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Active carbon: Raw materials - brown coal and turf


Name
Parameters
Destination
Production of activated carbon of good quality and fuel granules made of brown coal and turf
Trademark
LU-АU-1200 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
Raw materials feeding machine -2 units
Conveyors 27 units
Raw materials crusher 2 units.
Mixing machines -2 units
Magnetic separator 1 unit.
Drying machine -1 unit
Boiler - 1 unit
Granule-making press-1 unit
Bucket elevator - 1 unit
Metering and weighing machine -1 unit
Sealing machine -1 unit
Packing machine -1 unit
Fork lift -2 units
Hoppers - 3
Packing tables 12 units. (to be made by the customer )
Trays - 16 units (attached to the stove)
Electronic meter -1 unit
self-propelled lifting trolleys -4 units
Coal crusher -1 unit
Fine vibrating sieve  1 unit.
Carbonizing stove  4 units.
Activation stove  2 units
Crusher -1 unit.
Pallets  (8 units) in the stove assembly
Wash bath -1 unit
Weighting machine 1unit.
Measuring machine -1 unit.
Sealing machine - 1 unit.
Gasholder -1 unit
Commutation system , 2 units.
Instrument control system , 1 unit.
Ventilator    2 units.
Compressores -2 units
Lab systems 1set 
Decompression device, -6 units
Exhaust gas removal equipment-6 units.
Technology
Production technology
This production line affords production of both  high quality activated carbon and fuel granules without further processing
Activated carbon production technology  #1 
-Coal dust small and large sized pieces of brown coal are fed by special machines from hoppers to conveyors
the raw materials are conveyed to to the crusher to be crumbled to the homogeneous state
-The raw materials mixture is conveyed to double-roll mixing machine to become homogeneous and plactic.
-then the resultant mass is conveyed to vibration sieve to remove size-off-grade fragments
-Size-off-grade fragments are sent back by conveyor  to the re-crumbling .
-Homogeneous raw materials are conveyed to the magnetic separator,  to remove metal shavings, resultant from crushing and crumbling.
- then, if necessary, the raw materials are conveyed to the drying machine. In the machine the materials pass 16 meters in rotation mode, the moistured materials are processed  with dry steam as a result, the moisture is reduced from  40% to 4-5%.
Dried materials are conveyed to briquetting machine, the latter forms granules by pressing in the form of oval tablets
-From the briquetting machine finished granules are conveyed to  carbonization 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 granules are conveyed to the crusher to be crumbled to technological size.
-From the crusher the granule is conveyd to fine separation vibrating screen.
Depending on quality requirements the resultant granules can be conveyed to the nitriding bath
Nitiding is recommended for high quality carbons used in food industry and pharmaceutics.
-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..The steam is fed from the boiler through pipes.
- 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 .
-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.
 

Fuel carbon granules production, manufacturing technology #2

Coal dust  small and large sized pieces of brown coal (it is also possible to use stone coal, turf) are fed by special machines from hoppers to conveyors
-the raw materials are conveyed to to the crusher to be crumbled to the homogeneous state
-The raw materials mixture is conveyed to double-roll mixing machine to become homogeneous and plactic
If necessary, at this stage the raw materials are added by cementing materials, they are necessary if the coal loose and granules cannot hold shape.
-then the resultant mass is conveyed to vibration sieve to remove size-off-grade fragments
-Size-off-grade fragments are sent back by conveyor  to the re-crumbling .
-Homogeneous raw materials are conveyed to the magnetic separator,  to remove metal shavings, resultant from crushing and crumbling.
- then, if necessary, the raw materials are conveyed to the drying machine. In the machine the materials pass 16 meters in rotation mode, the moistured materials are processed  with dry steam as a result, the moisture is reduced from  40% to 4-5%.
Dried materials are conveyed to briquetting machine, the latter forms granules by pressing in the form of oval tablets
-From the briquetting machine finished granules are conveyed to the packing machine.

Note #1. There 7 units that are heat and addtional fuel consumers. These are drying machine (steam 500kg/hr), two activation stoves (steam, 5.5 tons/hr) starting of carbonization stoves, starting and operation of activation stoves. Gas is the best possible fuel from technical and economical points of view. 
At the coal deposit, coal gasification is the best possible source of gas, that's why  gas generator is included in the set.

Note #2 - Operation cycles.
Operation cycle: carbonization stove, 30 minutes, the stove's productivity for 24 hrs is 10-12 tons,
Activation stove - activation cycle- 4hrs
Unloading of the stove- 30 minutes
Loading of the stove 20min -1 hr
2.5 -4 tons of finished raw materials/hr. 
 
*Note #3 
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/year 
For activation shop and briquetting shop
Annual production of fuel granules at three-shift work 160 000 granules
Month production of fuel granules at three-shift work
13150 tons
Daily production of fuel granules at three shift operation 525 tons
Shift production of fuel granules at three-shift operation 175 tons
Hour production of fuel granules at three shift operation 25 tons
Number of granules required for production of 1 ton of activated carbon  
Shift 10-12 tons
Day 30 tons
Month 720 tons
Year 7200 tons
Activated carbon production/year. (Round-the-clock operation )
 1200 tons
 Activated carbon production/day. (Round-the-clock operation)
 4.5 tons
Activated carbon production/month (Round-the-clock operation)
100 tons
Attention
Activated carbon manufacturing technology requires 3-shift round-the-clock operation
staff
50 persons/shift
Power consumption
400  kW
Heat energy needs
10 000 kcal/hr
Composition of the set
All included
Warranty
1 year
areas
 
Design production area
Total 4000 m2, including 2600 m2 indoors and 1400 m2 outdoors
The production line is divided into shops
 
--raw materials preparation, crumbling and drying
1400 m2 Outdoors, 2 shelters 60m х 20 m
Function
-Raw materials feeding machines bring coal to conveyors
- raw materials are conveyed to the crusher ,
- raw mass is conveyed to double roll mixing machine
- raw material mixture is conveyrd to the vibration screen ,
- large fraction is conveyed back  to  crumbling
- homogeneous raw mass is conveyed to the magnetic separator
-raw mass is conveyed to the raw material drying machine
-steam is supplied from the boiler through pipes
Equipment
Raw materials feeding machines -2 units (see photos)
Conveyors 9 units.(see photos)
Crusher  2 units. see photo
Mixing machine - 2 units see photos
Magnetic separator - 1 unit.
Screen - 1 unit. (photo)
Boiler -1 unit (see photo)
Gas holder 1 unit -see phtoto
Pressing and packin g shop
450 m2 indoors  35 m х 12m
Function
Dried materials are conveyed to briquetting machine, -From the briquetting machine finished granules are conveyed to the carbonization stove feeding area  or  from the briquetting machine finished granules are send to the packing machine to be packed in bags (25 kg) or big bags (1000 kg)
The loader transports the packed granules to the warehouse
Equipment

Conveyor - 3 units 
Granule-making press, 1 unit
Bucket elevator -1 unit 
Batching and weighing machine -1 unjt
Sealing machine 1 unit
Packing machine 1 unit
Forklift 1 unit

Carbonization and activation shop
 1200 m2 indoors 20x60
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
Units
Conveyors 6 units.
Hopper 1 unit
Packing tables (8 units) should be made by the customer 
Trays (16 units) for the stove
Electronic metering device 1 unit
Self-propelled lifting trolleys 2 units
Crusher -  1 unit.
Fine vibration sieve -  1 unit.
Stoves - 4 units.
Washing and activation shop 750 m2. indoors 50x15
Function

the granules are conveyed to the nitriding bath,then the granules are conveyed to the activation stove; Near the activation stoves the granules are placed on special  pallets and fed to the activation stove using lift The lift takes the pallets with activated carbon the carbon gets cold at the packing tables and is then conveyed to crushing Following the crushing it is conveyed to fine screen then it is conveyed to the packing shop

Equipment
Conveyors 6 units.
Stoves 2 units
Crusher -1 unit
Self-propelled lifting trolleys 2 units
Trays (8 units) for the stove
Packing tables - 4 units (to be made by the customer)
Washing bath  - 1 unit. 
Packing and warehousing shop
200 m2. Indoors
Function
-in the packing shop the carbon  is packed into sealed paper bags with bunching attachment of  0,5-10kg.
Equipment
Conveyors 3 units.
Hopper - 1 unit.
Weighing machine - 1 unit
batching machine -1 unit.
Sealing machine - 1 unit.
Warehouse 1000 m2
Function To be transported by the loader to the finished products warehouse
Equipment Loader -1 unit
Specifications of raw materials
 
Raw materials brown coal, turf, black coal
To produce 1 ton of  activated  carbon it is necessary to have  
4 tons of black coal
To produce 1 ton of  activated  carbon   it is necessary to have  
5-8  tons of brown coal  
To produce 1 ton of activated carbon it is necessary to have 10 tons of high moor turf and 7-10 tons of lower-moor turf
Water requirements/hr
Water 10m3/hour
Needs for additional fuel
1 ton /hr .
Needs for electric energy
400  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)
Fuel granules  
Size 30-60 mm
Density No less than 1.80 gr/cm2 (depends on quality of the coal)
Heat transfer No less than 4500 kcal
Transportation
 
Transportation 21
Transportation of carbonization  stoves
Six 40ft.containers
Transportation of activation stoves two 40ft. containers
Transportation of remaining machines
three  40ft.containers
Transportation of shop's transport four separate places on the transport and one 20 ft.container
Transportation of boiler one platform
Transporation of conveyors two 40ft. containers
Transportation of packing equipment two 40 ft, containers
Transportation of   gas holder
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
10 persons
Time of mounting
1 month
Documents
 
Certificates of aggregates
22 pcs
Drawings of foundations
10 pcs
Drawings of  insets
8 pcs
Drawings of stove
5 pcs
Drawing of press 4 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
24  pcs

Power

Name
Number of units             
kw/unit                                 
kW/total                                
Conveyor
24 units
3
72
Elevator
1 unit
5
5
Weighing machine
1 unit
3
3
Batching machine
1 unit
2
2
Sealing machine
1 unit
5
5
Press
1 unit
 
55
Loader
1 unit
4
4
Mixer
1 unit
 
 
Crusher for raw materials
1 unit
 
 
Raw materials feeding machine
1 unit
4
4
Magnetic separator
1 unit
5
5
Drying machine
1 unit
8
8
Boiler
1 unit
52
52
Electronic meter
1 unit
5
5
Fine vbration screen
2 unit
5
10
Small crusher
3 unit
5
15
Gas holder
1 unit
32
32
Self propelled lifting trolleys
4 units
16
16
Carbonization stoves
4 units
10
40
Activation stoves
2 unit
15
30
Total
 
 
373 kW

 
Name
workers/shift
Engineers
total staff/shift
Staff (3 shifts)
1
-Raw materials preparation shop, crumbling and drying
12
4
13
40
 
Gas holder
2
1
 
 
 
Boiler
2
1
 
 
 
Drying machine
4
1
 
 
 
Feeding machine
1
 
 
 
 
Servicing of other units
3
1
 
 
2
--Pressing shop
2
-
2
6
 
Press
2
-
2
6
3
--Carbonization shop
10
3
11
33
 
 Carbonization stoves
8
3
 
 
 
Self-propelled trolleys
2
 
 
 
4
-- Activation and washing shop
8
 
8
24
 
 Activation stoves
6
 
 
 
 
 Self-propelled lift trolleys
2
 
 
 
5
-- Packing shop
3
-
3
9
 
Packing of activated coal
3
-
 
 
6
-Warehousing shop
3
4
4
11
 
Loader
1
 
 
 
 
Quality control
1
1
 
 
 
Storekeeper
1
1
 
 
 
Total
38
13
41
123


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