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Active carbon: Raw materials - sawdust


Name
Parameters
Destination
Production of high quality activated carbon, charcoal and fuel granules of sawdust 
Trademark
LU-АU-1200 EURO
Trademark owner
Mega Power Hong Kong Group Limited
Developer
China
Production license owner
Mega Power Hong Kong Group Limited
Assembly and Technology
 
A list of units for carbonization
Sawdust recycling section
Conveyors 5 units
Wood  crusher 1 unit.
Magnetic separator 1 unit.
Drying machine for sawdust -1 unit
Extruders for making briquettes out of sawdust - 5 units
Carbonization section
stoves - 10 units
self-propelled lifting trolleys (2 tons) -5 units
Trays -40 units (attached to the stove)
Decompression device, 10 units. attached to the stove
Exhaust gas utilization device, 10 units, attached to the stove
Switching system, 2 units
Panel control system, 1 unit
Ventilator, 12 units with the stove
Compressors -2 units
Conveyors -5 units
Packing and warehousing system
Conveyors -4 units
Crusher - 1 unit
Film packing machines-2 units
Self propelled lifting trolley, 2 tons -1 unit
Supplementary equipment
Hopper -3 units
Packing tables - 22 units (to be made by the Customer)
Lab systems, 1 set
A list of machines on activation
Conveyors 10 units.
Magnetic separator 1 unit.
Boiler -1 unit.
Forklift 1 unit.
Packing tables, -4 units, to be made by the Customer 
Electronic meter - 1 unit
Self propelled lifts - 2 units
Crusher -1 unit
Fine vibration sieve -1 unit
Activation stove - 2 units
Crusher 1 unit.
Pallets 8 units. attached to the stove
Washing bath  1 unit.
Dust -removal system - 1 unit
Weighing machine -1 unit
Batching machine -1 unit
Sealing machine -1 unit
Gas holder - 1 unit
Switching system -1 unit
Panel control system , 1 unit.
Ventilatior, 2 units
Compressors, 1 unit.
Lab systems, 1 set
Decompression device -2 units
Exhaust gas utilization system, 2 units
Dust removal system for crumbling - 2 units
  Production of charcoal for following activation
Sawdust section
Saw dust are conveyed to the crusher
-From the crusher they are conveyed to vibration sieve and magnetic separator .
-followed by conveying to coiler drier
then they are conveyed to extruders
From the extruders to carbonization section
Carbonization sections
Sawdust briquettes turn into coal in the same way as turf briquettes .
The briquttes are sent to the packing tables
-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 by the elevator
Finished pallets are placed to the packing tables for cooling
New pallets with raw materials are fed to the stoves
Packing, storing and warehousing 
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.
there are two variants of  packing
-Variant 1. Coal is packed into sealed paper bags with bunching attachment of 0.5-25 kg
-Variant 2. Coal briquettes are prepacked by 12 units into film in the form of packages 50cmx12 cm x 9 cm. Weight - 10 kg -
The finished coal is transported to the finished product warehouse
Technology
Activated carbon production technology  #1 
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 05-10 kg
-Then the active carbon is sent to the finished products warehouse
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
24 hrs/day, 300 days/year
For activation shop and briquetting shop
Annual production of fuel briquettes at  one-shift work 48 000 tons
Month production of fuel briquettes  at one-shift work
4000 tons
Daily production of fuel briquttes at one shift wotk 160 tons
Charcoal productivity /hr
5 tons
Charcoal productivity/ year at one shift operation
12 000 tons
Charcoal productivity/day at round-the clock operation
120 tons
Charcoal productivity/month at round-the clock operation
3 000 tons
activated carbon  productivity/year at round-the clock operation
1 200 tons
activated carbon  productivity/day at round-the clock operation
4,5 tons
activated carbon  productivity/month at round-the clock operation
100 tons
Personnel
40
Power consumption
400 kWh
Thermal energy consumption
4 000 kcal\hr
Completeness of the equipment
All is included
Warranty
1 year
Areas
 
Design production area
3600 м2. including 2600 indoors and  1 000 m2 outdoors
The factory is divided into shops
 
-- Raw materials preparation, crumbling and drying
600 m2 including 30м х10 м  indoors
Function
Sawdust are conveyed to the crusher
-From the crusher they are conveyed to vibration sieve and magnetic separator .
-followed by conveying to coiled drier
-followed by conveying to extruders
-From extruders to carbonization shop   .
Equipment
Conveyors 5 units.
Wood crysher  1 unit.
Vibration sieve 1 unit.
Magnetic separator - 1unit
Drying machine for sawdust - 1 unit
Exruders for making briquettes  5 units
Carbonization shop
1200 м2 ,indoors 20m х 60 m
Function
The briquttes are sent to the packing tables
-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 by the elevator
Finished pallets are placed to the packing tables for cooling
New pallets with raw materials are fed to the stoves
Equipment
stoves - 10 units
self-propelled lifting trolleys (2 tons) -5 units
Trays -40 units (attached to the stove)
Decompression device, 10 units. attached to the stove
Exhaust gas utilization device, 10 units, attached to the stove
Switching system, 2 units
Panel control system, 1 unit
Ventilator, 12 units with the stove
Compressors -2 units
Conveyors -5 units
--packing and storing shop
200 m2
Function
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.
there are two variants of  packing
-Variant 1 coal is packed into sealed paper bags with bunching attachment of  0.5-25 kg
-Variant 2. Coal briquettes are prepacked by 12 units into film in the form of packages 50cmx12 cm x 9 cm. Weight - 10 kg
The finished coal is transported to the finished product warehouse
Equipment
Conveyors - 4 units.
Crusher -  1 unit.
Film packing machines . 2 units.
Self-propelled lifting trolleys. 2 tons, 1 unit
--washing and activation shop
750 m2. indoors  (50 m х 15m)
Function
- are conveyed to the nitriding bath
-the granules are fed to the activation stove.
Near the activation stove the granules are placed on special pallers and loaded to the activation stove using elevator
the elevator takes out the pallet with activated carbon
the carbon gets cold on packing tables and is conveued to crumbling
from the crumbling it is conveyed to fine screen
then it conveys to packing shop
Equipment
Conveyors 6 units.
Stoves 2 units.
Crusher  1 unit.
Self-propelled lifting trolleys -2 units
Trays, 8 pcs, attached to the stove
Packing tables, 4 units to be made by the Customer
Washing bath, 1 unit
--packing shop
200 m2. indoors
Function
-The carbon is packed into sealed paper bags with bunching attachment of  0.5-10 kg.
Equipment
Conveyors 3 units.
Hopper 1 unit. (see photo ),
Weighing machine  1unit.
Batching machine -1 unit
Sealing machine -1 unit
--Warehousing shop
400 m2.
Function
-The loader transports the cargo to finished product waqrehouse
Equipment
Loader,  1 unit.
Specifications of raw materials
 
Raw materials
sawdust
the production of 1 ton of active carbon requires
4 tons of charcoal
 
the production of 1 tons of charcoal requires
3  tons of sawdust  
Water consumption
10 m3/ hr
Additional fuel
1 ton/hr  
Electric energy consumption
400 kw
Production stanfards
 
Activated carbon
 
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 stoves
6- 20ft.container
Transportation of remaining machines
2- 40ft.container
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
Price of equipment includes

The price at the factory in Harbin
The price of delivery to Chinese border
EC certificates
Technical documents

Price of equipment excude

Custom legalization at the Customer's country
Certification in the country of the factory's location
Transportation from Chinese border to the factory
Preparation of rooms
Mounting and filling of  foundations
Mounting of ventilation system and fire-fighting measures
Connected electic energy to the units

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

Active carbon production line 1200 tons/year. Staff  
 
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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