ACTIVATED CARBON (FROM COCONUT SHELL)
[EIRI/EDPR/4437] J.C.: 2641XL
INTRODUCTION
Many carbons of industrial value are prepared from coal and from organic vegetable and animal matter. The resulting amorphous products include charcoal, coke and petroleum coke. Several carbon products are prepared and used in the electrical and electro-chemical industry.
Carbon 13, a stable isotope of carbon (At wt 13) has recently come into prominence as a tracer element employed in the study of biological process. It is obtained from carbon compounds by concentrating the minute quantity of the heavier isotope, normally present in them, by thermal diffusion methods. Carbon 14 or radioactive carbon, a product of the uranium atomic pile, is used also as a tracer element in the study of plant and animal metabolism.
The term Activated carbon, active carbon, or active charcoal is usually applied to amorphous carbons possessing higher absorption capacities than wood or animal charcoal. Many processes were developed during world war for the production of effective absorbents for use in gas masks. Industrial activated carbons in the form of pellets, granules or fine powders, and with many industrial applications, are now available in the market under different trade names.
Commercial absorbent carbons may be grouped into decolorizing, gas absorbent, metal absorbent, and medicinal carbons according to their physical structure, properties, and applications. No one type of carbon can be used for all purposes. A large variety of raw materials are available for the manufacture of these products. Coal, petroleum coke, and wood charcoal are activated by gas activation. Industrial waste e.g. raw dust, bagasse, molasses, straw, coconut pericarp and shell, corn cobs, paddy and ground nut husk, corn bean shell, distillery slop, waste Mahua flowers, waste wood pulp laquor, and mud from sugar factories have been utilized for the production of active carbons by chemical activation.
Decolorizing Carbons
Decolorizing carbons are manufactured by gas activation, in which the raw materials are first carbonized and the resulting charcoal heated to a high temperature in an oxidizing atmosphere Chemical activation in which the raw materials are impregnated with a chemical extruded and carbonized and deposition of carbon on porous inorganic base activation is needed in this case.
In the gas activation process, the raw material is carbonized under controlled conditions in closed retorts, the resulting charcoal is crushed, screened and heated in a second retort at 1000oC for 10 to 12 hours in an atmosphere of air, carbon dioxide, chlorine, super-heated steam or a mixture of steam and air. Raw materials which do not possess the necessary density and structure for direct conversion are briquetted prior to carbonization. Pre-briquetting gives a higher yield and a better product. In the process for the direct conversion of coal to activated carbon the crushed-materials, screened to 11/8 in pieces, is carbonized at 450o - 500oC and steam activated at 950o in continuous vertical retorts, the yield is about 12 1/2% of the coal taken.
For activation by chemical treatment, the raw material is ground and formed into paste with chemicals, e.g. chloride of zinc, calcium and magnesium, alkalis, sulphuric acid, phosphoric acid, sodium, silicate, boric acid, potassium sulphide, lime, ferric chloride, or potassium thiocyanate. The paste is extruded under pressure dried and carbonized in gas retorts at about 1000oC. The charcoal is cooled, washed with hydrochloric acid and water to remove inorganic residues, and finally dried at about 300oC. A fluidized technique has been developed in France for the production of activated carbon.
The third process gives a product with a porous structure and appreciable mechanical strength. The raw materials viz. saw dust, sea weed, peat molasses, etc. is mixed with a insoluble salts and the mixture is strongly heated. The carbon gets deposited on the porous inorganic base. A similar product is obtained when a high ash vegetable product, such as paddy husk, containing an appreciable percentage of silica, is carbonized.
Gas Absorbent Carbons
Gas and vapour absorbent carbons are obtained by carbonizing coconut shells, apricot stones, vegetable ivory, and anthracite. In recent years, methods have been developed for using softer materials which are rendered hard and dense by briquetting. The carbons are gas activated. A preparation useful for gas masks has been obtained by chlorinate bituminous coal (6-20) mesh until a 100% increased in weight takes place, pelleting and chlorinated material with hydrolyzed starch as binder, baking, crushed and powdered to (8-20) mesh, and steam activated at 800oC. Gas absorbent carbons are available in granular form of specified mesh range, e.g. 4 x 6, 412, 20, i.e. retained on 6- and 20 mesh sieve and passing through 4.12 mesh sieve.
COST ESTIMATION
Plant Capacity 20 MT/Day
Land & Building (5460 sq.mt.) Rs. 6.37 Cr
Plant & Machinery Rs. 7.06 Cr
Working Capital for 0.25 Months Rs. 52.92 Lac
Total Capital Investment Rs. 14.62 Cr
Rate of Return 42%
Break Even Point 50%
CONTENTS
INTRODUCTION
DECOLORIZING CARBONS
GAS ABSORBENT CARBONS
METAL ABSORBENT CHARS
MEDICINAL CARBONS
USES & APPLICATIONS
APPLICATIONS OF ACTIVATED CARBON
END-USER INDUSTRIES OF ACTIVATED CARBON
OIL & GAS PLANTS
WATER TREATMENT PLANTS
MINERAL WATER
OVERSEAS COUNTRIES
PROPERTIES
PHYSICAL PROPERTIES
CHEMICAL PROPERTIES
LIGNITE ACTIVATED CARBON PRODUCTS ACTIVATED CARBON
THE PORE SIZE IN ACTIVATED CARBONS CAN BE DIVIDED INTO
BIS SPECIFICATIONS
PRODUCT SPECIFICATIONS
THE SIEVE ANALYSIS SHOULD BE AS FOLLOWS
PRODUCT TESTING
FOR TESTING GAS ABSORBENT CARBONS, THE ANALYTICAL DATA REQUIRED ARE
SERVICE TIME, TIME REQUIRED FOR THE VAPOUR UNDER STANDARD ABSORPTION
STRUCTURE OF ACTIVATED CARBON
ADSORPTION MECHANISM
FORMS OF ACTIVATED CARBON
THREE MAIN FORMS OF ACTIVATED CARBON ARE:
GRANULAR ACTIVATED CARBON (GAC):
POWDERED ACTIVATED CARBON (PAC):
PELLETIZED ACTIVATED CARBON:
MARKET OVERVIEW
IMPACT OF COVID-19 ON THE GLOBAL ACTIVATED CARBON MARKET
KEY COMPANIES & MARKET SHARE INSIGHTS
SOME INDIAN MANUFACTURERS OF ACTIVATED CARBON
CONSUMPTION OF ACTIVATED CARBON
PROCESSING DETAILS OF ACTIVATED CARBON
CHEMICAL ACTIVATION
REACTIVATION OF USED ACTIVATED CARBON
ACTIVATED CARBON FROM COCONUT SHELL
MANUFACTURING PROCESS/PROCESS FLOW
THE QUALITY OF THE FINAL PRODUCT DEPENDS UPON –
PROCESS FLOW
MANUFACTURERS/SUPPLIERS OF ACTIVATED CARBON
STATE AND CONTROL SUBSIDY SCHEME
FOR SUBSIDE YOU ARE ADVISE TO CONTROL COCONUT DEVELOPMENT BOARD.
PLANT & MACHINERY SUPPLIERS/TURNKEY
TURNKEY
PULVERISER
MIXERS
ROTARY KILNS
TRAY DRIER
HYDRAULIC LIFT
HEAVY MOBILE CRANES
EXTRUDER
TANKS
BOILER
COOLER
RAW MATERIAL SUPPLIERS
COCONUT SHELL
ZINC CHLORIDE
ENGINEERING DESIGN CONSIDERATIONS
ETP FACILITY
ETP FLOW DIAGRAM (TYPICAL)
SEWAGE AND WASTE WATER EFFLUENT
STP FLOW DIAGRAM (TYPICAL)
WASTE GENERATION & MANAGEMENT/GREEN BELT
GREEN BELT
WATER (ESTIMATED)
WASTE (ESTIMATED)
FLUE GAS (ESTIMATED)
PLANT/MACHINERY (BROADLY)
UTILITIES PER MONTH (ESTIMATED)
PRINCIPLES OF PLANT LAYOUT
MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:
PLANT LOCATION FACTORS
PRIMARY FACTORS
RAW-MATERIAL SUPPLY:
MARKETS:
POWER AND FUEL SUPPLY:
WATER SUPPLY:
CLIMATE:
TRANSPORTATION:
WASTE DISPOSAL:
LABOR:
REGULATORY LAWS:
TAXES:
SITE CHARACTERISTICS:
COMMUNITY FACTORS:
FLOOD AND FIRE CONTROL:
HEALTH SAFETY AND ENVIRONMENT
ANTICIPATED ENVIRONMENTAL IMPACTS
CONSTRUCTION PHASE
OPERATION PHASE
MITIGATION MEASURES (PROPOSED)
HSE REQUIREMENT
PROPOSED IMPLEMENTATION SCHEDULE
PROJECT FINANCIALS
BASIS & PRESUMPTIONS (FOR PROFITABILITY WORKINGS)
PRELIMINARY LAYOUT
CONCLUSIONS
APPENDIX – A:
01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)
