Industry Overview
Carbon is one of the most widely distributed elements in nature and occurs in crystalline forms such as graphite and diamond, as well as in amorphous forms including charcoal, coke, and carbon black. Industrial carbons are produced from coal and a wide range of organic vegetable and animal materials, including petroleum coke, wood charcoal, agricultural residues, and industrial wastes.
Activated carbon, also known as active carbon or active charcoal, refers to amorphous carbon materials with substantially higher adsorption capacity than ordinary wood or animal charcoal. Activated carbons are commercially available as pellets, granules, and fine powders and are used across gas purification, liquid decolorization, metal adsorption, water treatment, chemical processing, and medicinal applications.
Commercial activated carbons are broadly classified as decolorizing, gas-absorbent, metal-absorbent, and medicinal carbons, with different grades selected according to their physical structure, properties, and intended application. Manufacturing routes include gas or steam activation and chemical activation. Raw materials can include coal, petroleum coke, coconut shells, sawdust, rice husk, paddy husk, bagasse, molasses, corn cobs, and other biomass or industrial residues. The report describes several manufacturing and processing routes, together with product properties, quality-control testing, applications, market information, raw-material sources, equipment suppliers, and project economics.
Cost Estimation
| Cost / Financial Parameter | Value |
|---|---|
| Plant Capacity | 20 MT/Day |
| Land & Building (12,000 sq.mt.) | Rs. 7.44 Cr |
| Plant & Machinery | Rs. 6.19 Cr |
| Working Capital for 3 Months | Rs. 5.83 Cr |
| Total Capital Investment | Rs. 20.04 Cr |
| Rate of Return | 27% |
| Break Even Point | 53% |
Content Index
- 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
- SPECIFICATIONS
- THE SIEVE ANALYSIS SHOULD BE AS FOLLOWS
- TESTING
- STRUCTURE OF ACTIVATED CARBON
- ADSORPTION MECHANISM OF ACTIVATED CARBON
- MARKET POSITION
- THREE MAIN FORMS OF ACTIVATED CARBON ARE:
- THE TYPES OF THE PRODUCT AVAILABLE IN THE INDUSTRY ARE:
- IT FINDS WIDE APPLICATIONS IN THE FOLLOWING SEGMENTS:
- THE FEEDSTOCK CAN BE CATEGORISED AS FOLLOWS:
- GLOBAL ACTIVATED CARBON MARKET: REGIONAL SEGMENT ANALYSIS
- ACTIVATED COKE AS AN ADSORBING AGENT
- MANUFACTURING PROCESS OF ACTIVATED CARBON
- THE FURNACE IS A LARGE CYLINDRICAL CARBON STEEL SHELL SUPPORTED ON LEGS OF STEEL
- PROCESSING DETAILS 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
- GLOBAL ACTIVATED CARBON MARKET SHARE BY END-USE (% AGE)
- SOME INDIAN MANUFACTURERS 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)
- A. FROM RICE HUSK
- 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
- METHOD OF PET COKE ACTIVATION
- ACTIVATION OF SYRIAN PETROLEUM COKE
- PROCESSING DETAILS OF ACTIVATED CARBON FROM COCONUT SHELL
- PROCESS RATIONALE
- HEAT EXCHANGERS
- VESSELS
- REACTORS AND HEATERS
- FIG: SCHEMATIC OF THE FLUIDIZED BED REACTOR STAGES.
- SEPARATORS
- PUMPS, BLOWERS AND COMPRESSORS
- CONVEYORS
- SIZE REDUCERS
- PROCESS FLOW DIAGRAMS
- FIGURE: PFD OF THE PYROLYSIS PROCESS
- FIGURE: PFD OF THE ACTIVATION PROCESS
- 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
- STATE & CONTROL SUBSIDY SCHEME FOR ACTIVATED CARBON PROJECT
- COMPLETE PLANT SUPPLIERS FOR ACTIVATED CARBON
- ADDRESSES OF RAW MATERIAL SUPPLIERS
- SUPPLIERS OF COCONUT SHELL
- SUPPLIERS OF RICE HUSK
- SUPPLIERS OF SAW DUST
- SUPPLIERS OF CAUSTIC SODA
- SUPPLIERS OF ZINC CHLORIDE
- ADDRESSES OF PLANT & MACHINERY SUPPLIERS
- SUPPLIERS OF PULVERISER
- SUPPLIERS OF MIXERS
- SUPPLIERS OF ROTARY KILNS
- SUPPLIERS OF TRAY DRIER
- SUPPLIERS OF HYDRAULIC LIFT
- SUPPLIERS OF HEAVY MOBILE CRANES
- SUPPLIERS OF EXTRUDER
- SUPPLIERS OF TANKS
- SUPPLIERS OF BOILER
- SUPPLIERS OF COOLER
Appendix
- 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)
Frequently Asked Questions
Activated carbon is a highly porous form of carbon designed to provide high adsorption capacity. It is commonly produced by activating carbonaceous raw materials through gas or steam activation or chemical activation. The resulting pore structure gives the material the ability to adsorb gases, vapours, dissolved organic compounds, and certain other substances. Depending on its properties and grade, activated carbon can be supplied as powder, granules, or pellets and selected for applications such as water purification, gas treatment, decolorization, chemical processing, and medicinal products.
Activated carbon can be manufactured from coal, petroleum coke, wood-based materials, coconut shells, agricultural residues, and other carbonaceous feedstocks. The report specifically discusses materials such as rice husk, sawdust, coconut shell, lignite, paddy husk, bagasse, molasses, corn cobs, and industrial wastes. Feedstock selection affects the carbonization behaviour, pore structure, ash content, hardness, yield, and suitability of the finished activated carbon for particular applications.
The principal production routes described are gas or steam activation, chemical activation, and carbon deposition on porous inorganic bases. In gas activation, the raw material is carbonized and the resulting charcoal is treated at elevated temperature with an oxidizing or activating gas such as steam or carbon dioxide. Chemical activation involves impregnation with suitable chemicals followed by drying and carbonization. The selected route depends on the raw material, desired pore structure, product properties, and intended application.
Activated carbon is widely used for purification, adsorption, decolorization, gas treatment, and selected medicinal applications. Commercial grades can be designed for removing impurities from liquids, absorbing gases and vapours, treating water, and decolorizing or purifying process streams. The report also identifies applications in chemical processing and catalytic systems, as well as the use of activated carbon in pills and digestive tablets. The appropriate carbon grade depends on adsorption characteristics, pore structure, particle size, hardness, and other performance requirements.
Surface area, pore size distribution, hardness, bulk density, particle size, and ash content are important activated-carbon properties. These characteristics influence adsorption capacity, pressure drop, mechanical durability, handling behaviour, and suitability for a particular process. The report also discusses mesh size, density, and other testing parameters. Because different applications require different adsorption behaviour, activated carbon should be selected according to the contaminant or substance being removed and the operating conditions of the treatment process.
Activated carbon quality is evaluated using tests covering adsorption performance and physical characteristics. The report includes carbon tetrachloride activity, surface area, hardness, mesh size, ash content, density, and other tests. Testing may also be conducted through qualitative, semi-quantitative, and quantitative methods. These evaluations help establish whether the product meets specified requirements and whether its physical and adsorptive properties are appropriate for the intended application.
The report specifies a plant capacity of 20 MT/Day and a Total Capital Investment of Rs. 20.04 Cr. The stated cost estimation also includes Land & Building (12,000 sq.mt.) at Rs. 7.44 Cr, Plant & Machinery at Rs. 6.19 Cr, and Working Capital for 3 Months at Rs. 5.83 Cr. The report further states a Rate of Return of 27% and a Break Even Point of 53%. These figures are reproduced exactly from the supplied project report and have not been recalculated.
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