Complete Production Line
A complete production line links crushing and screening, carbonisation, activation, cooling/conveying and packing into one continuous flow. What you buy is the ability to produce tonnes of finished carbon — not a single kiln. The measure of a line is whether the stages balance and whether heat closes on itself. Capacity matching The activation kiln sets the rating; upstream and downstream carry margin: crushing/screening at 1.5×, carbonisation at 1.2×, cooling and packing at 1.3×. For 1 t/h of product: 1.5 t/h crushing, 1.2 t/h carbonisation feed, 1 t/h activation, 1.3 t/h packing. Energy basis (1 t/h coconut-shell line, measured) 267 kW installed, 208 kW running, about 210 kWh per tonne of product; 284 Nm³ of natural gas equivalent per tonne for activation steam; 375 kgce/t overall. The waste-heat boiler raises 1.8 t/h of steam, all consumed on site — no purchased steam. This single item sets the floor on operating cost; a poorly designed heat-recovery section costs 300–500 CNY more per tonne. Footprint The activation unit alone is 24×10 m; the full line with raw-material shed, carbonisation area and finished-goods store needs 45×18 m, with 8–9 m clear height at the carboniser feed end. Three common mistakes Comparing kiln prices instead of the plant mass balance; ignoring feed moisture (12% vs 25% doubles the dryer heat load and breaks heat self-balance); and specifying dust collection to the minimum environmental standard — activated-carbon dust is conductive and hygroscopic and destroys ordinary filter bags within three months.
