Industry Overview
Activated carbon is a highly porous form of amorphous carbon valued for its exceptional adsorption capacity and broad industrial applications. Carbon exists naturally in several forms, including graphite and diamond, while industrial carbon materials such as charcoal, coke, petroleum coke, and carbon black are produced from coal and various organic raw materials. Carbon is also a fundamental element in all plant and animal life and occurs in numerous natural compounds, including hydrocarbons, carbon dioxide, and carbonate minerals.
The development of activated carbon accelerated during World War due to the need for efficient gas mask absorbents. Since then, industrial production has expanded to supply activated carbon in pellet, granular, and powdered forms for diverse applications. Depending on their physical properties and intended use, commercial activated carbons are generally classified as decolorizing, gas absorbent, metal absorbent, and medicinal carbons. No single grade is suitable for every application, making raw material selection and activation methods important factors in determining product performance.
Activated carbon can be manufactured from a wide range of feedstocks, including coal, petroleum coke, wood charcoal, and numerous agricultural and industrial by-products such as bagasse, coconut shells, corn cobs, paddy husk, groundnut husk, molasses, straw, distillery waste, waste wood pulp liquor, sugar factory mud, and other biomass residues. Gas activation and chemical activation are commonly employed to enhance the adsorption characteristics of the final product, enabling its use across water treatment, gas purification, decolorization, metal recovery, pharmaceutical, and other industrial sectors.
Cost Estimation
| Particular | Value |
|---|---|
| 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% |
Content Index
- 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
- 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 carbon material with exceptional adsorption properties.
It is manufactured by activating carbon-rich raw materials such as coal, wood charcoal, petroleum coke, coconut shells, and agricultural residues. Its extensive internal surface area enables it to remove contaminants, odors, colors, and impurities from liquids and gases, making it valuable in industrial, environmental, and medical applications.
Activated carbon can be produced from a wide variety of carbon-rich raw materials.
Common feedstocks include coal, petroleum coke, wood charcoal, coconut shells, bagasse, corn cobs, paddy husk, groundnut husk, molasses, straw, distillery waste, and other agricultural or industrial by-products. The choice of raw material influences the pore structure, adsorption performance, and end-use suitability of the finished product.
Activated carbon is widely used for purification and adsorption processes.
Its applications include water treatment, gas purification, decolorization, metal recovery, pharmaceutical products, oil and gas operations, and various chemical processing industries. Different grades and forms are selected according to the adsorption requirements and operating conditions of each application.
Activated carbon is commonly supplied in granular, powdered, and pelletized forms.
Each form is designed for specific industrial requirements. Granular activated carbon is often used in filtration systems, powdered activated carbon is suitable for batch treatment and liquid purification, while pelletized activated carbon is commonly used for gas-phase adsorption due to its strength and low pressure drop.
Activation develops the porous structure responsible for the material's adsorption capacity.
Industrial production generally uses gas activation or chemical activation to create a network of microscopic pores within the carbon. This process significantly increases the available surface area, allowing the product to effectively capture impurities from liquids and gases across different industrial applications.
The quality of activated carbon depends on both raw materials and manufacturing conditions.
Important factors include feedstock selection, activation method, processing conditions, pore structure, particle size distribution, and quality testing. These characteristics determine adsorption efficiency, mechanical strength, and suitability for specific industrial uses such as water treatment, gas purification, or chemical processing.
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