SUPER FURNACE

Super furnace on National small industries corporation (NSIC)

Faridabad furnace manufacturerCONTACT PERSON

Mr. Pankaj chauhanSUPER FURNACE+919958837764

Email :- pankajchauhan.c@gmail.comsuperfurnace.c@gmail.com

Plot no- 44, 16/2 karkhana bagh, Mathura roadFaridabad (Haryana).

PRESENTATION ON PET COKE FIRED DIE CASTING FURNACE FOR ALUMINIUM

PRESENTATION ON PET COKE FIRED DIE CASTING FURNACE FOR ALUMINIUM

CALCULATION OF RUNNING COST

DEAR SIR IN THE PET COKE FURNACE THE RUNNING COST OF FUEL IS VERY LESS THEN OTHER FUEL LIKE DIESEL, GAS ,F.O. ETC. THE CALCULATION OF THE COST EFFECTIVENESS ARE AS FOLLWS:

LET US ASSUME IF YOU USE DIESEL FIRED FURNACE AND YOUR RUNNING COST WILL BE AS FOLLWS:

A). CONSUMPTION OF DISEL IN 150 KG DIESEL FIRED FURNACE IN EACH HOUR WILL BE 6 TO 6.5 LITERS.

SO TOTAL SONSUMPTION OF DIESEL IN 24 HOURS IN A DAY WILL BE 5.5*24= 132LITERS. AND COST OF 0NE LITER WILL BE 54 RUPEES SO TOTAL RUNNING COST IN A DAY WILL BE 132*54= 7128 RUPEES.

B). IN THE SECOND CASE IN PET COKE FIRED FURNACE TOTAL CONSUMPTION OF PET COKE IN A 150 KG DIE CASTING FURNACE WILL BE 175 TO 200 KG IN 24 HOURS AND PET COKE MARKET PRICE IS 13.5 PER KG.

SO TOTAL RUNNING COST ON 150 KG MATERIAL IN 24 HOURS WILL BE 200 KG*13.5= 2700 RUPEES.

SO TOTAL SAVING IN THE PE COKE FURNACE WILL BE 7128-2700= 4428 RUPEES IN A DAY.

SO PERCENTAGE OF SAVING WILL BE 4428/7128*100= 62%

Manufacturer & Exporter of Petcoke Fired Aluminum Melting Furnace.

We offer highly efficient Petcoke fired aluminium melting furnace to save the running cost of the fuel from 20-60 % less comparison with Oil(HSD, LDO, FO) , Gas (LPG , NG ) and Electric type furnace . The Pet coke can also be used in the melting of Non Ferrous metal like Zinc, Brass, Copper, Lead etc.

These type of furnace are available in different capacity of the crucible with following features :-

- Capacity Range of the furnace from 50 Kgs. To 500 Kgs./Batch

- Quick Start High Efficiency

- Unique Fuel feeding system to prevent back firing

- Compact & user Friendly

- Very Low Running Cost

The Petroleum Coke also known as Petcoke, has several remarkable features from the usage point of view that are:

Petcoke can be a good replacement of coal/lignite. It can be used in blend form along with coal/lignite or 100% in AFBC/CFBC boilers. Ash content in Petcoke is much lower than coal/lignite. Hence particulate emissions are

always lower as compared to coal.

All About Pet Coke

What is Petcoke ?

Cocking is a thermal cracking process characterized by long residence time and the production of petroleum coke (Petcoke), a heavy carbon residue. Petcoke is produced by thermal cracking of vacuum residue that is produced from crude oil.

In a petroleum refinery, atmospheric and vacuum distillation processes remove from the crude the oil the components that boil up to about 500oC. The distillation process separates the lighter part of the crude oil into fractions which are then processed into useful refined products such as LPG, petrol, kerosene, diesel, etc. The part of the crude oil which does not boil off during the distillation process even under vacuum is known as the vacuum reside. The vacuum residue consists of heavy, viscous, complex hydrocarbon molecules.

The coking process converts the vacuum residue into gas, liquid and solid products. In delayed coking, the heavy feedstock is heated in a tube still and pumped as rapidly as possible to insulated drums where it the large molecules are cracked into smaller molecules and residue, producing gas, liquid products and coke. The term 'delayed' comes from the delay between heating and coking. As coke builds up in the drum, the lighter products of cracking are recovered as overhead vapours and are taken to a fractionator for separation into various products.

Petcoke yield is mainly dependent on the carbon content of the feedstock, while the structural quality of the Petcoke is influenced chiefly by the type of feed, i.e., virgin crude or cracked products. Fuel grade Petcoke is produced from vacuum residues that have high sulfur contents. High sulphur Petcoke is used as fuel whereas low sulphur Petocoke is used in producing anodes.

Fuel grade Petcoke generally replaces iignite and coal.

How does Petcoke compare with Lignite ?

Lignite is a natural product and a fossil fuel Lignite is found at and around Panandro, Rajpardi and Bhavnagar in Gujarat Lignite is the first stage of conversion of wood and biomass product into coal. It has very high moisture content about 30-40%. The volitile content is also very high, about 30-40%. Fixed carbon is less unlike Anthracite and Petcoke. Sulphur content is 3.0-5.0%. Calorific vlaue of lignite is very low, about 2800-3800 kcal / kg where as calorific value of Petcoke is 8200-8500 kcal / kg. So, on heat equivalent basis, 2.5 to 3 kg of lignite is replaced by 1 kg of Petcoke. It means that whereas for the same heat equivalent just kg of Petcoke with about 75 gm of Sulphur is injected into the furnace. Hence, the generation of SO2 with lignite is 1.4 times higher as compared to Petcoke.

How does Petcoke compare with Coal ?Coal is also a natural fossil fuel. Domestic coal is mainly in Central and Eastern India and in the North East. The ash content in domestic coal is very high- it can go up to even 45%. Coal is also imported into India mainly from Indonesia and South Africa. The ash content in imported coal is generally about 2 -15%.

One of the main problems with the use of solid fuels is the emission of suspended particulate

matter (SPM) into the atmosphere along with the flue gasses. Against an ash content of about 15% in imported coal and about 35-45% in domestic coal, the ash content in Petcoke is less than 1% - typically about 0.6-0.7%. Thus, the main problem in furnaces and boilers i.e. emission of suspended particulate matter, is non-existent with Petcoke, as compared to coal.

Specifications of Petroleum Coke (Petcoke)

RIL is manufacturing three grades of Petcoke, Grade A, Grade B and Grade C Whose specifications are given below.

Property

As Received

Unit Petcoke Grade A

Petcoke Grade B

Petcoke Grade C

Typical Characteristics

Guaranteed

Limits

Guaranteed

Limits

Guaranteed

Limits

Total Moisture

Air Dried Basis

Ash

Volatile Matter

Fixed Carbon

Gross Calorific Value

Sulphur

%

%

%

%

Kcal/kg

%

8.0, max.

1.0, max.

8 min.

87, min.

8200, min.

7.0, max.

8.0, max.

1.0, max.

8 min.

87, min.

8200, min.

7.5, max.

8.0, max.

1.0, max.

8 min.

87, min.

8200, min.

8.5, max.

4.0, max.

0.6-0.8

9-11

89

8300-8500

6.0-7.0 Grade A

7.0-7.5 Grade B

7.5-8.5 Grade C

38-45 for Grade

HGI 35, min. 35, min.

A & Grade B

Conclusion

Petcoke can be used as a replacement of coal / lignite. It can be used in blend form along with coal / lignite or 100% in AFBC / CFBC boilers.

Ash content in Petcoke is much lower than coal / lignite. Hence particulate emissions are always lower as compared to coal.

PETROLEUM COKE (Petcoke)

SPECIFICATION OF PETCOKE

Property Unit Standard Typical CharacteristicsAs ReceivedTotal Moisture

% 10.0, max 4 to 8, max

Ash % 1.0, max 0.6 – 0.8Volatile Matter

% 8 min. 9 – 11

Fixed Carbon % 87 Approx 86Gross CV kcal/kg8200, min 8300 – 8500Sulphur % Grade-A 7.0

max6.5 – 7.0

Grade-B 7.5 max

7.0 – 7.5

Grade-C 8.5 max

7.5 – 8.5

HGI 35, min 40 – 50

WHY TO USE PET COKE?1. Very High Cost Advantage against Gas / Furnace Oil. Also Gives Competitive Cost

Advantage against Lignite. 2. Nil Ash Content (< 1%). So Less Pollution related problem due to the same as well as No

Disposal Problem. Also Due to Nil Ash content in Pet Coke unburnt material is reusable. This recovery of Unburnt is not possible in case of lignite due to high ash content.

3. Low Volatile Matters: Due to low volatile matters handling of Pet Coke is very easy rather than lignite as it easily gets burnt due to high volatile matter even in heavy sun light.

4. High GCV: As Pet Coke has high GCV, the actual material quantity to be handled reduces to 2 to 3 time than that of Lignite. Also Grinding requirement of Pet Coke is much lesser than that of Lignite. So ultimately it reduces the operating and material handling costs.

5. Manufactured Product: one can get Consistent Quality.

6. As Pet Coke is a Petroleum Product; it does not suck moisture by self.

So, on basis of above benefits, Pet Coke is much beneficial than Gas/FO, coal and Lignite.

ADVANTAGES OF PETCOKE AGAINST COAL

PARAMETER PETCOKE COAL

GCV VERY HIGH-8200 KCAL/KG

LOW-VARIES FROM 4000 TO 6200 KCAL/KG APPROX.

ASH NIL(<2%) 10% TO 30% MAY BE MORE DEPEND UPON THE QUALITY(DOMESTIC/IMPORTED)

NATURE OF ITEM MANFACTURED PRODUCT

NATURAL AVAILABLE

GRINDING REQUIREMENT

VERY LOW-APP. 20-25% NEED GRINDING

HIGH TO MEDIUM-APP. 1.5 TO 2 TIMES HIGHER THEN PETCOKE

MOISTURE LOW-DOES NOT SUCK MOISTURE BY SELF

HIGH-DOES SUCK MOISTURE FROM LAND & ATMOSPHERE

Super furnace on National small industries corporation (NSIC)

Faridabad furnace manufacturer

CONTACT PERSONMr. Pankaj chauhanSUPER FURNACE+919958837764Email :- pankajchauhan.c@gmail.com

superfurnace.c@gmail.comPlot no- 44, 16/2 karkhana bagh, Mathura road

Faridabad (Haryana).