Detailed Project Report on activated carbon from coconut shell

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)