Activated Carbon Production from Coconut Shell (Steam Activation)
Activated Carbon Production Costs Report | Issue A | Q3 2024
Report Details |
15 kta United States-based plant | Q3 2024 | 107 pages |
This report presents a cost analysis of a 15 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 report presents the economics of a typical steam activation process for Powdered Activated Carbon production from coconut shell in the United States. In the process examined, the coconut shells are crushed and then carbonized into a charcoal, which is activated by steam at high temperatures. The Activated Carbon is ground into powder of specified mesh size.
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, coconut shells are fed to a crusher, where the size of the shell is reduced. The crushed material is fed to a flash dryer for removal of moisture, and then fed to a rotary kiln to be carbonized: the shell fragments are heated under nitrogen, in such a way that non-carbonaceous material – elements such as hydrogen and oxygen – is volatilized and eliminated from the precursor. Carbonization produces charcoal with bio-oil vapors, steam, and incondensable gases as by-products. At this point, a carbon skeleton possessing a latent pore structure is formed. Oils and tars separated as by-product are used for fuel.
Steam Activation. In a fluidized bed reactor, the charcoal 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, 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, to steam and carbon dioxide. Then the activated carbon is passed through a sequence of steps in which it is cooled and ground to the desired particle size. The activated carbon is cooled to ambient temperature by indirect cooling, and then ground into powder of specified mesh size. At this point, powdered activated carbon is obtained and directed to Packing.
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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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Details: 25 kta United States-based plant | Q3 2024 | 107 pages | Issue B From $799 USD
The cost analyses presented in this report target a 25 kta (kilo metric ton per annum per annum) United States-based plant. For those interested in cost analyses considering other plant capacities and/or locations, Intratec offers a customized analysis as an optional feature.
Activated Carbon Production from Coconut Shell (Chemical Activation)
This study approaches an economic analysis of a typical chemical activation process for Powdered Activated Carbon production from coconut shell in the United States. Phosphoric acid is used as chemical activation reagent. Activation is carried out concomitantly with carbonization, in a rotary kiln.
Details: 20 kta United States-based plant | Q3 2024 | 107 pages | Issue C From $799 USD
The cost analyses presented in this report target a 20 kta (kilo metric ton per annum per annum) United States-based plant. For those interested in cost analyses considering other plant capacities and/or locations, Intratec offers a customized analysis as an optional feature.
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Other Related Production Cost Reports
Activated Carbon Production from Coconut Shell (Chemical Activation)
This study approaches an economic analysis of a typical chemical activation process for Powdered Activated Carbon production from coconut shell in the United States. Phosphoric acid is used as chemical activation reagent. Activation is carried out concomitantly with carbonization, in a rotary kiln.
Details: 20 kta United States-based plant | Q3 2024 | 107 pages | Issue C From $799 USD
The cost analyses presented in this report target a 20 kta (kilo metric ton per annum per annum) United States-based plant. For those interested in cost analyses considering other plant capacities and/or locations, Intratec offers a customized analysis as an optional feature.
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