Activated Carbon Production from Coal
Activated Carbon Production Costs Report | Issue B | Q4 2024
| Report Details |
| 25 kta United States-based plant | Q4 2024 | 107 pages |
This report presents a cost analysis of a 25 kta (kilo metric ton per annum) United States-based plant. You can add a customized cost analysis, assuming another location (country), when ordering a premium edition of this report.
Report Abstract
This study approaches the economics of Powdered Activated Carbon production from coal in the United States via a typical steam activation process. In the process examined, coal is carbonized into a hot coal char, which is activated by steam at high temperatures.
The report provides a comprehensive study of Activated Carbon production and related Activated Carbon production cost, covering three key aspects: a complete description of the Activated Carbon production process examined; an in-depth analysis of the related Activated Carbon plant capital cost (Capex); and an evaluation of the respective Activated Carbon plant operating costs (Opex).
The Activated Carbon production process description includes a block flow diagram (BFD), an overview of the industrial site installations, detailing both the process unit and the necessary infrastructure, process consumption figures and comprehensive process flow diagrams (PFD). The Activated Carbon plant capital cost analysis breaks down the Capex by plant cost (i.e., ISBL, OSBL and Contingency); owner's cost; working capital; and costs incurred during industrial plant commissioning and start-up. The Activated Carbon plant operating costs analysis covers operating expenses, including variable costs like raw materials and utilities, and fixed costs such as maintenance, labor, and depreciation.
Process Schematic
The process under analysis comprises two major sections: (1) carbonization; and (2) steam activation.
* Carbonization. Initially, coal is pulverized, briquetted and crushed to an appropiate particle size. The coal fragments are then stabilized by means of a pre-oxidizing step with air for further preventing the fluid phase from occurring during carbonization. The pre-oxidized coal is heated in a rotary kiln, under an inert atmosphere of nitrogen, in such a way that non-carbonaceous material – elements such as hydrogen and oxygen – is volatilized and eliminated from the precursor.
* Steam activation. In a fluidized-bed reactor, the char (devolatilized coal) is activated by reaction with steam at a temperature of 900–1,100 °C under controlled atmosphere. The activation promotes the elimination of volatile components and the simultaneous oxidation of the outer surface of the char, forming active sites. The gas escapes from the charcoal, leaving behind pores in the carbon solid. Air is also fed to the reactor, for the combustion of the carbon monoxide and hydrogen formed during activation. Carbon monoxide and hydrogen are converted to steam and carbon dioxide. Then the activated carbon is cooled to ambient temperature by indirect cooling, and then ground into powder of specified mesh size. At this point, the finished powdered activated carbon is directed to a packing system.
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Production Process Information
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Production Process Information
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Production Costs Datasheet
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Operating Cost Details
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Production Process Information
Process Consumptions
Labor Requirements
Plant Capital Cost Summary
Operating Cost Summary
Production Costs Datasheet
Plant Capital Cost Details
Operating Cost Details
Plant Cost Breakdowns
Plant Capacity Assessment
Process Flow Diagrams
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Content Highlights
Plant Capital Cost Summary
Summary outlining the capital cost required for building the Activated Carbon production plant examined
Plant Capital Cost Details
Detailing of fixed capital (ISBL, OSBL & Owner’s Cost), working capital and additional capital requirements
Plant Cost Breakdowns
Breakdown of Activated Carbon process unit (ISBL) costs and infrastructure (OSBL) costs; plant cost breakdown per discipline
Operating Costs Summary
Summary presenting the operating variable costs and the total operating cost of the Activated Carbon production plant studied
Operating Cost Details
Detailing of utilities costs, operating fixed costs and depreciation
Plant Capacity Assessment
Comparative analysis of capital investment and operating costs for different Activated Carbon plant capacities
Production Process Information
Block Flow Diagram, descriptions of process unit (ISBL) and site infrastructure (OSBL)
Process Consumptions
Raw materials and utilities consumption figures, by-products credits, labor requirements
Process Diagrams
Process flow diagrams (PFD), equipment list and industrial site configuration
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