ACTIVATED CARBON (RAW MATERIAL – WOOD CHIPS) – 1200 TPA
[EIRI/EDPR/4710] J.C.: 2930RUB, 2930INR
INTRODUCTION
Carbon is probably the most widely distributed element in nature. It occurs in two allotropic crystalline forms viz. graphite (hexagonal system) and diamond (isomeric system), the former is soft and black while diamond is hard and transparent. Charcoal, coke and carbon black, classified as amorphous carbon; are considered by some to represent a third allotropic form. They are said to be composed of very minute crystals of graphite by others. Carbon is an essential constituent of all vegetable and animal matter in which it occurs in combination with hydrogen, nitrogen, oxygen and other elements in immense variety of compounds. In combination with hydrogen it occurs as hydrocarbons in petroleum. It is also found in carbon dioxide in air (0.03% as sodium bicarbonate in sea water, and as calcium and magnesium carbonate in sedimentary rocks such as chalk and dolomite.
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.
COST ESTIMATION
Plant Capacity 4 MT/Day
Land & Building (2285 sq.mt.) Rs. 1.87 Cr
Plant & Machinery Rs. 5.36 Cr
Working Capital for 1 Month Rs. 40.50 Lac
Total Capital Investment Rs. 8.18 Cr
Rate of Return 36%
Break Even Point 54%
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
PROPERTIES
PHYSICAL PROPERTIES
CHEMICAL PROPERTIES
LIGNITE ACTIVATED CARBON PRODUCTS ACTIVATED CARBON
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
CONSUMPTION OF ACTIVATED CARBON
PROCESSING DETAILS OF ACTIVATED CARBON
CHEMICAL ACTIVATION
REACTIVATION OF USED ACTIVATED CARBON
MANUFACTURING PROCESS / PROCESS FLOW
THE QUALITY OF THE FINAL PRODUCT DEPENDS UPON –
PROCESS FLOW
MANUFACTURERS/SUPPLIERS FROM INDIA
PLANT & MACHINERY SUPPLIERS/TURNKEY
TURNKEY
PULVERISER
MIXERS
ROTARY KILNS
TRAY DRIER
HYDRAULIC LIFT
HEAVY MOBILE CRANES
EXTRUDER
TANKS
BOILER
COOLER
RAW MATERIAL SUPPLIERS FROM INDIA
WOOD CHIPS
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:
SPECIFIC FACTORS
TRANSPORTATION:
WASTE DISPOSAL:
LABOR:
REGULATORY LAWS:
TAXES:
SITE CHARACTERISTICS:
COMMUNITY FACTORS:
VULNERABILITY TO WARTIME ATTACK:
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)
