Activated Carbon (Raw Material – Wood Chips) – 1200 TPA

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)