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

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

 

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.

-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 .

 

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

2,5 tons

62 tons

staff

15 persons/shift

Power consumption

107 kW

Heat energy needs

4 500 kcal/hr

Composition of the set

All included

Warranty

1 year

 

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

Conveyors 2 units.

Crusher 1 unit.

Magnetic separator 1 unit.

Screen 1 unit.

Drying machine 1 unit.

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.

-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.

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.

 

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

 

 

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

 

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.

 

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

 

The equipment is certified

China, EC, Israel, Russia, Ukraine

Total number of certificates

12 pcs

 

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