ACTIVATED CARBON {GRANULAR AND POWDER}

[EIRI/EDPR/3994] J.C.: 2124XL

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 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 petroleum coke. Several carbon products are prepared and used in the
electrical and electro-chemical industry.

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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.

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DECOLORISING CARBONS

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.

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GAS ABSORBENT CARBONS

Gas and vapour absorbent carbons are obtained by carbonizing coconut shells,
apricot stones, vegetable ivory, and anthracit. 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.

METAL ABSORBENT CHARS

Metal absorbent chars are prepared by alkali activation. Structurally, they are
identical with decolorizing carbons and are converted into the lather by acid
treatment. An active product is obtained by heating bone charcoal with alkali at
850oC. The product obtained is negative changed material and important of its
metal absorbing power. It however, possesses the properties of a decolorizing char.
Treatment of flocculated material with alkali does not restore the metal absorbent
properly.

MEDICINAL CARBONS

Activated carbon finds application in the preparation of pills and digestive tablets.
Its absorptive properties are utilized in the treatment of the stomach due to hyper
acidity. It removes toxic amines, organic acids of decomposed foods, and probably
also bacteria from the intestinal tract and many other purposes.

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 CONTENTS
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
SPECIFICATIONS
THE SIEVE ANALYSIS SHOULD BE AS FOLLOWS
TESTING
STRUCTURE OF ACTIVATED CARBON
ADSORPTION MECHANISM OF ACTIVATED CARBON
MARKET POSITION
THREE MAIN FORMS OF ACTIVATED CARBON ARE:
THE TYPES OF THE PRODUCT AVAILABLE IN THE INDUSTRY ARE:
IT FINDS WIDE APPLICATIONS IN THE FOLLOWING SEGMENTS:
THE FEEDSTOCK CAN BE CATEGORISED AS FOLLOWS:
GLOBAL ACTIVATED CARBON MARKET: REGIONAL SEGMENT ANALYSIS
ACTIVATED COKE AS AN ADSORBING AGENT
MANUFACTURING PROCESS OF ACTIVATED CARBON
THE FURNACE IS A LARGE CYLINDRICAL CARBON STEEL
SHELL SUPPORTED ON LEGS OF STEEL
PROCESSING DETAILS 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

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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
GLOBAL ACTIVATED CARBON MARKET SHARE BY END-USE (% AGE)
SOME INDIAN MANUFACTURERS 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)
A. FROM RICE HUSK
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
METHOD OF PET COKE ACTIVATION
ACTIVATION OF SYRIAN PETROLEUM COKE
PROCESSING DETAILS OF ACTIVATED CARBON FROM COCONUT SHELL

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PROCESS RATIONALE
HEAT EXCHANGERS
VESSELS
REACTORS AND HEATERS
FIG: SCHEMATIC OF THE FLUIDIZED BED REACTOR STAGES.
SEPARATORS
PUMPS, BLOWERS AND COMPRESSORS
CONVEYORS
SIZE REDUCERS
PROCESS FLOW DIAGRAMS
FIGURE: PFD OF THE PYROLYSIS PROCESS
FIGURE: PFD OF THE ACTIVATION PROCESS
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
STATE & CONTROL SUBSIDY SCHEME FOR ACTIVATED CARBON PROJECT
COMPLETE PLANT SUPPLIERS FOR ACTIVATED CARBON
ADDRESSES OF RAW MATERIAL SUPPLIERS
SUPPLIERS OF COCONUT SHELL
SUPPLIERS OF RICE HUSK
SUPPLIERS OF SAW DUST
SUPPLIERS OF CAUSTIC SODA
SUPPLIERS OF ZINC CHLORIDE
ADDRESSES OF PLANT & MACHINERY SUPPLIERS
SUPPLIERS OF PULVERISER
SUPPLIERS OF MIXERS
SUPPLIERS OF ROTARY KILNS
SUPPLIERS OF TRAY DRIER
SUPPLIERS OF HYDRAULIC LIFT
SUPPLIERS OF HEAVY MOBILE CRANES
SUPPLIERS OF EXTRUDER
SUPPLIERS OF TANKS
SUPPLIERS OF BOILER
SUPPLIERS OF COOLER

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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)

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 COST ESTIMATION

Plant Capacity 10 Ton/Day

Land & Building (6000 sq.mt.) Rs. 2.76 Cr
Plant & Machinery Rs. 3.21 Cr
Working Capital for 1 Month Rs. 1.13 Cr
Total Capital Investment Rs. 7.30 Cr
Rate of Return 37%
Break Even Point 51%

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