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Coke Calcining Systems

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Proven Experience

Metso 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 waste

materials 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 Efficient

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

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

Flexibility in Operations

KVS 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 Quality

KVS’ coke calcining systems can produce a quality productspecification from sponge, needle, shot , fluid or tar pitchcokes. The real and vibrated bulk densities are opt imizedin 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 Systems

Rotary 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 Systems

Process 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.

Afterburners

KVS’ cylindrical afterburners are designed for sufficientresidence time, temperature, and effective mixing toaffect t he required volati le matter and part iculate

combustion. 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

Coolers

Metso’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 Pipe

The 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 Seals

Metso’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 limit ing air infiltration, fuel efficiency isimproved and power consumpt ion is reduced. The seals’simple, yet effective design requires little maintenanceand allows for easy replacement

Heat Recovery/Air Pollution Control

Equipment

Metso’s total project capabilit ies 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 Cont roller (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 condit ions. 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 access

to 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 cont rol 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 consumpt ion.

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101 Kiln Feed Bin

102 Weigh Feeder

103 Feed Hood

104 Rotary Kiln

105* Tertiary Air System

106 Firing Hood

107 Firing system

108* Secondary Air Fan

109 Transfer Chute

110* Cooler Inlet w/Water Quench

111 Rotary Cooler

112 Cooler Discharge Housing

113 Dust Collector114 Product Conveyor

115 Cooler Exhaust Fan

116 Afterburner

117 Bypass and Draft Control Guillot ine Dampers

118 Waste Heat Boiler

119 Induced Draft Fan

120 Natural Draft Stack

121 Baghouse Dust Collector

122* Dust Bin

123* Control Room

124* MCC Room

*Denotes Items Not Shown

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Green

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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 specificecificecificecificecificaaaaationstionstionstionstions

IIIIItttttememememem 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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Product bin 

8/7/2019 Coke Calcining En

http://slidepdf.com/reader/full/coke-calcining-en 8/8Subject 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 Minerals

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Fax: +44-117-923-1603

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Metso Minerals (Sala) AB

Norrängsgatan 2P.O. Box 31SE-733 25 SalaSweden  Tel.: +46-224-570-00

Fax: +46-224-369-50

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

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