4. Definition
Activated carbons are versatile adsorbents. Their
adsorptive properties are due to their high surface area, a
microporous structure, and a high degree of surface
reactivity. They are, used, therefore, to purify, decolorize,
deodorize, dechlorinate, separate, and concentrate in order
reactivity. They are, used, therefore, to purify, decolorize,
deodorize, dechlorinate, separate, and concentrate in order
to permit recovery and to filter, remove, or modify the
harmful constituents from gases and liquid solutions.
Consequently, activated carbon adsorption is of interest to
many economic sectors and concern areas as diverse as
food, pharmaceutical, chemical, petroleum, nuclear,
automobile, and vacuum industries as well as for the
treatment of drinking water, industrial and urban waste
water, and industrial flue gases.
5. Activated carbons have a microcrystalline structure. But
this microcrystalline structure differs from that of
graphite with respect to interlayer spacing, which is
0.335 nm in the case of graphite and ranges between
0.34 and 0.35 nm in activated carbons. The elemental
0.335 nm in the case of graphite and ranges between
0.34 and 0.35 nm in activated carbons. The elemental
composition of a typical activated carbon has been
found to be 88% C, 0.5% H, 0.5% N, 1.0% S, and 6 to 7%
O, with the balance representing inorganic ash
constituents. The oxygen content of an activated
carbon can vary, however, depending on the type of
the source raw material and the conditions of the
activation process.
7. Raw Material
Coconut shell and palm shell are the best raw materials for manufacturing of
activated carbon because of its hardness. Indonesia is the largest coconut
plantation with about 4 million hectares and the largest CPO producer in the
world with palm oil plantations more than 7 million ha, which is the ideal
location of the source of raw material for production of activated carbon.location of the source of raw material for production of activated carbon.
Indonesian coconut plantation area occupies 31.4% of the world with vast
coconut plantations of coconut production of approximately 12.915 billion
grains (24.4% of world production). And the Philippines famous as the world's
largest coconut producer. Coconut shell weight reached 12% of the weight of
coconuts. With a heavy coconut average 1.5 kg, the potential of Indonesia,
namely coconut shell 2324.7 million tons / year. The number of palm oil mills
in Indonesia and Malaysia more than 800 units. When an palm oil mill with a
capacity of 30 tons of fresh fruit bunches per hour, it will produce 1.95 tonnes
of palm shells / hour or about 46.8 tons / day. Certainly the number of very
abundant for the production of activated carbon.
9. Process Technology
Their preparation involves two main steps: the
carbonization of the carbonaceous raw material
at temperatures below 800°C and the activation
of the carbonized product. Thus, all carbonaceous
materials can be converted into activated carbon,materials can be converted into activated carbon,
although the properties of the final product will
be different, depending on the nature of the raw
material used, the nature of the activating agent,
and the conditions of the carbonization and
activation processes. But only a good hard
biomass used as activated charcoal such as
coconut shell and palm shell.
10. During the carbonization process, most of the
noncarbon elements such as oxygen, hydrogen,
and nitrogen are eliminated as volatile gaseous
species by the pyrolytic decomposition of the
starting material. The residual elementary carbonstarting material. The residual elementary carbon
atoms group themselves into stacks of flat,
aromatic sheets cross-linked in a random manner.
These aromatic sheets are irregularly arranged,
which leaves free interstices. These interstices
give rise to pores, which make activated carbons
excellent adsorbents.
11. During carbonization these pores are filled with the tarry matter or the
products of decomposition or at least blocked partially by disorganized
carbon. This pore structure in carbonized char is further developed andcarbon. This pore structure in carbonized char is further developed and
enhanced during the activation process, which converts the carbonized
raw material into a form that contains the greatest possible number of
randomly distributed pores of various sizes and shapes, giving rise to an
extended and extremely high surface area of the product. The activation
of the char is usually carried out in an atmosphere of air, CO2, or steam in
the temperature range of 800°C to 900°C. This results in the oxidation of
some of the regions within the char in preference to others, so that as
combustion proceeds, a preferential etching takes place. This results in the
development of a large internal surface, which in some cases may be as
high as 2500 m2/g.
12. Our continuous pyrolysis technology with capacity 60
up to 200 ton/day INPUT would very reliable in theup to 200 ton/day INPUT would very reliable in the
process of carbonization. Integration our continuous
pyrolysis technology in activated carbon plant would
be very beneficial because the most efficient
processes (self sustaining process with syngas) and
all products can be drawn. Then following with
activation process.
13. Carbonisation (Slow Pyrolysis Process) :
Charcoal Production
Primitive Charring Tehniques :large quantities of CO2 and
unburned methane directly to the atmosphere
Closed pit charcoal production
Advanced charcoal production : Charcoal as main
product, bio-oil and syngas as sideproduct. Syngas can
be used in activation process.
14. Rotary Kiln
For many years, rotary kilns have been used across various
industries to drive chemical reactions by thermal
processing. Rotary kilns have become very established in
fields such as cement, lime, and minerals.
15. Rotary Kiln
Rotary kilns can be custom-engineered to meet the
thermal processing needs of just about any material.
16. Rotary Kiln
Interior
The refractory is what protects the carbon steel shell from the high temperatures within.
Two kinds of refractories for lining a rotary kiln: castable, and brick. The choice of
refractory is dependent on the rotary kiln temperature, material chemistry, and
how abrasive the material is.
17. Rotary Kiln
Refractory
Castable refractory has a similar material cost to brick. However, brick installation is much more labor intensive,
as each brick is individually installed. This makes the overall cost of a brick lining more expensive than castable.
The disadvantage to using castable refractory in a rotary kiln is that it is very susceptible to installation problems.
When castable refractory is installed very well, it can nearly match the quality of brick. But if the castable is
installed incorrectly, there can be a considerable difference in quality, and the life of the refractory can be severely
compromised. Brick refractory is slightly more expensive than castable, but it does not require anchors, and it’s
quality is superior.
19. Application
The most important application of activated carbon
adsorption where large amounts of activated carbons are
being consumed and where the consumption is ever
increasing is the purification of air and water. There are two
types of adsorption systems for the purification of air. One
is the purification of air for immediate use in inhabited
types of adsorption systems for the purification of air. One
is the purification of air for immediate use in inhabited
spaces, where free and clean air is a requirement. The
other system prevents air pollution of the atmosphere from
industrial exhaust streams. The former operates at
pollutant concentrations below 10 ppm, generally about 2
to 3 ppm. As the concentration of the pollutant is low, the
adsorption filters can work for a long time and the spent
carbon can be discarded, because regeneration may be
expensive.
20. Air pollution control requires a different adsorption
setup to deal with larger concentrations of the
pollutants. The saturated carbon needs to be
regenerated by steam, air, or nontoxic gaseousregenerated by steam, air, or nontoxic gaseous
treatments. These two applications require activated
carbons with different porous structures. The carbons
required for the purification of air in inhabited spaces
should be highly microporous to affect greater
adsorption at lower concentrations. In the case of
activated carbons for air pollution control, the pores
should have higher adsorption capacity in the
concentration range 10 to 500 ppm.
21. For personal protection when working in a hostile
environment, the activated carbons used in respirators
are also different. When working in the chemical
industry, the respirators can use ordinary activatedindustry, the respirators can use ordinary activated
carbons because the pollutants are generally of low
toxicity. However, for protection against warfare gases
such as chloropicrin, cynogen chloride, hydrocynic acid,
and nerve gases, special types of impregnated
activated carbons are used in respirators and body
garments. These activated carbons can protect by
physical adsorption, chemisorption, and catalytic
decomposition of the hazardous gases.
22. More than 800 specific organic and inorganic chemical
compounds have been identified in drinking water. These
compounds are derived from industrial and municipal
discharge, urban and rural runoff, natural decomposition of
vegetable and animal matter, and from water and wastevegetable and animal matter, and from water and waste
water chlorination practices. Liquid effluents from industry
also discharge varying amounts of a variety of chemicals
into surface and ground water. Many of these chemicals are
carcinogenic and cause many other ailments of varying
intensity and character. Several methods such as
coagulation, oxidation, aeration, ion exchange, and
activated carbon adsorption have been used for the
removal of these chemical compounds.
24. Market
The global activated carbon industry is estimated to be around 1.1
million metric ton. Demand for virgin activated carbon is expected
to rise by around 10% annually through 2014, worldwide. The U.S is
the largest market, which will also pace global growth based on
anticipated new federal regulations mandating mercury removal at coal-
fired power plants. Nearly 80% of the total active carbon is consumed forfired power plants. Nearly 80% of the total active carbon is consumed for
liquid-phase applications, and the gas-phase applications consume about
20% of the total production. Because the active carbon application for
the treatment of waste water is picking up, the production of active
carbons is always increasing. The consumption of activecarbon is the
highest in the U.S. and Japan, which together consume two to four times
more active carbons than European and other Asian countries. The per
capita consumption of active carbons per year is 0.5 kg in Japan, 0.4 kg in
the U.S., 0.2 kg in Europe, and 0.03 kg in the rest of the world. This is due
to the fact that Asian countries by and large have not started using active
carbons for water and air pollution control purposes in large quantities.
25. Contact
Waste to Value EntrepreneurWaste to Value Entrepreneur
eko.sbs@gmail.com
Twitter : @ekosbs
Blog : jfe-project.blogspot.com
