Manufacturing

• We are the Largest Manufacturer, Exporter of Steam activated Coconut shell Carbon from India.
• Our Activation Capacity is 30000 TPA of medium CTC (55%).
• Pre Activation i.e Granulation (Kiln Feed) capacity is 80000 TPA.
• Value Added plant i.e Washing plant capacity is 6000 TPA

Our Raw Material

• The Raw Material Carbonized Coconut shell Charcoal is received in Bulk bags/Small Bags in trucks from the surrounding areas.
• Core carbons is gifted with 20 dedicated charcoal suppliers round the year.
• Core carbons has demarcated 12 acres (4.85 Hectare) to hold the charcoal stock. our charcoal stock holding capacity is almost 15,000 MTs at a time.
• Minimum inventory level is in the tune of 10,000 MTs.

Process Flow

Pre Activation (Granulation)

• The Coconut shell charcoal is subject to scalping screener to remove fine sand.
• Its then taken to the Demagnetizer to remove the contaminated iron particles.
• The cleaned charcoal is crushed in crushers.
• This crushed material screened thro, rotary screeners to the intended kiln feed size distribution.
• This is stored in the kiln feed storage point.

Activation

• The Sized Cleaned Charcoal material is feed to the kiln through a controlled feed mechanism.
• In the kiln the required temperature is maintained ,in controlled atmosphere.
• Being a self sustained temperature from the process, CCPL do not use fuel to raise the temperature.
• Simultaneously steam is impinched on the hot charcoal bed, water gas reaction starts.
• The residence time, steam injection and the bed movement determine the adsorption site of carbon.
• The activated carbon from the kiln is cooled and bagged in bags for further process.

Post Activation

• The cooled activated carbon is taken to the destoners were the clinkers are removed.
• The de stoned material is taken to the single stage or multistage crushers for the intend size reduction.
• Then the material is screened in the screeners for different particle size.
• The sized material is subject to magnetic drum separators , de magnetized and then taken to security screening before packing.
• In all this stages the material is de dusted by reverse pulse jet dust collector system
• The QA approved material taken to dispatch section for dispatch.

VALUE ADDED PLANT - I (Washing)

• Base carbon (Finished Product) is washed with Low Ph water and then with neutral in a mixer reactor (Food Grade Glass Fiber lined process Reactor).
• We have system to handle the following chemicals.
  • H2SO4 - Sulfuric acid
  • HCL - Hydrochloric acid
  • HNO₃ - Nitric acid
  • CH₂O₂ - Formic acid
  • CH₃COOH - Acetic acid
  • NaOH - Sodium hydroxide

• The Washed carbon is collected and allowed to Dewater.
• Then its taken to the Rotary Drier (Stainless Steel lines) to remove the moisture
• The Dried material is Demagnetized, screened and packed for Dispatched.
• The Drain out Washed water is treated in the ETP cum RO plant.
• The treated water is taken to the WHRSG for steam to be used in the process.
• The washing plant capacity is 6000 TPA

VALUE ADDED PLANT - II (Impregnation)

• We have the technical know how and the facilities for impregnation carbon of various metal/Chemicals loading such as Silver, Potassium Iodide, Sodium Hydroxide, Potassium Hydroxide , Sodium hydroxide, Phosphoric Acid, Sulphuric Acid, TEDA, Copper, Sulphur.
• Impregnation plant capacity 100 TPM .
• Consisting of State of Art
  • DCB ( Reactors)
  • Fluidized Bed Dryers
  • Tray Dryers
  • Pilot RCVD for product development
• Quality Assurance Dept consisting of
  • Atomic Adsorption Spectrometer. (AAS 7000)
  • UV Spectrophotometer
  • Turbidity Meter
  • Ag and Ammonia Leaching

VALUE ADDED PLANT - III (PAC)

• Powder Activated Carbon.
• PAC plant Capacity 200 TPM..
• The above plant produces :
  • Minus 140 (105 microns) -[95 %]
  • Minus 200 (75 microns) -[95 %]
  • Minus 325 (45 microns) -[95 %]
  • Minus 500 (25 microns) -[95 %]
  • Minus 625 (20 microns) -[90 %]

• As per customer spec. of D10 / D50 / D90.
• The Above PAC plant Comprising of
  • Micro Crushers
  • Classifiers
  • Powder Collectors
  • Dust Extractors
• Quality Assurance Dept consisting of
  • Laser Particle size Analyzer - Malvern 3000 E

VALUE ADDED PLANT - IV (CATALYTIC)

• Surface Modified Activated Carbon.

• SM plant Capacity 100 TPM
• The above plant produces grades - 4x8 Coarser to 100 x325 finer products.
• As per customer spec. of Hydrogen Per oxide Number, Hydrogen Per oxide %
• The Above SM plant Comprising of
  • Rotary Retorts
  • Nitrogen Generators
  • Nitrogen Pumping system
  • Inert Rotary Cooler
  • Ammonia Impregnation system

• Quality Assurance Dept consisting of
  • Tubular Muffle Furnace
  • Adiabatic system
• Quality Assurance Dept consisting of
  • Laser Particle size Analyzer - Malvern 3000 E