Activated Carbon (From Coconut Shell) Cap: 20 MT/Day

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)