Detailed Project Report on ACTIVATED CARBON (RAW MATERIAL – WOOD CHIPS) – 1200 TPA

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.

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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 (RAW MATERIAL
– WOOD CHIPS) – 1200 TPA
[EIRI/EDPR/4710]
J.C.: 2930RUB, 2930INR


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.

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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.

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CONTENTS


INTRODUCTION
DECOLORIZING CARBONS
GAS ABSORBENT CARBONS
METAL ABSORBENT CHAR S
MEDICINAL CARBONS
USES & APPLICATIONS
APPLICATIONS OF ACTIVATED CARBON
END-USER INDUSTRIES OF ACTIVATED CARBON
OIL & GAS PLANTS
WATER TREATMENT PLAN TS
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 REQUI RED ARE
SERVICE TIME, TIME REQUIRED FOR THE VAPOUR UNDER STANDARD AB SORPTION
STRUCTURE OF ACTIVAT ED CARBON
ADSORPTION MECHANISM
FORMS OF ACTIVATED CARBON
THREE MAIN FORMS OF ACTIVATED CARBON ARE :
GRANULAR ACTIVATED C ARBON (GAC):
POWDERED ACTIVATED C ARBON (PAC):
PELLETIZED ACTIVATED CARBON:

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MARKET OVERVIEW
IMPACT OF COVID-19 ON THE GLOBAL ACTIVATED CARBON MARKET
KEY COMPANIES & MARKET SHARE INSIGHTS
CONSUMPTION OF ACTIV ATED CARBON
PROCESSING DETAILS OF ACTIVATED CARBON
CHEMICAL ACTIVATION
REACTIVATION OF USED ACTIVATED CARBON
MANUFACTURING PROCES S / PROCESS FLOW
THE QUALITY OF THE FINAL PRODUCT DEPENDS UPON –
PROCESS FLOW
MANUFACTURERS/SUPPLI ERS 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 WAT ER EFFLUENT

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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 MU LTIPURPOSE 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 WAR TIME ATTACK:
FLOOD AND FIRE CONTROL:
HEALTH SAFETY AND ENVIRONMENT
ANTICIPATED ENVIRONM ENTAL IMPACTS
CONSTRUCTION PHASE

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OPERATION PHASE
MITIGATION MEASURES (PROPOSED)
HSE REQUIREMENT
PROPOSED IMPLEMENTAT ION 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)

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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%