Activated Carbon Manufacturing Plant

Features

Coconut char-coal is fed with a constant flow to the first hearth (No.1) of the multiple hearth furnace. The multiple hearth furnace consists of a steel shell which is refractory lined and has refractory made hearths. the movement of the material through the furnace is regulated by the rabble teeth, supported by rabble arms, which are attached drive mechanism. In order to withstand the high temperatures of up to 1000?? the rabbling system is cooled by air, supplied by a cooling air fan. The heated cooling air leaves the furnace top through the hollow centre shaft, from where a part of the hot cooling air can be recycled to the burner system for further use as combustion air. The design of the furnace permits an excellent gas-solid contact and exposure of large areas of solids to the gases. The hearths are designed alternatively as"IN"-hearths and "OUT"-hearths. The first hearth(No.1) is an "OUT"-hearth where material is fed inner the furnace at its periphery. It is then ploughed spirally across the hearth and drops through the "IN"-drop holes to hearth No.2 The material is then rabbled to the inside, until it falls through the "IN"-drop hole to hearth No.3 This pattern is repeated until the product is discharged from the bottom hearth.

Description of Major Equipment

Carbon Activation Furnace
The furnace has 9 hearths, with an outside diameter of 5,100mm. The steel shell encloses insulation and refractory materials. The furnace is designed for continuous operation to 1,000°C. with occasional temperature overshoots to 1,100°C, For long furnace life, it will be best if maximum temperature be maintained below 950°C.

Center Shaft, Rabble Arms and Teeth
The center shaft is constructed of heat resistant cast iron. The center shaft sections are constructed with male and female machined joints which are bolted together in accurate alignment.
The rabble arms are constructed of chrome-nickel alloy castings. Each hearth has four rabble arms. The rabble arms are inserted into sockets in the central shaft and are locked in place by heat resisting pins. The rabble arms and are removable through the furnace temperatures. The central shaft is covered with 75mm thickness of castable insulation to it from high furnace temperatures.

The rabble teeth and spacers are constructed of high temperature heat resisting chromium-nickel iron alloy castings. The rabble teeth slide on a groove in the bottom of each of each arm and are readily removable.
The center shaft is supported by a step bearing on the bottom and is guided at the top by a sleeve bearing which can be adjusted for alignment.
As the center shaft turns and rabble arms rotate, the rabble teeth are arranged to transfer the carbon out-flow on the odd-numbered hearths and in-flow on the even-numbered hearths. In this manner the carbon is moved down through the furnace and the activated carbon is discharged from hearth #9 through the outlet nozzle.

Center Shaft Drive
The center shaft drive consists of a totally enclosed 5 HP motor turning at 1750 RPM, 380 volt, 3 phase, 50 cycle. Included is a Foote Bros. speed reducer with a 120:1 speed reduction with a V-belt drive with speed reduction. The furnace shaft speed will be approximately 1 RPM. This shaft speed is correct for the rated furnace capacity of between 700 kg/hour virgin carbon. If at some future time it is desired to go to a substantially greater carbon throughput, then the V-belts on the input to the speed reducer may be changed so that the shaft is speeded up.
Conversely, if it is determined to activation at extremely low rates, then the shaft can be slowed down by replacing the V-belt drive. The shaft must turn fast enough so that the carbon is rabble through the furnace and does not build up the full depth of the teeth and in front of the arms. It must turn slow enough so that the entire hearth area.

Center Shaft Cooling Air Fan
The purpose of the cooling air fan is to provide cooling air for the shaft and arms in order to protect them from the high gas phase temperatures inside the furnace.
Therefore, the cooling air fan must be operating at all times that the furnace is at operating temperature. The cooling air fan is driven by a 50 HP, 1750RPM motor and should provide adequate cooling air so that the cooling air exhaust temperature at the top of the shaft does not exceed 150°C.

Combustion Burners
Fourteen(14) Korea Mfg. PLB-3 model light oil fuel burners rated at 14.2 ??H of air each with 600 mmAq air pressure at the burner are provided on this furnace.
When fired stoichiometrically, each burner has an output of 115,000 ??H on either light oil. This capacity is sufficient to provide the total heat requirements for activation of all carbon with a substantial safety factor and in addition, to heat all of the products combustion and water vapor to be exhausted to a temperature of 700°C.
The purpose of the burner system is to provide auxiliary heat to activate and dry the carbon, to provide heat for warming the furnace preliminary to operation, and to provide heat for standby service in the event that it is desired to keep the furnace in readiness for future operation.
Burners are provided with low pressure gas pilots complete with electric ignition equipment. Each burner has an interrupted type pilot.
The air-fuel ratio is adjusted by the setting of the sensitrol valve on the end of the burner. Please note that this sensitrol valve has a pointer on its calibrated dial. This pointer will be set during start-up to give the proper air-fuel ratio. Therefore, the sensitrol valve handle movable pointer should point exactly at the stationary pointer when in normal operation. During burner start-up, you will find it desirable to set the sensitrol valve to a somewhat higher number until the burner is warmed up. Then in normal operation if there is a special condition where you wish to operate the burner slightly more lean or more rich than the original setting, you should set the sensitrol valve to a lower number for a more lean mixture and to a higher number for a more rich mixture.
Each burner has 1" atomizing air connection. When firing fuel oil, this atomizing air valve should be open at all times.

When a burner is turned completely off, the atomizing air valve can be completely closed if desired but it would be preferable for the burners on hearth #9 that this atomizing air valve be left open somewhat even when the burner is turned off in order to project the burner parts from overheating.
Automatic controls are provided so that the furnace will be purged in accordance with insurance requirements requiring complete air changes of the furnace atmosphere prior to lighting the burners, Therefore a burner cannot be lit until the furnace has been suitably purged. Also inter locks are provided so that the burners must be lit on low fire.

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