ACTIVATED CARBON

CONTENTS

SECTION I

1.1

General Details

Activated carbon is an inert material with porous structure. It is broadly classified on the
basis of the following two applications.
1.

Those used for adsorption of gases and vapours. (granular and material)

2.

Those used for purification of liquids (usually powdered materials)

Activated carbon can be manufactured from wood, peat, hard coal and coconut shell.
1.2

Grades

Activated Carbon is generally produced in the following grades namely powder, granular
pellatised grade and pharmaceutical grade.

Powder grade

Used in batch type liquid systems

Granular and pelletised grade

Used in vapour adsorbing gaseous systems.

Pharmaceutical Grades :

Most Pharmaceutical Grades of carbon are made

from Pinewood Charcoals, as they have very low
ash and acid solubles.

1.3

Physical Properties

Porosity
Size

Porosity and the pore structure are the most

important characteristics of Activated carbon.
Size of the micropores is the deciding factor in
selective absorption.
Atleast two systems of pores of distinctly
different sizes exist in every carbon particle.
Macropores (1000 to 2600 Deg A) : Acts as
large access ways for diffusion of particles.

Surface area
Adsorption behaviour

Micropores (10 to 100 deg A) Contributes

towards large surface area which are
responsible for absorption action.
From 200 to 2000 sq.m.per gram, depending
upon the method and manner of preparation.
Depending on the process of activation, i.e.
steam, as or chemically activated, the
Activated Carbon differ in their adsorption
behaviour.

1.4

Product Specification

Chemical parameters
Moisture(%) max.
Methylene value(min)
KMnO4(min)
Iodine value
Ash(%) max.
Fe ppm
pH
Chlorine(%) max
Sulphate(%) max
Phosphate
Acid soluble matter(%)
Water soluble(%)
Bulk density

Acid washed
10
270
60
1100
3
200
6.5 to 7.2
0.4
0.4
Nil
1.5
0.5
4 to 6 gm/cc

Unwashed
10
280
60
1100
NA
1000
Adjustable
NA
NA
Nil
5
4
4-6 gm/cc

2.1

General Details

Activated carbon is a unique and effective agent for purification and for isolation and
recovery of trace materials.
During the last two to three decades, treatment with active carbon has become an
important unit process for separations and purifications in the food, pharmaceuticals,
sugar, chemical and other processing industries.
2.2

Nature of applications

Removal of colour or odour, oxidising chemicals, compounds responsible for foaming,

metallic ions which constitute impurity and invisible impurities,
To improve product stability and to provide better cystallisation.
For recovery of valuable materials,
To enhance purity, to improve the appearance of product and to act as barrier to prevent
migration of colour bodies.
2.3

Gradewise application

Grade

Sector

Powdered Activated carbon

Vegetable oils, fats, sugar, water treatment,

pharmaceuticals, fine chemicals and food
products.
Automotive
canisters,
air
purification,
chemical and pharmaceutical industry.
Solvent recovery, catalyst application etc

Granular Activated carbon

Pelletised Activated carbon

There are around 50 producers of Activated Carbon in the country, mostly in Medium and
SSI sector, which include the following
Indian producers
*
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Unichar International, Goa

Anil Starch Products Ltd.,Gujarat
Amar Carbon , Rajpipla
Baroda Carbons Limited,Baroda
J.C.Chemical Industries, Surat
Mahavir Industrial Corporation,Ahmedabad
Nikhil Intermediates Pvt. Ltd , Gujarat
Raj Carbons Pvt.Ltd.,Gujarat
Shri Rajpipla Amar Carbon & Chemical Industries,Dist.Bharuch
Unique Carbon and Chemicals, Gujarat
Industrial Carbons Pvt. Ltd.,Ankleshwar
Shreema Chemicals P.Ltd.,Himachal Pradesh
Balaji Chemicals,Karnataka
Key-Sun Enterprises,Mumbai
Kemie Industries, Mumbai
Advance Agro-Tech, Mumbai
Chandra Chemical Industries,Thane
Daisy Industries,Thane
Eurofine Chemicals, Mumbai
Kan-Carbon (P) Ltd.,Delhi
United Active Chars (P) Ltd.,Delhi
Amar Indl. & Fine Chemicals, Punjab
Brilex Chemicals,Amritsar
Century Absorbents, Punjab
Hindustan Indl.Carbon Products,Punjab
Hosch Industrial Absorbents,Punjab
Shriram Carbon Sales P.Ltd.,Dist.Hoshiarpur
Barium International, Rajasthan
Beta Gama Chemicals (P) Ltd.,Jaipur
Rajeshwari Industries, Rajasthan
Dass Rasayanik Carbo Udyog, Uttar Pradesh
Jains Carbons (P) Ltd.,U.P
Unicarbons & Chemicals, Ghaziabad
Arunodaya Industrial Corpn.,Calcutta
Global Enterprises, Calcutta
International Chemical Agenices, Calcutta
The Smitaja Chemicals P.Ltd., West Bengal

Important producers in South India

*

Metroblue Industries
P.B. No.5, 1, Quarry Road,
Evergreen Nagar, Thirupparam Kundram,
Madurai-625 005
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Factory : 153, Kodumudi Road
Perumal Pudur, Muthur-638 105,
Erode Dist.
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Indo German Carbon Ltd., has put up a joint venture with Kerala State Industrial
Development Corporation Ltd., (KSIDC), for 2500 tonnes per annum Activated carbon
plant with technology from Carbo Consult, Germany at a project cost of around Rs.15
crores at Kochi in Kerala. The company is promoted by Galfar India Group and KSIDC.

Indian installed capacity

Around 60,000 tonnes per annum

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Export Details

4.2.1. Present Export Level

Around 3300 tonnes per annum

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35000

32500

30000

20000
Demand
15000

10000

6100
3300
1750

1550

Glucose/
Dextrose
Monohydrate/
Sorbitol

2700

Plasticisers

5000

Sector

Export Sector

Miscellaneous

Vegetable Oil

Pharmaceutical

in tonnes per annum

25000

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Granular Carbon
25%

Powder Carbon
75%

Activated carbon can be produced from any carbonaceous material, which on activation attain
porous structure and consequently a large surface area.
Raw materials such as wool, lignite, woods, coconut-shells, agricultural waste like bagasse, rice
husk are generally used for the manufacture of Activated carbons. Raw materials having high
carbon and low ash content are preferred.
Coconut shell has been found to be most suitable raw material for making gas adsorption grade
Activated carbon.
The shell char is activated with direct steam and fired with liquid fuel in temperature of 1000 to
12000 deg.C in specially designed rotary kiln in controlled conditions to obtain granulated
activated carbon.
Process flowsheet for Activated carbon from Coconut shells by steam activated process
Raw coconut shells (halfs)

(Ap. 100 to 150 mm size)

Crushing

(3 mm to 4 mm size)

Carbonisation

(500 to 600 deg.C)

Cooling

Steam activation

(1000 to 1200 deg.C)

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Source of technology
*

Indian Institute of Chemical Technology,

Uppal Road, Tarnaka, Hyderabad-500 007.
Telefax : 040-7160387, 7160757, 7193461
Website : www.iictindia.org

Major plant and machinery and suppliers

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8.1

Raw Material Requirement

1000 kg of raw coconut shells yield about 100 kgs of vapour grade activated carbon.
Utility
Fuel
Power
8.2

400 litres
1240 units
Raw material availability

The coconut shell availability depends upon production level of coconut in the country.
In view of the extensive coconut plantations available in India, there is unlikely to be any
problem in procurement of the coconut shell for the project.
All India estimate of Coconut production
States/Union Territories

Area (000 hectares)

Percentage share

Andhra Pradesh
Assam
Goa
Karnataka
Kerala
Maharashtra
Orissa
Tamil Nadu
Tripura
West Bengal
A&N Islands
Lakshadweep
Pondicherry
All India

101.7
20.2
25
320.6
899.1
15.1
29
304
9.1
24.2
24.7
2.8
2.2
1777.7

5.72
1.14
1.41
18.03
50.58
0.85
1.63
17.10
0.51
1.36
1.39
0.16
0.12
100

Production
(million nuts)
1051.8
150.1
121.6
1670.3
5167
226.7
163.3
3222
7.5
324.3
87.5
28.3
31.2
12251.6

Demand for Activated Carbon:

Around 0.5 million tonnes per annum

Major Producing Countries

The Philippines and Sri Lanka are

the major producers and exporters
of Activated Carbon.
Sri Lanka has increased its export
volume of Activated Carbon to
around 10,000 tonnes per annum.

Growth rate in Demand

2% to 3%

Global Capacity :

According to Roskill, capacity expansions

worldwide exceeded 65,000 tonnes per year in the
nineties with more than 30,000 tonnes coming
onstream in Asia. and the US. Competition from
Chinese and Southeast Asian producers is strong.

International Manufacturers

Norit and Chemviron accounts for 70% of Western Europe production and Ceca accounts
for 13%.
Important International manufacturers include the following :

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FACA SA, Argentina

CDF Chimie-Societe Chimique des Charbonnages, France
Chemviron Carbon Ltd.,UK
Degussa AG, Germany
ICI Specialty Chemicals, Germany
Mitsui Pharmaceuticals Inc.,Japan
Mitsui Toatsu Chemicals Inc.,Japan
Philippine Japan Activated Carbon Corp., Manila
China Active Carbon Co.Ltd., Taiwan
Taiwan Active Carbon Industry Co.Ltd., Taipei
Win Chain Enterprises Co.Ltd., Taipei
Chemitreat Pvt. Ltd., Singapore
Singapore Activated Carbon Pte. Ltd., Singapore
Haycarb Limited, Colombo
Jacobi Carbon Ltd.,UK
Norit Americas, Inc.,USA
Sutcliffe Speakman Carbon Ltd.,UK

*
*
*
*

Waterlink Sutcliffe Carbons, UK

Activated Carbon Resources Inc, USA
Calgon Carbon Corp., USA
Carbochem Inc., USA

Global use pattern

Use
Solvent recovery
Automotive/gasoline recovery
Industrial offgas control
Catalysts
Pressure swing separation
Air conditioning
Gas mask
Cigarette filters
Nuclear

In %
25.6
23.3
18.2
15.4
6.3
2.8
2.8
2.8
2.8

Economic capacity

300 tonnes per annum

Project cost

Rs.142 lakhs

Assessment of project cost

1.

Land

S.No.

Description

1.1

Cost of land of one acre at Rs.5.5 lakh per acre

1.2

Cost of levelling, laying internal roads/fencing and

Compound wall
Subtotal

Cost
Rs.in lakhs
5.5
0.55
6.05

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S.No.

Description

2.1
2.2

Factory building of area 420 sq.m. at Rs.3200/sq.m.

Non-factory building of area 80 sq.m.at Rs.4500/sq.m.
Subtotal

Cost
Rs.in lakhs
13.44
3.6
17.04

Cost of Plant & Machinery

S.No.

Description

3.1
3.2
3.3
3.4

Cost of basic plant and machinery

Instrumentation and control
Pipelines and valves
Structurals for erection
Subtotal
Octroi, excise duty, sales tax, etc.at 12%
Packaging and insurance charges (2%)

3.5
3.6

&

Cost
Rs.in lakhs
41
3.08
4.1
2.05
50.23
6.03
1

3.7
3.8
3.9
3.10

Transportation charges (2%)

Machinery stores and spares (2%)
Foundation charges (2%)
Installation charges (2%)
Total cost of plant and Machinery

4.

Technical know-how fees

5.

Miscellaneous fixed assets

1
1
1
1
61.27

Rs. 2.5 lakhs

S.No.

Description

5.1.
5.2.
5.3.
5.4.
5.5.
5.6.
5.7.

Electrification
Steam boiler and auxillaries
Water storage tank, borewell etc.
Fuel storage tank
Laboratory equipment
Office machinery & equipment
Material handling equipment, packaging machinery,
Weigh balance, etc.
Diesel generator
Effluent treatment
Total

5.8.
5.9.

6.

Cost
Rs.in lakhs
4.8
2.8
1.7
2.8
2.5
3
3.5
4.4
1.3
26.8

Preliminary & Pre-operative expenses:

S.No.

Description

6.1.
6.2.
6.2.1
6.2.2
6.2.3
6.2.4
6.2.5
6.2.6
6.2.7

Preliminary expenses
Pre-operative expenses:Establishment
Rent rates and taxes
Travelling expenses
Interest and commitment charges on borrowings
Insurance during construction period
Other preoperative expenses and deposits
Interest on deferred payment
Total

Cost
Rs.in lakhs
0.7
1.4
0.8
2.6
5
1.7
12.2

7.

Provision for contingency

Rs.7.71 lakhs

8.

Working capital margin

Rs.8.91 lakhs

9.

Total project cost

Rs.142.lakhs
A

10.

Means of Finance

Promoter's contribution
Term loan from financing institutions
Total project cost

Rs.57 lakhs
Rs.85 lakhs
Rs.142 lakhs

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Activated Carbon finds wide spread applications in variety of growth oriented sectors.
Therefore, the demand for the product is likely to go up steadily in the coming years.
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applications for the product becoming obsolete in the

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The production of Activated carbon from Coconut Shell Charcoal is viewed as providing
superior end properties. Therefore, Activated Carbon produced from Coconut Shell is

preferred all over the world. India has number of advantages in view of the abundant
availability of Coconut shell for the production of Activated Carbon.
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The technology for the production of Activated Carbon is fairly wellknown in the
country.
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In setting up the Activated Carbon project from Coconut Shell, technology aspects have
to be given utmost priority, since high quality and specification of the product is required
to get a fair share in the market and also enter into the export market in significant way.