Detailed Project Report on ACTIVATED CARBON OR CHARCOAL FROM COCONUT SHELL (CAP: 5 MT/DAY)

Activated carbon is a group of industrial adsorbent material with highly developed internal surface area and porosity (microcrystalline porous carbon matrix with pore diameter range of 50 nm with large internal surface area to the extent of 400-3000 m2/g as measured by the nitrogen BET method and adsorption volumes of 0.2-0.8 cm3/g depending on activation conditions), and hence a large capacity for adsorbing chemicals from fluids; produced by pyrolysis and activation of carbonaceous natural as well as synthetic precursors.

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ENGINEERS INDIA RESEARCH INSTITUTE
4/54, Roop Nagar, Delhi-110007 (India)
Phone: [phone]
E-mail: [email protected]
Website: www.eiriindia.org



ACTIVATED CARBON OR CHARCOAL FROM
COCONUT SHELL (CAP: 5 MT/DAY)
[EIRI/EDPR/4694] J.C.: 2911INR, 2911US$


Activated carbon is a group of industrial adsorbent material with highly developed
internal surface area and porosity (microcrystalline porous carbon matrix with
pore diameter range of <2 nm to > 50 nm with large internal surface area to the
extent of 400-3000 m2/g as measured by the nitrogen BET method and
adsorption volumes of 0.2-0.8 cm3/g depending on activation conditions), and
hence a large capacity for adsorbing chemicals from fluids; produced by pyrolysis
and activation of carbonaceous natural as well as synthetic precursors.

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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CONTENTS


INTRODUCTION 8
DECOLORISING CARBONS 11
GAS ABSORBENT CARBONS 12
METAL ABSORBENT CHARS 12
MEDICINAL CARBONS 12
USES & APPLICATIONS 13
ACTIVATED CARBON IN AIR PURIFICATION 16
MERCURY REMOVAL BY ACTIVATED CARBON INJECTION 16
ACTIVATED CARBON IN WATER PURIFICATION 17
MUNICIPAL AND INDUST RIAL WASTEWATER TREA TMENT 17
GROUNDWATER REMEDIATION 17
ACTIVATED CARBON REGENERATION (REACTIVAT ION) 18
BUYERS IN OVERSEAS COUNTRIES 19
PROPERTIES AND CHARACTERISTICS 20
PHYSICAL PROPERTIES 20
CHEMICAL PROPERTIES 21
RAW MATERIALS 22
ADVANTAGEOUS PROPERT IES OF COCONUT SHELL ACTIVATED CARBON 23
STRUCTURE OF ACTIVAT ED CARBON 24
ADSORPTION MECHANISM OF ACTIVATED CARBON 27
MARKET POSITION OF ACTIVATED CHARCOAL 30
ACTIVATED CARBON MARKET TRENDS 31
WATER TREATMENT INDUSTRY TO DOMINATE THE MARKET 31
ASIA-PACIFIC TO DOMINATE THE MARKET 33
ACTIVATED CARBON INDUSTRY 34

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ACTIVATED CARBON MARKET LEADERS 34
ACTIVATED CARBON MARKET NEWS 34
ACTIVATED COKE AS AN ADSORBING AGENT 35
MANUFACTURING SEQUENCES OF ACTIVATED CARBON FROM
COCONUT SHELL (STEAM, CO2) 38
STEP BY STEP GUIDE TO MANUFACTURE ACTIVATED CARBON 39
PREPARATION OF RAW MATERIALS 40
CARBONIZATION 41
ACTIVATION 42
WASHING AND DRYING 43
QUALITY CONTROL 44
PRODUCTION DETAILS OF ACTIVATED CARBON FROM COCONUT SHELL 45
ACTIVATED GRANULAR SHELL CARBON FROM CHARCOAL 46
DETAILS OF ACTIVATION 47
CHEMICAL ACTIVATION 47
ACTIVATED CARBON FROM COCONUT SHELL 48
TABLE: TYPES OF ACTIVATED CARBON 49
PROPERTIES OF ACTIVATED CARBON 50
ADSORPTIVE CHARACTERISTICS 50
SURFACE AREA 50
PORE SIZE DISTRIBUTION 50
PHYSICAL CHARACTERISTICS 52
HARDNESS 52
TABLE: TYPICAL PROPERTIES OF ACTIVATED CARBON 52
BULK DENSITY 53
PARTICLE SIZE DISTRIBUTION 53
APPLICATION 54
OTHER APPLICATIONS OF ACTIVATED CARBON I NCLUDE: 55
TABLE: APPLICATIONS OF ACTIVATED CARBON 56
TABLE: APPLICATIONS IN THE CHEMICAL INDUSTRY 57

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PROCESS FLOW DIAGRAM FOR ACTIVATED CARBON 59
CONSUMPTION PATTERN OF ACTIVATED CARBON 60
BUYERS OF ACTIVATED CARBON 61
MANUFACTURERS/SUPPLI ERS OF ACTIVATED CARBON 62
DIFFERENT TYPES OF ACTIVATED CARBON 65
ABSORBING GASES OR VAPOUR (GAS ABSORBENT CARBON) 65
DECOLORIZING AND PURIFY ING LIQUID 66
CATALYST & CATALIST SUPPORT (GAS ABSORBENT CARBON) 66
MEDICINE 66
QUALITY CONTROL TEST ING OF ACTIVATED CARBON 67
CARBON TETRACHLORIDE ACTIVITY 67
SURFACE AREA 68
HARDNESS 69
MESH SIZE 71
ASH CONTENT 71
DENSITY 71
INTERRELATION OF PROPERTIES 72
OTHER TESTS 72
TESTING OF ACTIVATED CHARCOAL 73
QUALITATIVE METHOD 73
SEMI-QUANTITATIVE METHOD 74
QUANTITATIVE METHOD 75
GLOBAL MACHINERY SUPPLIERS 76
COMPLETE PLANT SUPPLIERS FOR ACTIVATED CARBON 77
ADDRESSES OF RAW MAT ERIAL SUPPLIERS 80
SUPPLIERS OF COCONUT SHELL 80
ADDRESSES OF PLANT & MACHINERY SUPPLIERS 82
SUPPLIERS OF PULVERI SER 82
SUPPLIERS OF MIXERS 87
SUPPLIERS OF ROTARY KILNS 89

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SUPPLIERS OF TRAY DRIER 90
SUPPLIERS OF HYDRAULIC LIFT 91
SUPPLIERS OF HEAVY MOBILE CRANES 92
SUPPLIERS OF EXTRUDER 93
SUPPLIERS OF TANKS 96
SUPPLIERS OF BOILER 97
SUPPLIERS OF COOLER 98
APPENDIX – A :
01. PLANT ECONOMICS A-1
02. LAND & BUILDING A-2
03. PLANT AND MACHINERY A-3
04. OTHER FIXED ASSESTS A-4
05. FIXED CAPITAL A-5
06. RAW MATERIAL A-6
07. SALARY AND WAGES A-7
08. UTILITIES AND OVERHEADS A-8
09. TOTAL WORKING CAPITAL A-9
10. TOTAL CAPITAL INVESTMENT A-10
11. COST OF PRODUCTION A-11
12. TURN OVER/ANNUM A-12
13. BREAK EVEN POINT A-13
14. RESOURCES FOR FINANCE A-14
15. INSTALMENT PAYABLE IN 5 YEARS A-15
16. DEPRECIATION CHART FOR 5 YEARS A-16
17. PROFIT ANALYSIS FOR 5 YEARS A-17
18. PROJECTED BALANCE SHEET FOR (5 YEARS) A-18

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COST ESTIMATION

Plant Capacity 5 MT/Day

Land & Building (5000 sq.mt.) Rs. 5.36 Cr

Plant & Machinery Rs. 5.81 Cr

Working Capital for 2 Months Rs. 1.51 Cr

Total Capital Investment Rs. 13.34 Cr

Rate of Return 24%

Break Even Point 59%