Question 1

What temperature is used for carbonization?

Accepted Answer

Carbonization temperature is typically 400-600℃ depending on the feedstock. Coal-based materials require higher temperatures (500-600℃), while wood and shell materials need lower temperatures (400-500℃). Songrui rotary carbonization furnaces feature zoned temperature control for flexible adjustment.

Question 2

How is steam flow controlled during activation?

Accepted Answer

Steam is the core activation medium, and its flow rate directly affects pore development. The typical steam-to-char ratio is 0.8-1.5 times the carbonized material mass per hour. Songrui activation furnaces are equipped with steam flow meters and automatic control systems for stable regulation.

Question 3

How is residence time calculated for rotary activation furnaces?

Accepted Answer

Residence time is determined by drum length, tilt angle, and rotation speed, typically 30-90 minutes. Songrui uses variable-speed drives for flexible adjustment based on feedstock and target iodine value.

Question 4

What is the heating curve for Slep furnace drying?

Accepted Answer

The Slep furnace heating follows a strict curve: 10-15℃/h from room temperature to 200℃, 8-10℃/h to 400℃, 5-8℃/h to 600℃, then holding for 24-48h. Total cycle is 7-12 days. Songrui provides complete heating curve design and on-site guidance.

Question 5

How does carbonized material moisture affect activation?

Accepted Answer

Moisture should be controlled below 5%. Excess moisture consumes heat for evaporation, lowers activation zone temperature, and increases energy consumption. Songrui can integrate drying stages into production line designs.

Question 6

What preparations are needed before furnace ignition?

Accepted Answer

Pre-ignition checks include: furnace sealing inspection, combustion system verification, flue gas system check, instrument calibration, and refractory inspection. Songrui provides a complete ignition checklist upon delivery.

Question 7

How often should the rotary furnace shell be inspected?

Accepted Answer

External inspection every 3 months for deformation, cracks, and overheating marks. Annual internal inspection during shutdown to check refractory lining wear and measure shell thickness. Songrui offers periodic inspection services.

Question 8

What is the replacement cycle for Slep furnace refractory bricks?

Accepted Answer

Refractory bricks in the activation zone typically last 2-3 years under normal conditions. Signs for replacement include abnormal outer wall temperature rise, gas leakage, or iodine value instability. Songrui manufactures its own saddle-shaped bricks for fast supply.

Question 9

How often should furnace seals be replaced?

Accepted Answer

Rotary furnace head/tail seals are typically replaced every 6-12 months. Aging seals cause gas leakage, increased energy consumption, and atmosphere loss. Songrui uses high-temperature resistant seal materials for easy replacement.

Question 10

What are the maintenance points for carbonization furnace flue gas systems?

Accepted Answer

Weekly flue cleaning, monthly fan inspection, quarterly filter replacement, annual instrument calibration, and regular desulfurizer replenishment. Songrui provides complete maintenance guidance.

Question 11

How to maintain rotary furnace rollers?

Accepted Answer

Roller maintenance includes: daily bearing temperature checks (<60℃), monthly wear inspection, quarterly thrust roller adjustment, and annual grease replacement. Songrui provides detailed lubrication manuals.

Question 12

What are the burner maintenance considerations?

Accepted Answer

Weekly nozzle cleaning, monthly filter inspection, quarterly flame detector calibration, annual refractory nozzle brick inspection. Songrui uses branded burners with widely available parts.

Question 13

What after-sales services does Songrui provide?

Accepted Answer

Songrui offers full lifecycle services: installation guidance, furnace drying and production ramp-up, operator training, warranty repairs, periodic inspections, 24/7 remote support, and spare parts supply. Based in Gongyi, Henan for fast nationwide response.

Question 14

How long is the installation and commissioning period?

Accepted Answer

Installation takes 30-45 days for a single furnace, 60-90 days for a complete production line. Songrui provides detailed installation schedules with milestone acceptance at each stage.

Question 15

Can you provide operator training?

Accepted Answer

Yes. Songrui provides on-site training during commissioning, covering equipment principles, operation procedures, troubleshooting, maintenance, and safety. Training certificates are issued upon completion.

Question 16

What is the spare parts supply lead time?

Accepted Answer

Standard parts (seals, bearings, valves) ship in 3-7 days. Custom parts (refractory bricks, drum sections) take 15-30 days. Songrui can provide recommended spare parts lists.

Question 17

How long is the warranty period?

Accepted Answer

Songrui provides a 12-month warranty from acceptance. Manufacturing defects are repaired or replaced free of charge. Consumables are excluded but supplied at cost. Annual maintenance contracts are available post-warranty.

Question 18

Can I replace only the activation furnace in an existing line?

Accepted Answer

Yes. Songrui assesses existing production lines and can replace only the activation furnace. We evaluate compatibility with existing equipment and provide investment estimates and expected capacity improvements.

Question 19

What is the difference between activation furnace and carbonization furnace?

Accepted Answer

A carbonization furnace pyrolyzes raw materials into charcoal under oxygen-deficient conditions (first stage); an activation furnace reacts the charcoal with steam at high temperature to develop pores and produce activated carbon (second stage). They work together: carbonization first, then activation.

Question 20

What feedstocks suit the rotary activation furnace?

Accepted Answer

The rotary activation furnace accepts a wide particle size range and suits continuous activation of coal-based, wood-based and shell charcoals, especially for large-scale production.

Question 21

How to choose between Slep furnace and rotary furnace?

Accepted Answer

Choose the Slep furnace for high-iodine shell-based granular carbon with low steam cost; choose the rotary furnace for continuous, high-capacity production with mixed feedstocks. We can provide investment and energy comparison.

Question 22

What equipment is needed for a new activated carbon line?

Accepted Answer

Mainly: crushing & screening, carbonization furnace, activation furnace, combustion & heating system, dedusting & desulfurization system, and finished product screening & packaging. We offer turnkey solutions.

Question 23

What if my old activation furnace consumes too much energy?

Accepted Answer

Retrofit options include insulation upgrade, combustion system retrofit, waste heat recovery and automation upgrade, which usually cut energy consumption notably. We provide on-site diagnosis.

Question 24

How often should furnace refractories be replaced?

Accepted Answer

Depending on furnace type and operation, activation-zone refractories typically need inspection or partial replacement every 1-3 years. Regular inspection and proper drying extend life. We offer inspection and replacement services.

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