1. Kuwait Petroleum Coke Calcination Plant
Human & Technologies Corp.
Change for the future, Value for the Customer

2. Contents 1.Project Outline 2.Calcination Process of PC
3.Product & Application
4.Plant Operation
5.Problem Noted in PCIC
Project
6.Construction Photograph
7.Slip Form Construction
Method for Silo
8.Construction Video

3. 1. Project Outline

4. 1. Project Outline NO. ITEM DESCRIPTION 1 Project Name
Petroleum Coke Calcination Plant (1060 TPD) Project 2
Location
Shuaiba, Kuwait 3
Client
Petroleum Coke Industries Co.(PCIC) 4
Contractor
Human & Technologies Corp. (H&TC) 5
Work Scope
C (Main Process Equipment)
E.P.C (Utility, Tie-in, Refractory, Fire fighting, HVAC) 6
Contract Amount
19,090,000 KD (Excluding Main Process Equipment) 7
Construction Period
24 months (May 2006 ~ April 2008) 8
Major Material of
Construction
Con’c : 55,000 m3 (Incl. Silo(12,400 m3) x 3)
Steel Str. : 4,000 Ton
Equip. Erection : 3,700 Ton (Incl. Conveyor 1,600 Ton)
Pipe Welding : 8,000 D/I

5. 2. Calcination Process of PC

6. 2. Calcination Process of PC
1. Definition of Words
PC : Petroleum Coke(or Green Coke), Raw Material
CPC : Calcined Petroleum Coke, Product
Calcinations : Heat treatment that bring about chemical changes in
raw materials
2. Calcinations Process of PC
Petroleum Coke Calcining is converting the Petroleum Coke to Purity Carbon.
The Calcined Coke is used to produce carbon anodes for the Aluminum Smelting
Process.
Calcin-ation
Coke composition ratio and sintering temperature must be properly maintained.
Carbon Anode PC
CPC
Aluminum Smelting

7. 2. Calcination Process of PC
3. Characteristic of Process
1) Humidity elimination
2) Volatile elimination
3) Densification
4) Increase physical strength
5) Increase electrical conductivity
4. System of Process
1) Rotary Kiln Method.
Most petroleum coke is calcined in a Rotary Kiln.
Raw petroleum coke is sized to 50 to 100mm lump and fed to the rotary kiln at the high end.
The kiln is sloped downward towards the discharge end at slope of 13 to 19mm per 300mm.
Moisture is driven off the coke in the “Heat-Up Zone.”
Devolatilization occurs mostly at 500 to 1,000 ºC in the “Calcining Zone.”
Further dehydrogenation, some desulfurization, and coke structure shrinkage (densification) take place in the “Calcined Coke Zone” at 1,200 to 1,400 ºC
The coke moves through the kiln in 40 to 60 minutes and drop off the discharge end of the kiln into a refractory-lined chute and into a rotary cooler.

8. 2. Calcination Process of PC
5. Process Diagram
Coke
Cold Stack
Green Coke Shed
Dump Hopper Station
Air Cleaning
System
Hot Stack
Day Bin
Silo
Boiler
Incinerator
K i l n
Cooler
Product
Shipping
550℃
Gas Burner
Coke Products
Steam
Boiler Feed Water
Zone A : Raw material
Loading (PC)
Fuel Gas
Zone B : Main Process
KNPC
(Kuwait National
Petroleum Company)
KOC
(Kuwait Oil Company)
Zone C : Storage / Product
Shipment (CPC)
Zone D : Auxiliary System

9. 2. Calcination Process of PC
6. Other System of Process (For Reference)
Rotary Hearth Method
▶ System of Process
ㆍ The rotary hearth consists of a large rotating disk-type furnace that
slopes from outside toward the center. Raw coke is fed into the outer
edge of the rotary hearth and is plowed inward with water cooled plows
called rabbles that push the coke toward the center.
▶ Rotary Hearth Advantages Over Rotary Kiln
① Reduced Refractory Cost
- Since the refractory on the hearth is covered with a layer of coke, there is very
little wear. Refractory on the top of the kiln is stationary, eliminating problem
with brick lock and rotating forces that are present in a rotary kiln.
② Lower Particulate Emissions - The coke fines are not entrained into the kiln exhaust.
③ Reduced Heat Losses and Less Fuel Consumption
- Little or no extra fuel is required if combustion air is preheated.
④ Elimination of Extra Combustion Chamber for Incinerating Fines and
Volatile Matter - Complete combustion occurs within the calciner.
⑤ Variable Operation
- Varying the turntable speed and coke bed depth can change operating
conditions and residence time over a wide range.

10. 2. Calcination Process of PC
▶ Rotary Hearth Disadvantages Over Rotary Kiln
ㆍ Some of the major problems with rotary hearth calciners has been
with the rapid up-heat rate of the coke and calcined coke particle
sizing. Rapid up-heat of the coke causes coke structure to become
bloated, distorting the structure of the coke. This leads to poor bulk
densities for the calcined product.
2) There are two primary methods of continuous calcination of petroleum coke. But to our knowledge, there is only one other method in use today for calcining coke. Located in Russia, it is a special type of heated wall vertical shaft calciner (sort of like a moving slot oven) that can produce a good density coke. The operating cost is higher than a rotary kiln or hearth, but the slower up-heat rates allow them to use higher volatile matter green coke to achieve similar calcined densities.

11. 3. Product(CPC)
& Application

12. 3. Product(CPC) & Application
Coke + Impurity
H2O
Calcined
Coke S2
Product : Calcined Petroleum Coke (CPC)
CPC are used as follows,
ㆍ Raw material for Electrolysis Electrode of Aluminum
Products (70%)
ㆍ Raw material for Graphite Electronic Boards (10%)
ㆍ Raw material for Titanium dioxide/Steel/Refractory
materials (20%)
Production Capacity : 350,000 ton/year

13. 4. Plant Operation

14. 4. Plant Operation 3/30 5/10 3/12 4/15 4/10 Green Coke 2Mt received
March 2008
April
May
Green Coke 2Mt received
3/30
First shipping 2Mt
Of Calcined Coke
5/10
Incinerator Burning
3/12
Product Calcined Coke
4/15
Kiln burning
4/10
Commissioning
Production
Product Shipping

15. 5. Problem Noted
in PCIC Project

16. 5. Problem Noted in PCIC Project
1. Phenomenon
▶ Improper Split of Scope of Work between H&TC and PCIC
  ⇒ PCIC responsible for design/engineering and procurement of main process facilities.
  ⇒ H&TC responsible for construction/installation of main process facilities, and for
EPC for all other facilities (Utility, Tie-In, Refractory, Fire-Fighting, HVAC)
▶ Improper Project Management
  ⇒ PCIC manage the project by its own personnel (temporarily hired).
- Project management group is in lack of expertise.
2. Problem Noted
▶ Design Engineering
⇒ Drawings not issued on time.
  ⇒ Insufficient descriptions given in drawings.
  ⇒ No full details provided in drawings.
  ⇒ Frequent revisions made.
  ⇒ Drawings not fully and properly provided.(i.e., piecemeal provision)
  ⇒ Delay in approving AFC drawings, etc.
▶ Supply of Equipment
  ⇒ Delay in delivery of equipment.
  ⇒ No delivery of full package of equipment.(partial delivery)
  ⇒ Delivered equipment not matched with descriptions in drawings.
  ⇒ Lack of constructability of the delivered equipment.
  ⇒ Missing of parts, etc.
 Having caused numerous Field Correction Activities.

17. 5. Problem Noted in PCIC Project
3. Key Equipment
▶ Ovality noted in Incinerator (during installation)
   ⇒ Seven (7) stiffener rings installed outside the Incinerator.
   ⇒ Design failure.
▶ Severe ovality (approx. 0.87%) noted in Kiln, having caused fall-down of
refractory bricks during commissioning.
   ⇒ Cause : Too thin thickness (20mm) of Kiln Shell
(Kiln shell Inner Dia 4.35M, Length 78M)
 Thinnest thickness in the world.
   ⇒ Five (5) stiffener rings installed outside the Kiln shells.
   ⇒ Design failure (on the part of Designer)
(probably in Designer’s intention to seek for cost reduction of materials, thus
seducing clients’ attention)

18. 5. Problem Noted in PCIC Project
4. Project Management
▶ PCIC manage the project by its own personnel (temporarily hired).
    ⇒ Project management group is in lack of expertise.
   ⇒ Project management group is in lack of capability to lead the project.
   ⇒ Delay in approval of works, frequent change of instruction.
   ⇒ Lack of responsibility, etc.
▶ Consultant improperly exerted its right to review the project.
⇒ Not cooperative attitude.
   ⇒ Lack of professional qualification.
▶ Government approval (Power)
   ⇒ Responsibility for getting permit (especially for permanent power) mixed
between the parties.

19. 5. Problem Noted in PCIC Project
Solution 
Require contractor to do whole project on EPC basis and take single line responsibility for the maximum efficiency in managing the project.
Solution 
Employment of qualified and experienced PMC (Project Management Company) working under
independent authority.
Solution 
Full cooperation and support to be given to
contractor for government permit.

20. 6. Construction Photograph

21. 6. Construction Photograph
1. Panoramic View (Site Location)
Total Area : 330,000M2
Location : Shuaiba Complex, Kuwait

22. 6. Construction Photograph
(North View)
(East View)

23. 6. Construction Photograph
2. Main Equipment
(Kiln)
Capacity : 40ton/hr
Size : 4.35mDia. x 78mL

24. 6. Construction Photograph
(Incinerator)
Size : 7.33mDia. x 113mL
Characteristic - Flue Gas Combustion (1,200 ºC)
- Each shell supplied in segment
and welded on site.

25. 6. Construction Photograph
(Green Coke Shed & Reclaimer)
PEB Structure : 62.5mW x 242mL x 25mH
(Storage 3,500ton)
Reclaimer Capacity : 500ton/hr
Erection Weight : 322ton

26. 6. Construction Photograph
(Day Bin)
Size : 11.5mDia. x 19mH x 4sets
Storage : 800ton x 4sets = 3,200ton
Characteristic : Total Three(3) Days Consumption

27. 6. Construction Photograph
(Silo)
Size : 22.7mDia. x 55mH x 3sets
Storage : 10,00ton x 3sets = 30,000ton
Characteristic - Total Thirty(30) Days Consumption
- Applied “Slip Form Construction Method”
- Construction Concrete Volume : 12,400m3

28. 6. Construction Photograph
(Waste Heat Boiler)
Capacity : 135MTPH (Steam)
Characteristic - Product 435 ºC Superheated Steam
- Using Waste Heat from Incinerator

29. 6. Construction Photograph
(Gas Suspension Absorber(GSA) & Gas Conditioning Tower(GCT))
Function : Desulfurization System
GSA : Desulfurization Reaction
GCT : Supply Water & Drop Temperature

30. BFW(Boiler Feed Water) Line
6. Construction Photograph
(Fuel, BFW, Seam Piping)
Fuel : 4 inch x 2.5km
BFW : 8 inch x 1.9km
Steam : 16 inch 3.0km
Steam Line
Fuel Line
BFW(Boiler Feed Water) Line

31. (Shell Alignment & Fit-up) (Riding Ring Assembly)
6. Construction Photograph
3. Kiln Erection
(Pier Construction)
(Shell Erection)
(Shell Alignment & Fit-up)
(Shell Welding)
(Riding Ring Assembly)
(Girth Gear Assembly)

32. (Driving Unit Assembly) (Refractory Erection)
6. Construction Photograph
3. Kiln Erection
(Driving Unit Assembly)
(Burner Assembly)
(Air Fan Assembly)
(Erection Complete
& Rotation)
(Refractory Erection)

33. 7. Slip Form Construction
Method for Silo

34. (Slip Form Installation)
7. Slip Form Construction Method for Silo
1. Process Photograph
(Excavation)
(Placing Concrete)
(Basic Formwork)
(Tunnel Formwork)
(Slip Form Installation)
(Slip form Work)

35. (Roof Steel Frame Work) (Silo Top Gallery Installation)
7. Slip Form Construction Method for Silo
(Slip Form Parallel)
(Slip Form Work)
(Roof Floor Work)
(Roof Steel Frame Work)
(Silo Top Gallery Installation)

36. 7. Slip Form Construction Method for Silo
2. Form Work Comparison (Slipform & Traditional)
SLIPFORM
TRADITIONAL
0.00
0.20
0.40
0.60
0.80
1.00
1.20
1.40
1.60
1.80
2.00 1
0.95
0.9
0.85
0.8
0.75
0.7
0.65
0.6
0.55
0.5
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9 2 20 40 60 80
100
120
140
160
180
200
220
COST / M2
HEIGHT (M)

37. 7. Slip Form Construction Method for Silo
3. Slip Form System

38. 7. Slip Form Construction Method for Silo
3. Slip Form System
Shuttering

39. 7. Slip Form Construction Method for Silo

40. 7. Slip Form Construction Method for Silo

41. 7. Slip Form Construction Method for Silo

42. 7. Slip Form Construction Method for Silo

43. 7. Slip Form Construction Method for Silo
Slip form rig
Target
Lane of sight
Auto plumb
Slip formed wall
Concrete base
Ground level

44. 8. Construction Video

45. 8. Construction Video

46. Thank You!