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Active carbon: production of activated carbon from fruit stones, sawdust, agricultural wastes


Name
Parameters
Destination
Production of activated carbon of good quality
Trademark
LU-АU-750 automated line
Trademark owner
Mega Power Hong Kong Group Limited
Developer
Israel
Production license ownet
Mega Power Hong Kong Group Limited
Assembly and Technology
 
A list of units
Conveyors7 units.
Raw materials crusher 1unit.
Magnetic separator 1 unit.
Material fractions  separating sieve  1 unit.
SIngle-headed drying machine  1 unit.
packing tables 4 units. (to be made by the customer )
Carbonizing stove  1 unit.
Pallets  (4 units) in the stove assembly
Activation stove  1 unit.
Pallets  (4 units) in the stove assembly
Crusher -  1 unit.
Fine vibrating sieve  1 unit.
Hopper 1 unit.
Weighting machine 1unit.
Measuring machine -1 unit.
Compressor -  1 unit.
Sealing machine - 1 unit.
Commutation system , 1 unit.
Instrument control system , 1 unit.
Ventilator in the stove;s assembly   2 units.
Lab systems 1set 
Decompression device, added to the stove 2 units.
Exhaust gas removal equipment, added to the stove -  2 units.
Technology
Production technology
This production line affords production of  high quality activated carbon.
Activated carbon production technology
-Fruit stone shells are fed to the crusher to be crumbled to the required size .
-then the resultant mass is conveyed to vibration sieve to remove size-off-grade fragments
-Size-off-grade fragments are sent to the re-crumbling .
-Homogeneous raw materials are conveyed to the magnetic separator,  to remove metal shavings, resultant from crushing and crumbling.
-the raw materials are conveyed to the drying machine.The moisture is reduced from  40% to 4-5%. The drying is made using dry hot air
-Dried materials are conveyed to carbomization stoves feeding zone .
-Granules are placed in special pallets as layers (thickness of the layers is determined by technology) and fed into carbonization stoves. Then the primary burning off and carbonization of granules take place.
-Then aften some time period, determined by technology. the pallets with carbonized materials are taken from the stove
-Baked coal granules are conveyed to the crusher to be crumbled to technological size of the activated carbon.
-From the crusher the granule is conveyd to fine separation vibrating screen.
-Size-off-grade coal is sent to  secondary crumbling 
-From the vibrating screen the coal is fed to  packing tables by the activation stove
-Near the activation stove the granules are placed into special pallets and fed to the activation stove.
- In the stove coal granules are activated with the steam..
- When technologically specified time period is over, the elevating machine takes pallets with activated carbon.
-If the manufacturing technology was deranged  thus causing activated carbon to clink, the clinker should be sent back to the crusher .
-After secondary crumbling the activated carbon is sent to packing .
-the carbon gets cold and is conveyed to the packing section.
-In the packing section the coal is packed into sealed paper bags with bunching attachment of 5-10 kg
-Then the active carbon is sent to the finished products warehouse.
 
*Notes
For active carbon production various manufacturing technologies have been developed. The choice of technology depends on requirement to quality of the final product. Medicine active carbon and that used for air cleaning or water purification have different quality requirements. Manufacturing technologies differ in temperature and time activation modes and by supplementary raw materials, fed to the mixer .
General Info
 
Operating mode
21 hrs/day, 300 days/yer 
Charcoal production/year
2 250 tons
Charcoal production/month
187 tons
Charcoal production/day
7,5 tons
Charcoal production/shift
2,5 tons
Activated carbon production/year. (Round-the-clock operation )
750 tons
Activated carbon production/day. (Round-the-clock operation)
2,5 tons.
Activated carbon production/month (Round-the-clock operation)
62 tons
Attention
Activated carbon manufacturing technology requires 3-shift round-the-clock operation
staff
15 persons/shift
Power consumption
107 kW
Heat energy needs
4 500 kcal/hr
Composition of the set
All included
Warranty
1 year
areas
 
Design production area
700 m2
The production line is divided into shops
3
--raw materials preparation, crumbling and drying
200 m2 Outdoors, 2 shelters 10m х 20 m
Function
- raw materials are fed to the crusher ,
- raw mass is sent to the vibration screen ,
- large fraction is sent to the secondary crumbling
- homogeneous raw mass is sent to the magnetic separator
-raw mass is conveyed to the raw materiall drying machine
-dried materials are conveyed to the carbonization stove
Equipment
Conveyors2 units.
Crusher  1 unit.
Magnetic separator1 unit.
Screen  1 unit.
Drying machine 1 unit.
Carbonization and activation shop
250 m2 indoors  25 m х 10 m
Function
- granules are conveyed to the hopper in  carbonization stove feeding stove .
-granules are sent to the packing tables 
-granules are placed on special pallets
- the pallets are fed into carbonization stove using loaders
- pallets with carbonized materials are taken from the stove using lifter .
-granules are conveyed to the crusher
-from the crusher the granules are fed to fine vibrating screen
-the granules are conveyed to the activation stove .
-Near the activation stove the granules are placed into special pallets and fed to the activation table.
- the lifter takes the pallet with activated carbon 
-after getting cold on the packing tables the coal is conveyed to crumbling
-is conveyed to the packing shop .
Units
Conveyors 3 units.
Carbonization stove 1 unit.
Crusher 1 unit. ,
Self-propelled hoisting trolleys  1unit.
Trays (4 units).for carbonization stove
Packing tables (4 units) should be made by the customer 
Trays (4 units) for activation stove
Crusher -  1 unit.
Fine vibration sieve -  1 unit.
Activation stove - 1 unit.
Packing and warehousing shop
250 m2. Indoors
Function
-in the packing ship the coal is packed into sealed paper bags with bunching attachment of  0,5-25 kg.
Equipment
Conveyors 3 units.
Hopper - 1 unit. Weighing machine - 1 unit
batching machine -1 unit.
Sealing machine - 1 unit.
Compressor 1 unit.
Specifications of raw materials
 
To produce 1 ton of  Charcoal  it is necessary to have as follows 
4 tons of organic materials. moisture - 4%.
To produce 1 ton of active carbon from charcoal it is necessary to have
3 tons of  Charcoal
Water requirements/hr
Water 4m3/hour
Needs for additional fuel
75 kg/hr 
Needs for electric energy
107 kW
Production stanfards
 
Activated coal
 
Grain's size of 1mm
< 1,0
Grain's size of  1–3,5 mm
>96,5
Grain's size of  3,5-5 mm
< 2,5
Moisture contents
<10,0
Ash contents
< 8,0
Porosity (by acetone)
> 74
Static activity by chlorine
>35
Mass of 1 L of coal that should be
no more than 220 gr (determination without compaction)
Transportation
 
Transportation of drying machine
One 40ft container.
Transportation of stoves
One 40ft.container
Transportation of remaining machines
One 40ft.container
Transportation of heating equipment 
One 20 -ft.container
Other conditions
 
Time of mounting
4-5  weeks including training courses for foreign workers
Payment terms
50% -advance payment, 50% -after the line is ready for shipment and checked but before leaveing the territory of  PR China
Start-and-adjusting
15% of the price of the production line. The price of the production line doesn't include start-up and adjusting
Incomplete delivery
It is possible to deliver separate units and/or sections
Start-up and adjustment staff
3 persons
Time of mounting
1 month.
Documents
 
Certificates of aggregates
12 pcs
Drawings of foundations
no
Drawings of  insets
no
Drawings of stove
2 pcs
Installation drawing
1 pc
Electrical exploration drawings
1 pc
Drawings of separate units
6 pc
Language of documents
Chinese, English, Hebrew, Russian
Certification
 
The equipment is certified
China, EC, Israel, Russia, Ukraine
Total number of certificates
12 pcs

Active carbon production line 750 tons/year. Staff 

 
Name
workers
shift
Engineers
Total staff/shift
Total staff/3 shifts
1
Raw materials preparation, crumbling and drying shop
3
-
3
9
 
Drying machine
1
-
 
 
 
Servicing of other units
2
-
 
 
2
Carbinization and activation
5
1
6
18
 
Carbonization stove
1
-
 
 
 
Activation stove
1
1
 
 
 
Self-propelled hoisting trolleys
1
-
 
 
 
Servicing of  other units
2
 
 
 
3
Packing and warehousing shop
3
-
4
11
 
Packing of activated carbon
3
-
 
 
 
Warehouseman
1
-
 
 
 
Quality control
 
1
 
 
 
total
11
3
 
38
 
Active  carbon production line 750 tons/year. Raw materials - fruit stones 
POWER 
 
Number of units
kW/unit
kW/total
Conveyers
7 units.
3
21
Rough  vibration screen
1 unit.
5
5
Weighting machine
1 unit.
3
3
Batching machine
1 unit.
2
2
Sealing machine
1 unit.
5
5
Compressor
1 unit.
2
2
Raw materials crusher
1 unit.
7
7
Magnetic separator
1 unit.
3
3
Drying machine
1 unit.
8
8
Fine vibration sieve
1 unit.
5
5
Small crusher
1 unit.
5
5
Self propelled hoisting trolleys
4 units.
4
16
Carbonization stove
1 unit.
10
10
Activation stove
1 unit.
15
15
Total
 
 
107 kW

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