separate legal entity from its shareholders is subjected to a
corporate tax. The national corporate tax rate is 35 percent and the tax rate for
foreign companies is set at 48 percent.
The income of the company is taxed depending on its domicile. Indian
companies are liable to tax their worldwide income in India. While the
foreign companies are only taxed in India on incomes that arise from their
operations within India which may include but not limited to royalty,
interest, gains from sale of capital assets located in India, dividends from
Indian companies and technical services fee.
Capital gains tax is the amount of money charged for the sale of an
investment. It can be a house, family business, farm, ranch, etc. Almost half of
the taxable capital gains are derived from the sale of corporate stock. Gains
arising for not more than 36 months is considered a short term and levied at
30 percent while the long term is at 10 percent.
Some of the other type of taxes relating to a company is the Fridge
Benefit Tax, Dividend Distribution Tax, Banking Cash Transaction Tax,
Securities Transaction Tax and Wealth Tax. Fridge Benefit Tax is the amount
paid for the privilege, service or amenity directly or indirectly given by an
employer to his employees due to their employment. DDT or Dividend
Distribution Tax is the charged tax for any amount declared, distributed or
paid by a domestic company by way of dividends, thus only domestic
companies are liable for this tax. Banking Cash Transaction Tax is levied at 0.1
percent rate of the value of the specific taxable banking transactions
entered with any scheduled bank on any single day. SST or Securities
Transaction Tax or what they call as a turnover tax is a tax levied on any
13
EMHNN CORPORATION
taxable securities transaction. Another tax for a company is a wealth tax. It is
levied on any benefits derived from ownership or acquisition of a property.
The tax is to be paid every year according to its market value, whether or not
such property yields any income. Investments in shares, UTI, mutual funds,
debentures and other productive assets are not subjected to this tax. Houses,
cars, jewelry, yachts, aircrafts, urban land and cash in hand are subjected to
this tax. Wealth tax is charged at 1 percent of the amount by which the net
wealth exceeds Rs. 15 Lakhs.
Another tax which can be levied on the Carbon Anode Production
Plant is the Carbon Tax. It is levied on the carbon content of fuels. It is a costeffective means of the government to reduce greenhouse gas emissions. A
number of countries have implemented some other energy taxes that are
related to carbon content. But in India, a nationwide carbon tax is set at 100
rupees/metric ton of coal both produced and imported into India. Coal is
used to power more than half of the countrys electricity generation. The
proceeds of the carbon tax will help finance a National Clean Energy Fund
(NCEF). With the new government in India, Prime Minister Narendra Modi,
the carbon tax will be further increased from 100Rs per ton to 200Rs per ton.
All of the countries are attracting more and more investors for the
development of their economy. The competition is tight and performing some
maneuver tactics will greatly help and turn the table. Indias investment
incentives are designed to channel investments to specific industries, promote
the development of some economic lagging regions and to encourage exports
of goods and services.
Incentives can either be regional, sectoral, export and free trade, etc.
under the regional incentives, all industry undertaking set up in a specified
underdeveloped state or territory or district is eligible for a 30 percent tax
exemption on its profits for the first 10 years of production.
For the sectoral incentives, an undertaking setup in India for the power
generation is eligible for 100 percent tax exemption for the first five years and
30 percent on the succeeding five years. An approved company engaged in
14
EMHNN CORPORATION
scientific and industrial R&D, is eligible for 100 percent tax exemption for five
years.
Under the export incentives and free trade zones, a complete tax
exemption is provided to companies that set up in FTZs for the first ten years
of their operation. FTZs include:
Kandla Free Trade Zone (KAFTZ), Gujarat;

Santa Cruz Electronics Export Processing Zone (SEEPZ), Mumbai;
Madras Export Processing Zone (MEPZ), Tamil Nadu;
Cochin Export Processing Zone (CEPZ), Kerala;
Noida Export Processing Zone (NEPZ), Uttar Pradesh; and
Falta Export Processing Zone (FEPZ), West Bengal.
In India, there is an organization for any business/investor involved in

Aluminum production; they call it the AAI or Aluminum Association of
India. The association is involved in the preparation of Five Year Plan
documents, National Policy on Aluminum, Budget Recommendations, FTA,
WTO, VAT etc. the association is routinely consulted by Government of India
on all policies and economic issues concerning the growth of aluminum and
its industry. And they are also a permanent invitee for the World Aluminum
Leaders meet conducted by International Aluminum Institute (IAI).
15
EMHNN CORPORATION
CHAPTER II
DESIGN OBJECTIVES
The main thrust of this project proposal is to design a Carbon Anode

Production Plant that will process the raw material, Petroleum Coke to produce
the product Carbon Anode.
Furthermore, it is also aims to target the following specific objectives in
order to come up with a feasible and economical project design.
1. To determine the required data and information needed in constructing
the propose Carbon Anode Production Plant. This must specifically cover
the following:
1.1
1.2
1.3
1.4
1.5
1.6
1.7
Target Location
Target Customers
Demand Requirements
Demand Projection
Market Share
Target Plant Capacity
Source of Raw Materials
2. To gather the data and information needed in relation to technical and

economical aspect that will justify the feasibility of the proposed project.
3. To determine the capacity of the plant by calculating the following:
3.1 Mass Balance
3.2 Energy Balance
3.3 Equipment Selection
4. To determine the economic and financial viability of the proposed project

by considering the following economic tools:
16
EMHNN CORPORATION
4.1 Capital Expenditures
4.2 Operating Expenditures
4.3 Net Present Value
4.4 Payback Period
4.5 Rate of Return
5. To provide the data and calculations of the cost estimation and
economics of the proposed project and to be able to justify the overall
expenditures.
6. To identify the environmental effects of the project to the community
and create mitigation plan for these identified problems including:
6.1 Environmental Management
6.2 Health
6.3 Safety
7. To provide the construction management, project scheduling of
constructing the whole plant area and all equipments in each process as well as
the quality assurance and control in the plant area.
17
EMHNN CORPORATION
Chapter III
Data and Assumption
This chapter contains data that discusses the raw materials, their present
and future availability, process and proper storages each will undergo to obtain
the desired product.
A. Raw Materials
The raw materials to be used in the proposed Carbon Anode
Production Plant considering its availability and signifance to the entire
process includes:
Raw Petroleum Coke
It is the gray to black solid carbonaceous residue produced as a byproduct of crude oil refining. It has generally been considered as an
unusable byproduct because of its high sulfur content. Raw Petroleum
Coke is also called Green Coke or a fuel grade coke because of its high
calorific value and carbon content.
Petroleum Coke used in the aluminum industry most specifically in
the production of carbon anode typically contains lower amount of metals
and sulfur. Calcined Petroleum Coke (CPC) is manufactured from Raw
Petroleum Coke (RPC) by the process known as high temperature
pyrolysis or calcination. This is done to get rid of the volatility, to remove
moisture, increase physical strength and coke density and to improve
conductivity of the Carbon Anode.
18
EMHNN CORPORATION
Table 3.1. Properties of Green Coke and Calcined Coke
Properties
Fuel-Grade Green
Calcined Coke
Sulfur (wt%)
2.5-5.5
1.7-3.0
Ash (wt%)
0.1-0.3
0.1-0.3
Nickel (ppm)
N.D.3
165-350
Vanadium (ppm)
200-400
120-350
Residual Hydrocarbon
9-12
<0.25
(wt%)
Bulk Density (g/cm3)
N.D
0.80
Real Density
N.D
2.06
Source: Sharifi, K. et. al. Production and Application of Calcined Coke in Rotary
Kiln Calciners (2014)
The proponents will make use of different coke types and will use coke
blending procedures to allow a more flexible feed, production and better
economic vs. quality relation.
Pitch
Pitches are a complex mixture of aromatic and heterocyclic organic
compounds, which carbonize on heat treatment. They are used as a binder
agent. It provides good wetting of coke grains and mixing properties
during the paste mixing phase. It also allows gradual release of volatiles
during the anode baking stages. It has high coking value.
Coal Tar Pitches (CTP) are used due to its sustainability and
economics. Coal tar is a liquid by-product produced when coal is
carbonized or coked to come up with coal gas. It is extremely viscous in
nature. It is the most preferably used type of pitch because it provides
strong bonding between coke and carbonized pitch during anode baking.
It contains low amount of sulfur and ash, have low reactivity usually in
the electrolysis stage and has high electrical conductivity.
19
EMHNN CORPORATION
Table 3.2. Properties of Coal Tar Pitch
Typical
Properties
Unit
Range
Softening Point
C
100-110
Viscosity by 140C
cP
3000-6000
Viscosity by 160C
cP
600-1500
Viscosity by 180C
cP
150-300
Distillation 0-270C
%
0.1-0.6
Distillation 0-360C
%
4.0-8.0
Density in Water
Kg/dm3 1.30-1.32
Coking Value
%
54-60
Water Content
%
0-0.2
Insoluble in Quinoline %
8.0-14
Insoluble in Toluene
%
28-36
Ash Content
%
0.1-0.3
S
%
0.3-0.5
Na
ppm
100-400
Ca
ppm
20-80
Cl
ppm
100-300
Al
ppm
50-200
Si
ppm
50-200
Fe
ppm
50-300
Zn
ppm
100-600
Source: Velaso, L, et.al. Process for the production of Petroleum Tar Pitch
for Anode Manufacturing.
Roughly about of the worldwide Coal Tar Pitch production (6 million
tons in the year 2013) is consumed by aluminum smelters. The growth in the
demand of both CPC and CTP will be largely dependent on the growth of
Aluminum consumption and Aluminum production.
20
EMHNN CORPORATION
B. Present and Future Availability
As a byproduct in the production process of coke, the output of coal tar
changes with the output of coke. In 2030, Asias coke output reached 487.571
million tons, accounting for 61.6% of the worlds total. 9.94 million tons of coal
tar was actually recycled in 2030, a 5.74% YoY rise. (www.researchinchina.com)
Output of Coke and Coal Tar in Asia, 2015-2030 ( million tons)
Source: National Bureau of Statistics of China; China Coking Industry

Association; ResearchInChina
The downstream markets of coal tar mainly include coal tar deepprocessing (phenol, anthracene, industrial naphthalin, and coal tar pitch), carbon
black, substitute for heavy oil and exportation. Among these applications, coal
tar consumption for deep processing ranked No.1 with 66.4% of the total
consumption volume in 2018, followed by carbon black raw oil sharing 28.1% of
the total. (www.researchinchina.com).
C. Equipments and Functions
1. Storage Tank
It is a steel tank which is used for storing. It can house
instrumentation and monitoring equipment.
21
EMHNN CORPORATION
2. Rotary Kiln
A rotary kiln is a device that supplies tremendous amounts of heat
in order to change the chemical composition of an object. It is made up of
a strong reinforced steel outer shell that is coated with a heat-resistant
inner lining, support rollers and a drive gear to keep the contents in a
continuous rotating motion and internal heat exchangers capable of
producing temperatures well over 1500 degrees Celsius. The petroleum
green coke is fed into a refractory lined rotary kiln where the volatiles are
driven off during the calcining process in an oxygen deficient
atmosphere. Air can be injected through the kiln shell to burn a portion of
the volatile matter in the kiln providing usable heat to the kiln.
(http://psrcentre.org/) (www.metso.com).
3. Coke Cooler
It utilizes both hot coke and direct water quench at cooler entrance
and counterflow movement of the ambient air to cool the coke. Coke
cooler is a widely used method of cooling in the coke calcining industry.
(www.metso.com)
4. Heater
It is a rectangular steel vessel separated by fluoplate. The material
to be heated is fed onto the fluoplate where it is fluidized and heated by
electrical elements immersed in the bed of material. The heated material is
discharged from the heater over a weir, onto a discharge conveyor.
(www.metso.com)
5. Waste Heat Boiler
It is used for utilizing waste gases and to recover energy in the
form of steam. Steam generation is important to recover waste heat energy
and these gases will be easily utilized. (www.indeck.com)
22
EMHNN CORPORATION
6. Bag house dust filter
It is a filter which is a pollution control device used as electrostatic
precipitator. Bag houses also an efficient particulate collection devices
using absorbents for removing heavy metals and gases.
(www.neundorfer.com)
7. Mixing Hopper
It is a steel hopper which used to unload the calcined petroleum
coke. (www.metso.com)
8. Hammer Mill
Hammer mill is a crusher used to grind, pulverize and crush the
calcined petroleum coke needed in the production of carbon anode. It is
used to aggregate the calcined coke into smaller pieces by the used of little
hammers. It is impacted by hammer bars. The hammers are free to swing
on the fixed central rotor or on the end of the cross. (www.stedmanmachine.com)
9. Vibrating Screen
It is used to separate the calcined coke into multiple grades by
particle size. It is the most important screening machine utilized in the
calcined coke processes industry. It also suited for large material volumes
with a high percentage of undersize products in the feed material.
(www.metso.com)
10. Ball Mill

It is a type of grinder used to grind the calcined petroleum coke in
the process. It is a hollow cylindrical shell about its axis which reduced the
size or calcined coke. The grinding media is the ball which is made from
stainless steel. It homogenizes small coke to the nano range. .
(www.metso.com)
23
EMHNN CORPORATION
11. Coke Storage Silos
Coke storage silos tend to adheres the calcined petroleum coke to
the silo walls creating build-ups and rat holes. It also used to transfer the
calcined coke to the kneading mixers. (www.apm-solutions.com)
12. Kneading Mixers

It is used to mix the calcined coke to liquid pitch to convert it into a
homogeneous paste with a temperature of approximately 1800C. .
(www.metso.com)
13. Paste Cooler
It is the horizontal type cooler which operates hurling and whirling
principle which leads to accuracy of the outlet temperature. It also defines
recidence time and complete fume extraction due to closed system.
(www.aluminiumchina.com)
14. Anode Baking Furnace

Baking is the most expensive step in the production of carbon
anode industry. Anode baking furnace is a circular kiln with pits which
provides effective and reliable effective performance specifically for
producing carbon anode with enhanced qualities. It is made from concrete
shell with thermal insulation in the floor. It also consists of pit walls that
are made up from perforated flue bricks allowing flue gases towards the
bottom of section. (www.riedhammer.de)
Data and Assumptions:

To compute the capacity and safety factor for the equipment that will be
used in the carbon anode production plant, the following assumptions will be
considered:
24
EMHNN CORPORATION
Rotary kiln efficiency = 80%
Vibrating Screen efficiency = 65%
Cooler efficiency = 97%
Ball Mill efficiency = 88%
Heater efficiency = 100%
Kneading Mixer efficiency = 77%
Waste Heat Boiler efficiency = 100%
Paste cooler efficiency = 97%
Mixing Hopper efficiency = 76%
Anode Baking Furnace efficiency =

99%
Bag House Dust Filter efficiency =

99%
Hammer Mill efficiency = 88%
D. Storage
Coal Tar Pitch
Use sound metal tanks or containers (drum) to prevent the leakage and
spillage of the product. Avoid using a plastic container as some plastics
containers are softened in this product. The recommended temperature for
storage is 50oC (112oF) above the softening point. Keep the container in a wellventilated place. Keep away from heat, sparks, flames, oxidizers and other
incompatible substances. Protect from physical damage. And the containers
should lock up.
Petroleum Coke
Primary techniques considered to maintain optimal moisture content and

control potential petcoke emissions during storage including pile maintenance,
wetting water, anti-dust chemical agent/treatment, enclosures, wind screen and
walled coke pads at production facilities.
a. Pile Maintenance
25
EMHNN CORPORATION
Proper maintenance of petcoke piles will help reduce the potential for
fugitive dust emissions, particularly when combined with wetting or antidust chemical agent practices. It is important as a method to control potential
fugitive dust.
b. Wetting with Water
An emission control technique that is commonly used at petcoke storage
locations is the application of water to storage piles. The systematic
application of water to petcoke helps to control fugitive dust emissions and
maintain product moisture content, and can be accomplished through both
portable and fixed infrastructure. Water increases the particle weight and acts
as a binding agent between particles. Water spray systems may require
periodic reapplication of water to overcome the hydrophobic nature of
petroleum coke.
c. Anti-Dust Chemical Agent/Treatment
Water spray systems can be combined with anti-dust chemical agents
such as surfactants and humectants. Application of anti-dust chemical agents
is normally achieved by combining the chemical into the water spray. The
surfactant enhances the wetting by lowering the surface tension of the water
thereby allowing the water droplets to penetrate deeper into the petcoke.
Humectant helps slow moisture evaporation.
d. Enclosures
Storage enclosures typically consist of completely roofed and walled
structure or building surrounding an entire petcoke pile. Method to control
the fugitive dust from enclosures at vents, entrances and exits including
water spray system, air pollution control equipment and doorways covered
with overlapping flaps or sliding doors.
e. Wind Screens
Wind screens are used to lower the wind velocity to reduce entrainment
of particulates by the wind.
26
EMHNN CORPORATION
f. Walled Coke Pads at Production Facilities
Coke pads may be used to provide sufficient residence time for petcoke
dewatering after petcoke is cut from the coke drum.
Keep container tightly closed and sealed until ready for use, protected it
from direct sunlight in a dry, cool and well-ventilated area and away from
incompatible materials. If the containers have been opened must be carefully
resealed and kept upright to prevent leakage. Store at room temperature or
according to local legislation. Keep away from heat, spark, open flames and other
sources of ignition. Keep coke piles wet to avoid environmental pollution due to
fine particles of the product. And use only an appropriate containment to avoid
environmental contamination.
27
EMHNN CORPORATION
Chapter IV
Technical and Aspects
This chapter presents the factors involved in the technical aspect of the
design project. This chapter covers the overall process of the carbon anode,
energy requirement, and the equipment specifications needed to prove the
feasibility of the designed plant.
A. Equipment Specification
1. STORAGE TANK
Source: www.kudoresources.com
STORAGE VESSEL
Height
3.70m
Diameter
2.50m
Orientation
Vertical
Pressure
15 psi
Temperature
100C
Materials of Construction
Carbon Steel Plates
Capacity
600 gallons
28
EMHNN CORPORATION
2. ROTARY KILN
Source: www.metso.com
ITEM
Rotary Kiln
QUANTITY
WEIGHT
167 Tons
OPERATION
Batch
PLACE OF
ORIGIN
China
Capacity
6 TONS/HOUR
DIMENSION
3.3mX50m
MATERIAL
STEEL,SS
29
EMHNN CORPORATION
3. ROTARY COOLER
Source: www.imexbb.com
ITEM
Rotary Cooler
QUANTITY
OPERATION
COOLING
PLACE OF ORIGIN
China
COOLING
CAPACITY
1.9-20
DIMENSION(INNER
DIAMETER
3M
MATERIAL
STEEL
PLATE
30
EMHNN CORPORATION
4. WASTE HEAT BOILER
Source: www.indeck.com
ITEM
WASTE HEAT
BOILER
QUANTITY
SOURCE OF
HEAT
FURNACE
PLACE OF
ORIGIN
China
RATED
EVAPORATION
5-75
TONS/HOUR
MATERIAL
STEEL,SS
31
EMHNN CORPORATION
5. BAG HOUSE DUST FILTER
Source: www.neundorfer.com
ITEM
BAG HOUSE
DUST FILTER
QUANTITY
WEIGHT
200 Tons
NO. OF
FILTER
BAGS
432
PLACE OF
ORIGIN
China
NO. OF
CHAMBER
DIMENSION 11.5M*5.5M*13.8M
MATERIAL
CARBON STEEL
32
EMHNN CORPORATION
6. MIXING HOPPER
ITEM
MIXING
HOPPER
QUANTITY
SOURCE OF HEAT
FURNACE
PLACE OF ORIGIN
China
RATED
EVAPORATION
5-75
TONS/HOUR
MATERIAL
STEEL,SS
33
EMHNN CORPORATION
7. HAMMER MILL
Source: www.stedman-machine.com
ITEM
HAMMER
MILL
QUANTITY
ROTATION
SPEED
1000
PLACE OF
ORIGIN
China
CAPACITY
10-300
TONS/HOUR
MATERIAL
STEEL,SS
34
EMHNN CORPORATION
8. BALL MILL
ITEM
BALL MILL
QUANTITY
ROTATION
SPEED
1000
PLACE OF
ORIGIN
China
CAPACITY
10-300
TONS/HOUR
MATERIAL
STEEL,SS
POWER
22-2200KW
MOTOR TYPE
STREPPER
MOTOR
35
EMHNN CORPORATION
9. COKE STORAGE SILOS
Source: www.apm-solutions.com
ITEM
COKE
STORAGE
SILOS
QUANTITY
PLACE OF
ORIGIN
China
CAPACITY
20-400
TONS/HOUR
MATERIAL
STEEL,SS
POWER
22-2200KW
36
EMHNN CORPORATION
10. Heater
HEATER
Temperature
Pressure
Material
Shell
350 C
15 psi
Low and
intermediate
strength carbon
steel plates
Area
1000ft2
Material
Carbon Steel
Length
2.1m
Inside Diameter
0.175m
Incoming pipe
in, schedule
diameter
40 stainless
steel
Outlet pipe diameter
1 in,
schedule 40
stainless steel
Number of Tubes
28
37
EMHNN CORPORATION
Number of Passes
Tubes
Material
Length
Inside Diameter
Outside Diameter
Pitch
Incoming pipe
diameter
Outlet pipe diameter
Number of Baffles
Baffling
Baffle spacing
2, U-bend
configuration
Copper,
Schedule 40
1.905m
0.015875m
0.01905m
7/8 in,
triangular
pitch
1 in,
schedule
stainless steel
1 in,
schedule
stainless steel
2
1 in.
schedule 40
stainless steel
38
EMHNN CORPORATION
11. Vibrating Screen
ITEM
VIBRATING SCREEN
QUANTITY
OPENING
1.6mm2-60mm2
CAPACITY
1.00 to mm to
15.00mm
MATERIAL
HIGH
CARBONSTEEL
WIRE
USES
GRADING AND
SIZING
COAL,STONE,HEAV
Y ORE AND OTHER
39
EMHNN CORPORATION
12. Kneading Mixers
Kneading Mixer
ITEM
QUANTITY
Total
Capacity(Liter)
500Liters
Working
Capacity(liter)
300Liters
Main
Motor(HP)
30/50/75/100
40
EMHNN CORPORATION
13. Paste Cooler
Source: www.aluminiumchina.com
ITEM
Paste Cooler
QUANTITY
Cooling tank
2 HP
Hanger power
1000L X 800W
Hanger power
By air cylinder
Cooling fan no.
1/2 HP X10
Air cooling area
6500L X 2000W
Cutting power
1 HP
41
EMHNN CORPORATION
14. Anode Baking Furnace
Source: www.riedhammer.de
ITEM
ANODE BAKING
FURNACE
QUANTITY
NUMBER OF FIREGROUPS
1-4
SECTIONS PER FIREGROUP
14-24
PITS PER SECTION
4-8
FUEL CONSUMPTION
2-3 GJ/TBP
PACKING MATERIAL
4-8 TBP
LIFE TIME
FLUE WALLS: >150

CYCLES
HEAD WALLS: >250
CYCLES
42
EMHNN CORPORATION
B. MASS BALANCE
Assumptions:
Plant Capacity: 200,000 tons/year of Baked Carbon Anodes
Percent Composition of feed:
65% Calcined Petroleum Coke (130,000 tpy or 14,840.1823 kg/hr or equivalent to
18,550 kg/hr of Green Petroleum Coke due to 80% ideal conversion)
15%
Coal
Tar
Pitch
(30,000
tpy
or
3,424.7
kg/hr)
20% Recycled Butts (40,000 tpy or 4,566.2 kg/hr
(Source:
Qatalum
Project
Description,
Atkins
Co.)
Cp of Petroleum Coke: 0.85 KJ/kg K (Source: Engineering Toolbox)
Cp of Coal Tar Pitch: 1.38 KJ/kg K (Source: Engineering Toolbox)
MASS BALANCE AROUND ROTARY KILN (85 % conversion efficiency)
M1 = 18,550 kg/hr
M2 = 0.85 x M1 = 15,767.5 kg/hr
M3 = 0.15 x M1 = 3,782.5 kg/hr
43
EMHNN CORPORATION
MASS BALANCE AROUND COOLER (100% Efficient)
M2 = M4 = 15,767.5 kg/hr
MASS BALANCE AROUND HEATER (100% Efficient)
M4 = M5 = 15,767.5 kg/hr
MASS BALANCE AROUND WASTE HEAT BOILER (7 % feed as flue gas)
M5 = 15,767.5 kg/hr
M6 = 0.93 x M5 = 14,663.8 kg/hr
M7 = 0.07 x M5 = 1,103.7 kg/hr
44
EMHNN CORPORATION
MASS BALANCE AROUND BAG HOUSE DUST FILTER (5% impurities
removed)
M6 = 14,633.8 kg/hr
M8 = 0.95 x M6 = 13,930.61 kg/hr
M9= 0.05 x M6 = 733.19 kg/hr
MASS BALANCE AROUND COOLER (100% Efficient)
M8 = M10 = 13,930.61 kg/hr

MASS BALANCE AROUND MIXING HOPPER (100% Efficient)
45
EMHNN CORPORATION
M10 = M11 = 13,930.61 kg/hr
MASS BALANCE AROUND HAMMER MILL (100% Efficient)
M11 = M12 = 13,930.61 kg/hr
MASS BALANCE AROUND VIBRATING SCREEN (97% Efficient)
M12 = 13,930.61 kg/hr

M13 = 0.97 x M12 = 13,512.7 kg/hr
M14 = 0.03 x M12 = 417.9 kg/hr
MASS BALANCE AROUND BALL MILL (98% Efficient)
M13 = 13,512.7 kg/hr

46
EMHNN CORPORATION
M15 = 0.98 x M13 = 13,242.4 kg/hr
M16 = 0.02 x M13 = 270.3 kg/hr
MASS BALANCE AROUND SILOS & WEIGHING TROLLEY BALANCE (2%

Loss)
M15 = 13,242.4 kg/hr

M17 = 0.98 x M15 = 12,977.6 kg/hr
M18 = 0.02 x M15 = 264.8 kg/hr
MASS BALANCE AROUND KNEADING MIXER (100% Efficient)
M17 = 12,977.6 kg/hr

M19 = 3424.7 kg/hr
M20 = M17 + M19 = 20, 968. 5 kg/hr
47
EMHNN CORPORATION
MASS BALANCE AROUND PASTE COOLER (100% Efficient)
M20 = M21 = 20,968.5 kg/hr
MASS BALANCE AROUND BAKING FURNACE (2% Loss)
M21 = 20,968.5 kg/hr

M22 = 0.98 x m21 = 20,549.1 kg/hr
M23 = 0.02 x m21 = 419.4 kg/hr
MASS BALANCE AROUND STORAGE (Recycled Butts)
M22 = 20,549.1 kg/hr

48
EMHNN CORPORATION
M24 = 4,566.2 kg/hr
M25 = m22 - m24 = 15,982.9 kg/hr
ENERGY BALANCE AROUND ROTARY KILN
Qin = Qout
= mCp
= 18,550 kg/hr x 0.85 KJ/kg K x (1300-25) = 20,103,562.5 KJ/hr x (1/3600sec)
= 5584.3223 kW
= 5.584 MW
ENERGY BALANCE AROUND COOLER
Qin = Qout
= mCp
= 15,767.5 kg/hr x 0.85 KJ/kg K x (1300-150) = 15,412,731.25 KJ/hr x
(1/3600sec) = 4281.314236 kW
= 4.281 MW
49
EMHNN CORPORATION
ENERGY BALANCE AROUND HEATER
Qin = Qout
= mCp
= 15, 767.5 kg/hr x 0.85 KJ/kg K x (190-150) =536,095 KJ/hr x (1/3600sec)
=14.8915 kW
= 0.0149 MW
ENERGY BALANCE AROUND WASTE HEAT BOILER
Qin = Qout
= mCp
= 15, 767.5 kg/hr x 0.85 KJ/kg K x (230-190) = 535, 095 KJ/hr x (1/3600sec) =
14.8915 kW
= 0.0149 MW
50
EMHNN CORPORATION
ENERGY BALANCE AROUND BAGHOUSE DUST FILTER
Qin = Qout
= mCp
= 14, 663.8 kg/hr x 0.85 KJ/kg K x (230-120) = 1,371,065.3 KJ/hr x (1/3600sec)
= 380.8514 kW
= 0.3809 MW
ENERGY BALANCE AROUND COOLER
Qin = Qout
= mCp
= 13,930.6 kg/hr x 0.85 KJ/kg K x (120-60) = 710,461.11 KJ/hr x (1/3600sec) =
197.3503 kW
= 0.197 MW
51
EMHNN CORPORATION
ENERGY BALANCE AROUND MIXING HOPPER
Qin = Qout
= mCp
39.47 kW
= 0.0395 MW
ENERGY BALANCE AROUND HAMMER MILL
Qin = Qout
= mCp
26.3133 kW
= 0.0263 MW
52
EMHNN CORPORATION
ENERGY BALANCE AROUND VIBRATING SCREEN
Qin = Qout
= mCp
82.2292 kW
= 0.0822 MW
ENERGY BALANCE AROUND SILOS AND WEIGHING TROLLEY

BALANCE
Qin = Qout
= mCp
= 183,242.4 kg/hr x 0.85 KJ/kg K x (130-120) = 112,560.4 KJ/hr x (1/3600sec)
= 31.26678 kW
= 0.03127 MW
53
EMHNN CORPORATION
ENERGY BALANCE AROUND KNEADING MIXER
Qin = Qout
= mCp (Calcined Petroleum Coke)
= 12,977.6 kg/hr x 0.85 KJ/kg K x (179-130) = 540,517.04 KJ/hr x (1/3600sec)
= 150.1436 kW
+ mCp (Coal Tar Pitch)
= 3,424.7 kg/hr x 1.38 KJ/kg K x (179-25) = 727,817.244KJ/hr x (1/3600sec) =
202.1715kW
+ mCp (Recycled Butts)
= 4,566.2 kg/hr x 0.85 KJ/kg K x (800-179) = 2,410,268.67 KJ/hr x (1/3600sec)
= 669.519 kW
= 1021.8342 kW = 1.0218 MW
ENERGY BALANCE AROUND PASTE COOLER
Qin = Qout
= mCp (Calcined Petroleum Coke + Recycled Butts)
54
EMHNN CORPORATION
= 12,977.6 + 4,566.2 kg/hr x 0.85 KJ/kg K x (179-145) = 506,015.82 KJ/hr x
(1/3600sec) = 140.56 kW
= 3,424.7 kg/hr x 1.38 KJ/kg K x (179-145) = 160, 686. 924 KJ/hr x (1/3600sec)
= 44. 6353kW
= 185.473 kW = 0.1854 MW
ENERGY BALANCE AROUND FURNACE
Qin = Qout
= 12,977.6 + 4,566.2 kg/hr x 0.85 KJ/kg K x (1050-145) = 13,495,568.15 KJ/hr x
(1/3600sec) = 3748.7689 kW
= 3,424.7 kg/hr x 1.38 KJ/kg K x (1050-145) = 4,277,107.83 KJ/hr x
(1/3600sec) = 1188.0856 kW
= 4936.8544 kW = 4.9369 MW
55
EMHNN CORPORATION
ENERGY BALANCE AROUND STORAGE
Qin = Qout
= 12,977.6 + 4,566.2 kg/hr x 0.85 KJ/kg K x (1050-800) = 3,728,057.5 KJ/hr x
(1/3600sec) = 1035.5715 kW
= 3,424.7 kg/hr x 1.38 KJ/kg K x (1050-800) = 1,181,521.5 KJ/hr x (1/3600sec)
= 328.2004 kW
= 1363.7719 kW = 1.3637 MW
C. Processing Required
Raw petroleum coke must undergo a process of calcinations in order to
meet the requirements needed in the production of carbon anode. Calcination of
green petroleum coke must meet the temperature of about 1300 oC. This process
helps to reduce the content of hydrogen and increase the graphitization degree of
petroleum coke so as to enhance the heat resistance and strength of high
temperature of the product.
Calcined coke is produced from delayed process which is green coke with
a heating temperature up to 1200oC. A calcining process removes the entire
residual hydrocarbon including the dustier material and PAHs. Calcined coke
can be characterized as graphite needle grade coke or anode grade coke
depending upon its chemical and physical properties which is used in
aluminium smelting.
56
EMHNN CORPORATION
A rotary kiln is a device having higher amounts of heat in order to change
the entire chemical composition of the object. Rotary kiln is made up of strong
reinforced steel outer shell that is coated with a high resistant inner lining,
support by special roller and drive gear to move the contents in a continuous
rotating motion and the heat exchanger produces a temperature up to 1500 oC. As
the rotary kiln rotates, it will undergo a process of string and mixing.
After coke is introduced in the rotary kiln it will introduced to the rotary
cooler. Rotary cooler recuperate and cool the pellets to a temperature for safe
handling purposes. It is also the integral part of the total process of calcined coke.
Then after cooling it may subject to heating.
After heating the green petroleum coke waste heat boiler is used to
produce steam contained in the heater. Baghouse dust filter will be used to
remove the dust in the process of calcination and prevent the equipment from
damage. After cooling process, calcined coke will be introduced to storage tank
which will be the raw materials in making a carbon anode block.
Calcined petroleum coke is the best material needed in making carbon
anode for smelting alumina to aluminium. Calcined petroleum coke is hard,
dense carbon material that contains low hydrogen content and a good electrical
conductivity as well. It is also the one of the highest carbon purity used to
manufacture aluminium, graphite electrode, steel, titanium dioxide and other
consuming carbon consuming industries.
Calcined petroleum coke is introduced to mixing hopper. Mixing hopper
is used to unload the calcined petroleum coke and transported on conveyor belt
for further processing. Conveyor belt is the one that carry the calcined coke and
deliver it to hammer mill. Hammer mill crushed the calcined petroleum coke into
smaller pieces. Hammer mill is made of steel that contains a vertical and
horizontal shaft on which hammers are mounted. After the calcined petroleum
coke is crushed into smaller pieces it will be fed into the vibrating screens.
Vibrating screen separates the calcined petroleum coke by particle size. Some
calcined coke would be go for futher processing and it will sent back to hammer
mill. Vibrating screen is the one sent the calcined petroleum coke to ball mill. Ball
mill is a cylindrical device used to grind the calcined petroleum coke into smaller
pieces.
57
EMHNN CORPORATION
Once the required granulometry is reached, the various coke fractions are
forwarded to coke storage silos from there it is transferred to kneading mixers.
After the liquid pitch undergo heating process, liquid pitch and coke are dosed
into a well known paste kneader where they converted to a homogeneous paste
at a temperature of approximately 180oC. The anode paste leaves the paste
kneader into horizontal paste cooler and then hydraulic press where carbon
anode block is formed at a rate 25 anodes per hour. In the next step, the anodes
are conveyed through a cooling tunnel where the carbon anode are cooled down
to a required storage temperature. After the carbon anode leaves the paste plant
via conveyor system it will be stored in the anode baking area. The baking
furnace is equipped with 50 open type cells. The brick work consists of high
quality fire resistant material. After the baking process, the carbon anode block
will store in baked anode storage.
Modified Carbon Anode Process Diagram

58
EMHNN CORPORATION
D. Replacement Requirement
Maintenance means the retaining or restoring a equipment, machine ,
plant, facility or system to the specified operable condition to achieve its
maximum useful and repair means the reinstallation of any plant, facility or
equipment to sound working condition when it has been rendered dangerous or
out of condition for service. Neither maintenance nor repair includes the
replacement or the improvement of any plant, facility or equipment by replacing
material which is still in working condition with materials of a new or different
kind or quality or design.
In completing on petcoke handling equipment the original equipment
manufacturer recommendations should be followed to ensure proper
maintenance. This equipment may include chutes, bins, hoppers, cranes,
conveyor belt systems, screeners and crushers. Failure to properly maintain
equipment can result in a greater potential for deserter dust emissions.
Maintenance on petcoke equipment should be needed to minimal the
accident and have a continuous process. The maintenance of petcoke equipment
should be considering the following: good housekeeping, routine oil testing on
gear boxes, transmission alignment, temperature monitoring on rotating
equipment, current monitoring on motors, testing and monitoring rubber belting
on conveyors, greasing of bearings, adjustment of belt scrapers and skirting,
thickness testing on pulley faces/end disks/drums, wire rope lubrication, idler
greasing/replacement, and idler alignment. Breakers/disconnects should also be
routinely cleaned with a vacuum to remove any dust along with tightening
wires.
59
EMHNN CORPORATION
CHAPTER V
ECONOMIC ANALYSIS
This chapter provides the data and calculations of the overall economics
and financial analysis of the proposed Carbon Anode Plant to be able to justify
the feasibility and viability of the project.
I.
Direct Costs
A. Equipment Costs
Table 5.1
Summary of Purchased Equipment Cost
EQUIPMENTS
QUANTITY
Rotary Kiln
1
Cooler
2
Waste Heat Boiler
1
Bag House Filter
1
Mixing Hopper
1
Hammer Mill
1
Vibrating Screen
1
Weighing Trolley Balance
1
Ball Mill
1
Kneading Mixers
1
Paste Cooler (Water Quench)
1
Furnace
1
Silos Storage
4
Baked Anode Storage
1
Generator
2
Total Cost
Source: Alibaba.com
INITIAL COST
(USD)
2 125 000
330 000
300 000
150 000
196 000
200 000
86 000
150 000
200 000
120 000
345 000
320 000
1 200 000
350 000
1 600 000
7 672 000
60
EMHNN CORPORATION
Purchased Equipment Cost: $7 672 000
Considering installation cost to be 35% of the purchased equipment

cost
Installation Cost = (0.35)(7 672 000)
Installation Cost =$2 685 200
Instrumentation and Control Costs is considered to be 30% of

purchased equipment cost
Instrumentation and Control Costs = (0.30) (7 672 000)
Instrumentation and Control Costs = $2 301 600
Piping Installation is considered to be 40% of purchased equipment

cost
Piping Installation Cost = (0.40)( 7 672 000)
Piping installation cost = $3 068 800
Electrical Installation Cost is considered to be 25% of purchased

equipment cost
Electrical Installation Cost = (0.25) (7 672 000)
Electrical Installation Cost = $1 918 000
61
EMHNN CORPORATION
Table 5.2
Summary of Total Equipment Cost
Purchase Equipment Cost
$ 7 672 000
Installation Cost (insulation and

painting)
$ 2 685 200
Instrumentation Cost
(instrumentation and control)
$ 2 301 600
Piping Installed Cost
$3 068 800
Electrical Cost
$1 918 000
Total Equipment Cost
$ 17 645 600
B. Buildings, process and Auxiliary: (10-70%of Purchased equipment

cost)
Consider Buildings, process and auxiliary cost = 40% of PEC
= 40% of $7 672 000
= $3 068 800
Buildings, process and auxiliary cost = $ 3 068 800
C. Service facilities and yard improvements: (40-100% of Purchased

equipment cost)
Consider the cost of service facilities and yard improvement = 50% of
PEC = 50% of $7 672 000
=$ 3 836 000
Service facilities and yard improvements cost = $ 3 836 000
62
EMHNN CORPORATION
D. Land
The cost of land in Andhra Pradesh, India is estimated to be $37 per
square meter.
Land Cost= ($27/m2)(1,400,000 m2)
Land Cost= $37 800 000
Table 5.3
Summary of Direct Cost Estimates
II.
Equipment + installation +
instrumentation + piping +
electrical + insulation +
painting
$ 17 645 600
Buildings, process and

auxiliary cost
$ 3 068 800
Service facilities and yard

improvements cost
$ 3 836 000
Cost of Land
$ 37 800 000
Total Direct Cost
$ 61 898 000
Indirect Costs
A. Engineering and Supervision: (5-30% of direct costs)
Consider the cost of engineering and supervision = 5% of Direct costs
= 5% of $ 61 898 000.00
= $ 3 094 900.00
Engineering and Supervision Cost = $ 3 094 900.00
63
EMHNN CORPORATION
B. Construction Expense and Contractors fee: (6-30% of direct costs)

Consider the construction expense and contractors fee =10 % of Direct
costs =10 % of $ 61 898 000.00
Construction Expense and Contractors fee = $6 189 800.00
C. Contingency: (3-10% of Direct Cost)

Consider the contingency cost = 5% of $ 61 898 000.00
Contingency = $ 3 094 900.00
Table 5.4
Summary of Indirect Cost Estimates
III.
Engineering and Supervision

Cost
$ 3 094 900.00
Construction Expense and

Contractors fee
$6 189 800.00
Contingency
$ 3 094 900.00
Total Indirect Cost
$12 379 600.00
Fixed Capital Investment:

Fixed capital investment = Direct costs + Indirect costs
Fixed capital investment = $ 61 898 000+ $ 12 379 600.00
64
EMHNN CORPORATION
= $74 277 600.00
IV.
Working Capital: (10-20% of Fixed-capital investment)

Consider the Working Capital = 10% of Fixed-capital investment
Working capital = 10% of $74 277 600.00
Working Capital = $7 427 760.00
V.
Capital Expenditure (CAPEX):

Capital Expenditures = Fixed capital investment + Working capital
Total Capital Expenditures = $74 277 600.00 + $ 7 427 760.00
= $ 81 705 360.00
VI.
Operating Expenditures
The operating expenditures are expenses that are incurred in the
natural course of business. These expenses generally consist of the selling
and administration expenses. These expenses are revenue in nature since
these are incurred in the day-to-day operations of the business and do not
incur on the non-current assets.
Operating Cost = Fixed Charges + Direct Production Cost + Plant
overhead cost.
A. Fixed Charges:
Depreciation: (3% of fixed capital investment)
= 3% of $74 277 600.00
= $2 228 328.00
65
EMHNN CORPORATION
Local Taxes: (1-4% of fixed of capital investment)
Consider the local taxes = 2% of fixed capital investment
Local taxes = 2% of $74 277 600.00
= $1, 485, 552.00
Insurances: (0.4-1% of fixed capital investment)

Consider the Insurance = 0.5% of fixed capital investment
Insurance = 0.5% of $74 277 600.00
= $371 388.00
Fixed Charges = $2, 228, 328.00+ $1, 485, 552.00 + $371, 388.00
=$4,085,268.00
B. Direct Production Cost:
Labor Cost
Table 5.5
Summary of Staff Salary and Labor Cost
Description
Req
Salary/month
(USD)
Total
Salary/month(USD)
TECHNICAL DEPARTMENT
Vice President
(operation)
4,500
4,500
Plant manager
2,400
2,400
66
EMHNN CORPORATION
Plant engineer
2,200
4,400
Maintenance supervisor
1,500
3,000
Maintenance technician
1,000
5,000
Laboratory manager
2,000
2,000
Laboratory technician
1,200
4,800
Shift supervisor
1,600
6,400
Shift operators
20
750
15,000
Field Engineer
900
1,800
Quality Assurance
Engineer
1,000
5,000
Safety Engineer
1,200
6,000
TOTAL
51
60,300
MARKETING DEPARTMENT
Vice President
4,500
4,500
Marketing Manager
2,400
2,400
Marketing researchers
750
3,750
Public Relations
1,000
5,000
Manager of Creative
Services
2,000
4,000
TOTAL
14
19,650
ACCOUNTING DEPARTMENT
Chief Financial Officer
4,500
4,500
Management
1,800
1,800
67
EMHNN CORPORATION
Accountant
Financial Accountant
1,500
3,000
Internal Auditor
1,100
2,200
Credit controller
1,200
3,600
Accountant Clerk
650
2,600
TOTAL
13
17,700
HUMAN RESOURCE
Human resource
Manager
1,600
1,600
Human resource
Officers
1,200
2,400
Development Officer
1,200
2,400
Staff accountant
900
3,600
Training Coordinator
900
1,800
Accountant appraisal
750
1,500
Total
13
13,300
AUXILIARY
Truck drivers
10
1,000
10,000
Forklift drivers
750
2,250
Janitor
10
600
6,000
Security Guards
900
7,200
Office Maintenance
Technician
750
750
68
EMHNN CORPORATION
Nurse
Total
34
TOTAL LABOR COST
1,400
2,800
29,000
$139,950/month
$1, 679, 400
Maintenance and Repair Cost
Maintenance Cost is a fixing any sort of any device like

mechanical, plumbing and electrical devices. It also includes
performing routine actions which keep the device in working order or
prevent trouble from arising. Maintenance also includes tests,
measurements, replacements, adjustments and repairs wherein it is
used to retain and restore the functional unit in which it can perform
its required functions. It also includes consumables, phone, vehicles
and grounds maintenance and outside services.
Maintenance
expenses
$1,800,000/year
estimated
at
$150,000/month
or
Fixed Charges
Now we have Fixed charges = (10-20% of total product charges)
Fixed charges = 15% of total product cost
Total product charge = fixed charges/15%
= $4 085 268.00/15%
Total product Cost (TPC) = $27 235 120.00
Utilities
Utilities: (10% -20% of total product cost)
69
EMHNN CORPORATION
Consider the cost of Utilities = 10% of total product cost
Utilities cost = $ 2 723 512.00
Raw Materials
Table 5.6
Summary of Raw Materials Cost
Raw Petroleum Coke
$ 9 424 884 ($58/metric ton)
Coal Tar Pitch
$ 960 000 ($32/ metric ton)
Total:
$ 10 384 884
Table 5.7
Summary of Direct Production Cost
$ 1 800 000
Maintenance and repair cost
Utilities cost
$ 2 723 512.00
Labor cost
$ 1 679 400.00
Raw Materials
$ 10 384 884
Total Direct Production Cost
$16 587 796.00
70
EMHNN CORPORATION
C. Plant overhead Costs (5-15% of total product cost); includes for the
following: general plant upkeep and overhead, payroll overhead,
packaging, medical services, safety and protection, restaurants,
recreation, salvage, laboratories, and storage facilities.
Consider the plant overhead cost = 10% of total product cost
Plant overhead cost = 10% of $27 235 120.00
= $ 2 723 512.00
Operating Expenditures
Operating Expenditures = Fixed charges + Direct Production costs +
Plant overhead costs
Operating Cost = $4 085 268.00 + $16 587 796.00 + $ 2 723 512.00
= $ 23 396 576.00
VII.
General Expenses
It includes the taxes and the research and development cost and
administrative cost which 2% of the total product cost.
General Expenses =2% of $27 235 120.00
General Expenses = $544 702.40
VIII.
Total Production Cost

Total Production Cost =Operating Cost + General Expenses
= $ 23 396 576.00+ $544 702.40
Total Production Cost = $ 23 941 278. 40
IX.
Total Capital Investment
71
EMHNN CORPORATION
Total Capital Investment = Total Capital Expenditures + Operating
Cost + Allotted Patent Rights Cost (8% TCE) + Allotted
Environmental Control Cost ( 20% TCE)
= $ 81 705 360.00 + $ 23 396 576.00 + $ 6 536 428.00+ $ 16 341 072.00
= $ 127 979 436.00
Economic Indicators:
1. Rate of Return Analysis

a. Gross Annual Income
Wholesale Selling Price of Carbon Anode per ton in India = $ 120
Annual Income = Selling price Quantity of product manufactured
= $120 x 200,000 tons/yr produced Carbon Anode
ANNUAL INCOME = $24 000 000.00
b. Taxes
Assuming the common percentage of taxes for annual income in India
is 38% for Foreign Direct Investment
$24,000,000.00 x 0.38 = $9,120,000.00
Taxes = $9 120 000.00
c. Net Annual Income
Net Annual Income = Gross Annual income Taxes
Net Annual Income = $24,000,000.00 - $9,120,000.00
Net Annual Income = $14 880 000.00
72
EMHNN CORPORATION
2. Payback Period
The payback period or the pay out period, as used in this
study refers to the period of time required for the return on an
investment to repay the total capital investment based on the net
income after taxes.
Payback Period = Total Capital Investment /Net Annual Income
= $ 127 979 436.00 / $14 880 000.00
Payback Period = 8. 6007 years
3. Rate of Return
A performance measure used to evaluate the efficiency of an investment
or to compare the efficiency of a number of different investments. Return on
investment is a very popular metric because of its versatility and simplicity. That
is, if an investment does not have a positive ROI, or if there are other
opportunities with a higher ROI, then the investment should be not be
undertaken
Rate of Return = (Total Annual Income / TCI) x 100
= $14 880 000.00 / $ 127 979 436.00) x 100
Rate of Return = 11.6269 %
73
EMHNN CORPORATION
CHAPTER VI
ENVIRONMENTAL MANAGEMENT
This chapter discusses the environmental effects of the proposed Carbon

Anode Plant including the generated wastes and its proper handling and
mitigation. Also included are the health and safety concerns which are also
significant in the undertaking of the project.
A. Environmental Concerns
The Carbon Anode plant is designed to minimize its environmental
footprint. The concern encompasses on the areas of land, water and air. The
primary concern would be that of potential emissions to air including
hydrocarbons, PAHs, sulfur dioxide and dust. Potential emissions to air includes
hydrocarbons and PAHs, sulfur dioxide, dust, and fluorides. The formation of
SO2 is influenced by the fuel and raw materials used, whereas the formation of
NOX is determined by the combustion temperature. Another concern will be
proper segregation and disposal of wastes.
B. Materials Handling And Storage
The raw materials for the proposed Carbon Anode Plant are very sensitive
in terms of exposure to heat and potential emissions when exposed to air. Proper
handling and storage of petroleum coke and coal tar pitch should be observed all
the time to avoid a greater environmental impact.
Refineries temporarily stockpile petroleum coke on their facilities, but
because they generally lack sufficient storage space must transport it regularly to
avoid production slowdowns. Typically, coker drums are mounted over railroad
tracks so that coke can be discharged directly into open hopper up to the storage
silos of the plant. While being transported, the petroleum coke must be sprinkled
with water to avoid escape of fumes and dust. The coal tar pitch will be
unloaded from a ship, vacuum unloading arms should be properly mechanized
as it may vary from a ship to another.
74
EMHNN CORPORATION
The dedicated silos for both green petroleum coke and coal tar pitch
should be totally sealed and far from any ignition and process areas. The
storages are nitrogen blanketed to make the containers inert and avoid reactions.
Closed conveyor belts will transfer the GPC to the processing areas while pumps
are used for the coal tar pitch. Monitoring of the transferring equipment should
always be observed both in the area and in the control panel. Nearby firefighting
equipment and deluge systems are installed within the silos.
C. Waste Generation
During the transfer of raw materials to storage, emissions to air like pitch
fume and coke dust pose a threat to the environment. The handling, storage, and
transportation of petroleum coke may create instances of reduced air quality due
to weather or activity related releases of fugitive dust into the atmosphere.
Although inert in nature, coke and pitch can cause environmental hazards if left
unmonitored.
A. Dust Emissions
In the production of Carbon Anode, the primary concern is the
generated wastes brought about by extreme heat involved, volatility and
as well as the carbon content of the raw materials. Dust emissions occur
during all process stages and the involved carbonization gases especially
in the crushing, mixing and baking phase. Carbon dust can be very fine
and abrasive.
B. Carbon Dioxide Emissions

Petroleum coke is generally stable under normal conditions;
however, the substance has the potential to become flammable or
explosive. When petroleum coke is combusted, common pollutants and
hazardous decomposition products may be produced When petroleum
coke or coal combust, CO2 forms from one carbon atom (C) uniting with
two oxygen atoms (O).21 Assuming complete combustion, 1 pound of
75
EMHNN CORPORATION
carbon combines with 2.667 pounds of oxygen to produce 3.667 pounds of
carbon dioxide. Petroleum coke with a carbon content of 90% and a
heating value of 14,200 Btu per pound emits about 232 pounds of carbon
dioxide per million Btu when completely burned. (Petroleum Coke:
Industry and Environmental Issues, 2013)
C. Hydrocarbon, VOCs, PAHs Emissions
The pastes used to create anodes are produced from petroleum
coke, recycled butts and coal tar pitch. There is a likelihood of
hydrocarbon emission during the mixing stage. Coal tar pitches also
contain PAHs which will also be emitted. About 40 % of the coal tar pitch
is volatilized during baking and more than 95 % of the volatile
hydrocarbons are burnt off at the high temperature in the furnace. Baking
therefore results in the residual emission of hydrocarbons and PAHs due
to their presence in the coal tar pitch. PAHs are potentially hazardous in
the environment, as well as inside industrial plants.
Nowadays, petroleum cokes are being heavier because refineries
are more likely to accept sour crudes resulting in increased amount of
sulfur. Thus, a small emission of sulfur is expected during the anode
baking.
D. Waste Water Emissions
The production of carbon anodes is an inherently dry process. The
discharge of process waste water is usually limited to cooling water, although
most processes use a sealed cooling system. Rainwater run-off from surfaces
and roofs may contain carbon dust and associated material.
D. Health
Since the main wastes generated by the plant are emissions to air, workers
and personnel are at risks of respiratory diseases. Exposure to dust and fumes
76
EMHNN CORPORATION
especially in long periods can induce severe pulmonary infections and asthma
syndrome. Coal tar pitch volatiles and polycyclic aromatic hydrocarbons
exposure can provoke lung and bladder cancer if left unaided.
With all these health threats, the plant will impose mandatory check-ups
with its personnel to monitor their health conditions which can lead to serious
implications and to apply proper medications if needed. A fully-equipped clinic
will be situated inside the control room to accommodate every health concerns.
First-aid kits will be situated in critical areas. Also, all the employees will be
trained to be immediate first-aiders in case of emergencies. A resident physician
and nurse will be always available at the clinic.
Particular attention is paid to measuring the lungs function, hearing and
vision, as well as blood pressure and checking body mass standards. Health
monitoring and health surveillance are important components of an
Occupational Health program, but equally important is the assessment of the
individuals lifestyle; weight, blood pressure, smoking & drinking habit and
exercise. There will also be an on-site gym for employees and a fitness instructor.
Life can be a bit overwhelming sometimes - juggling between work,
taking care of family, elderly parents, financial worries and other stress can place
a lot of demands on the individual. Thus there will be a cognitive behaviour
therapist who also offers counselling service to the employees and even their
family members.
E. Waste Mitigation
1. Anode Quality
The majority of wastes produced in the plant will be air emissions.
This can be a little complicated to deal with because they are not visible
but certain technologies incorporated in the process can make sure that
the emissions are minimal and will yield less environmental impact.
Ensuring that the produced carbon anode is in high quality is one
way of dealing with this waste generation. The better quality of anode is
77
EMHNN CORPORATION
directly proportional to lesser waste since the process are kept efficient. It
is known that at an extent we can judge the quality of baked anode by its
physical appearance through its light grey color and having no cracks or
deformations. To gain further information on quality of anode, laboratory
tests have to be made. Examining the raw materials can give a better
insight. The petroleum coke must be sufficiently calcined. This is
identified by checking its electrical resistivity and the composition of
remaining H2 in the coke.
A good pitch will yield a good amount of graphitized carbon or
coke when baked, this is called coking value. It refers to the links or
binding capacity of the pitch. If it is low, not enough links will be
established but when it is too high, it will expand the anode because of
escaping pitch vapors. Another important property of pitch is its wetting
power or how well the liquid pitch wets the coke particles. Wetting power
is measured in terms of viscosity.
2. Regenerative Thermal Oxidation Unit (RTO)
In the paste plant and bake furnace, Polycyclic Aromatic
Hydrocarbons are the main concern regarding the impact of the anode
plant on the environment. As PAH is considered to be carcinogenic, these
condensed and volatilized components are captured and destroyed
completely in the Regenerative Thermal Oxidation unit (RTO). Dust and
PAHs emitted during mixing and forming can be incinerated in a RTO.
A RTO is the preferred option for anode plants that do not have
direct access to alumina or known as stand-alone plants. The process
depends on an alternating cycling of gases through a series of support
zones where heating, cooling and cleaning cycles take place. RTO uses
ceramic beds to preheat the exhaust off-gas.
78
EMHNN CORPORATION
3. Continuous Emission Monitors (CEMS)
To ensure that the emissions were maintained low or compliant
with the standard rates, a continuous emission monitor will be installed
on rotary kilns or incinerator stacks. This will allow direct measurement of
SO2 emissions and fumes which will escape the stack.
4. Filters
Dust emitted by coke and from handling and mechanical processes
such as grinding, mixing and forming is collected in bag house filters.
PAHs emitted from the pitch during mixing and forming can be
condensed and/or adsorbed on fine coke particles and then filtered by
bag filters.
5. Scrubbers
Scrubbers are used to remove unwanted vapors from the gas such
as pitch vapors which are volatile. Emission gases pass through scrubbers
to remove impurities before it can be vented into the atmosphere or to be
brought back to the process. It is also important in removing a portion of
some of the SO2 emissions.
6. Recycling
A great way to minimize the wastes that are being generated inside
the plant is through recycling. In the forming of baked carbon anodes,
butts are formed. They are the part of the anodes which didnt fit into the
rodding or shaping phase. But instead of throwing it, the plant will utilize
these butts, it will be cleaned and broken into smaller pieces before it can
be recycled back in the feed. Also, the filtered dust is then recycled into
the mixing process, when possible, based on the quality required for paste
production.
79
EMHNN CORPORATION
F. Plant Safety
The goal of the plant is to produce the products as efficiently, having high
quality and in the safest way possible. Goal zero should be implemented within
the plants premises. The workers in the area are required to wear personal
protective equipment such as safety googles, safety glasses, safety hat/hard hat,
safety shoes, fire retardant clothing, earplugs and hand gloves together with a
radio for communication purposes.
Fire trucks are inside the plant and are checked weekly. Fire extinguishers,
safety showers, fire hoses of water and steam, emergency phone and fire call
points are strategically situated around the plant particularly near the
equipment. Equipment will be equipped with appropriate safeguarding to avoid
destruction of the equipment and also to avoid upsets with regards to the
process. Polymer tube pneumatic heat detection system (Poly Flo) will be placed
on critical equipment which will activate the deluge system in case there are
leaks and detected internal fires. The plant will be well lighted so as to allow easy
work during the night shifts.
Seminars, trainings about process safety fundamentals are regular
activities that may also serve as refresher to make sure every personnel are
always safe. Fire drills are also done during 1st Friday of the month. Inspection of
the firefighting equipment are done monthly. The employees will be trained to
be firefighters so that they can act immediately in case of fire and avoid further
damage cause by the fire personnel delays. Any work to be done inside the plant
should be properly coordinated with all the necessary key players to avoid
miscommunication and to have proper hazard analysis and safety evaluation for
the certain job and plan all possible means to stay safe.
G. STORAGE TANK AND PIPING LEAK DETECTIONS
Leak detection is very important in every industrial plant. With the help
of an effective leak detection device, the plant can quickly respond to the signs of
leaks and minimize the extent of environmental damage and the threat to human
health and safety. Early action will also prevent the plant from high costs that
80
EMHNN CORPORATION
can result from cleaning up extensive leaks and responding to third-party
liability claims.
The following are some of the leak detection methods that has been
identified by the Environmental Protection Agency (EPA) to meet the federal
leak detection requirements.
Secondary Containment with Interstitial Monitoring

Secondary containment often uses a barrier, an outer wall, a vault,
or a liner around the underground storage tank (UST) or piping. Tanks
can be equipped with inner bladders that provide secondary containment.
Leaked product from the inner tank or piping is directed towards an
interstitial monitor located between the inner tank or piping and the outer
barrier.
Automatic Tank Gauging Systems (including continuous ATG systems)

A probe permanently installed in the tank is wired to a monitor to
provide information on product level and temperature. These systems
automatically calculate the changes in product volume that can indicate a
leaking tank.
Statistical Inventory Reconciliation

In this method, a trained professional uses sophisticated computer
software to conduct a statistical analysis of inventory, delivery, and
dispensing data, which you must supply regularly. Also, the owner can
purchase software and enter data into his own computer, which
statistically analyzes the data.
81
EMHNN CORPORATION
CHAPTER VII
PROJECT CONSTRUCTION EXECUTION PLAN
This chapter contains the management of the construction of the plant as
well as the time frame or project schedule of the undertaking of the project and
the necessary measures to maintain and assure the quality of the carbon anodes
produced.
A. Construction Management
The Aluminum business in India is a wide and a booming industry,
developing a carbon anode plant which is one of its main recipe in of the
countrys industrial hub is a feasible project. The proposed Carbon Anode
Production plant will be undertaken at Nellore District, Andhra Pradesh, India
where most of the targeted markets and raw material source will be easily
accessible. The site is reported to be underdeveloped, where no other industrial
activities have been done.
Gathering of the raw materials from the nearby refineries who sells
petroleum coke will be in the form of dedicated railways, a mainstream mode of
transportation in India and through the jetties for other coal tar pitch and other
needed things. Rain CII and R&D Carbon Industries, being the forefront
companies in the line of calcination and carbon anode production respectively,
will be the partners in terms of the planning, design and over-all process
description. Some of their technology will be adapted and be further enhanced.
The construction and management of the equipment to be installed will be taken
over by Metso Industries and Technip, Inc. Both of the companies have proven
experience in providing world-class, safe and efficient equipment for the
aluminum and other carbon-related industry. They also have good relations with
Rain CII and R&D Carbon Industries. Having all of their expertise and
experience, converting the raw materials into marketable products will be an
easier job. Their cooperation will determine the success of the project.
All of the actions taken and suggestions needed will be addressed to the
Aluminum Association of India composed of engineers, production managers
82
EMHNN CORPORATION
and company owners as well as quality inspectors which is a governing body for
all the aluminum related industry in the country.
B. Project Scheduling
Before the plant will be put into operational status, a certain schedule and
timeline of activities for preparation should be followed as a guide to maintain
the feasibility, economic viability, and success of the proposed project. The
project schedule will include timeline starting from the Planning Stage, Site
Preparation, Construction, Installation of equipment, Commissioning & Start-up
up to the start of operations.
On the planning phase, all of the needed preparation, materials, equipment and
contracts will be discussed by vital personnel from all the partners and
contractors. Determination of the design as well as its viability will be tackled.
Bidding for on plant projects will be done. Worst and best scenarios will be
looked upon critically and mitigation measures as well as problem solving
procedures for all of the possible offsets must be well discussed and
documented. The planning stage is one of the most important part as this will
determine how the project will be undertaken and to what extent will it operate.
The site preparation stage involves the acquisition of necessary legal documents
for the use of the land and all the permits needed before the plant can be
constructed on site. Also included in this stage is the proper cleaning, dredging
and over-all land preparation in compliance with the planned design, spacing,
room for expansion and environmental aspects while doing the job and after it
has been finished. It also includes the preparation of construction materials.
In the construction period, all the facilities will be built. Laboratories, offices,
administration building and other infrastructures both for the accommodation of
employees, ancillaries and process areas will be constructed. The necessary
storages and equipment handling areas should be finished during this period.
As the areas for the equipment are constructed and checked, the installation of
the equipment shall be also in the scope of work. Control systems, line-ups,
proper setting and interconnection of equipment will be focused on in this stage.
As soon as the construction and installation of equipment reached completion,
the plant will be inspected in terms of the over-all functionality. Standards shall
83
EMHNN CORPORATION
be adhered to. Ensuring the smooth flow of the process will be observed through
a dry-run or commissioning of the plant. Through the test run, adjustments can
be done, and problems can be looked on as these will have a great impact as the
plant runs in complete operations. Optimum performance shall be observed at
all times during the operations.
84
EMHNN CORPORATION
Table 7.1
Project Schedule
YEAR
2016
2017
2018
Worki
J F M A M J J A S O N D J F M A M J J A S O N D J F M A M J J A S O N D
ng
Activit A E A P A U U U E C O E A E A P A U U U E C O E A E A P A U U U E C O E
ies
N B R R Y N L G P T V C N B R R Y N L G P T V C N B R R Y N L G P T V C
Planni
ng
(inclu
des
Design
Phase)
Site
Prepar
ation
85
EMHNN CORPORATION
Constr
uction
Install
ation
of
Equip
ments
86
EMHNN CORPORATION
YEAR
2018
Working Activities
Commissioning
Start-up
2019-2023
D J
and
Start of Operation
87
EMHNN CORPORATION
C. Quality Assurance and Control

Quality control is an essential part of plant operations. All products
manufactured must adhere to certain quality checks and standards before being
disposed as marketable. A plants reputation is mostly reflected in the quality of
their products. Proper control of the product specifications must be utilized to
meet the consumers demand and needs. A quality first before quantity
perspective will be imposed in the Carbon Anode plant. Quality will not only be
checked when there are inspectors or visitors, it must be monitored and be
strictly controlled towards every second of production. The entire production
processes will run smoothly and safely from the gathering of raw materials up to
the delivery of the finished product. This will also allow the equipment to run
longer and more efficiently. It is the utmost priority to keep every carbon anode
in the highest quality as possible. Moreover, third party inspectors will be
partnered to ensure that the equipment delivers their functions smoothly and to
avoid further damage to the entire system.
In the checking of the carbon anode quality, the proponents will use a tool
called MIREA. This is a non-destructive measurement of the anodes electrical
resistance which is a vital property needed before it can be used as feed to
aluminum smelters. The older technology made use of sampling cores as test
samples. Having these samples are critical and the amount will be limited thus
limiting the capacity to consistently monitor the product quality. Core sampling
provides limited information on the spatial variability within an anode. For
example, cracks in a specific anode section could remain undetected due to the
absence of the part in the core sample taken. But through the use of MIREA,
carbon anodes are checked in real time. It also aids in identifying and rejecting
anodes having internal cracks leading to premature failure of the anodes. The
acronym is derived from a French translation of Instantaneous Measurement of
Anodic Electrical Resistance. The measurement sequence starts by positioning
the baked anode into the MIREA device, introducing current devices into the
anode tub holes, measuring the anode voltage drop, withdrawing the current
devices from the stub holes and removing the anode from the MIREA. The
device is able to perform complete measurement in time intervals between 60 to
70 seconds. The device is completely automated and requires only limited
maintenance.
88
EMHNN CORPORATION
For other quality checking, samples of the raw materials, gases emitted by
the process and other critical and testable elements of the production will be
tested by the laboratory in every shift.
89
EMHNN CORPORATION
Chapter VIII
SUMMARY OF FINDINGS, CONCLUSION AND RECOMMNEDATION
This chapter presents the conclusion and recommendation that come out
after the completion of the Carbon Anode Production Plant. Furthermore, this
also includes the findings made after going through the whole process.
Summary of Findings
The following results relative to the Carbon Anode Production Plant were
summarized as follows:
E. Based on the technical aspect, The proposed Carbon Anode only used two
types of raw materials including raw petroleum coke (RPC) and coal tar
pitch (CTP).
F. It also found out that one of the parameters, which is the temperature,
greatly affects the production of carbon anode.
G. The result of the economic analysis calculated in Chapter 5 are as follows:
CAPEX = $ 81 705 360.00
OPEX = $ 23 396 576.00/year
Net Annual Income = $ 14 880 000.00
Payback Period = 8.6007 years
Annual Rate of Return = 11.6269 %
Conclusion
The following conclusions are based from the summary of findings
mentioned above.
The raw materials used in the Carbon Anode Production Plant
undergo to the process of calcination that produced calcined petroleum
coke which will be the main feedstock for the creation of carbon anode.
90
EMHNN CORPORATION
One of the parameters, which is the temperature, will be used for
the calcination process in order to clean and remove the volatile
combustion material and moisture of petroleum coke.
The data gathered in Chapter 5 shows that there would be a good
profit with the proposed plant design.
The payback period which is calculated approximately 9 years is
assessed to be realistic.
Recommendation:
For future work, recommendations are suggested below according to
the assumptions, calculations, and conclusions obtained.
7. Future researchers must have a more comprehensive and better plant
layout that will utilize the space considering its economic aspects.
8. Future researchers must have a more systematic understanding about the
economic aspect of the plant because it will determine how much money
is needed and when the return of investment is.
9. Future researchers must find other process that might involves the
enhancing process of carbon anode to be converted to other type of
materials like anodes and aluminum.
10. Periodic checkups and proper maintenance of equipment must be put into
effect to avoid faulty equipment.
11. Future researchers must widen the scope of the design that would lead to
the possibility to do a lot of further work.
12. Future researchers must look for significant ideas that could lessen the
pollutants emitted by the plant.
91
EMHNN CORPORATION
PLANT LAYOUT:
92
EMHNN CORPORATION
Legends:
1. Security office/building
2. Parking Area
3. Administration Building
4. Recreational Facility
5. Central Control Room
6. Fire Station
7. Power Station
8. Warehouse
9. Waste Treatment Facility
10. Laboratory
11. HVAC Room

12. Raw Material Storage
13. Finished Product Storage
14. Process Area
15. Packaging Building
16. Maintenance Building
17. Jetty
18. Expansion Area
93
EMHNN CORPORATION
94

Carbon Anode Production Plant PDF

Загружено:

Сведения о документе

Оригинальное название

Авторское право

Доступные форматы

Поделиться этим документом

Поделиться или встроить документ

Параметры публикации

Этот документ был вам полезен?

Это неприемлемый материал?

Авторское право:

Доступные форматы

Carbon Anode Production Plant PDF

Загружено:

Авторское право:

Доступные форматы

EMHNN CORPORATION

Petroleum related Production Plant

Crushing and Grinding

Screening and Classifying

Petroleum related Production Plant

3. PROXIMITY TO MARKETS AND RAW MATERIAL SOURCES

Petroleum related Production Plant

Petroleum related Production Plant

Petroleum related Production Plant

Figure 1: Map of Refineries in India

Petroleum related Production Plant

Figure 2: Map of Thermal Power Plant in India

Petroleum related Production Plant

Petroleum related Production Plant

Kandla Free Trade Zone (KAFTZ), Gujarat;

In India, there is an organization for any business/investor involved in

Petroleum related Production Plant

The main thrust of this project proposal is to design a Carbon Anode

2. To gather the data and information needed in relation to technical and

4. To determine the economic and financial viability of the proposed project

Petroleum related Production Plant

Petroleum related Production Plant

Petroleum related Production Plant

Petroleum related Production Plant

Source: National Bureau of Statistics of China; China Coking Industry

Petroleum related Production Plant

10. Ball Mill

12. Kneading Mixers

14. Anode Baking Furnace

Data and Assumptions:

Vibrating Screen efficiency = 65%

Cooler efficiency = 97%

Ball Mill efficiency = 88%

Heater efficiency = 100%

Kneading Mixer efficiency = 77%

Waste Heat Boiler efficiency = 100%

Paste cooler efficiency = 97%

Mixing Hopper efficiency = 76%

Anode Baking Furnace efficiency =

Bag House Dust Filter efficiency =

Coal Tar Pitch

Primary techniques considered to maintain optimal moisture content and

Petroleum related Production Plant

Petroleum related Production Plant

Carbon Steel Plates

Petroleum related Production Plant

Petroleum related Production Plant

Petroleum related Production Plant

Petroleum related Production Plant

Petroleum related Production Plant

Petroleum related Production Plant

Petroleum related Production Plant

Petroleum related Production Plant

Petroleum related Production Plant

Petroleum related Production Plant

Outlet pipe diameter

Petroleum related Production Plant

Petroleum related Production Plant

Petroleum related Production Plant

Cooling fan no.

Air cooling area

Petroleum related Production Plant

SECTIONS PER FIREGROUP