Calcined Petroleum Coke

The production of CPC encompasses an eight-step procedure, which are as follows:

Raw Petroleum Coke or RPC is produced in Petroleum Refineries Coking Units where the Vacuum Distillation Residues of crude oils are Thermally Cracked and separated into Gases, Liquids and Coke. The Coke is known as Green Coke. The process begins with careful selection of Raw Materials (Green Coke) from Petroleum Refineries both domestic as well as those located outside the country.

Green Cokes are brought into AIPL’s premises where they are placed within our Storage Bunkers. The Cokes are separated based on type and quality. CPC can be produced from different grades of RPC. RPC’s are segregated into Domestic and Imported. Different grades of RPC’s collected from our Domestic Refineries are stored in separate storage areas and Imported RPC's from different countries are also stored in separate areas. Sufficient care is taken so that the RPC is not blown away by air or washed away by water.

Sufficient Green Coke storage capacity allows the company a flexibility in blending of different qualities of Green Coke as per customer requirements before the Calcination Process begins. This is a very crucial step. If the mixing is not done in proper ratios then the CPC may not suit the customer’s parameters. AIPL has experts who constantly monitor the blending process and keeps a check so that the mixing is done in a predefined ratio, such that the CPC suits the customer’s requirements.

Raw Petroleum Coke (RPC) can not be directly used in Aluminum Industry as an Anode of proper density can not be obtained due to difficulty in binding the RPC particles. Moreover Extrusion is difficult with RPC and Volatiles are evolved during baking. In order to overcome the above mentioned problems Calcination is done. Calcination is a process by which useful changes in chemical and physical properties are brought about in Raw Petroleum Coke. During Calcination of RPC, Volatiles are removed, ratio of Carbon to Hydrogen is increased from 20 to as high as 1000 or higher, density is increased and it is converted into an electrically conductive Carbon.

While the Calcination is going on AIPL keeps a strict control on the process so that the Finished Product suits Customer's specifications. Instruments record the temperature, air blowing speed and furnace oil consumption. All these are controlled and constantly monitored by an expert and if any deviations are noticed it is immediately attended to. Sample testing is an integral part of Operations Control and Review. Samples are taken at regular intervals to see that the product is in conformity with the customer specifications. Each customer shipment is developed through close communication, careful planning, and technical understanding of respective customer needs.

The Calcined Coke is transported to storage areas. Different Bunkers are allotted for CPC’s of different blends. Care is taken that the material does not absorb moisture or water. CPC is a highly customized product with sensitive parameter and AIPL ensures that adequate and proper storage is arranged for the Final Product.

The CPC is packed in special HDPE bags and is weighed before loading. It is weighed twice, once after packing and next, at the time of loading.

Proper care is taken while transporting the material. A preplanned transportation schedule is drawn out to ensure that the product reaches the customer within the stipulated period mentioned by the customer. AIPL has a sound Logistics team, which prepares various plans to ensure fast and timely delivery of the product. The factory is well connected by Roads, Railways and Waterways.