ACTIVATED CARBON FROM COCONUT SHELL [3612]
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 emorphous 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 protroleum 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 absorbant, metal absorbant, 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. Decolourizing 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. Prebriquetting 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, alkalies, sulphuric acid, phosphoric acid, sodium, silicate, boric acid, potassium sulphide, lime, ferric chloride, or potassium thiocynate. 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.
COST ESTIMATION
Plant Capacity 15 MT/Day
Land & Building (4 Acre) Rs. 5.10 Cr
Plant & Machinery Rs. 3.60 Cr
Working Capital for 2 Months Rs. 3.01 Cr
Total Capital Investment Rs. 11.93 Cr
Rate of Return 24%
Break Even Point 59%
INTRODUCTION
DECOLORISING CARBONS
GAS ABSORBENT CARBONS
METAL ABSORBENT CHARS
MEDICINAL CARBONS
USES & APPLICATIONS
END-USER INDUSTRIES OF ACTIVATED CARBON
WATER TREATMENT PLANTS MFGRS.
BY MINERAL WATER MFGR.
BUYERS IN OVERSEAS COUNTRIES
PROPERTIES
PHYSICAL PROPERTIES
CHEMICAL PROPERTIES
LIGNITE ACTIVATED CARBON PRODUCTS ACTIVATED CARBON
B.I.S. SPECIFICATIONS
THE SIEVE ANALYSIS SHOULD BE AS FOLLOWS
TESTING
STRUCTURE OF ACTIVATED CARBON
ADSORPTION MECHANISM OF ACTIVATED CARBON
MARKET SURVEY
THREE MAIN FORMS OF ACTIVATED CARBON ARE:
MANUFACTURING PROCESS OF ACTIVATED CARBON
CHEMICAL ACTIVATION
ACTIVATED CARBON FROM COCONUT SHELL
ACTIVATED CARBON FROM COAL
WASTE TYRE UTILIZATION
REACTIVATION OF USED ACTIVATED CARBON
TYPES OF ACTIVATED CARBON
PROPERTIES OF ACTIVATED CARBON
ADSORPTIVE CHARACTERISTICS
SURFACE AREA
PORE SIZE DISTRIBUTION
PHYSICAL CHARACTERISTICS
HARDNESS
TYPICAL PROPERTIES OF ACTIVATED CARBON
BULK DENSITY
PARTICLE SIZE DISTRIBUTION
APPLICATION
OTHER APPLICATIONS OF ACTIVATED CARBON INCLUDE:
APPLICATIONS OF ACTIVATED CARBON
APPLICATIONS IN THE CHEMICAL INDUSTRY
GLOBAL MARKET OVERVIEW
U.S. ACTIVATED CARBON MARKET SIZE BY PRODUCT, 2014 - 2014 (USD MILLION)
GLOBAL ACTIVATED CARBON MARKET SHARE BY END-USE (% AGE)
SOME INDIAN MANUFACTURERS OF ACTIVATED CARBON
INSTALLED CAPACITY, PRODUCTION & CAPACITY UTILIZATION
OF ACTIVATED CARBON (MT)
APPARENT CONSUMPTION OF ACTIVATED CARBON (MT)
ESTIMATED DEMAND OF ACTIVATED CARBON
CONSUMPTION OF ACTIVATED CARBON
GLOBAL SCENARIO & RECOMMENDATION
BUYERS OF ACTIVATED CARBON
MANUFACTURERS/SUPPLIERS OF ACTIVATED CARBON
DIFFERENT TYPES OF ACTIVATED CARBON
ABSORBING GASES OR VAPOUR (GAS ABSORBENT CARBON)
DECOLORIZING AND PURIFYING LIQUID
CATALYST & CATALIST SUPPORT (GAS ABSORBENT CARBON)
MEDICINE
MANUFACTURING PROCESS OF ACTIVATED CARBON (BY STEAM ACTIVATION)
PROCESS FLOW DIAGRAM FOR THE MANUFACTURE OF ACTIVATED
CARBON FROM RICE HUSK (BY STEAM ACTIVATION)
MANUFACTURING PROCESS OF ACTIVATED CARBON FROM COCONUT
SHELL (BY STEAM ACTIVATION)
RAW MATERIALS REQUIREMENT FOR ACTIVATED CARBON FROM
COCONUT SHELL
CARBON SOURCE
CHARCOAL PRODUCTION
ACTIVATION PROCESS
PROCESS FLOW DIAGRAM FOR THE MANUFACTURE OF ACTIVATED
CARBON FROM COCONUT SHELL
MANUFACTURING PROCESS OF ACTIVATED CARBON FROM SAW DUST
PROCESS FLOW SHEET FOR MANUFACTURE OF ACTIVATED CARBON
FROM SAW DUST
MANUFACTURING PROCESS OF ACTIVATED CARBON FROM LIGNITE
TIME FOR COMPLETION OF PROJECT
PROCESS IN DETAILS
RAW MATERIALS
METHODS OF MANUFACTURE
CHEMICAL ACTIVATION
STEAM ACTIVATION
QUALITY CONTROL TESTING OF ACTIVATED CARBON
CARBON TETRACHLORIDE ACTIVITY
SURFACE AREA
HARDNESS
MESH SIZE
ASH CONTENT
DENSITY
INTERRELATION OF PROPERTIES
OTHER TESTS
TESTING OF ACTIVATED CHARCOAL
QUALITATIVE METHOD
SEMI-QUANTITATIVE METHOD
QUANTITATIVE METHOD
PLANT LAYOUT
STATE & CONTROL SUBSIDY SCHEME FOR ACTIVATED CARBON PROJECT
COMPLETE PLANT SUPPLIERS FOR ACTIVATED CARBON
ADDRESSES OF RAW MATERIAL SUPPLIERS
COCONUT SHELL
RICE HUSK
SAW DUST
CAUSTIC SODA
ZINC CHLORIDE
ADDRESSES OF PLANT & MACHINERY SUPPLIERS
PULVERISER
MIXERS
ROTARY KILNS
TRAY DRIER
MANUFACTURER, EXPORTER OF HYDRAULIC LIFT
MANUFACTURER OF HEAVY MOBILE CRANES
EXTRUDER
TANKS
BOILER
COOLER
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)
