The document discusses the advantages of using a pet coke fired die casting furnace for aluminum, highlighting significant fuel cost savings compared to diesel, saving up to 62%. It also details the production process of petroleum coke (petcoke) and its benefits over lignite and coal, such as lower ash content and higher calorific value. Additionally, it covers the specifications and characteristics of different grades of petcoke and the operational advantages for melting non-ferrous metals.

1. SUPER FURNACE
Super furnace on National small industries
corporation (NSIC)
Faridabad furnace manufacturer
CONTACT PERSON
Mr. Pankaj chauhan
SUPER FURNACE
+919958837764
Email :- pankajchauhan.c@gmail.com
superfurnace.c@gmail.com
Plot no- 44, 16/2 karkhana bagh, Mathura road
Faridabad (Haryana).
PRESENTATION ON PET COKE FIRED DIE CASTING
FURNACE FOR ALUMINIUM

2. PRESENTATION ON PET COKE FIRED DIE CASTING FURNACE FOR
ALUMINIUM

3. CALCULATION OF RUNNING COST
DEAR SIR IN THE PET COKE FURNACE THE RUNNING COST OF FUEL IS VERY LESS
THEN OTHER FUEL LIKE DIESEL, GAS ,F.O. ETC. THE CALCULATION OF THE COST
EFFECTIVENESS ARE AS FOLLWS:
LET US ASSUME IF YOU USE DIESEL FIRED FURNACE AND YOUR RUNNING COST
WILL BE AS FOLLWS:
A). CONSUMPTION OF DISEL IN 150 KG DIESEL FIRED FURNACE IN EACH HOUR WILL
BE 6 TO 6.5 LITERS.
SO TOTAL SONSUMPTION OF DIESEL IN 24 HOURS IN A DAY WILL BE 5.5*24= 132
LITERS. AND COST OF 0NE LITER WILL BE 54 RUPEES SO TOTAL RUNNING COST IN A
DAY WILL BE 132*54= 7128 RUPEES.
B). IN THE SECOND CASE IN PET COKE FIRED FURNACE TOTAL CONSUMPTION OF
PET COKE IN A 150 KG DIE CASTING FURNACE WILL BE 175 TO 200 KG IN 24 HOURS
AND PET COKE MARKET PRICE IS 13.5 PER KG.
SO TOTAL RUNNING COST ON 150 KG MATERIAL IN 24 HOURS WILL BE 200 KG*13.5=
2700 RUPEES.
SO TOTAL SAVING IN THE PE COKE FURNACE WILL BE 7128-2700= 4428 RUPEES IN A
DAY.
SO PERCENTAGE OF SAVING WILL BE 4428/7128*100= 62%
Manufacturer & Exporter of Petcoke Fired Aluminum Melting Furnace.
We offer highly efficient Petcoke fired aluminium melting furnace to save the running cost of the
fuel from 20-60 % less comparison with Oil(HSD, LDO, FO) , Gas (LPG , NG ) and Electric type
furnace . The Pet coke can also be used in the melting of Non Ferrous metal like Zinc, Brass,
Copper, Lead etc.
These type of furnace are available in different capacity of the crucible with following features :- Capacity Range of the furnace from 50 Kgs. To 500 Kgs./Batch
- Quick Start High Efficiency
- Unique Fuel feeding system to prevent back firing
- Compact & user Friendly
- Very Low Running Cost
The Petroleum Coke also known as Petcoke, has several remarkable features from the usage
point of view that are:

4. 


Petcoke can be a good replacement of coal/lignite.
It can be used in blend form along with coal/lignite or 100% in AFBC/CFBC boilers.
Ash content in Petcoke is much lower than coal/lignite. Hence particulate emissions are
always lower as compared to coal.
All About Pet Coke
What is Petcoke ?
Cocking is a thermal cracking process characterized by long residence time and the production
of petroleum coke (Petcoke), a heavy carbon residue. Petcoke is produced by thermal cracking
of vacuum residue that is produced from crude oil.
In a petroleum refinery, atmospheric and vacuum distillation processes remove from the crude
the oil the components that boil up to about 500oC. The distillation process separates the
lighter part of the crude oil into fractions which are then processed into useful refined products
such as LPG, petrol, kerosene, diesel, etc. The part of the crude oil which does not boil off
during the distillation process even under vacuum is known as the vacuum reside. The vacuum
residue consists of heavy, viscous, complex hydrocarbon molecules.
The coking process converts the vacuum residue into gas, liquid and solid products. In delayed
coking, the heavy feedstock is heated in a tube still and pumped as rapidly as possible to
insulated drums where it the large molecules are cracked into smaller molecules and residue,
producing gas, liquid products and coke. The term 'delayed' comes from the delay between
heating and coking. As coke builds up in the drum, the lighter products of cracking are
recovered as overhead vapours and are taken to a fractionator for separation into various
products.
Petcoke yield is mainly dependent on the carbon content of the feedstock, while the structural
quality of the Petcoke is influenced chiefly by the type of feed, i.e., virgin crude or cracked
products. Fuel grade Petcoke is produced from vacuum residues that have high sulfur
contents. High sulphur Petcoke is used as fuel whereas low sulphur Petocoke is used in
producing anodes.
Fuel grade Petcoke generally replaces iignite and coal.
How does Petcoke compare with Lignite ?
Lignite is a natural product and a fossil fuel Lignite is found at and around Panandro, Rajpardi
and Bhavnagar in Gujarat Lignite is the first stage of conversion of wood and biomass product
into coal. It has very high moisture content about 30-40%. The volitile content is also very
high, about 30-40%. Fixed carbon is less unlike Anthracite and Petcoke. Sulphur content is
3.0-5.0%. Calorific vlaue of lignite is very low, about 2800-3800 kcal / kg where as calorific
value of Petcoke is 8200-8500 kcal / kg. So, on heat equivalent basis, 2.5 to 3 kg of lignite is
replaced by 1 kg of Petcoke. It means that whereas for the same heat equivalent just kg of
Petcoke with about 75 gm of Sulphur is injected into the furnace. Hence, the generation of
SO2 with lignite is 1.4 times higher as compared to Petcoke.
How does Petcoke compare with Coal ?
Coal is also a natural fossil fuel. Domestic coal is mainly in Central and Eastern India and in
the North East. The ash content in domestic coal is very high- it can go up to even 45%. Coal
is also imported into India mainly from Indonesia and South Africa. The ash content in
imported
coal
is
generally
about
2
-15%.
One of the main problems with the use of solid fuels is the emission of suspended particulate

5. matter (SPM) into the atmosphere along with the flue gasses. Against an ash content of about
15% in imported coal and about 35-45% in domestic coal, the ash content in Petcoke is less
than 1% - typically about 0.6-0.7%. Thus, the main problem in furnaces and boilers i.e.
emission of suspended particulate matter, is non-existent with Petcoke, as compared to coal.
Specifications of Petroleum Coke (Petcoke)
RIL is manufacturing three grades of Petcoke, Grade A, Grade B and Grade C Whose
specifications are given below.
Property
Unit
Petcoke
Grade A
Petcoke
Grade B
Petcoke
Grade C
Guaranteed
Guaranteed
Guaranteed
Limits
Limits
Limits
%
8.0, max.
8.0, max.
8.0, max.
4.0, max.
%
1.0, max.
1.0, max.
1.0, max.
0.6-0.8
%
8 min.
8 min.
8 min.
9-11
%
87, min.
87, min.
87, min.
89
Kcal/kg
8200, min.
8200, min.
8200, min.
8300-8500
%
7.0, max.
7.5, max.
8.5, max.
6.0-7.0 Grade A
As Received
Typical
Characteristics
Total Moisture
Air Dried
Basis
Ash
Volatile
Matter
Fixed Carbon
Gross
Calorific Value
Sulphur
7.0-7.5 Grade B
7.5-8.5 Grade C
38-45 for Grade

6. A & Grade B
HGI
35, min.
35, min.
Conclusion
Petcoke can be used as a replacement of coal / lignite. It can be used in blend form along with
coal / lignite or 100% in AFBC / CFBC boilers.
Ash content in Petcoke is much lower than coal / lignite. Hence particulate emissions are
always lower as compared to coal.
PETROLEUM COKE (Petcoke)
SPECIFICATION OF PETCOKE
Property
As Received
Total
Moisture
Ash
Volatile
Matter
Fixed Carbon
Gross CV
Sulphur
HGI
Unit
Standard
Typical Characteristics
%
10.0, max
4 to 8, max
%
%
1.0, max
8 min.
0.6 – 0.8
9 – 11
%
87 Approx
kcal/kg 8200, min
%
Grade-A 7.0
max
Grade-B 7.5
max
Grade-C 8.5
max
35, min
86
8300 – 8500
6.5 – 7.0
7.0 – 7.5
7.5 – 8.5
40 – 50
WHY TO USE PET COKE?
1. Very High Cost Advantage against Gas / Furnace Oil. Also Gives Competitive Cost
Advantage against Lignite.
2. Nil Ash Content (< 1%). So Less Pollution related problem due to the same as well as No
Disposal Problem. Also Due to Nil Ash content in Pet Coke unburnt material is reusable.
This recovery of Unburnt is not possible in case of lignite due to high ash content.
3. Low Volatile Matters: Due to low volatile matters handling of Pet Coke is very easy rather
than lignite as it easily gets burnt due to high volatile matter even in heavy sun light.
4. High GCV: As Pet Coke has high GCV, the actual material quantity to be handled reduces
to 2 to 3 time than that of Lignite. Also Grinding requirement of Pet Coke is much lesser than
that of Lignite. So ultimately it reduces the operating and material handling costs.
5. Manufactured Product: one can get Consistent Quality.

7. 6. As Pet Coke is a Petroleum Product; it does not suck moisture by self.
So, on basis of above benefits, Pet Coke is much beneficial than Gas/FO, coal and Lignite.
ADVANTAGES OF PETCOKE AGAINST COAL
PARAMETER
GCV
ASH
PETCOKE
VERY HIGH-8200
KCAL/KG
NIL(<2%)
NATURE OF ITEM
GRINDING
REQUIREMENT
MOISTURE
MANFACTURED
PRODUCT
VERY LOW-APP. 20-25%
NEED GRINDING
LOW-DOES NOT SUCK
MOISTURE BY SELF
COAL
LOW-VARIES FROM 4000 TO 6200 KCAL/KG
APPROX.
10% TO 30% MAY BE MORE DEPEND UPON
THE QUALITY(DOMESTIC/IMPORTED)
NATURAL AVAILABLE
HIGH TO MEDIUM-APP. 1.5 TO 2 TIMES HIGHER
THEN PETCOKE
HIGH-DOES SUCK MOISTURE FROM LAND &
ATMOSPHERE
Super furnace on National small industries
corporation (NSIC)
Faridabad furnace manufacturer
CONTACT PERSON
Mr. Pankaj chauhan
SUPER FURNACE
+919958837764
Email :- pankajchauhan.c@gmail.com
superfurnace.c@gmail.com
Plot no- 44, 16/2 karkhana bagh, Mathura road
Faridabad (Haryana).