A. . Process Description 

The primary process equipment at the RainCII Purvis facility includes a natural gas fired rotary kiln, a cooler 

quencher, and cyclones for control of particulate matter (PM) emissions. Process support services 

include bulk material receiving, storage, and handling systems for green and calcined coke. 

The plant receives green coke via railcar or truck. The material is off loaded into storage buildings, is 

then transferred by front-end loader onto a covered conveyor, then into a bucket elevator to the 

green coke day storage tank. The green coke continuously feeds from the day tank into the elevated 

end of the inclined rotary kiln for processing to reduce volatile organic compounds (VOCs) and 

moisture content of the coke and chemically reform the carbon content of the material to produce the 

final product, calcined coke. 

The kiln is 120 feet long and 9 feet in diameter with an approximate 0.5-inch slope per foot. Since the 

kiln is inclined, the coke flows by gravity into the cooler and the flue gases flow countercurrent to the 

coke. The coke is heated to a temperature of approximately 2,400°F as it proceeds through the kiln 

for approximately SO minutes to one hour. As the coke is heated, the VOCs and water are removed 

and enter the flue gas stream along with entrained coke particles. The coke proceeds through the kiln 

and is discharged from the low end into the quench section (rotary cooler), which is 52 feet in length 

and 8 feet in diameter. The calcined coke is "quenched" using a water spray of approximate 20-30 

gallons per minute to reduce the coke temperature to about 350-400°F. 

A natural gas fired burner with a rated capacity of 40 million British Thermal Units (MMBTU) per hour 

is used during startup to heat the kiln prior to introducing feed. The burner is then throttled to 20 to 

35 MMBTU per hour until the kiln reaches an operating temperature of approximately 2,400°F. 

Combustion of volatilized compounds from the coke and consumption of green coke, itself, provide 

the primary source of heat for the calcining process. The process consumes approximately 20% of the 

green coke feed with the remaining 80% calcined to form the high purity carbon product, known as 

calcined coke. 

Flue gases from the kiln are directed into two parallel cyclones to remove particulate matter (PM) 

prior to exhausting to the atmosphere. The flue gases exit the cyclones and discharge to the 

atmosphere via an approximate 113-foot stack. 

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