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Essar at a Glance
International Footprint
Petcoke
Petcoke Advantage
Government administered prices for coal and natural gas are lower than market prices
Challenges
Petcoke High carbon higher calorific value High fixed carbon higher combustion time Lower volatile matter difficult to ignite Lower ash less waste disposal High sulphur increased corrosion & pollution Dom. coal Very low carbon very low calorific value Very low fixed carbon lower combustion time High volatile matter easier to ignite Very high ash heat loss, disposal problem Low sulphur lower corrosion & pollution
Strengths
Weaknesses
Petcoke is the preferred fuel of choice for the Global cement industry after coal and lignite Petcoke is by far the preferred fuel of choice for European cement industry Cement industry is the largest consumer of petcoke in India (3.7 million tons per annum) Technology to use petcoke in cement plants is mature and easily available
Volatile Matter
Fixed Carbon
Petcoke has higher fixed carbon and needs more residence time to burn completely. As petcoke has lower ash, more raw feed will be required per unit of clinker. More oxygen is required for complete combustion Higher flame temperature increases NOx emissions
Ash
Provision of more secondary air NOx control technologies if NOx levels are higher than regulated levels
Modification of the raw mix so that combinability temperature is reduced. Bypass line might be required
Sulphur cycle
Refractory bricks can be replaced with AluminaZirconia-Silica or silicon carbide based castable which has low adherence property.
Process Modifications
Finer grinding of petcoke Larger blower for primary air More secondary air Modify raw mix to account for higher S & lower ash
Financial Benefits
OPEX Savings
Cement production is energy intensive Energy cost is around 20% of sales Any saving in energy cost boosts profits tremendously
Base Case
Total Energy Cost ($ K) Saving % 13,316 -
Petcoke in Kiln
12,248 8%
Profit Improvement
% Revenue Basis
$ / MT Basis
Sensitivity Analysis
EBITDA compared to Base Case: $ 1.33 /MT Cement
Sensitivity Analysis
PAT compared to Base Case: $ 0.9 /MT Cement
Petcoke in India
Supply
< 0.5 MMTPA to > 10 MMTPA in the last decade Addition of coker units to boost supply
Demand
< 0.5 MMTPA to > 10 MMTPA in the last decade Coal shortage boosting demand Cement sector is the major user
Prices
Generally set relative to imported coal prices
Regional Data
Production
New cokers to produce fuel grade petcoke Surplus in West to increase Fuel grade petcoke will be produced in East and South too by 2015
Facilities
Production
1.8 million tons per annum petcoke production capacity
Storage
2 silos with capacity of 1000 tons each Open storage yard Storage near rail siding
Logistics
24 7 road loading Integrated rake loading Coastal loading facilities from Bedi port
Quality
Stringent quality control at all stages State of the art quality control lab
Customer Service
Dedicated sales team for customer delight Customized solution for converting from other fuels Support in troubleshooting
Specifications
S.No 1 2 Ash Parameter Moisture (ARB) Unit % wt % wt Limits 8.0 max 0.5 max
3
4 5 6
Volatile Matter
Fixed Carbon Gross Calorific Value (ADB) Sulphur
% wt
% wt Kcal/Kg % wt
8.0 min
85 min 8,200 min 4-7
HGI
36 - 52
Benefits
Cost
Cheaper than many fuels on a calorific basis Capture of entire calorific value of fuel leading to higher efficiency
Availability
Increasing supply Reliable supplies from various refineries
Calorific Value
High net calorific value
Ash
Lower ash with no disposal problems Lower abrasion
Handling
Lower quantity of fuel to be handled Lower area required for storage Non hygroscopic - doesn't absorb moisture Lower handling and transportation losses
Thank You