Activated carbon: Raw materials - brown coal and turf
Productiviy 1200 tons/year
Productiviy 1200 tons/year
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Name
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Parameters
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Destination
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Production of activated carbon of good quality and fuel granules made of brown coal and turf
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Trademark
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LU-АU-1200 automated line
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Trademark owner
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Mega Power Hong Kong Group Limited
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Developer
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Israel
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Production license ownet
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Mega Power Hong Kong Group Limited
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Assembly and Technology
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A list of units
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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.
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Technology
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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.
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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 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 .
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General Info
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Operating mode
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21 hrs/day, 300 days/year
For activation shop and briquetting shop
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| Annual production of fuel granules at three-shift work | 160 000 granules | |
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Month production of fuel granules at three-shift work
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13150 tons
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| 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 | |
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Activated carbon production/year. (Round-the-clock operation )
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1200 tons
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Activated carbon production/day. (Round-the-clock operation)
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4.5 tons
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Activated carbon production/month (Round-the-clock operation)
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100 tons
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Attention
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Activated carbon manufacturing technology requires 3-shift round-the-clock operation
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staff
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50 persons/shift
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Power consumption
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400 kW
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Heat energy needs
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10 000 kcal/hr
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Composition of the set
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All included
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Warranty
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1 year
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areas
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Design production area
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Total 4000 m2, including 2600 m2 indoors and 1400 m2 outdoors
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The production line is divided into shops
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--raw materials preparation, crumbling and drying
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1400 m2 Outdoors, 2 shelters 60m х 20 m
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Function
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-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
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Equipment
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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
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| Pressing and packin g shop |
450 m2 indoors 35 m х 12m
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| 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
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| Equipment |
Conveyor - 3 units |
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Carbonization and activation shop
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1200 m2 indoors 20x60
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Function
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- 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
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Units
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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.
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| 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 |
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| 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.
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Packing and warehousing shop
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200 m2. Indoors
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Function
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-in the packing shop the carbon is packed into sealed paper bags with bunching attachment of 0,5-10kg.
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Equipment
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Conveyors 3 units.
Hopper - 1 unit.
Weighing machine - 1 unit
batching machine -1 unit.
Sealing machine - 1 unit.
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| Warehouse | 1000 m2 | |
| Function | To be transported by the loader to the finished products warehouse | |
| Equipment | Loader -1 unit | |
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Specifications of raw materials
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| Raw materials | brown coal, turf, black coal | |
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To produce 1 ton of activated carbon it is necessary to have
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4 tons of black coal
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To produce 1 ton of activated carbon it is necessary to have
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5-8 tons of brown coal
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| 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 | |
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Water requirements/hr
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Water 10m3/hour
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Needs for additional fuel
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1 ton /hr .
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Needs for electric energy
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400 kW
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Production stanfards
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Activated coal
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Grain's size of 1mm
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< 1,0
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Grain's size of 1–3,5 mm
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>96,5
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Grain's size of 3,5-5 mm
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< 2,5
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Moisture contents
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<10,0
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Ash contents
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< 8,0
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Porosity (by acetone)
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> 74
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Static activity by chlorine
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>35
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Mass of 1 L of coal that should be
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no more than 220 gr (determination without compaction)
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| 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 | |
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Transportation
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| Transportation | 21 | |
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Transportation of carbonization stoves
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Six 40ft.containers
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| Transportation of activation stoves | two 40ft. containers | |
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Transportation of remaining machines
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three 40ft.containers
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| 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 | |
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Transportation of gas holder
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One 20 -ft.container
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Other conditions
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Time of mounting
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4-5 weeks including training courses for foreign workers
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Payment terms
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50% -advance payment, 50% -after the line is ready for shipment and checked but before leaveing the territory of PR China
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Start-and-adjusting
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15% of the price of the production line. The price of the production line doesn't include start-up and adjusting
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Incomplete delivery
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It is possible to deliver separate units and/or sections
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Start-up and adjustment staff
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10 persons
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Time of mounting
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1 month
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Documents
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Certificates of aggregates
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22 pcs
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Drawings of foundations
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10 pcs
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Drawings of insets
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8 pcs
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Drawings of stove
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5 pcs
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| Drawing of press | 4 pcs | |
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Installation drawing
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1 pc
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Electrical exploration drawings
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1 pc
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Drawings of separate units
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6 pc
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Language of documents
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Chinese, English, Hebrew, Russian
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Certification
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The equipment is certified
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China, EC, Israel, Russia, Ukraine
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Total number of certificates
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24 pcs
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Power
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Name
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Number of units
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kw/unit
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kW/total
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Conveyor
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24 units
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3
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72
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Elevator
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1 unit
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5
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5
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Weighing machine
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1 unit
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3
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3
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Batching machine
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1 unit
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2
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2
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Sealing machine
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1 unit
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5
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5
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Press
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1 unit
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55
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Loader
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1 unit
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4
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4
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Mixer
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1 unit
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Crusher for raw materials
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1 unit
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Raw materials feeding machine
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1 unit
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4
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4
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Magnetic separator
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1 unit
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5
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5
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Drying machine
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1 unit
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8
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8
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Boiler
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1 unit
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52
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52
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Electronic meter
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1 unit
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5
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5
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Fine vbration screen
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2 unit
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5
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10
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Small crusher
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3 unit
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5
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15
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Gas holder
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1 unit
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32
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32
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Self propelled lifting trolleys
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4 units
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16
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16
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Carbonization stoves
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4 units
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10
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40
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Activation stoves
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2 unit
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15
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30
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Total
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373 kW
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Name
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workers/shift
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Engineers
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total staff/shift
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Staff (3 shifts)
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1
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-Raw materials preparation shop, crumbling and drying
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12
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4
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13
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40
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Gas holder
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2
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1
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Boiler
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2
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1
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Drying machine
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4
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1
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Feeding machine
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1
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Servicing of other units
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3
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1
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2
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--Pressing shop
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2
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-
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2
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6
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Press
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2
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-
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2
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6
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3
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--Carbonization shop
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10
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3
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11
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33
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Carbonization stoves
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8
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3
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Self-propelled trolleys
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2
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4
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-- Activation and washing shop
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8
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8
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24
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Activation stoves
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6
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Self-propelled lift trolleys
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2
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5
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-- Packing shop
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3
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-
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3
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9
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Packing of activated coal
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3
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-
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6
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-Warehousing shop
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3
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4
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4
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11
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Loader
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1
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Quality control
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1
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1
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Storekeeper
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1
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1
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Total
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38
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13
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41
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123
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