Industry Overview
Carbon is one of the most widely distributed elements in nature and occurs in crystalline forms such as graphite and diamond, as well as in amorphous forms including charcoal, coke and carbon black. Carbon is an essential constituent of vegetable and animal matter and occurs in numerous compounds, including hydrocarbons, carbon dioxide and carbonates. Industrial carbons are produced from coal, petroleum coke and various organic materials and are widely used in electrical and electro-chemical applications.
Activated carbon, also known as active carbon or active charcoal, refers to amorphous carbon with higher adsorption capacity than ordinary wood or animal charcoal. Its development accelerated during the World War period, particularly for absorbents used in gas masks. Today, activated carbon is available in granular, powdered and pelletized forms for diverse industrial applications. Commercial absorbent carbons are broadly used for decolorization, gas and vapour adsorption, metal adsorption and medicinal purposes.
A wide range of raw materials can be used to manufacture activated carbon, including coal, petroleum coke, wood charcoal and agricultural or industrial residues such as coconut shells, corn cobs, paddy husk and other biomass materials. Production may involve gas activation, chemical activation or carbon deposition on porous inorganic bases. Gas absorbent carbons are commonly produced from dense carbonaceous materials such as coconut shells, apricot stones and anthracite and are activated to develop the required porous structure and adsorption characteristics.
Cost Estimation
| Particular | Value |
|---|---|
| Plant Capacity | 20 MT/Day |
| Land & Building (5460 sq.mt.) | Rs. 6.37 Cr |
| Plant & Machinery | Rs. 7.06 Cr |
| Working Capital for 0.25 Months | Rs. 52.92 Lac |
| Total Capital Investment | Rs. 14.62 Cr |
| Rate of Return | 42% |
| Break Even Point | 50% |
Content Index
Appendix
Frequently Asked Questions
Activated carbon is an amorphous carbon material developed to provide a high adsorption capacity. It is commonly produced by treating carbonaceous raw materials through activation processes that develop a porous structure. The report describes activated carbon as also being known as active carbon or active charcoal. Depending on its physical structure, properties and intended application, commercial activated carbons are used for decolorization, gas and vapour adsorption, metal adsorption and medicinal purposes. Products can be supplied in granular, powdered or pelletized forms for different industrial requirements.
Activated carbon can be manufactured from a wide range of carbonaceous raw materials, including coal, petroleum coke, wood charcoal and biomass residues. The report also identifies materials such as coconut shells, corn cobs, paddy and groundnut husk, straw, bagasse, molasses and other industrial or agricultural residues. Selection depends on the required product characteristics and the suitability of the material for the chosen activation method. Raw materials may be carbonized, briquetted, chemically treated or otherwise processed before activation to obtain the desired porous structure and mechanical properties.
Activated carbon is manufactured by carbonizing a suitable raw material and then developing its pore structure through activation. The report describes gas activation, chemical activation and carbon deposition on a porous inorganic base as production routes. In gas activation, carbonized material is heated at high temperature in an oxidizing atmosphere involving media such as steam, air or carbon dioxide. Chemical activation involves treatment with selected chemicals followed by extrusion, drying, carbonization, washing and drying. The process route is selected according to the raw material and required product characteristics.
Gas activation develops porosity by heating carbonized material in an activating atmosphere, while chemical activation uses chemical treatment before carbonization. In the report, gas activation involves controlled carbonization followed by high-temperature treatment using media such as steam, air or carbon dioxide. Chemical activation involves forming a paste with chemicals, extruding and drying it, followed by carbonization and subsequent washing to remove inorganic residues. Both approaches are intended to create the porous structure required for adsorption, but the appropriate route depends on the raw material, process design and desired product properties.
The three main forms of activated carbon identified in the report are granular activated carbon, powdered activated carbon and pelletized activated carbon. These forms differ primarily in physical configuration and are selected according to handling, process and application requirements. Granular material is supplied within specified particle-size ranges, while powdered carbon consists of finer particles suitable for applications requiring rapid contact with the treated medium. Pelletized carbon is formed into defined shapes and can provide useful mechanical characteristics for particular gas or liquid treatment systems.
Activated carbon is used for decolorization, gas and vapour adsorption, metal adsorption and medicinal applications. The report also identifies applications and end-user areas associated with oil and gas plants, water treatment plants, mineral water and overseas markets. Different carbon grades are selected for different duties because no single activated carbon type is suitable for every purpose. Physical structure, pore characteristics, adsorption performance, particle size and mechanical properties are among the factors that influence product suitability for a particular industrial application.
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