GCF MULTIPRODUCTS

LKT CORPORATE PLANNING

AND MARKETING
Copyright DECEMBER 2011
ACTIVATED CARBON
A Feasibility Study on Manufacturing Coconut
Shell Activated Carbon



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Contents

Introduction

3
Activated Carbon Manufacturing
Steam Activation
Chemical Activaton


5
7
Activated Carbon Properties

9
Activated Carbon Output Description

10
Estimation of Equipment and Capital Cost
Steam Activated Coconut Shell Carbon
Chemically Activated Coconut Shell Carbon


12
14
Comparison of Adsorption Properties

16
World Demand Supply Trends

17
Regional Market Scenario

17
Global Market Scenario

17
Numerous Applications for Activated Carbon Worldwide

19
Sales Projection Estimates

23
Summary and Conclusion

25



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Introduction
GCF Multiproducts have been in the export and manufacturing industry of coconut and
banana products since 1997. Among these coconut products are being developed are coconut
charcoal briquettes and granulated coco charcoal. With the rapid growth of activated carbon market,
this study is intended to investigate the feasibility of marketing granulated activated carbon to
International markets by gathering a compilation of studies from activated carbon manufacturers.
Additional specific goals of this study are to determine both steam process activation and chemical
process activation and estimated cost of production for granular activated carbon.
GCF Multiproducts is situated in Padada, Davao del Sur where 65% of the total land area is
planted with coconuts. In 2010, Davao Del Sur region produced 842,342 MT of coconuts (Bureau
of Agricultural Statistics, 2010) as copra as their main produce and the coconut shells and husk
serving as byproducts.
The company started helping the coconut farmers improve the
utilization of their coconut products by developing new products for
export market. In line with their products include coconut charcoal
briquettes, granulated coconut charcoal, coconut peat and coconut
fiber manufacturing.
From the charcoal manufacturing sector of GCF Multiproducts,
the company is seeing the huge international market for activated
carbon. Based on Freedona International Market study on 2008,
global demand for activated carbon will expand at 9.9% yearly
through 2014 to 1.7 million metric tons. Currently, Global Industry
Analyst (GIA) on their research entitled Activated Carbon: A Global
Strategic Business Report on April 2011, indicates that the global
market for activated carbon is forecast to reach a market size of 2.3
million metric tons by the year 2017. They also recognized the US
and Asia-Pacific (China, Indonesia, Philippines, Sri Lanka and
Thailand) as countries who traditionally dominate the largest
activated carbon producers across the world.
In relation to activated carbon manufacturing industry to supply the increasing demand of
activated carbon, China has become the worlds largest activated carbon producer and exporter
reaching to 445,000 or more or less 400,000 metric tons as semi -finished carbon products that
needs to be re-processed (23% from the global demand of 1.7 million metric tons) . From 2008-
2010, China imported over 12,000 tons annually of high value-added activated carbon or 0.7%
from the global demand for activated carbon. This spurted the immediate move of coal giants in
China to enter the field of coal based activated carbon, for example, the Datong Coal Mine Group.
Despite the move by coal giants in the world, there is still a huge gap in the supply demand market
for activated carbon, this is due to the raw material constraints where manufacturers have moved
to set plants in regions where there are abundant raw materials such as the Asia pacific region.
GCF MULTIPRODUCTS has a plant capacity
to produce 600 MT of granulated charcoal
made from coconut shells.


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Generally most activated carbon manufacturers produce 2,000 - 5,000 MT annually which
generates at least $10 M 25M in revenue. In relation to GCF multiproducts manufacturing
capacity, in 2011 the company has produced an average estimate of 3600 MT of coconut shell
charcoal. The current plant capacity can produce at most 7200 MT of charcoal which shows an
interesting potential to manufacture activated carbon products.
GCF Multiproducts intends to use its technology and coconut shells to produce granulated
activated carbon (GACs). Using coconut shells to produce GACs provides a less expensive raw
material and a more preferred material by the international market due to its quality of adsorption.
Aside from this, GAC manufactured from coconut shells is a renewable resource instead of a non-
renewable one and coconut shell, rather than coal- or peat-based material, is considered to be the
greener choice; aside from being renewable, it is sustainable and easily harvested. There is no
requirement for the mining or digging of non-renewable fossil fuel resources, such as coal or peat.
The objectives of this investigation were to estimate the cost of production of these carbons
through process descriptions and economic analysis. The depiction of process flow diagrams for
the production of activated carbon from coconut shell is derived from researches, publications
posted in the internet by various institutions and manufacturers. Estimated production costs
were derived from equipment manufacturers costs and capital and operating costs based on the
process flow diagrams and posted market prices of the equipments.
















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ACTIVATED CARBON MANUFACTURING
STEAM ACTIVATION
Activation/Oxidation:
Raw material or carbonised material is exposed to oxidizing atmospheres (carbon dioxide,
oxygen, or steam) at temperatures above 250 C, usually in the temperature range of 600-1100 C.
Steam activated carbon manufacturing is generally considered a three stage process
consisting of pre-activation, activation and post-activation.
Pre-activation is concerned with quality
checking and correct sizing and screening of
material prior to activation. At this point
material can be called kiln-feed.

Activation is the process by which charcoal
raw material kiln-feed is turned into activated
carbon. Steam activation for this process is
where coconut shell charcoal is subjected to
high temperatures and steam within
specially designed activation kilns. The
coconut shell charcoal is activated by
reaction with steam at a temperature of
900
o
C -1100
o
C under controlled atmosphere
in a rotary kiln. The reaction between steam
and charcoal takes place at the internal
surface area, creating more sites for
adsorption. The temperature factor, in the
process of activation is very important.
Below 900
o
C the reaction becomes too slow and is very uneconomical. Above 1100
o
C
the reaction becomes diffusion controlled and therefore takes place on the outer surface
of the charcoal resulting in loss of charcoal.

Finally, post-activation consists of quality checking the parameters of kiln output material.
Further screening is then undertaken and additional special processes such as washing
(for example, for ash/impurity removal), demagnetising and impregnation that are applied
to meet the requirements of the customer's application.





Steam activation is done
through injecting steam
inside the heated rotating
kiln with carbonized
coconut charcoal

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Figure 1. Steam Activated Process






Product Specification
pH Value 6.5 - 7.5
Methylene Value adsorption mgm / gm 190 - 350
Adsorption capacity at % by mass (min) 45
Moisture (max.) 5%
Ash (max) 5%
Hardness 90

Machinery
Jaw crusher Hammer mill Vibratory feeder
Elevator Carbonization kiln Soaking tanks
Cyclones
Rotary kiln with heat
recovery unit
Coolers
Centrifuge Rotary drier Micro pulverizer
Sieving machine Pneumatic filling machine




ROTARY
KILN
GRANULATED
COCO
CHARCOAL
STEAM GENERATOR
ROTARY
COOLER
WASHING
DEMAGNETIZING

PELLETING /
PACKAGING

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Chemical activation
Prior to carbonization, the raw material is impregnated with certain chemicals. The chemical is
typically an acid, strong base, or a salt (phosphoric acid, potassium hydroxide, sodium hydroxide,
zinc chloride, respectively). Then, the raw material is carbonized at lower temperatures (450-900 C).
It is believed that the carbonization / activation step proceeds simultaneously with the chemical
activation. This technique can be problematic in some cases, because, for example, zinc trace
residues may remain in the end product. However, chemical activation is preferred over physical
activation owing to the lower temperatures and shorter time needed for activating material.
Activated carbon is produced from coconut shell powder by chemical activation. In commercial
production of activated carbon from waste material as coconut shell powder is done by chemical
activation.
The coconut shell is first grounded in the form of powder by use of pulverizer.
The powdered raw material is taken into a mechanical mixer. Now the solution of 50% Zinc
Chloride is prepared and incorporated into the mechanical mixer. The mixing is done by use
of stirrer and heating is applied so that thick paste of raw material powder and zinc chloride
is formed.
The thick paste is then passed through an extruder of having an extrusion plate with 1/8 size
perforation.
The paste is extruded under pressure into the form of granulated mass.
The granulated mass is then dried by blowing hot air and taken into the rotary kiln.
The klin is heated to the temperature of 850to 1000C by means of furnace flue gas.
The hot activated carbon produced is then
cooled in an iron box in the absence of air.
The cooled product is then taken into a
washing tank where the dilute hydrochloric
acid are sprayed on the activated carbon to
remove the inorganic chemicals like zinc
compound and the residual acid.
Now, washed activated carbon is dried in the
air stream heated kiln at the temperature of
275to 300C.
The activated carbon is then pulverized and
screened as per the requirement and then
packed in polythene laminated jute bags.


Chemical Activation is done
through treating the raw
materials into chemicals before
carbonizing at lower heat


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Fig. 2 Chemical Activation Process











PRODUCT SPECIFICATIONS OF CHEMICALLY ACTIVATED CARBON
Chemical parameters Acid washed Unwashed
Moisture(%) max. 10 10
Methylene value(min) 270 280
KmnO
4
(min) 60 60
Iodine value 1100 1100
Ash(%) max. 3 NA
Fe ppm 200 1000
pH 6.5 to 7.2 Adjustable
Chlorine(%) max 0.4 NA
Sulphate(%) max 0.4 NA
Phosphate Nil Nil
Acid soluble matter(%) 1.5 5
Water soluble(%) 0.5 4
Bulk density 4 to 6 gm/cc 4-6 gm/cc



PULVERIZER
COCO CHARCOAL
MECHANICAL MIXER
CaCl2 or
ZnCl2
EXTRUDER
GRANULATED MASS
DRIER

ROTARY KILN /
CARBONIZATION
Pressurized Cooling
Box
WASHING TANK
DRYER
Pulverizing / Pelleting
/Packaging

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ACTIVATED CARBON PROPERTIES
Generally, most manufacturers can customize the properties of activated carbon to cater
different client preferences. Different applications for activated carbon demands different activated
carbon properties. Listed below are the important properties of activated carbon that manufacturers
are customizing for increased marketability and serves as a gauge for quality.
SURFACE AREA
o Determines the adsorption capacity. Usually
found by the adsorption of nitrogen (BET method)
o Depends on the micropores

PHYSICAL PROPERTIES
o Density, hardness, particle size

IODINE NUMBER
o Adsorption of iodine from solution
Represented as milligram of iodine
adsorbed per gram of carbon

The iodine number is nearly equal to the
surface are in m
2
/g.


DECOLORIZING POWER
o Adsorption of dyes from solution Methylene blue number

ADSORPTION CAPACITY
o Adsorption of organic vapors from air stream
Carbon tetra chloride
Benzene

OIL RETENTION and FILTERABILITY

HARDNESS NUMBER percentage retained in a sieve of a given mesh size after shaking
the material along with steel balls for a specific time






Activated Carbon
surface area of 500 m
2





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ACTIVATED CARBON OUTPUT
DESCRIPTION FOR BOTH STEAM AND
CHEMICALLY ACTIVATED CARBON
A. PRODUCT CHARACTERISTICS
Form Powder,
Pellets
Granules
Grade Liquid phase or de-colouring carbon.
Gas phase or vapour absorbent carbon.
Liquid phase or decolouring carbon
Form Light fluffy powder
Characteristics Large percentage of transitional or
macropores

Gas phase or vapour absorbent carbon.
Form Granules or pellet
Characteristics Large percentage of micropores
Pore size
Porosity and the pore structure are the most important characteristics of Activated carbon. Size of
the micropores is the deciding factor in selective absorption.
At least two systems of pores of distinctly different sizes exist in every carbon particle.
Macropores (1000 to 2600 Deg A) acts as large access ways for diffusion of particles.
Micropores (10 to 100 deg A) contributes towards large surface area which are responsible for
absorption action.

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Surface area
From 200 to 2000 m
2
/g, depending upon the method and manner of preparation.
Adsorption behavior and Product Specifications
Depending on the process of activation, i.e. steam, as or chemically activated, the Activated Carbon
differ in their adsorption behaviour.
Gradewise application
Grade Sector
Powdered Activated carbon Vegetable oils, fats, sugar, water
treatment, pharmaceuticals, fine
chemicals and food products.
Granular Activated carbon Automotive canisters, air purification,
chemical and pharmaceutical industry.
Pelletised Activated carbon Solvent recovery, catalyst application
etc














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Estimation of Equipment and Capital
Cost
Once the process flow diagrams were constructed, equipment and capital costs were
estimated from a combination of vender quotes from Alibaba.com, web publication and printed
literature. Equipment costs represent actual purchase costs and not investment costs. This
capital cost estimate was then used in a procedure to estimate fixed capital investment using
ranges of process-plant component costs. Land cost, building cost, and service facilities are
estimates and transportation of materials and equipments are not included. Procedures are
intended for a high degree of automatic control and outdoor operation.
Rotary kilns were sized based on Zhengzhou Huaye Heavy Industry & Machinery Co., Ltd.,
China from Alibaba.com and so are the other machinery estimates.
Estimation of Equipment and Capital Cost for Steam Activated Coconut Shell
Carbon

Table 1. ESTIMATED CAPITAL COST


Equipment Cost (P)
Hammer mill 150,000
2 Rotary kilns (500,000 each) 1,000,000
Rotary cooler 500,000
Sieve 100,000
Total equipment cost 1,750,000
Equipment installation 250,000
Instrumentation 200,000
Electrical installation 100,000
Buildings 2,500,000
Service facilities 500,000
Land 5,000,000
Construction expense 500,000
Contingency 2,970,000
Total capital costs 13,770,000









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Table. 2 ANNUAL OPERATING COST
Item Annual cost (P) Raw materials
Coconut Shell (1000 MT/mo at 9.00 kl)
9,000,000
Utilities

Steam 240,000
Water 180,000
Natural gas 360,000
Electricity (300,000/mo)
3,600,000
Labor

Operating labor (6x10000/mo) 720,000
Maintenance labor (3x12000/mo) 432,000
Supervision (2x15000/mo) 540,000
Supplies

Operating supplies (50,000/mo) 600,000
Maintenance supplies (50,000/mo)
600,000
General Works

General and administrative (5x10000/mo) 600,000
Depreciation 17,144,400
Total cost
34,016,400

Table 3. Summary of Cost of Activated Coconut Shell Carbon
Purchased equipment cost Php 1,750,000
Capital cost 12,020,000
Total fixed capital investment 13,770,000
Total annual operating cost 34,016,400
Estimated annual production of carbon 2,400,000 kg
Estimated cost for activated carbon Php 14.1735

Cost Analysis for Steam Activated Coconut Shell Carbon
Costs were developed assuming a 20 percent yield of coconut shell -based activated carbon
(7.5 MT/day output), 320 days per year of production and two men per shift (three shifts) for 24
hours a day at P385 per day. Production of 2400 MT/year of steam-activated coconut shell
carbon requires a fixed capital investment of P 13 million (Table 1) and an annual operating cost
of P39 million (Table 2). The estimated product cost is P14.17/kg (Table 3).





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Estimation of Equipment and Capital Cost for Chemically Activated Coconut Shell
Carbon
Table 4. Estimated capital costs for CaCl activation of coconut shells
Equipment Cost (P)
Hammer mill 150,000
2 Glass-lined, acid soak tanks

400,000
Rotary dryer 500,000
2 Rotary kilns

1,000,000
Rotary cooler 500,000
2 Glass-lined, acid wash tanks 300000
2 Glass-lined, acid recovery tanks 300000
2 Glass-lined, acid storage tanks 300000
Rotary dryer 500,000
Sieve 100,000
Total equipment cost 4,050,000
Equipment installation 250,000
Instrumentation 200,000
Electrical installation 100,000
Buildings 2,500,000
Service facilities 500,000
Land 5,000,000
Construction expense 500,000
Contingency 2,970,000
Total capital costs 16,070,000
















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Table 5. Annual operating costs for Cacl activation of coconut shells
I tem Annual cost ($)
Raw materials
Coconut Shell (1000 MT/mo at 9.00 kl) 9,000,000
Zinc Chloride (1 L per kg of coconut shell at P8/L) 96,000,000
Utilities
Steam 240,000
Water 180,000
Natural gas 360,000
Electricity 500,000
Labor

Operating labor (6x10000/mo) 720,000
Maintenance labor (3x12000/mo) 432,000
Supervision (2x15000/mo) 540,000
Supplies

Operating supplies (50,000/mo) 600,000
Maintenance supplies (50,000/mo) 600,000
General Works
General and administrative (5x10000/mo) 345,000
Depreciation 22,403,400
Total cost 131,920,400

Table 6. Summary of costs for CaCl activation of coconut shells
Purchased equipment cost Php 4,050,000
Capital cost 12,020,000
Total fixed capital investment 16,070,000
Total annual operating cost 131,920,400
Estimated annual production of carbon 4,800,000 kg
Estimated cost for activated carbon Php 27.05/kg

Cost Analysis
Costs were developed assuming a 40 percent yield of coconut shell -based activated
carbon (15 MT/day output), 320 days per year of production and two men per shift (three shifts) for
24 hours a day at P385 per day. Production of 2400 MT/year of chemically activated coconut shell
carbon requires a fixed capital investment of P 16 million (Table 4) and an annual operating cost of
P131 million (Table 5). The estimated product cost is P27.05/kg (Table 6).



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Comparison of adsorption properties
of a chemically activated and a steam-
activated carbon,
using inverse gas chromatography

By: Eva D

az, SaIvador Ordez

Department of Chemical Engineering and Environmental Technology, University of viedo, ulin
Claver

a s/n, 3300 viedo, Spain

Adsorption properties of two different activated carbons, steam and chemically activated,
respectively, were examined by inverse gas chromatography (IGC). The influence of acid, basic and
combined washings, carried out in order to remove ashes, on the adsorption properties of these
materials was also tested using this technique. Chemical and textural characterization was carried
out by nitrogen adsorption, ICP-MS and temperature programmed desorption, whereas
thermodynamic properties (enthalpy of adsorption, surface free energy characteristics) have been
determined by IGC. Washing procedures (specially those involving acid washing) removes almost
completely the mineral ashes of the carbons. Concerning to the effect on porous structure, this
procedures only affect significantly to the properties of chemically activated carbon, with increases of
micropore volume of up to 43%.
The steam activated carbon shows the best adsorptive behavior, with an enthalpy of adsorption up
to 16% higher than the corresponding to chemically activated one, as well as a large amount of
micropores. The removal of these ashes enhances the adsorption of studied compounds, especially
for alkanes and chlorinated ones. Washing procedures also modify the chemical structure of the
organic functionalities, but this effect does not seem to be very important on the adsorption
properties of these materials.








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WORLD DEMAND SUPPLY TRENDS
Sector wise demand
Sector Demand in Metric tons annually
Pharmaceutical 2630
Plasticisers 1750
Glucose/Dextrose Monohydrate/Sorbitol 1550
Vegetable Oil 32500
Miscellaneous sector 6100
Export Sector 400
Total 44930
Likely growth rate in demand : 9 to 10% per annum (Global Industry Analyst, 2010)
REGIONAL MARKET SCENARIO
Region XII has only three (3) major manufacturers of activated carbon

There are only three identified major manufacturers of activated carbon in Davao, namely:
Davao Central Chemical Corporation, Premium Active Carbon Incorporated, and Cenaprochemical
Corporation.
GLOBAL MARKET SCENARIO
Demand for Activated
Carbon:
Around 1.7 million tonnes per annum
Raw material
The wood based Activated Carbon accounts
for around 40% of the total world
production.
Major Producing
Countries
The Philippines and Sri Lanka are
the major producers and exporters
of Activated Carbon.
Sri Lanka has increased its export
volume of Activated Carbon to
around 10,000 tonnes per annum.
Global growth rate in
demand
9 to 15% per annum

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The new industry study by Freedonia on World Activated Carbon, presents historical demand
data (1999, 2004, 2009) plus forecasts for 2014 and 2019 by type, market, world region and major
country. The study also considers market environment factors, evaluates company market share and
profiles 32 industry competitors worldwide. It summarizes the following points:
a) Global demand to expand 9% annually through 2014

World demand for virgin activated carbon is forecast to expand an impressive 9.0
percent per annum through 2014 to 1.7 million metric tons. The US represents the largest
national market for activated carbon in the world, and through 2014, the country will also
pace global growth. This extremely optimistic outlook is based on US new federal
environmental regulations mandating mercury removal at coal-fired power plants by 2014. A
number of states have already passed their own regulations, resulting in US activated carbon
demand from coal fired power plants rising significantly in 2009. If federal regulations pass,
which is likely, gains are expected to really take off in 2013 and 2014.

b) US market to be aided by DBP & mercury control rules

Demand in the US will also be aided by regulations that will require mercury control
at cement kilns and at industrial boilers. Moreover, demand from the water sector will benefit
from the US Environmental Protection Agency (EPA)s Stage 2 Disinfection Byproducts Rule
(DBP Rule). This rule was promulgated in 2006 and establishes maximum levels at which
disinfection byproducts (DBPs) are permitted to be present in drinking water supplies. DBPs
are potentially harmful compounds that are formed when chlorine that is used to disinfect
drinking water reacts with naturally occurring organic materials in the water. By removing the
organic materials, activated carbon prevents the formation of DBPs.

c) Chinas market to be driven by economic growth

Unlike the US, where federal regulations will dictate demand growth, strong gains
of around nine percent per year in Chinas market for activated carbon will result from
continuing healthy economic growth in the country. All end uses for activated carbon in
China will benefit from this economic growth. Although the country relies on coal to supply a
majority of its energy requirements, UStype mercury removal regulations are unlikely to pass
in China in the near future.

d) Coal fired power plants may boost Western European market

Demand for activated carbon in Western Europe and Japan will register weak
gains through 2014. In Western Europe, there is some concern that coal will make a
comeback (something that is already occurring in Italy) as a key source of energy supply due
to declining oil and gas reserves in the North Sea, the pending end of life for some nuclear
power plants in the region, and security issues and public disapproval preventing further
reliance on energy imports from Russia. If coal fired power plants proliferate in Western
Europe, they are likely to also use activated carbon to curtail mercury emissions.


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APPLICATIONS FOR
ACTIVATED CARBON
WORLDWIDE
Activated carbon is used in gas purification, gold
purification, metal extraction, water purification, medicine, sewage
treatment, air filters in gas masks and filter masks, filters in
compressed air and many other applications.

One major industrial application involves use of activated
carbon in the metal finishing field. It is very widely employed for purification of electroplating
solutions. For example, it is a main purification technique for removing organic impurities from bright
nickel plating solutions. A variety of organic chemicals are added to plating solutions for improving
their deposit qualities and for enhancing properties like brightness, smoothness, ductility, etc. Due to
passage of direct current and electrolytic reactions of anodic oxidation and cathodic reduction,
organic additives generate unwanted break down products in solution. Their excessive build up can
adversely affect the plating quality and physical properties of deposited metal. Activated carbon
treatment removes such impurities and restores plating performance to the desired level.

Analytical chemistry applications

Activated carbon, in 50% w/w combination with celite, is used as stationary phase in low-pressure
chromatographic separation of carbohydrates (mono-, di- trisacchardes) using ethanol solutions (5-
50%) as mobile phase in analytical or preparative protocols.

Environmental applications

Activated carbon is usually used in water filtration systems. In this illustration, the activated carbon is
in the fourth level (counted from bottom).

Carbon adsorption has numerous applications in removing pollutants from air or water streams both
in the field and in industrial processes such as:
Spill cleanup Groundwater remediation
Drinking water filtration
Air purification
Volatile organic compounds capture from painting, dry cleaning, gasoline dispensing
operations, and other processes.
In 2007, West-Flanders University (in Belgium) began research in water treatment after
festivals . A full scale activated carbon installations, was built at the Dranouter music festival


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in 2008, with plans to utilize the technology to treat water at this festival for the next 20
years.
Activated charcoal is also used for the measurement of radon concentration in air.

Medical applications

Activated carbon is used to treat poisonings and overdoses following oral ingestion.
It is thought to bind to poison and prevent its absorption by the gastrointestinal tract. In cases of
suspected poisoning, medical personnel administer activated charcoal on the scene or at a hospital's
emergency department. Dosing is usually empirical at 1 gram/kg of body weight ( for adolescents or
adults, give 50100 g ), usually given only once, but depending on the drug taken, it may be given
more than once. In rare situations activated charcoal is used in Intensive Care to filter out harmful
drugs from the blood stream of poisoned patients. Activated carbon has become the treatment of
choice for many poisonings, and other decontamination methods such as ipecac-induced emesis or
stomach pumping are now used rarely.
While activated carbon is useful in an acute poisoning situation, it has been shown to not be
effective in long term accumulation of toxins, such as with the use of toxic herbicides.

Mechanisms of action:

Binding of the toxin to prevent stomach and intestinal absorption. Binding is
reversible so a cathartic such as sorbitol may be added as well. It interrupts the
enterohepatic circulation of some drugs/toxins and their metabolites
Incorrect application (e.g. into the lungs) results in pulmonary aspiration which can
sometimes be fatal if immediate medical treatment is not initiated. The use of
activated charcoal is contraindicated when the ingested substance is an acid, an
alkali, or a petroleum product.
For pre-hospital use, it comes in plastic tubes or bottles, commonly 12.5 or 25 grams,
pre-mixed with water. The trade names include InstaChar, SuperChar, Actidose, and
Liqui-Char, but it is commonly called Activated Charcoal.
Ingestion of activated carbon prior to consumption of ethanol has been shown to
reduce absorption of alcohol into the blood. 5 to 15 milligrams of charcoal per
kilogram of body weight taken at the same time as 170 ml of pure ethanol (which
equals about 10 servings of an alcoholic beverage alcohol, or 12 shots), over the
course of one hour, has very apparent effects at reducing potential blood alcohol
content other studies showed that this is not the case and that ethanol blood
concentrations were increased because of activated charcoal use. This ineficciency
together with risk of aspiration make it a dangerous drug when in improper hands.
In the past charcoal biscuit was sold in England in the early 19th century, originally
as an antidote to flatulence and stomach trouble.
Tablets of activated charcoal are still used as a folk remedy and over-the-counter
drug to treat diarrhea, indigestion, and flatulence. They were also used in the past by
doctors for this purpose. There is some evidence of its effectiveness as a treatment
for irritable bowel syndrome (IBS), and to prevent diarrhea in cancer patients who
have received irinotecan. It can interfere with the absorbency of some medications,

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and lead to unreliable readings in medical tests such as the guaiac card test. A type
of charcoal biscuit has been marketed as a pet care product.
Activated charcoal is also used for bowel preparation by reducing intestinal gas
content before abdominal radiography to visualize bile, pancreatic and renal stones.
Fuel Storage
Research is being done testing various activated carbons ability to store natural gas and
hydrogen gas. The porous material acts like a sponge for different types of gasses. The gas is
attracted to the carbon material via Van der Waals forces. Some carbons have been able to achieve
bonding energies of 5-10 KJ per mol. The gas may then be desorbed when subjected to higher
temperatures and either combusted to do work or in the case of hydrogen gas extracted for use in a
hydrogen fuel cell. Gas storage in activated carbons is an appealing gas storage method because
the gas can be stored in a low pressure, low mass, low volume environment that could would be
much more feasible than bulky on board compression tanks in vehicles.
The United States Department of Energy has specified certain goals to be achieved in the
area of research and development of nano-porous carbon materials. As of yet all of the goals are yet
to be satisfied but numerous institutions, including the ALL-CRAFT program, are continuing to
conduct work in this promising field.

Gas purification
Filters with activated carbon are usually used in compressed air and gas purification to
remove oil vapours, odours, and other hydrocarbons from the air. The most common designs use a
1 stage or 2 stage filtration principle in which activated carbon is embedded inside the filter media.
Activated charcoal is also used in spacesuit Primary Life Support Systems. Activated charcoal filters
are used to retain radioactive gases from a nuclear boiling water reactor turbine condenser. The air
vacuumed from the condenser contains traces of radioactive gases. The large charcoal beds adsorb
these gases and retains them while they rapidly decay to non-radioactive solid species. The solids
are trapped in the charcoal particles, while the filtered air passes through.

Chemical Purification
Commonly used to purify homemade non-dangerous chemicals such as sodium acetate. It is
then filtered out.

Distilled alcoholic beverage purification
Activated carbon filters can be used to filter vodka and whiskey of organic impurities which
can affect color, taste, and odor. Passing an organically impure vodka through an activated carbon
filter at the proper flow rate will result in vodka with an identical alcohol content and significantly
increased organic purity, as judged by odor and taste.

Mercury scrubbing
Activated carbon, often impregnated with iodine or sulfur, is widely used to trap mercury
emissions from coal fired power stations, medical incinerators, and from natural gas at the wellhead.

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This carbon is a specialty product costing more than $4.00 per kg. However, it is often not recycled.

Disposal in the USA
The mercury laden activated carbon presents a disposal dilemma. If the activated carbon
contains less than 260 ppm mercury, Federal regulations allow it to be stabilized (for example,
trapped in concrete) for landfilling. However, waste containing greater than 260 ppm is considered to
be in the high mercury subcategory and is banned from landfilling (Land-Ban Rule). It is this material
which is now accumulating in warehouses and in deep abandoned mines at an estimated rate of
1000 tons per year.
The problem of disposal of mercury laden activated carbon is not unique to the U.S. In the
Netherlands this mercury is largely recovered and the activated carbon is disposed by complete
burning.




















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SALES PROJECTION ESTIMATES
Sales projection estimates is based on the plant capacity of GCF multi-products in producing
granulated coco charcoal, a semi-finished charcoal product which has not yet been activated. Their
plant capacity is 600 MT/mo. Their current production for 2011 stands at the average of 200 MT/mo
in producing granulated coco charcoal which has a yield of 20-25% from raw materials which is
basically closer to the yield of producing activated carbon by steam activation.
The average selling price is the lowest current market price from different activated carbon
manufacturers worldwide.
SALES PROJECTION OF STEAM ACTIVATED COCONUT SHELL CARBON
SALES (mo)

200,000
AVERAGE SELLING PRICE

300.00
VARIABLE COST (per unit)

14.71
GROSS MARGIN (per unit)

285.29
GROSS REVENUE

60,000,000.00
TOTAL GROSS MARGIN

57,058,000.00
OTHER EXPENSES

500,000.00
NET PROFIT

56,558,000.00

Sales projection estimates for chemical activated coconut shell carbon is still based on the
plant capacity of GCF multi-products in producing granulated coco charcoal, a semi-finished
charcoal product which has not yet been activated. Their plant capacity is 600 MT/mo. Their current
production for 2011 stands at the average of 200 MT/mo in producing granulated coco charcoal
which has a yield of 20-25% from raw materials which is basically closer to the yield of producing
activated carbon by steam activation. However, for chemical activation process we used a 40-45%
yield, factors for higher yield includes lower heat temperature and shorter time of activation.
The average selling price is the lowest current market price from different activated carbon
manufacturers worldwide for chemically activated carbons.
SALES PROJECTION OF STEAM ACTIVATED COCONUT SHELL CARBON
SALES (mo)

400,000
AVERAGE SELLING PRICE

800.00
VARIABLE COST (per unit)

27.05
GROSS MARGIN (per unit)

772.95
GROSS REVENUE

320,000,000.00
TOTAL GROSS MARGIN

309,180,000.00
OTHER EXPENSES

500,000.00
NET PROFIT

308,680,000.00


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Example price range from www. buyactivatedcharcoal.com
4 lbs 1 gal. jug ($24.87)
8 lbs 2 gal. pail ($39.89)
20 lbs 5 gal. pail ($79.56)




















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Summary and Conclusions
Indeed the manufacturing of activated carbon is a lucrative business and has a huge market
demand for the many years to come, especially for its numerous applications in widening
industries that includes medical applications and chemical purifications.
Steam-activated coconut shell carbon manufacturing requires less equipment in the process
flow sheet and fewer steps, but had a lower yield compared with chemical activation. Chemical
activation through CaCl required more steps and more equipment, but the product costs only a
little more to manufacture, because of the higher yield of final product in the acid activation
process. The factors that causes this difference in yield are mainly the heating temperatures and
the rate that the coconut shell carbon is activated. In summary, chemical activation is preferred
over physical activation owing to the lower temperatures and shorter time needed for activating
material in terms of efficiency. However, in terms of market demand for quality activated carbon,
steam activated carbon is much more preferred due to its adsorption properties
Our estimated product cost for steam-activated coconut shell carbon was P 14.71. High
quality, high surface area, granular activated carbons made from steam activation of coal or
coconut shell sell for P215/kg and more, depending on their particular use. If the coconut shell -
based carbons are used effectively in a particular niche market, they could sell for P300 to 500/kg.
In this case, the difference in product manufacturing cost and product sales cost could be
sufficient to realize a profit for the manufacturer. In the case of chemically activated coconut shell
carbons, our estimated product cost was P 27.05/kg. Acid-activated, coconut shell carbons are
shown to possess superior metal ion adsorption compared to steam-based commercial carbons.
Therefore, these carbons could be sold in a niche market for metal ion-adsorbing carbons.
Effective, metal ion-sequestering carbons made from coal sell for about P 800 to 1200/kg.
Therefore, there is a considerable cost differential between the manufacturing cost and a potential
selling price for this type of carbon in the commercial marketplace.
Additional value can be added by addressing niche markets, such as metals adsorption or
portable water treatment, either in point-of-use (POU) or point-of entry (POE) water filtration
systems. In these selected niche markets, commercial carbons sell for P 250/kg and up. Moreover,
the difference in manufacturing cost (P 222.25/kg) and product sales cost, as determined by the
manufacturer, could be sufficient to realize a profit for the seller.
The possibility of manufacturing activated carbons at less cost than P 14.71/kg should be
considered, since the sale of activated carbons takes place in a competitive market. Carbons can
be manufactured more economically in plants with selecting a more cheaper but effective
machineries like the rotary kiln and moving to alternative types of chemicals for activation aside
from calcium chloride (CaCl) or zinc chloride (ZnCl) like phosphoric acid. Substantial savings in
equipment and infrastructure could be realized by renovating existing structures of GCF
Multiproducts and retrofitting existing manufacturing facilities and equipment. In an example, GCF
current setup of manufacturing granulated coconut charcoal can be realigned with steam activated
carbon setup. This type of carbon manufacturing could modify an existing process with little or no
equipment change and a substantial cost savings could be realized. Additionally, raw materials
costs can be minimized and construction costs can be reduced as well.

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References:

World Activated Carbon: Industry Forecast for 2014 & 2019 (2010). Freedonia Group, Cleveland OH.
China Activated Carbon Industry Report 2011-2012. www.researchinchina.com
Activated Carbon: Market Research Report:Global Industry Analyst, Inc. 2011.
WEHRLE Umwelt GmbH Activated Carbon Manufacturers
Activated Carbon for Purification of Alcohol. Gert Strand 2001.
Granular Activated Carbons from Agricultural By-products: Sugar Cane Bagasse and Pecan Shell by Chilton Ng
and co.
Commercial Process for Low Cost Production of Charcoal, Activated Carbon by L.Conti, S.Mascia, and G.Scano,
University of Sassari, Belgium
Industrial Technology Development Institute. Gen. Santos Ave., Taguig City. http://itdibiz.com/
Alibaba.com list of manufacturers, equipments and industrial machineries and general information.
Wikipedia.com for general information.
www.buyactivatedcharcoal.com for general information on market price