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Calcined Petroleum
Coke (CPC) is a form of highly electrically
conductive, densed Carbon with very low
specific Electrical Resistance, and having
fixed Carbon of approximately 99.5%.
CPC is used extensively
as Anode in Alumina Smelters, as Soderberg's
Electrode for Ferroalloy Industries, and
in the manufacturing of Graphite/ Graphite
Electrodes, and Thermal Paste for Ferro
Alloys & allied industries in Submerged
Arc Furnaces.
CPC is also used in various Steel Industries
for - Melting of Steel , Recurburisation
and for making Special Steels & Alloys.
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Click here for material specification
available for export
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Calcination
Process
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Raw
Coke is Calcined to develop
specific properties to
make it suitable for industrial
purposes. The Calcination
(of Raw Coke) involves
controlled heating of
the Raw Coke to the temperature
in the range of 1250°C
to 1350°C. This process
drives off moisture, hydrocarbons
and other volatile matter
present in the Raw Coke
is burnt off - thereby
densified the particles
and changes the electrical
properties from insulating
to conducting. Raw Coke
after Calcination is known
as Calcined Petroleum
Coke.
At India Carbon, Calcination
is performed in an oil
fired rotary kiln with
suitable refractories.
Raw Coke crushed into
lumps is fed through Conveyor
System to the slightly
elevated end of the rotary
kiln. The coke progresses
towards the firing end
of the kiln and during
it's passage down the
kiln any moisture present
is driven off by the counter
current of hot combustion
gasses. Volatile (Hydrocarbon)
present in the Raw Coke
also evolves and burn
as the temperature increases,
providing additional heat
energy to the calcination
process. |
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| Manufacturing
Process |
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burner is regulated only
to achieve desired final
temperature. When the
Coke reaches the firing
end at the kiln, it drops
into a chute and is led
into a rotary cooler positioned
beneath the kiln. The
cooler is equipped with
water spray to directly
quench and cool the Coke.
The amount of cooling
water is controlled so
that the coke does not
get wet and remains dry
within limit of moisture
content. The cooled Calcined
Coke coming out of the
cooler, is then routed
by the conveyor system
to bulk storage and further
bagged for shipment to
customers. |
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Click
here to view diagram specification |
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Electrode Carbon
Paste is a Soderberg paste processed
from a mix of a specific fraction of Calcined
Petroleum Coke (CPC) and / or Electrically
Calcined Anthracite Coal (ECA), impregnated with selective
Coal Tar Pitch Binder at a definite temperature.
It is used in submerged Arc Furnaces for
production of various Ferro Alloys and Calcium
Carbide.
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| Manufacturing
Process |
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The
first step in the manufacture
of Electrode Carbon Paste
is screening the Calcined
Petroleum Coke (CPC) and
/ or (ECA) to different
fractions and pulverizing
and storing it separately.
Following this, pre-determined
quantities of different
fractions are weighed
and transferred to a Sigma
Mixer which is heated
to about 150ºC by
thermic fluid. The required
quantity of binder is
also weighed separately
and added to the mixer.
The mixing is continued
for a pre-determined period
known as the mixing cycle.
At the end of the mixing
cycle, the mixed material
is dumped on the mould
box and cast into blocks
for shipment. |
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| Quality
Specification |
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the customer's end the
paste is fed in the upper
part of the electrode.
As the paste moves downwards
in the electrode it softens
and melts forming the
shape of the electrode
casing. Flowability of
Carbon Paste is essential
for proper operation of
the electrode. It is important
that the paste flows at
a reasonable temperature
and fills the casing of
the Electrode, maintaining
a consistent mixture of
components. The paste
then gets baked to a solid
mass as it moves down
and is capable of passing
the required current to
the furnace charge. The
plasticity of Paste, the
measure of its flowability
is controlled in the mixer
by adjusting the Binder
content or percentage
of coke fines. The lower
baked part of the electrode
is the final Electrode
Product. The physical
properties of this Paste
are of vital importance
to ensure proper electrode
operation with out breakages. |
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A
Typical Characteristics of CPC based Carbon Electrode
Paste is as follows |
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| Green
Paste |
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Baked
Paste at 1000deg Centigrade |
| Volatile
Matter |
15%
Max |
| Fixed
Carbon |
84%
Min |
| Ash
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1.0%
Max |
| Plasticity |
45
- 55% |
| Apparent
Density |
1.55
gms/cc Min |
| Binder
Content |
22
- 24% |
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| Apparent
Density |
1.35
gms/cc Min |
| Electrical
Resistivity |
90
ohm-meter Max |
| Compressive
Strength |
150
Kg/cm2 Min |
| Porosity |
35%
Max |
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Click
here to view flow chart |
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Tamping Paste,
also known as Thermal Paste is used
in the Ferro Alloys & Allied Industries
for the lining of the furnace. The paste
is produced from a mixture of different
carbonaceous material (Calcined Petroleum
Coke, Calcined Anthracite Coal etc.) and
Soft Pitch as binder. |
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| Manufacturing
Process |
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| The
first step in the manufacture
of Tamping/Thermal Paste
is screening the Calcined
Petroleum Coke (CPC) and
/ or (ECA) to different
fractions and pulverizing
and storing it separately.
Following this, pre-determined
quantities of different
fractions are weighed
and transferred to the
Sigma Mixer which is heated
to a predefined temperature
by the thermic fluid.
The required quantity
of binder is also weighed
and added into the mixer.
The mixing is continued
for a specific period
known as the mixing cycle.
At the end of the mixing
cycle, the mixed material
is dumped onto the mould
box and cast into blocks
which are then ready for
shipment. |
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| Quality
& Specification |
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thermal insulation of
the furnace pots is essential.
It is important that the
Tamping paste does not
have any excess binder
and fills the wall of
the furnace, maintaining
proper insulation &
minimizing the heat loss |
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Typical
Characteristics of CPC based Tamping Paste are as
follows |
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| Green
Paste |
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Baked
Paste at 1000deg Centigrade |
| Volatile
Matter |
12%
Max |
| Fixed
Carbon |
87%
Min |
| Ash
|
1.0%
Max |
| Plasticity |
8-15% |
| Apparent
Density |
1.55
gms/cc Min |
| Binder
Content |
19-21% |
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| Apparent
Density |
1.35
gms/cc Min |
| Electrical
Resistivity |
90
ohm-meter Max |
| Compressive
Strength |
150
Kg/cm2 Min |
| Porosity |
35%
Max |
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