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Coke Calcining Systems

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Proven ExperienceMetso Minerals, Inc. is the world’s leading supplier of cokecalcining systems and equipment, having furnished 50plants representing approximately 70 percent of theworld’s coke calcining capacity. These plants range incapacity from 50,000 STPY to over 400,000 TPY.

Metso provides systems and equipment for thermalprocessing of solid materials such as ores, minerals, bulkgranular chemicals, agricultural products, and wastematerials to change their physical and/or chemicalproperties.

With over 80 years of successful experience in servingthe minerals and chemical processing industries, Metsohas the proprietary technology and know-how to designand build coke calcining systems best suited to the specificrequirements of each customer.

Energy EfficientDue to the rotating action in a rotary kiln, the coke bed isin constant gentle motion exposing coke particles to the

process heat. Additionally, the incinerator will convertvolatile matter and fine coke particles entrained in thekiln exit gases into energy for steam and/or electricalpower generation.

Flexibility in OperationsKVS rotary kilns can handle a wide range of green cokefeeds including needle, sponge, shot, fluid or tar pitchgreen cokes. The rotary kiln is also able to optimize thecoke calcining operating parameters, be it residence time,temperature gradient, and heat up rate, all of which impactproduct quality.

Product QualityKVS’ coke calcining systems can produce a quality productspecification from sponge, needle, shot, fluid or tar pitchcokes. The real and vibrated bulk densities are optimizedin the KVS rotary kiln calcining system. Also, fines in thecalcined product are decreased thus enhancing criticalelements of product quality.

Two Coke Calciners in Bahrain

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Product Presentation

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KVS Coke Calcining SystemsRotary KilnThe KVS rotary kiln is a tried and proven technologysuccessfully used in various pyro-processing industriesaround the world. Rugged construction and conservativedesign is the trademark of KVS’s rotary kilns. Operatorsfind them easy to operate and maintenance is minimal.

Calcining of petroleum coke is done in the rotary kiln. Thekiln components consist of shell, tires, carrying stations,seals, refractory and a drive train which includes girth gear,pinion, speed reducer and variable speed motor. The drivetrain also includes an auxiliary drive for use during startupand periods of power failure.

Burner SystemsProcess heat is furnished to the rotary kiln from twosources. The first is the kiln burner system, which can bedesigned to handle gaseous, liquid, or solid fuels. Thesecond source of process heat is the burning of acontrolled amount of the evolved volatile matter and asmall amount of coke fines in the kiln.

Combustion of volatile matter is enhanced by theintroduction of secondary and tertiary combustion air.Secondary air is introduced through the firing hood andtertiary air introduced through ports in the kiln shell tocontrol combustion of the volatile matter and coke fines.Tertiary air utilization results in significant reduction in kilnfuel requirements.

AfterburnersKVS’ cylindrical afterburners are designed for sufficientresidence time, temperature, and effective mixing toaffect the required volatile matter and particulatecombustion. Combustion air to the afterburner isfurnished by a combustion air fan and preheated air fromthe cooler exhaust system. Afterburners can be designedfor 100% firing capacity when the kiln is down, thusproviding the operator uninterrupted steam productionand/or electrical power generation.

Two 250,000 MPTY Rotary Kiln Coke Calciners

Heavy duty carrying station

Efficient cylinderical afterburner

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Features and Benefits

CoolersMetso’s rotary cooler design utilizes both a direct waterquench of the hot coke at the cooler entrance andcounterflow movement of ambient air to cool the coke.The direct quench type is the most widely used methodof cooling in the coke calcining industry.

Kiln Feed PipeThe stainless steel double wall construction, refractorylining, and forced fluid cooling of the pipe enhances thedesign reliability and extends its operating life. A carbonsteel ‘Y’ piece outside the kiln hood provides easy cleanoutaccess.

Air SealsMetso’s air seals (marketed as Goodeal and Superdealseals) with their overlapping steel plates provide an airseal that significantly reduces ambient air infiltration intothe rotary kiln. By limiting air infiltration, fuel efficiency isimproved and power consumption is reduced. The seals’simple, yet effective design requires little maintenanceand allows for easy replacement

Heat Recovery/Air Pollution Control

EquipmentMetso’s total project capabilities provide the client with a‘one stop shopping’ approach. Metso includes in our totalequipment package waste heat boilers to recover a largepercentage of heat released in the afterburner and airpollution control systems to meet applicable environ–mental regulations.

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Instrumentation & Controls

Programmable Logic Controller (PLC)A Programmable Logic Controller (PLC) – the heart of thecontrol system – provides monitoring and interlockingfunctions. The PLC constantly checks for any abnormalconditions. Based upon its intended sequence, the PLCwill take appropriate corrective action to keep the processor sequence within proper operating conditions. Metsoprograms and pre-commissions the PLC at its facility orsequence within proper operating conditions. Metsoprograms and pre-commissions the PLC at its facilitybefore shipping to the calcining plant. Metso supplies theMan-Machine Interface software, which provides accessto the operating system through industrial personalcomputers. The total coke calcining plant as well asexploded details of sections of the plant area readilyavailable to the system operator through the graphicscreens provided by Metso.

Optimization Control System (OCS)Metso has developed an advanced control system usingour proprietary Optimization Control System (OCS), whichis superimposed on top of the PLC control system. OCS isan upper level control application used to determine setpoints and to stabilize and maximize coke kilnperformance. This software can be run on the samecomputer as the existing Man-Machine Interface or on astand-alone computer. The OCS will execute a proprietaryset of rules created by Metso for the coke calcining system.OCS has improved product quality, system capacity, fueland electrical consumption.

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101 Kiln Feed Bin102 Weigh Feeder103 Feed Hood104 Rotary Kiln105* Tertiary Air System106 Firing Hood107 Firing system108* Secondary Air Fan109 Transfer Chute110* Cooler Inlet w/Water Quench111 Rotary Cooler112 Cooler Discharge Housing113 Dust Collector114 Product Conveyor115 Cooler Exhaust Fan116 Afterburner117 Bypass and Draft Control Guillotine Dampers118 Waste Heat Boiler119 Induced Draft Fan120 Natural Draft Stack121 Baghouse Dust Collector122* Dust Bin123* Control Room124* MCC Room

*Denotes Items Not Shown

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Green coke feed

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Technical Specifications

Moisture 6%-14% 0.1%Volatile Matter 8%-14% 0.5%Sulfur 1.0%-4.0% 1.0%-4.0%

Silicon 0.02% 0.027%

Iron 0.013% 0.02%Nickel 0.02% 0.03%Ash 0.25% 0.4%Vanadium 0.015% 0.3%Bulk Density 45-50 PCF 45-50 PCF

(720-800 Kg/m3) (720-800 Kg/m3)Real Density 2.06 g/cm3

Moisture 6%-14% 0.1%Volatile Matter 4%-7% 0.5%Sulfur 0.5%-3.0% 0.5%-3.0%Silicon 0.02% 0.025%Iron 0.013% 0.02%Nickel 0.02% 0.03%Ash 0.25% 0.4%Vanadium 0.01% 0.02%Bulk Density 45-50 PCF 45-50 PCF

(720-800 Kg/m3) (720-800 Kg/m3)Real Density 2.11 g/cm3

TTTTTable 1.able 1.able 1.able 1.able 1. TTTTTypicypicypicypicypical spal spal spal spal sponge conge conge conge conge cokokokokoke spe spe spe spe specificecificecificecificecificaaaaationstionstionstionstions TTTTTable 2.able 2.able 2.able 2.able 2. TTTTTypicypicypicypicypical needle cal needle cal needle cal needle cal needle cokokokokoke spe spe spe spe specificecificecificecificecificaaaaationstionstionstionstionsIIIIItttttememememem GGGGGrrrrreen Ceen Ceen Ceen Ceen Cokokokokokeeeee CCCCCalcined Calcined Calcined Calcined Calcined Cokokokokokeeeee IIIIItttttememememem GGGGGrrrrreen Ceen Ceen Ceen Ceen Cokokokokokeeeee CCCCCalcined Calcined Calcined Calcined Calcined Cokokokokokeeeee

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Subject to alteration without prior notice Brochure No. 1324-03-02-MPR/Danville-English © 2004 Metso Minerals Printed in Sweden

Metso Minerals Industries Inc.350 Railroad StreetDanville, PA 17521-2046USAPhone: +1 (570) 275-3050Fax: +1 (570) 275-6789

Metso Minerals52 Ahston Vale RoadBristol BS3 2HQUnited KingdomPhone: +44-117-978-6200Fax: +44-117-923-1603

Metso Minerals16 Lidco StreetArndell Park, Sydney NSW 2148AustraliaPhone: +61-2-8825-1600Fax: +61-2-8825-1799

Metso Minerals64 Jet Park RoadJet Park, Johannesburg 1600South AfricaPhone: +27-11-961-4000Fax: +27-11-397-5960

Metso Minerals (Sala) ABNorrängsgatan 2P.O. Box 31SE-733 25 SalaSwedenTel.: +46-224-570-00Fax: +46-224-369-50

www.metsominerals.comE-mail: pyro@metso.com

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Metso Minerals (Canada)4900 Thimens Blvd.St. Laurent, Quebec H4R 2B2CanadaTel.: +1-514-335-5426Fax: +1-514-908-7093