Petroleum Coke Handling and Firing in

Rotary Lime Kiln

August 21, 2015
G. Ram Manohar
Technical Director
Agro Pulping Machinery (P) Ltd.
www.petcokefuel.com
112 Walter Jetton Blvd Paducah, KY 42001
Ph. (270) 442-5600

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Matrix Expertise
 Matrix Engineering, PLLC
 Founded 1995
 Consulting Engineering in Chemical, Pulp and
Paper, Food and Pharmaceutical Sectors.
 Specializing in Handling Bulk Materials and
Problematic Powders.
 Developed 1ST Petcoke Feed & Delivery System –
2003

 Matrix Industrial Systems, Inc.

 Founded 2007
 This is a equipment/system supply firm for
our patented Petcoke Fuel Systems.
 Received Patent for Petcoke System in
January 2012
 First petcoke system for lime kiln in India. JK
Paper, LTD – December 2014
 Recently Completed 17th Lime Kiln Petcoke
Conversion project. – IP Prattville, AL.

MATRIX IS THE INDUSTRY LEADER ON

PETCOKE CONVERSION PROJECTS FOR
LIME RECOVERY KILNS.

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www.petcokefuel.com
Advantages of PetCoke Systems
 Raw Petroleum Coke is a carbon based waste by-product of the oil refining
industry.
 PetCoke costs are historically lower and more steady than FO.
 PetCoke is increasing in world supply.
 Petcoke is a proven and excellent fuel for pulp and paper lime kilns.
 PetCoke has a hotter more emissive flame (like FO) that has the effect of
lengthening your kiln over Biogas or Producer Gas.

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Petcoke Cost vs. FO Cost

• Since PetCoke is a waste/by-

product of a finished fuel/gasoline –
it will ALWAYS be less expensive
than Fuel Oil.
• In India it is typically 1/3rd the price
of FO
• PetCoke pricing is more stable and
predicable – not as volatile as FO
and NG.
• Historically PetCoke has been in the
range of 25% - 75% the cost of FO.
• An important consideration is your
proximity to the fuel supply and
transportation costs to deliver it to
the mill.
• PetCoke is not only less expensive,
but it is also similar or equal in
quality to FO as far as performance
in the lime kiln is concerned…IF
YOU HAVE A PROVEN RELIABLE
SYSTEM TO FEED AND BURN IT!

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 Composition of Petcoke

Tests Method As Received Dry

Moisture % ASTM D4931 6.93 0.00
Ash % ASTM D4422 (Mod) 0.35 0.38
Volatile Matter % ASTM D4421 11.77 12.65
Fixed Carbon (by diff) % ASTM D3172 (by diff) 80.95 86.97
Sulfur % ASTM D4239 Method B 5.64 6.06
Gross Calorific Value Btu/lb ASTM D5865 14209 15267
(8224 –
8600
kcal/kg)
Carbon % ASTM D5373 81.85 87.94
Hydrogen % ASTM D5373 3.44 3.70
Nitrogen % ASTM D5373 1.53 1.64
Oxygen (by diff) % ASTM D5373 (by diff) 0.26 0.28

• Petcoke also contains trace amounts of Vanadium –

Typically 325 – 2300 ppm.
• Nickel – Typically 300 ppm.
• Mercury – Less than 1 ppb.
• Since approx. 87% Fixed Carbon – Heating Value is
HIGH and CONSISTENT (8400 – 8600 kcal/kg)

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 Petcoke Fuel Specification
(for Indirect Fire Rotary Lime Kiln)
• Direct Fire Systems – typically cement kilns
• Indirect Fired Systems – typically rotary lime kilns
• Petcoke shall be pulverized to 90% passing 200 mesh or
finer. (75 micron).
• Ash content shall be less than 1%. (Typically 0.5% - dry
basis)
• Moisture shall be less than 1%. (Typically 0.5%)
• Heating Value shall be between 8300 – 8600 kcal/kg.
(Will be CONSISTENT variance is among refineries.)
• Sulfur content will vary among refineries. (Typically
between 4%-7% - dry basis)

• Petcoke can be delivered in raw form and pulverized on

site.
• Petcoke can be pre-pulverized off-site delivered in 1
tonne bulk bags.
• Pre-pulverized Petcoke may also be delivered in 22
tonne pneumatic truck trailers.

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Petcoke Compared Fuel Oil

• Fuel Oil Heating Value: 9990 kcal/kg

• FO Ignition Temperature: 260 C
• FO is a liquid fuel more difficult to burn than a gas but
easier than a solid fuel. FO can be burned by itself in
the lime kiln.
• FO has a low Ash Content 0.2%.
• FO has low Hydrogen content which prevents
moisture in the combustion reaction.
• FO has a sulfur content around (3% - 4.5%).
100% FO Flame

• Petcoke Heating Value: 8200 kcal/kg – 8600 kcal/kg

• Petcoke Ignition Temperature: 400 C
• Petcoke is a great fuel that is more difficult to burn. It must
be burned alongside a gas or a liquid fuel. The kiln must be
good and hot before it is introduced.
• Petcoke has a very low Ash Content at generally less than
0.5%.
• Petcoke also has a very low Hydrogen content which also
yields a dry, hot, more efficient flame.
• Petcoke has a higher sulfur content (4% - 7%).
FO/PetCoke Co-fire Flame
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Petcoke Conversion Project
THREE KEYS to SUCCESS!
• PetCoke is currently available in India….both
Domestic and Imported.
• Find a supplier that can deliver petcoke to your mill
in pulverized powder form per our provided fuel
PETCOKE specification.
FUEL • Select an experienced petcoke fuel feed system
provider in pulp and paper sector with instantaneous
SUPPLY and precise control with accurate measurement over
this historically difficult powder.
– Raw coke is much easier to handle and feed than
powdered coke (direct fire).
– This is a fuel system. Not just a convey system.
Instantaneous, second by second control is imperative.
Lime quality and production will be adversely affected
by fuel feed inconsistencies. (indirect fire)
• Select a burner provider with petcoke experience in
Lime Recovery Kilns.
PETCOKE –
PETCOKE Petcoke is the Great Fuel that is Difficult to Burn.
READY – Having a high quality consistent feed system with an
FUEL FEED experienced burner will maximize your FO substitution
MULTI-FUEL level and your money savings.
SYSTEM • If possible combine the Petcoke Feed System and
BURNER Burner into one contract.

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 J-K Paper Limited, Unit: JKPM
Jaykaypur, Odisha India

• Matrix commissioned this system (#16)

in December 2014.
• This is the first petcoke fuel system for
a lime kiln in India.
• The DENSI-FEED System was design
for a maximum rate of 2.5 mtph.
• Storage Silo is 240 tonnes capacity.

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 J-K Paper Limited, Unit: JKPM
• The kiln was previously using 100% FO.
• The conversion project was on time and
is outperforming our promises.
• Currently they are burning at 65%-73%
substitution level.

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 J-K Paper Limited, Unit: JKPM
• Petcoke silo and storage area.
• Currently JK receives 1000 kg bulk bags for filling
the DENSI-FEED® Storage Silo.

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 J-K Paper Limited, Unit: JKPM
• Matrix provided the new dual fuel burner. PC/FO
• DENSI-FEED® Silo is over 200 m from the kiln
burner.

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Questions or Doubts??

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 MATRIX INDUSTRIAL SYSTEMS,
112 Walter Jetton Blvd
Paducah, KY 42001, USA

AGRO Pulping Machinery (P) Ltd., Phone : +1 – 270-462 - 5600

14, SIDCO Industrial Estate
Ambattur, Chennai 600 098
Tamil Nadu, India.
Phone : 91 - 44 - 2625 1271
91 - 44 - 2624 6510
E-Mail : info@agropulping.com