TECHNICAL PROPOSAL

OF
PDVSA INTEVEP- CALCINING PETCOKE UNIT
IN VENEZUELA

China Aluminum International Engineering Corporation Limited

(CHALIECO)
No.: 13Q-VE/PD/003
July 15th, 2013
 Table of Contents
1. Introduction .....................................................................................................................1
2. Basic Project Parameters and Battery Limit .................................................................. 1
2.1 Basic Project Parameters ................................................................................... 1
2.2 Project Location .................................................................................................. 1
2.3 Battery Limit ........................................................................................................ 1
2.4 Units of Project ................................................................................................... 2
3. Design Basis...................................................................................................................3
3.1 Green Petcoke .................................................................................................... 3
3.2 Product Quality ................................................................................................... 4
3.3 Battery Limit Conditions...................................................................................... 6
3.4 Turndown Ratio .................................................................................................. 6
3.5 Environmental Standards ................................................................................... 6
3.6 Meteorological Design Conditions ...................................................................... 7
3.7 Ground Features ................................................................................................ 8
3.8 Utilities ................................................................................................................ 8
3.9 Design Standards ............................................................................................... 9
3.10 Units of Measurement ........................................................................................ 9
4. Description of Calcining Process .................................................................................10
5. Technical Scheme of Calcinations Process ................................................................. 13
5.1 Stacking of Raw Materials ................................................................................ 13
5.2 Crushing of Petcoke ......................................................................................... 13
5.3 Feeding of Petcoke........................................................................................... 13
5.4 Calcining of Petcoke ......................................................................................... 14
5.5 Cooling of Calcined Petcoke ............................................................................ 15
5.6 Screening and Crushing of Calcined Petcoke ................................................. 15
5.7 Storage and Packaging of Calcined Petcoke ................................................... 15
5.8 Burning of Calcining Fume ............................................................................... 16
5.9 Dust Collection System .................................................................................... 16
6. Description of Major Calcining Equipment ................................................................... 16
6.1 Rotary Kiln ........................................................................................................ 16
6.2 Cooler ............................................................................................................... 18
6.3 Incinerator ......................................................................................................... 19
6.4 Combustion Control System of Rotary Kiln ...................................................... 21
6.5 Combustion Control System of Incinerator ...................................................... 21
6.6 Semi-portal Reclaimer ...................................................................................... 22
7. Waste Heat Utilization Proposal...................................................................................22
7.1 Process Description.......................................................................................... 22
7.2 Waste Heat Boiler House ................................................................................. 22
7.3 Desulfurization Device ...................................................................................... 24
7.4 Steam Turbine Generator House...................................................................... 24
8. Material Flow ................................................................................................................25
9. Material Balance and Heat Balance ............................................................................. 26
10. Main Equipment and Material List ................................................................................ 31
11. Proprietary Technology ................................................................................................32
12. Achievement .................................................................................................................33
13. Plants Proposed to Visit ...............................................................................................34
1. Introduction

The project involves a cooperation agreement between two national companies

PDVSA and CVG Carbonorca to build calcining petcoke unit to produce 750kt/a
calcined petcoke from green petcoke. The raw material of green petcoke is
by-product of two oil refineries in Venezuela.

After design, installation, startup and operation, the calcining petcoke unit will
produce 450t/a packing-grade calcined petcoke and 300kt/a anode-grade
calcined petcoke for aluminum industry.

2. Basic Project Parameters and Battery Limit

2.1 Basic Project Parameters

Basic parameters:

Calciner Rotary kiln

Production lines Two (2)

Specification of rotary kiln φ4.05X72m

Raw material Green petcoke

Capacity 1x60 t/h, packing grade calcined coke

1x40 t/h, anode grade calcined coke

Annual operating time 330 days/year

Operating mode Continuous

Service life of refractory material Three years

2.2 Project Location

It is located in Matanzas Industrial Complex in Venezuela.

2.3 Battery Limit

As required by the Owner (showed as ISBL), the working scope mainly includes
green petcoke storage, green petcoke pretreatment, rotary kiln calcination,
cooling system, incineration room system, ventilation and dust collection system,
intermediate silo, calcined coke storage, heat recovery and emissions treatment
system, etc.

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 Figure 1 ISBL and OSBL Calcining Petcoke Unit

2.4 Units of Project

Table 1 Unit of Project

No. Scope Remarks
1 Petcoke calcination
1.1 Raw material stacking
1.2 Petcoke crushing
1.3 Petcoke feeding
1.4 Petcoke calcination
1.5 Calcined petcoke cooling
1.6 Calcined petcoke screening
and breaking
1.7 Calcined petcoke storage and
packaging
1.8 Calcined fume incinerating
2 Heat recovery Fume from outlet of incinerator shall
enter into waste heat boiler to
generate steam for power generating.
2.1 Waste heat boiler house
2.2 De-sulfurization device
2.3 Turbine generator house

Notes:

1) The ventilation and dust collection of each unit shall be included in the Calcining
Petcoke Unit.

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2) Each cooling water system, chemical water system, firefighting water system,
potable water system and compressed air are not included in the design, which
shall be provided by the Owner.

3. Design Basis

3.1 Green Petcoke

The physical and chemical characteristics of green petcoke are shown in Table
2 and Table 3.

Table 2 Typical properties of green petcoke (fuel grade) from

Petroanzoátegui Upgrader

(Test run: October 2010 – January 2011). Sample number: 19. Lot size: 4000 t

No. Parameters Unit Index Measurement

method
1 Moisture % 6 ISO-11412
2 Volatile % 14 ISO-9406
3 Ash % 1.3 ISO-8005
4 Bulk density kg/cm3 0.79 ISO-10236
5 HGI (Hardgrove 75 ISO5074
Grindability Index)
6 Micro element
S % 4.7 ISO-12980
Si PPm 310 ISO-12980
Fe PPm 71 ISO-12980
Na PPm 100 ISO-12980
Ca PPm 108 ISO-12980
V PPm 2055 ISO-12980
Ni PPm 434 ISO-12980
7 Sizing
≥19mm % 8
19~9.5 % 25
9.5~6.3 % 15
6.3~4.75 % 7
4.75~2.36 % 11
2.36~0.85 % 13
0.85~0.15 % 15
≤0.15mm % 6

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 Table 3 Typical properties of green petcoke from Amuay CRP Refinery

(Test run: October 2010 – January 2011). Sample number: 19. Lot size: 4000 t

No. Parameters Unit Index Measurement

method
1 Moisture % 6 ISO-11412
2 Volatile % 14 ISO-9406
3 Ash % 0.2 ISO-8005
4 Bulk density kg/cm3 0.79 ISO-10236
5 HGI (Hardgrove
75 ISO5074
Grindability Index)
6 Micro element
S % 3.5 ISO-12980
Si PPm 140 ISO-12980
Fe PPm 70 ISO-12980
Na PPm 80 ISO-12980
Ca PPm 80 ISO-12980
V PPm 350 ISO-12980
Ni PPm 250 ISO-12980
7 Sizing
≥19mm % 8
19~9.5 % 25
9.5~6.3 % 15
6.3~4.75 % 7
4.75~2.36 % 11
2.36~0.85 % 13
0.85~0.15 % 15
≤0.15mm % 6

3.2 Product Quality

The project will produce such two products as packing-grade and anode-grade
calcined petcoke, of which the composition index are listed in Table 4 and Table
5.

Table 4 Calcined petcoke – packing grade specifications

No. Parameter Unit Index Measurement method

1 Bulk density kg/cm 3
≥0.8 ISO-10236
2 Moisture % ≤5 ISO-11412
3 Ash % ≤8 ISO-8005
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 No. Parameter Unit Index Measurement method
4 Volatile % ≤3 ISO-9406
5 Phosphorous % ≤0.05
HGI (Hardgrove
6 25~40 ISO5074
Grindability Index)
7 Particle stability % ≥75 ISO-10142
8 Micro element
S % ≤4.7 ISO-12980
Si PPm ≤1000 ISO-12980
Fe PPm ≤900 ISO-12980
Na PPm ≤200 ISO-12980
Ca PPm ≤180 ISO-12980
V PPm ≤2600 ISO-12980
Ni PPm ≤600 ISO-12980
9 Sizing
≥19mm % 5
19~9.5 % 24
9.5~6.3 % 21
6.3~4.75 % 11
4.75~2.36 % 15
2.36~0.85 % 10
0.85~0.15 % 11
≤0.15mm % 3

Table 5 Calcined petcoke – anode grade specifications

No. Parameter Unit Index Measurement

method
1 Real density kg/cm3 ≥2.05 ISO-8004
2 Resistivity μΩ.m ≤520 ISO-10143
3 Bulk density kg/cm3 ≥0.85 ISO-10236
4 CO 2 reactivity % ≤10 ISO-12981-1
5 Air reactivity %/min ≤0.2 ISO-12981-2
6 Moisture % ≤0.2 ISO-11412
7 Ash % ≤0.3 ISO-8005
8 Volatile % ≤0.3 ISO-9406
9 HGI (Hardgrove 30~40 ISO5074
Grindability Index)
10 Particle stability % ≥75 ISO-10142
11 Micro element
S % ≤3.0 ISO-12980

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 No. Parameter Unit Index Measurement
method
Si PPm ≤180 ISO-12980
Fe PPm ≤250 ISO-12980
Na PPm ≤100 ISO-12980
Ca PPm ≤100 ISO-12980
V PPm ≤450 ISO-12980
Ni PPm ≤200 ISO-12980
12 Sizing
≥19mm % 5
19~4.75 % 25~35
4.75~0.85 % 50
≤0.85mm % 25

3.3 Battery Limit Conditions

The operating conditions of main systems, inlet and outlet of the Calcining
Petcoke Unit are listed in the Table 6:

Table 6 Operating conditions

Streams Pressure Temperature(℃)
(kg/cm2g)
Feed-stocks (input) Green Petcoke Ambient Ambient
Products (out-put) Calcined Petcoke Ambient Ambient

3.4 Turndown Ratio

The Calcining Petcoke Unit shall be designed at least to operate at 60% of its
normal capacity.

3.5 Environmental Standards

Concentrations of emission from Calcining Petcoke Unit should not exceed the
limits in Table 7.

Table 7 Environmental standards and legislation

Pollutant or parameter Limit Standards

(mg/m3)
NOx 150 638 Venezuelan Decree
SO2 350 (1-hour) European community
125 (25-hour)
H2S 5 638 Venezuelan Decree
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 Particulate matter (PM)
PM2.5 (annual arithmetic mean) 25 European community
PM10 (maximum 24-hour 50
average)
PM10 (annual arithmetic mean) 40
CO (maximum 8-hour average) 10 European community

Table 8 Limits for process wastewater

Pollutant of parameter Limit (mg/liter, exception PH and
temperature)
Ph 6-9
BOD 50
COD 250
Oil and grease 10
Metals
Heavy metals, total 10
Arsenic 0.1
Cadmium 0.1
Chromium
Hexavalent 0.1
Total 0.5
Copper 0.5
Iron 3.5
Lead 0.1
Mercury 0.01
Nickel 0.5
Selenium 0.1
Silver 0.5
Zinc 2.0
Ammonia 10
Fluoride 20
Chlorine total residual 0.2
Phenols 0.5
Phosphorus 2.0
Sulfide 1.0

3.6 Meteorological Design Conditions

Table 9 Meteorological conditions in Matanzas Industrial Complex

Design ambient conditions
Ambient temperatures (℃) 2009 2010
Max. 38 39
Min. 23 25
Max. Abs 311 312
Min. Abs 296 298
Relative humidity (%)
Max. 100 93
Avg. 86.7 85.9

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 Min. 21 56
Design wind speed (m/s) (10m above
ground level
Max. 15.2 15
Avg. 9.2 7.8
Min. 2.7 1.8
Prevailing wind direction SE SE

Notes: Due to such data as rainfall, atmosphere pressure, earthquake grade,

altitude, environment erosion are not provided by the Owner, the process
parameters and process option shall be subject to adjustment in the execution
stage as the case may be.

3.7 Ground Features

Due to the fact that geological survey information is not provided by the Owner,
so the design is developed according to the following assumptions.
 Natural foundation
 No influence of the underground water

3.8 Utilities

Table 10 Utilities provided by Owner

Utility Installed Consume Available Comments
capacity (monthly) capacity
(monthly) (monthly)
Electricity 8MVA 3MVA 5MVA There is electricity
back up of 13.8kV
(breakers of 1.200A)
Compressed 7,500,000 1,000,000 6,500,000 There are 3 lines of
air m3 m3 m3 compressors (7 bar
working pressure)
and reserves to
install 2 additional
compressor lines
Gas 7,345,000 2,000,000 5,345,000 Inlet pressure: 20
m3 m3 m3 bar
Water 303,26 m3 Potable: 284,064 m3 There are tanks with
6,500 m3 the following
Raw: capacity: Potable
12,700 m3 water: 300m3
Total: Industrial water:
19,200 m3 1,000m 3

Firefighting system:
4,500 m3, 6 bar

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3.9 Design Standards

 Design shall be made in accordance with ISO drawing standards;

 Electrical design shall be made in accordance with IEC standard;

 Design of standard and non-standard equipment made in China shall be

prepared in accordance with the Chinese standards;

 Design of fire fighting, health and safety shall be made in accordance with

Venezuela standards if provided by the Owner or Chinese standards if not.

3.10 Units of Measurement

The international measurement unit in Table 11 shall be adopted.

Table 11 International Measurement Unit

Property Units
Current Amps, milliamps (A, Ma)
Density (bulk, volumetric) Kg/ m3 or metric ton/ m3(t/ m3)
Flow (gas) Normal m3/ h (N m3/ h)
(normal conditions-0℃ &1.0atm)
(Actual m3/h Am3/ h)
Cubic meters per hour (m3/ h)
Flow (liquid)
Kilo Newton (kN), Newton (N)
Force (loading)
Hertz (Hz)
Frequency
Millimeters (mm) or meters (m)
Length/ displacement
Kilograms (kg), metric tons (t)
Mass
Kg-m2
Moment of inertia (mass)
Kilowatts (kW), horse power (hp)
Power
Pascal (Pa), bar (bar) mmH2O, mmHg
Pressure
Ohms
Resistance
Decibels (dBA)
Sound pressure level
Mega Pascal (MPa)
Stress
Temperature Degrees Celsius (℃)
Time Seconds (s), minutes (min), or hours (h)
Torque/moments kilo Newton-meters (Kn-m)
Velocity kilo meters (km/h)
meters/second (m/s)
Voltage Volts, kilo Volts, milli Volts (V, kV, mV)
Volume Cubic meters (m3)
Weight Kilograms (kg) or metric tons (t)
Viscosity Centi poise (cP)
Energy Giga calories (Gcal), kilo Joules (kJ)
Wave length Meters (m)
Vibration velocity Mm/sec

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4. Description of Calcining Process

The green petcoke is sent to raw materials stacking area for direct storage via
truck or belt conveyor. When it’s needed, green petcoke is loaded by the
reclaimer and delivered to gear-roll crusher via belt conveyor for primary
crushing. The crushed petcoke is transferred to the silo via bucket elevator for
storage.

The petcoke in the silo is conveyed to the bin before calcining through
electromagnetic vibrating feeder, belt conveyor and bucket elevator. The green
coke in the bin is weighed by the constant weight feeder, and sent to the rotary
kiln via air-cooled feeding chute. The petcoke is fed from the feed end of rotary
kiln. The petcoke moves to the other end along with the rotation of the kiln. The
coke goes through three sections respectively as pre-heating, calcining and
cooling, and green petcoke is heated gradually from the ambient temperature to
about 900~1350℃ after pre-heating and calcining .

High temperature calcined petcoke is sent to the cooler via discharge end.
Cooler runs with direct water spraying, and the cooling water is directly sprayed
on the surface of hot calcined coke. With the moving of calcined coke in the
cooler, its temperature is lowered to about 120 ℃ . The calcined coke is
discharged from the outlet of cooler.

The calcined petcoke after cooling is delivered to coke screening and crushing
system through bucket elevator and belt conveyor. The screened calcined
petcoke is entered into calcined petcoke silo for storage, which can be directly
transported outside of the plant via belt conveyor or transferred to the
warehouse for storage or sale after packaging.

The steam containing much dust generated from the cooler is collected by
multi-clone. The fume is sent to the incinerator for treatment to reduce the
amount of fume. The collected calcined coke powder is sent back to production
system for recycling.

The feed end is connected with incinerator and the high temperature fume
generated in the kiln will enter into the incinerator. A great deal of petcoke dust
contained in the fume settles and gathers at the cover body, and goes into the
collecting box through heavy cover valve, and then returns to the production
system for recycling. The fume entering into the incinerator contains lots of
volatile, so it shall be further burned and after that sent to the waste heat
recovery system.
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 Please refer to process flow sheet as follows:

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Process flow sheet

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5. Technical Scheme of Calcinations Process

5.1 Stacking of Raw Materials

The main raw material of calcination is green petcoke, so fluctuation of its

performance index shall directly affect the operation of rotary kiln and quality of
calcined coke, and also affect the emission level of greenhouse gas of the plant.
The qualities of two kinds of green petcoke vary greatly as follows:

 S content in the green petcoke varies greatly;

 Contents of Na, V and Ni in petcoke vary greatly;

Therefore, the petcoke from two origins are stored separately. The coke stack
yard is a building of double-span with a width of 39m. Each span is divided into
three sections, storing one kind of raw material for production in each section.
Namely, the double-span building has six section, capable to store six kinds of
different green petcoke.

Two semi-portal reclaimers are arranged inside two semi-portal buildings,

reclaiming two different types of petcoke.

The raw materials are delivered to the discharging belt conveyor at the top of the
building via truck or belt conveyors for stacking. The stacking capacity of two
different raw materials is 35,000 tons respectively, with storage capacity of 30
days for anode grade calcined coke and storage capacity of 20 days for the
packing grade.

5.2 Crushing of Petcoke

The petcoke shall be crushed before feeding into the rotary kiln. The particle size
after crushing is required to less than 70mm. Two roll crushers are provided for
the treatment of two kinds of green petcoke. After crushing, the petcoke is fed
into the respective silo with a diameter of 12m and a storage period of one day.

5.3 Feeding of Petcoke

The petcoke from two silos are sent respectively to the bins before calcining of
two rotary kilns. The capacity of petcoke storage shall be calculated based on
production process with a storage period of 4 hours.

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5.4 Calcining of Petcoke

The rotary kiln calcining technology is adopted.

The rotary kiln uses direct heating and calcining process, i.e. the volatile in green
petcoke, the mixture of some fuel and air burn in the kiln and to realize direct
high temperature calcining. The material fed from the feed end of the kiln
realizes countercurrent heat exchange in the kiln. As the kiln is installed in a
slope, so when the kiln body turns, the material moves along the axial direction.
The burner injects the fuel from the discharging end, and the fume exhausts
from the feed end. The material is heated during the movement, and after
physical and chemical reaction, the qualified product shall be discharged from
the discharging end.

Two rotary kilns with identical specification are adopted to treat two kinds of
materials, with a capacity of 60t/h for the packing grade calcined coke and that of
40t/h for the anode grade. The first kiln is only for producing the packing grade
calcined coke, the second only for anode grade.

The heat during the calcining of rotary kiln is mainly from the combustion of
volatile of green petcoke and petcoke and supplementary natural gas. If the
content of volatile is high, volatile will seriously overflow under high temperature
to cause the pulverization of raw materials and difficulty to control the
temperature inside the kiln. Therefore, the volatile content of green petcoke is
normally kept in the range of 8~14.5%.

In the process of calcining, SO2 from the loss of ignition of green petcoke and
the extraction of sulphur under high temperature will give rise to the corrosion of
refractory materials inside the rotary kiln, incinerator and flue, seriously affecting
the service life of equipment and pipelines. Thus, the sulphur content shall be
kept below 4.5%.

When the powder in the green petcoke is high, the powder will directly go
through the incinerator, causing the increase of loss of ignition, reducing the
actual yield and increasing the load of incinerator. Therefore, powder of less
than 1mm shall be controlled below 25%.

In addition, the water content of green petcoke shall be kept below 12% and HGI
is limited to be 80~120.

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5.5 Cooling of Calcined Petcoke

The calcined petcoke is cooled via cooler which is rotating equipment with its
body mounted in a slope. Direct cooling with spray water is adopted. One stage
of refractory is used at the feed end. The cooler is featured with simple structure
and high running rate. The high temperature fume generated during cooling is
primarily treated via multi-clone collector, and then the fume treated is sent back
to the incinerator by the fan for secondary treatment.

5.6 Screening and Crushing of Calcined Petcoke

The calcined coke shall be first screened before delivery to the storage silo. For
two different raw materials, one set of screening and crushing system shall be
mounted respectively; the oversize ≥
( 20mm) returns crusher for crushing and
crushed calcined coke returns to continue screening while the undersize enters
into the respective calcined storage silo.

5.7 Storage and Packaging of Calcined Petcoke

There are totally two storage silos for different kinds of calcined petcoke with a
diameter of 30m and a height of 46m. The storage capacity of each silo is
20,000 tons, with storage capacity of 24 days for anode grade calcined coke and
storage capacity of 16 days for the packing grade.

The calcined petcoke is discharged respectively into belt conveyor via the
electromagnetic vibrating feeder at the bottom of storage silos, and then
transferred to six loading silos via bucket elevator and belt conveyor. There are
three loading silos for each kind of calcined products.

Each loading silo can feed the transportation truck via the telescopic chute. With
the sustained accumulation of calcined petcoke, the telescopic chute equipped
with dust collector slowly rises upward.

Calcined petcoke can also be packed in bag via packing machine at the bottom
of storage silo. There are three packing machines for each storage silo. The
bagged calcined petcoke is directly sent to finished product warehouse with a
capacity of 20,000 tons through roller, stacked via hook crane.

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5.8 Burning of Calcining Fume

The high-temperature fume from rotary kiln contains a great deal of coke and
unburned volatiles, so it is necessary to be burnt. In this project, one incinerator
is used to treat the high-temperature calcination fume. The incinerator is a fixed
cylinder equipment installed horizontally, which can be used for the further
burning of dust and volatiles. Fume from its outlet is sent to the power generation
system for further utilization.

5.9 Dust Collection System

The carbon dust generated from the crushing/conveying of green pet coke and
calcined coke is collected by the bag filter, which is returned to and reused in the
production system.

6. Description of Major Calcining Equipment

6.1 Rotary Kiln

Specification for the rotary kiln in this project: Φ4.05 × 72m

The secondary/tertiary air facilities are arranged on the front and rear parts of
the kiln to better support combustion. Two slip-ring power supply units are
arranged for the motors of secondary/tertiary air combustion fans. The rotary kiln
is composed of burner, kiln discharge end hood, rolling ring, forming air, tertiary
air facility, cylinder body, transmission gear, kiln feed end hood, support device,
slip-ring power supply unit, support device with a catch wheel, lubrication device
and other components.

The cylinder body of the rotary kiln is made of steel sheets with different
thicknesses, and has different diameters including the expansion zone and
non-expansion zone. There are three supporting sections for cylinder body. The
transmission system drives kiln body to rotate via the big gear ring in the middle
of the cylinder body in variable frequencies.

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 The kiln discharge end hood is a part connecting the kiln discharge end and the
cooling cylinder. The air for burner and combustion is sent into the kiln through
the kiln discharge end hood. Refractory castable is lined inside discharge end
hood. The calcined petcoke is discharged from the lower part of the kiln
discharge end hood, and the kiln discharge end hood can move along the rail
(axial direction of the cylinder body) when it is dismantled for repairing.

The kiln feed end hood is a part connecting the end of the cylinder body, material
feeding equipment and fume treatment equipment. The fume is emitted from the
kiln feed end hood, and the materials are fed through the material feeding
equipment directly from the feed end of the kiln. The sealing device (kiln feed
end sealing device) is arranged between the stationary kiln end hood and the
rotary cylinder body.

The front and end secondary/tertiary air facilities (including fans, motors, air duct,
etc.) cylinder are arranged on the rotary kiln. Six air inlets are arranged for the
secondary air facilities at the kiln discharge end, and six air inlets are arranged
for the tertiary air facilities at the kiln feed end. All the air pipes (12) are somehow
bended after they are inserted into the cylinder body. Both the secondary and
tertiary air facilities are fixed on the cylinder body, which rotate together with the
cylinder body.

The slip-ring power supply unit is composed of the rotary part and the fixed part.
The power is led to the slip ring via wires through the fixed current collector, and
then connected to the fan motors of secondary/tertiary air facilities via wires.

The stainless steel anchors are welded on the inner wall of the cylinder body, on
which the steel mesh and refractories are applied. The refractory material of the
rotary kiln is subject to corrosion, abrasion and damage. The service life of
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 refractory materials is designed to be three years.

Rotary kiln has the following advantages:

 New lining casting method is adopted to prolong the maintenance cycle and

improve yearly operation rate;

 Tertiary air pipe made of special material can avoid air pipe lining dropping

and air pipe burning-out;

 Proper location of tertiary air pipe installation can make the volatile overflow

location match the time during petcoke calcining, improve physical and

chemical indexes of calcined petcoke, solve the problems of higher energy

consumption and tail gas emission in carbon industry;

 Scale sealing for feed end and discharging end are adopted to lower fume

overflow;

 Rolling ring power supply device adopts current collector to realize

continuous power supply;

 More precise control of rotary kiln revolution and more flexibility of residence

time of materials according to production conditions.

6.2 Cooler

Specification for the cooler: Φ3.1 × 31.5m.

The cooler is composed of movable chute, rolling ring, transmission gear,

discharging end device, supporting device, supporting device with a catch wheel,
lubrication device and dust collecting hood, etc.

The cylinder body of the cooler is made of steel sheets with different thicknesses,
and cylinder body is of straight cylinder type with refractory materials at 7m on
high end of the cylinder body. The service life of refractory materials is designed
to be three years.

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 Two supporting devices are arranged for the cylinder body. The weight of
cylinder body, lining, materials, gear ring of transmission gear and all the others
rotary parts shall be transferred to the supporting device through the rolling ring.
The catch wheel is arranged on the second supporting device (supporting device
with a catch wheel).

The transmission system drives kiln body to rotate via the big gear ring on the
cylinder body in variable frequencies.

The movable chute is a part connecting the rotary kiln discharge end and the
cooling cylinder. The calcined petcoke from rotary kiln are sent into the cooler
through the movable chute, the refractory materials are also lined inside the
movable chute. Inside moving chute, there is water-spray cooling device to inject
water into the cylinder body through the pipe, and the water volume can be
adjusted.

The discharging end device is a part connecting the end of the cylinder body and
materials conveying equipment. The material is discharged from the discharging
end.

The dust collection hood is used to collect the steam generated during the
water-spray cooling process and the dust emitted from the turning of materials.

6.3 Incinerator

Specification for the incinerator in the project: Φ7 .6× 70m.

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 The incinerator is used to treat the high-temperature fume from the rotary kiln,
and the high-temperature fume contains the unburned volatiles and carbon dust,
which can be fully burnt and settled after treatment. The fume inlet of incinerator
is connected with the material feeding end of rotary kiln. Given the relatively
higher temperature of fume, a layer of refractory material is necessary to be
lined inside incinerator. The refractory material of the rotary kiln is subject to
corrosion, abrasion and damage. The service life of refractory materials is
designed to be three years.

The combustion system is available at the inlet of incinerator, which is used for
the incinerator preheating before the system startup and fuel makeup for normal
operation, so as to stabilize the fume flow of waste heat system. Meanwhile, one
cooling fan is arranged to provide oxygen gas for the incinerator, so as to ensure
full combustion of volatiles and carbon dust. The monitoring device of oxygen
concentration is arranged on the rear part, in order to adjust the fan revolution
and regulate the flow rate. Moreover, the monitoring device of temperature and
carbon monoxide are also arranged at the outlet, so as to monitor the
combustion conditions in the furnace.

The incinerator is equipped with two dust hoppers to collect the falling dust. The
dust is discharged from the incinerator through the heavy cover valve.

The incinerator has two outlets, and one outlet is connected to the waste heat
power generation system, and the other is connected to the emergency flue. In
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20
 the case of emergency, the high-temperature fume can be discharged directly
through the chimney.

6.4 Combustion Control System of Rotary Kiln

Each rotary kiln is equipped with one set of combustion control system at the
material outlet of rotary kiln, with the natural gas nozzle, which is mainly used for
kiln preheating before the system startup and fuel makeup during the normal
operation. The nozzle is equipped with the primary air fan to provide oxygen for
the fuel. The air volume is adjusted through the regulation of the fan damper.
Meanwhile, the forming fan is also arranged to regulate the air volume through
fan damper, so as to change the shape of flame.

The nozzle is installed in the rail convenient for coming into and going out of the
rotary kiln. The fan is installed on a nearby platform, which is connected to the
nozzle through hose.

The combustion control system is composed of a set of valve stand, including

pipes, control valves and shut-off valves, so as to achieve the automatic supply
and regulation of fuels. The valve stand is installed on the platform, which is
connected to the nozzle through hose.

6.5 Combustion Control System of Incinerator

Each incinerator is equipped with one set of combustion control system at the
fume inlet of the incinerator, with the natural gas nozzle, which is mainly used for
the incinerator preheating before the system startup and fuel makeup when the
rotary kiln is operating under lower capacity. The nozzle is equipped with the
primary air fan, to provide oxygen for the fuel. The air volume is adjusted through
the regulation of the fan damper. The nozzle is installed on the incinerator, and
the pipes of ring type are arranged. The fan is installed on the nearby floor slab,
which is connected to the nozzle through the hose.

The combustion control system is composed of a set of valve stand, including

pipes, control valves and shut-off valves, so as to achieve the automatic supply
and regulation of fuels. The valve stand is installed on the floor slab, which is
connected to the nozzle through the hose.

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6.6 Semi-portal Reclaimer

Two semi-portal reclaimers are mainly used for green petroleum coke, and the
reclaimer can be operated automatically with the reclaiming capacity of 200t/h,
in variable frequencies. The semi-portal reclaimer is widely used in raw materials
stack yard, with larger stacking area, higher utilization rate of volume and greater
capacity.

7. Waste Heat Utilization Proposal

7.1 Process Description

Under normal working conditions, the high-temperature fume from rotary kiln is
sent through the flue into the desulfurization tower via the waste heat boiler, dust
filter and induced draft fan. The acceptable fume from the desulfurization tower
is then discharged into the atmosphere after dust collection and desulfurization.
Under the abnormal working conditions, the high-temperature fume from rotary
kiln is sent through the flue into the emergency chimney, from which it is
discharged into the atmosphere. The fume from the boiler can be sent into the
emergency chimney via the induced draft fan and bypass without passing
through the desulfurization tower. The superheated steam generated from the
waste heat boiler is used for the power generation of turbo-generator. The
condensed water generated from the superheated steam of turbo-generator is
sent into the deaerator via the shaft seal heater. Both the condensed water and
the boiler makeup water after deoxidization are boosted and sent into the high
pressure heater through the water feed pump. The boiler makeup water is used
to produce the superheated steam through the waste heat boiler’s economizer,
cooled wall, boiler barrel and superheater.

7.2 Waste Heat Boiler House

To fully utilize the waste heat of fume and reduce energy consumption, each
rotary kiln is equipped with one waste heat boiler.

The rotary kiln anode grade calcined petcoke is equipped with one waste heat
boiler as follows:

Rated evaporation D=145t/h

Fume temperature of boiler t=200℃

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 Pressure of superheated steam P=3.82MPa

Temperature of superheated steam t=450℃

Temperature of water supply t=105℃

Fume temperature at inlet of boiler t=1150℃

The rotary kiln for packing grade calcined petcoke is equipped with one waste
heat boiler as follows:

Rated evaporation D=200t/h

Fume temperature of boiler t=200℃

Pressure of superheated steam P=3.82MPa

Temperature of superheated steam t=450℃

Temperature of water supply t=105℃

Fume temperature at inlet of boiler t=1150℃

The heating system of the waste heat boiler house is composed of the waste
heat boiler, thermal deaerator, continuous blowdown expansion device, regular
blowdown expansion device and boiler water supply pumps, etc.

The steam generated from the waste heat boiler is used for the power
generation of turbo-generator, and the demineralized water is supplied by an
external water treatment station.

In order to prevent the waste heat boiler from calcium scales, the phosphate
treatment system is applied to the boiler, with one phosphate-dosing device in
the design.

The continuous blowdown and regular blowdown are arranged for the boiler, one
continuous blowdown expansion device and two regular blowdown expansion
devices are arranged.

In order to remove ashes from the boiler heating surface, the boiler is equipped
with the soot blower.

The steam generated from the waste heat boiler is used for the power
generation of turbo-generator.

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23
7.3 Desulfurization Device

As for the sulfur dioxide content of boiler fume, one set of desulfurization unit is
arranged at the rear part of each waste heat boiler (two sets in total). The fume is
dedusted by the multiclone dust collector before it enters desulfurization device.
The desulfurization system adopts the “lime-gypsum” wet desulfurization
process. The alkaline solution such as lime slurry (Ca(OH)2) is used as the
desulfurization agent with respect to the wet desulfurization process, and the
desulfurization agent reacts with SO2 in the absorption tower. The wet
desulfurization process enjoys a relatively higher utilization rate and better
desulfurization result, with the desulfurization efficiency exceeding 95%. The
“lime-gypsum” wet desulfurization process mainly includes the following: The
fume is washed in the washing tower to reduce temperature, with some dusts
removed from the fume at the same time. The cooled fume is desulfurized in the
absorption tower with lime slurry, which is demisted, heated and discharged from
the chimney. The mixed slurry which contains the calcium sulfite and calcium
sulfate is oxidized, then the gypsum slurry is treated by centrifugal filtration and
washed to produce the finished gypsum.

7.4 Steam Turbine Generator House

Two condensing steam turbines and two steam turbine generator sets are
adopted for the design and the technical characteristics are as follows.

Condensing steam turbine:

Main technical parameters:

Model: N40-3.43-1 two sets

Revolution rated/critical: 3600r/min

Rated power: 40000kW

Rated initial steam pressure: 3.43+0.196-0.294MPa

Rated initial steam temperature: 435+10-15 ℃

Rated steam flow: 170t/h

Rated exhaust steam pressure: 4.4kPa

Main technical parameters of generator:

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 Model: QF-K40-2

Rated power: 40MW

Rated stator voltage: 13800V

Rated revolution: 3600r/min

Rated power factor: 0.8

Efficiency: 97.5%

Phase number: 3

Connection: Y

Frequency: 60Hz

Diversion: Clockwise along the airflow direction

Excitation: SCR excitation

Arrangement: Bilayer

Main auxiliary equipment for each steam turbine generator set: one condenser,
one oil system composed of oil tank, oil cooler, main oil pump and auxiliary oil
pump, one water jet extraction system composed of two-stage water vapor
extractor and start-up vapor extractor and one generator air cooler

The waste heat power generation system is temporarily designed to run 6,500
hours a year with annual power generation of about 4.5×108kWh.

8. Material Flow

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Technical Proposal Ref. No.: 13Q-VE/PD/003
25
9. Material Balance and Heat Balance

Table 12 Rotary kiln (#1) mass balance

Input Output

Item Mass/
kg ⋅ h −1 % Item Mass/
kg ⋅ h −1 %

Green Calcined
55976.62 37.14 40029.94 26.56
petcoke coke output
Natural gas 493.04 0.33 Dust output 2127.39 1.41

Air volume 94241.26 62.53 Fume output 108553.59 72.03

Total 150710.92 100 Total 150710.92 100.00

Table 13 Rotary kiln (#1) heat balance

Input Output

Item Heat/ kJ ⋅ h −1 % Item Heat/ kJ ⋅ h −1 %

Chemical
Chemical heat of
heat of
volatiles in raw 502588.08 83.50 526308.55 60.64
unburned
material
volatile
Heat taken
Combustion heat
24001.21 3.99 out by 119337.95 13.75
of natural gas
calcined coke
Heat taken
Combustion heat out by
4744.98 0.79 12424.52 1.43
of sulphur moisture
vaporization
Heat from carbon Heat taken
70586.14 11.73 173882.59 20.03
combustion out by fume
Physical heat
taken out by 6360.32 0.73
dust
Rotary kiln
28825.00 3.32
heat emission
Calculation
822.87 0.09
error
Total 601920.40 100.00 Total 867961.81 100.00

Table 14 Incinerator (#1) mass balance

Input Output

Item Mass/
kg ⋅ h −1 % Item Mass/
kg ⋅ h −1 %
Rotary kiln 110680.98 30.93 Fume 357785.47 99.998
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Technical Proposal Ref. No.: 13Q-VE/PD/003
26
 outlet fume volume at
and dust outlet
volume
Cooler outlet
Dust
fume and dust 72947.00 20.39 5.71 0.002
volume
volume
Air volume into
174164.00 48.68
incinerator
Total 357791.98 100.00 Total 357791.18 100.00

Table 15 Incinerator (#1) heat balance

Input Output

Item Heat/ kJ ⋅ h −1 % Item Heat/ kJ ⋅ h −1 %

Physical heat
taken in by Heat taken
142951.97 24.59 567591.51 97.64
rotary kiln fume by fume
and dust
Physical heat
Incinerator
taken in by
15975.60 2.75 heat 13209.88 2.27
cooler fume
emission
and particle
Heat of
Calculation
unburned 351564.26 60.48 498.79 0.09
error
volatile
Heat from
carbon 69783.59 12.00
combustion
Combustion
1024.76 0.18
heat of sulphur
Total 581300.18 100.00 Total 581300.18 100.00

Table 16 Cooler (#1) mass balance

Input Output

Item Mass/
kg ⋅ h −1 % Item Mass/
kg ⋅ h −1 %
Calcined Cooling
40029.94 35.44 40000.00 35.41
petcoke output coke output
Cooling air Dust
48098.38 42.58 29.94 0.03
volume volume
Cooling water Fume
24818.56 21.97 72916.94 64.56
volume volume
Total 112946.89 100.00 Total 112946.89 100.00

Table 17 Cooler (#1) heat balance

Input Output
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27
 Item Heat/ kJ ⋅ h −1 % Item Heat/ kJ ⋅ h −1 %
Heat taken in Heat taken out
by calcined 79559.51 100.00 by cooling 3552.00 4.46
petcoke petcoke
Heat taken out
9321.11 11.72
by steam
Heat taken out
9444.84 11.87
by off gas
Heat taken out
28.88 0.04
by fume
Kiln heat
1601.20 2.01
emission
Latent heat of
vaporization of 55543.95 69.81
water vapor
Calculation error 67.54 0.08

Total 79559.51 100.00 Total 79559.51 99.92

Table 18 Rotary kiln (#2) mass balance

Input Output

Item Mass/
kg ⋅ h −1 % Item Mass/
kg ⋅ h −1 %
Green Calcined
83756.61 42.96 62556.96 32.08
petcoke coke output
Air volume 111219.41 57.04 Dust output 3185.47 1.63
Fume output 129233.59 66.28
Total 194976.02 100 Total 194976.02 100.00

Table 19 Rotary (#2) kiln heat balance

Input Output
Item Heat/ kJ ⋅ h −1 % Item Heat/ kJ ⋅ h −1 %

Chemical
Chemical
heat of
heat of
volatiles in 644581.48 85.54 458909.52 60.90
unburned
raw
volatile
material
Heat taken
Combustion
out by
heat of 6534.29 0.87 124331.95 16.50
calcined
sulphur
coke
Heat taken
Heat from
out by
carbon 102432.80 13.59 12367.50 1.64
moisture
combustion
vaporization
Heat taken
121876.32 16.17
out by fume
Physical 6331.13 0.84

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28
 heat taken
out by dust
Rotary kiln
heat 28825.00 3.83
emission
Calculation
907.15 0.12
error
Total 753548.56 100.00 Total 753548.56 100.00

Table 20 Incinerator (#2) mass balance

Input Output

Item Mass/
kg ⋅ h −1 % Item Mass/
kg ⋅ h −1 %
Rotary kiln
outlet fume Outlet fume
132419.06 27.11 488391.45 99.989
and dust volume
volume
Cooler outlet
Dust
fume and dust 113995.67 23.34 54.61 0.011
volume
volume
Air volume into
242031.33 49.55
incinerator
Total 488446.06 100.00 Total 488446.06 100.00

Table 21 Incinerator (#2) heat balance

Input Output
Item Heat/ kJ ⋅ h −1 % Item Heat/ kJ ⋅ h −1 %
Physical heat
taken in by Heat taken
128207.45 17.92 694491.85 97.08
rotary kiln fume out by fume
and dust
Physical heat
Incinerator
taken in by
24965.94 3.49 heat 20643.80 2.89
cooler fume and
emission
particle
Heat of
Calculation
unburned 458909.52 64.15 276.71 0.04
error
volatile
Heat from
carbon 101268.16 14.16
combustion
Heat from
sulphur 2061.29 0.29
combustion
Total 715412.35 100.00 Total 715412.35 100.00

Table 22 Cooler (#2) mass balance

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29
 Input Output

Item Mass/
kg ⋅ h −1 % Item Mass/
kg ⋅ h −1 %
Calcined Cooling
62556.96 35.44 60000.00 33.99
petcoke output coke output
Cooling air Dust
75165.94 42.58 2556.96 1.45
volume volume
Cooling water Fume
38785.31 21.97 113951.25 64.56
volume volume
Total 176508.20 100.00 Total 176508.20 100.00

Table 23 Cooler (#2) heat balance

Input Output
Item Heat/ kJ ⋅ h −1 % Item Heat/ kJ ⋅ h −1 %
Heat taken in Heat taken out
by calcined 124331.95 100.00 by cooling 5328.00 4.29
petcoke petcoke
Heat taken out
14566.60 11.72
by steam
Heat taken out
14759.96 11.87
by off gas
Heat taken out
45.13 0.04
by fume
Kiln heat
2502.28 2.01
emission
Latent heat of
vaporization of 86879.10 69.88
water vapor
Calculation error 250.88 0.20

Total 124331.95 100.00 Total 124331.95 99.80

Table 24 Waste heat power generation and desulfurization system balance

Fume Fume
volume volume
from rotary from rotary Demineralized Fresh
Item Lime
kiln for kiln for water water
anode packing
grade grade
Input Temperature
1100~1200 1100~1200
℃ 18t/h 584t/a 158400t/a
3
Flow Nm /h 280000 390000

Item Steam Steam

Intermediate Pressure
3.82 3.82
output MPa
Temperature
450 450
℃

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30
 Flow t/h 145 200

Item Power generated Gypsum SO2

Final output Annual 8
4.5×10 kWh 1277.5t/a 722304kg/a
output

10. Main Equipment and Material List

Table 25 Main equipment and Material list

Equipment or
No. Specification Unit Qty. Vendor
material name
Calcination
I
Shop
Citic Heavy Industries
Co, Ltd., Lanzhou
Lanshi Group Co., Ltd.,
1 Rotary kiln Φ4.05x72m pcs 2
China Nonferrous
Metallurgical Machinery
Co., Ltd.
Citic Heavy Industries
Co, Ltd., Lanzhou
Lanshi Group Co., Ltd.,
2 Cooler Φ3.1x31.5m pcs 2
China Nonferrous
Metallurgical Machinery
Co., Ltd.
Citic Heavy Industries
Co, Ltd., Lanzhou
Lanshi Group Co., Ltd.,
3 Incinerator Φ7.6x70m pcs 2
China Nonferrous
Metallurgical Machinery
Co., Ltd.
Citic Heavy Industries,
Lanzhou Lanshi Group
Co., Ltd., China
4 Movable chute pcs 2
Nonferrous
Metallurgical Machinery
Co., Ltd.
Double-geared
5 φ1200×1200 pcs 2
roller crusher
Semi-portal SCHADE, FAM and
6 200t/h pcs 2
type reclaimer Shandong Taier
Sinosteel Refractory
Co., Ltd., Henan
Jundao New Material
Refractory
7 Company and Henan
material
Pingdingshan
Refractory Material
Plant
II Waste heat
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 Equipment or
No. Specification Unit Qty. Vendor
material name
boiler house
Q=145t/h,
Waste heat P=3.82MPa,
1 pcs 1 China
boiler
t=450℃
Q=200t/h,
Waste heat P=3.82MPa,
2 pcs 1 China
boiler
t=450℃
Q=356000~
Induced draft 498000m3/h,
3 pcs 2 China
fan P=4523~3413P
a
Q=52800~
Induced draft
4 583000m3/h, pcs 2 China
fan
P=4264~3787Pa
5 Deduster Q=700000m3/h pcs 1 China
6 Deduster Q=1200000m3/h pcs 1 China
Desulfurization
7 pcs 2 China
system
Steam turbine
III generator
room
Extraction
N=40MW
1 condensing pcs 2 China
P=3.43MPa
turbine
Steam turbine N=40MW
2 pcs 2 China
generator U=13800V

11. Proprietary Technology

Table 26 Proprietary technology

Application
Patent name Type
number
A temperature measuring device for
CN200810229440.9 Invention
rotary kiln
Rotary kiln of carbon calcining CN200710158243.8 Invention
Rotary kiln burner installation device CN201110214197.5 Invention
An air supply device for rotary kiln CN200720012733.2 Invention
A rotary kiln incinerator for carbon
CN200410087652.X Invention
calcination
Petroleum coke calcination device of
CN200720014613.6 Invention
large rotary kiln
Rotary kiln and incinerator configuration CN201120450282.7 Invention

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32
 Application
Patent name Type
number
structure
A rotary kiln anchoring part for carbon
CN200810229430.5 Invention
calcining
Rotary kiln two-stage calcining coke
CN200910012571.6 Invention
system
Rotary kiln calcining coke air cooling feed
CN201010565001.2 Invention
chute
Rotary kiln calcining coke dust settling
CN200810229429.2 Invention
chamber pressure balance device
Waste heat recovery device and system
CN200810229427.3 Invention
of rotary kiln calcining coke
Petroleum coke calcining process and
CN200810013199.6 Invention
equipment of large rotary kiln
Coke calcining high temperature fume
scrubbing method and device of rotary CN200710012648.0 Invention
kiln
A lining and secondary vent structure of
CN200810011889.8 Invention
rotary kiln for carbon calcining
A cooling method and device of rotary kiln
CN201110342778.7 Invention
high temperature calcined coke
Coke calcining cooling treatment device
CN200710012650.8 Invention
and method of rotary kiln
Secondary air duct installation structure
and method of rotary kiln for carbon CN201010294285.6 Invention
calcining
Continuous supplying heat transfer oil
system and method to waste heat boiler CN200910012572.0 Invention
of rotary kiln
Mobile device for cooler movable chute CN200910188376.9 Invention
A high temperature flue gate with cooling
CN200810228118.4 Invention
water duct

12. Achievement

Table 27 Achievement list

Time to
Rotary kiln Unit
No. Name put into Qty. Product
specification capacity
operation
Carbon Plant
of Qinghai
1 1985 Φ2.5x45m 6.0 t/h 3 Anode
Aluminum
Smelter
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 Carbon Plant
of Liancheng
2 2003 Φ2.84x55m 8.0 t/h 1 Anode
Aluminum
Smelter
Expansion
Project of
3 Qinghai 2004 Φ2.84x55m 8.0 t/h 1 Anode
Aluminum
Smelter
Jinzhou
Calcined
4 Petrochemical 2006 Φ2.84x55m 8.0 t/h 1
coke
Company
Carbon Plant
of Yichuan
5 2003 Φ2.84x55m 8.0 t/h 2 Anode
Aluminum
Smelter
Liaohe Oilfield
Calcined
6 Petrochemical 2007 Φ2.84x55m 8.0 t/h 2
coke
Project
Carbon Plant
of Lanzhou
7 2007 Φ2.84x58m 9.0 t/h 2 Anode
Aluminum
Smelter
Renovation
and expansion
project of
8 2011 Φ3.3x60m 14 t/h 2 Anode
Liancheng
Aluminum
Smelter
Huomei Hongj
9 un Carbon 2010 Φ3.5x62m 16 t/h 2 Anode
Plant
Tianjin Dagang
Oilfield Calcined
10 2007 Φ3.5x62m 16 t/h 2
Petrochemical coke
Company
Carbon Plant
of Shanxi
11 2004 Φ3.5x67m 24 t/h 1 Anode
Aluminum
Smelter
CPI Huanghe
Hydropower
12 2009 Φ3.5x67m 24 t/h 2 Anode
Development
Company
LLP Atyrau
Calcined
13 Refinery in 2014 Ф3.0×60m 15~18t/h 1
coke
Kazakhstan

13. Plants Proposed to Visit

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34
 Please refer to the following list of calcining petcoke plants we propose to visit.
Table 28 List of calcining petcoke plants proposed to visit
Capacity
No. Name Place Put-into-operation
(t/a)
Qinghai Huanghe
Shangyou Carbon Plant
1 Xining 350,000 2012
of CPI (rotary kiln
technology)
Huomei Hongjun Carbon
2 Plant of CPI (rotary kiln Huolinhe 300,000 2011
technology)
Jiangsu Zhenjiang
Coking Coal Gas
3 Zhenjiang 500,000 2013
Company (shaft kiln
technology)
Jiayuguan Anode Plant
4 of Sunstone (shaft kiln Jiayuguan 250,000 2011
technology)

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