3000 t/a Rotary Activation Furnace New Build for a Coconut-Shell Activated Carbon Plant
Activated Carbon Production
Background
A coconut-shell activated carbon producer planned a new 3000 t/a rotary activation furnace line using carbonized coconut shells, requiring iodine value 950-1100 mg/g, stable activation yield, continuous operation, low energy consumption and compliant emissions, while leaving room for capacity expansion.
Specifications
| Item | Value |
|---|---|
| Capacity | 3000 t/a |
| Raw material | Carbonized coconut shell |
| Iodine value | 950-1100 mg/g |
| Main equipment | HRS rotary activation furnace |
| Activation temperature | 850-1000 C |
| Refractory | High-alumina castable + insulation |
| Emission control | Off-gas combustion + heat recovery + dedusting |
Solution
Songrui delivered an HRS rotary activation furnace (2.2 m diameter, 9 m effective length) with feeding, discharging and off-gas treatment systems. The rotary furnace uses zone temperature control and constant-speed rotation so the carbonized material is mixed evenly; steam and CO2 are injected per zone. The shell is cast with high-alumina castable plus lightweight insulation to reduce heat loss.
Milestones: foundation and fabrication (months 1-2), installation (month 3), single-machine test (month 4), drying and commissioning (months 5-6), acceptance (month 7).
Results
| Indicator | Target | Actual |
|---|---|---|
| Capacity | 3000 t/a | Achieved |
| Iodine value | 950-1100 mg/g | 980-1050 mg/g |
| Activation yield | >=42% | 45% |
| Unit energy | - | About 15% lower than Slep furnace |
| Emissions | Compliant | Better than standard |
Customer feedback: stable continuous operation, energy and emission targets met, providing a reliable basis for future expansion.