Sustainable Production of Activated Carbon from Pyrolytic Chars

Sustainable Production of Activated Carbon from Pyrolytic Chars

Contents

1.0 Abstract

2.0 Introduction

2.1        Process overview

Are Paper Services Legal?

Yes, completely! They’re a valid tool for getting sample papers to boost your own writing skills, and there’s nothing shady about that. Use them right—like a study guide or a model to learn from—and they’re a smart, ethical way to level up your grades without breaking any rules.

2.3        Design constraints

2.4        Choice of equipment

3.0 Kinetic study

How Much for a Paper?

Prices start at $10 per page for undergrad work and go up to $21 for advanced levels, depending on urgency and any extras you toss in. Deadlines range from a lightning-fast 3 hours to a chill 14 days—plenty of wiggle room there! Plus, if you’re ordering big, you’ll snag 5-10% off, making it easier on your wallet while still getting top-notch quality.

4.0 Unit description

4.1         Process flow diagram

4.2         Mass balance

4.3         Energy balance

Will Anyone Find Out I Used You?

Nope—your secret’s locked down tight. We encrypt all your data with top-tier security, and every paper’s crafted fresh just for you, run through originality checks to prove it’s one-of-a-kind. No one—professors, classmates, or anyone—will ever know you teamed up with us, guaranteed.

5.0         Rate Based Equipment sizing

5.1         Fluidized bed reactor

5.2         Centrifugal Fan

5.3         Furnace

Do You Rely on AI?

Not even a little—our writers are real-deal experts with degrees, crafting every paper by hand with care and know-how. No AI shortcuts here; it’s all human skill, backed by thorough research and double-checked for uniqueness. You’re getting authentic work that stands out for all the right reasons.

5.4        Cyclone separator

6.0 Discussion of Assumptions

7.0 Optimisation

7.1 Particle diameter……………………………………………………………………………………………………..14                                                                                                                                

Why Are You Top for Research Papers?

Our writers are Ph.D.-level pros who live for nailing the details—think deep research and razor-sharp arguments. We pair that with top plagiarism tools, free revisions to tweak anything you need, and fast turnarounds that don’t skimp on quality. Your research paper won’t just shine—it’ll set the bar.

8.0 Sensitivity study

8.1 Bubble size

8.2 Superficial velocity

9.0 Mechanical design

Who’s Behind My Essays?

You’re in good hands with degree-holding pros—many rocking Master’s or higher—who’ve crushed our tough vetting tests in writing and their fields. They’re your partners in this, hitting tight deadlines and academic standards with ease, all while tailoring every essay to your exact needs. No matter the topic, they’ve got the chops to make it stellar.

9.1 Reactor Thickness

9.2 Stresses

9.2.1 Longitudinal stress and circumferential stress

9.2.2 Direct stress

Is My Paper Original?

100%—we promise! Every paper’s written fresh from scratch—no AI, no copying—just solid research and proper citations from our expert writers. You can even request a plagiarism report to see it’s 95%+ unique, giving you total confidence it’s submission-ready and one-of-a-kind.

9.2.3 Bending stress

9.2.4 Support sizing

9.2.5 Distributor

10.0 Economics

Can You Do Any Citation Style?

Yep—APA, Turabian, IEEE, Chicago, MLA, whatever you throw at us! Our writers nail every detail of your chosen style, matching your guidelines down to the last comma and period. It’s all about making sure your paper fits academic expectations perfectly, no sweat.

10.1 Equipment cost………………………………………………………..20

10.2 Operating cost………………………………………………………..20

11.0 Process control……………………………………………………….21

12.0 Safety and maintenance23

Can I Adjust Instructions Later?

Absolutely—life happens, and we’re flexible! Chat with your writer anytime through our system to update details, tweak the focus, or add new requirements, and they’ll pivot fast to keep your paper on point. It’s all about making sure the final draft is exactly what you need, no stress involved.

13.0 Design specifications……………………………………………………26

14.0 Conclusion and recomendation……………………………………………..27

15.0 References………………………………………………………….27

How Do I Get Started?

It’s super easy—order online with a few clicks, then track progress with drafts as your writer works their magic. Once it’s done, download it from your account, give it a once-over, and release payment only when you’re thrilled with the result. It’s fast, affordable, and built with students like you in mind!

1. Abstract

The motivation of this report is to detail a design to convert thermally activated pyrolytic chars to activated carbon in the most sustainable manner. Activated carbon can have high commercial value if produced to a high grade. The 170 kg/hr feed of char is incrementally fed into fluidized bed reactor heated directly by an encapsulating furnace. An overall carbon conversion of 93% is achieved through manipulation of the random pore model by introducing pore size parameter. The reacting material are designed to enter the reactor 298K and are rapidly heated to the reacting temperature 1232K. A calculated residence time of 38 minutes is found to complete the designed reaction. Through comparing different reaction mechanics and equipment choices the goal of the design is successfully achieved as Activated carbon with a BET surface area greater than 1100m2/g is produced. In addition to safety and process control, annualised costs are of extreme importance and are evaluated thoroughly on Microsoft excel, the conclusions are presented towards the conclusion of this report. This report can be used to understand this gasification reaction in a fluidized bed at a fundamental level and considered when designing a similar system to process pyrolytic char.

2. Introduction

1. process overview

Char is a solid material generally produced as a by-product in processes which heat carbonaceous substances to high temperatures. Normally, char is disposed of as waste in industrial operations. However, since the early 1990s environmental sustainability has become a significant concern across all industries. Manufacturers have taken the position to transform waste into useful products, especially those which can yield energy. Activated Carbon is one of these; it has many uses ranging from teeth whitening to filtration. Recently, its price has risen as increasingly more uses are being found for the material in the pharmaceutical industry. As a result, the engineering of activated carbon has received much attention over the last two decades (Tchoffor, Davidsson and Thunman, 2015).

As shown in the process flow diagram in figure 6 Char and oilenter a separator which segregates the solid from the oil with 100% efficiency. The heavy oils are fed to a catalytic reformer to crack the hydrocarbons into more valuable, smaller hydrocarbons. Whereas, char is fed to a heated fluidized bed reactor. The bed is supplied with pre-heated CO₂ (purity 99.9%) a product of syngas combustion which acts as a gasification agent, the high CO₂ purity improves conversion.  CO₂ reacts with carbon in an endothermic reversible reaction shown in the reaction scheme considered in part 3.0. The activated carbon product is then collected and prepared for sale (Molina-Sabio, González and Rodrı́guez-Reinoso, 2004). There is still considerable uncertainty with regard to profitability of carbon activation processes, therefore a detailed economic evaluation is completed and evaluated in 10.0to establish an overall cost

How Fast for Rush Jobs?

We can crank out a killer paper in 24 hours—quality locked in, no shortcuts. Just set your deadline when you order, and our pros will hustle to deliver, even if you’re racing the clock. Perfect for those last-minute crunches without compromising on the good stuff.

Reactor conditions determine the conversion. 100% conversion is targeted however; conversion is coupled with residence time. Longer residence times at elevated temperatures causes fragmentation of carbonaceous material. Conversely, time determines the development of pores in the solid. Through comprehensive comparative kinetic study optimal process criterion were found. This led to an achievement 93% carbon conversion.  Approaches to scale up these findings are addressed at a later stage of this report.

The extensive literature survey on present research revealed that research is more focused on verification that the process is practicable at laboratory level. Few engineers have attempted to scale-up the process to show economic performance at an industrial level which is put down to lack of understanding of the reaction kinetics and hydronamic fluidized bed behaviour work together to produce a commercial grade activated carbon. However, the Office of coal research and American oil company have showed successful industrial operation (Office of coal Research, 1962).

2. Design objectives

The principal objective of this report is to outline a detailed design for a fluidized bed reactor which will process pyrolytic char to make the highest amount possible of commercial grade activated carbon. In industry, high product manufacture may not always be ideal because of factors such as; sustainability, safety and cost. Process engineers take these factors into account and seek to optimize operation and select instruments thus an economically worthwhile process can be developed. Through the iterative technique of optimisation and investigation of hydronamic behaviour of the fluidized bed coupled with an enquiry into process control and safety this report will provide a comprehensive demonstration of the use of fluidized beds in industry to make activated carbon.

3. Design constraints

Temperature constrains the reaction. Temperature drives the reaction, determines conversion and the rate of reaction however, hinders pore formation if heated too high. A maximum temperature of 1473K constrains the reaction as this would begin causing pores to collapse. Further research into the effect of temperature on the reaction kinetics found that at temperatures above 1223K the rate constant changes at a slower rate than is predicted by Arrhenius’s law (Lee and Kim, 1996).

As fluidized bed reactors are often quite long in vertical height therefore the plant height constrains the design. In the case that the vertical height exceeds that of a plant fluidized beds may be placed outside which exposes the reactor to the effects of adverse weather and external damage.

Can You Handle Complex Subjects?

For sure! Our writers with advanced degrees dive into any topic—think quantum physics or medieval lit—with deep research and clear, sharp writing. They’ll tailor it to your academic level, ensuring it’s thorough yet easy to follow, no matter how tricky the subject gets.

The conversion of the char particle is a constrained by its composition. Although the char is postulated to contains 100% carbon, some of the carbon is present in char in the form of ash. This ash does not react with CO­2 it is instead further burnt by the hot temperatures and collected at the solid exit of the reactor.

4. Choice of equipment

Traditionally, carbonaceous material is thermally activated using fixed bed reactors. Extensive literary research of recent developments in the field of gasification reactors oppose the usage of fixed beds. A lack of understanding of fluidized bed standardised fixed bed employment in industry. This section will provide justification for the design decisions made, comparing circulating and bubbling fluidized bed (BFB) configurations. The circulating fluidized bed (CFB) was considered however, the  conclusions demonstrated in figure 1 justified its rejection.

Fluidized beds can perform both activation and gasification of the carbonaceous material. Solid particles are fed into the reactor and the gasification fluid from the bottom. The incoming fluid forces the reactor bed to operate as if it were a fluid. In this case, a uniform particle mixing is achieved, coupled with the expulsion of radial and axial concentration gradients a promotion of higher degrees of gas-solid contact is attained. The increased contact improves the extent of activation achieved and consequently increases the surface area of micro and mesopores of the material accessible through CO₂ adsorption. A pitfall of CFB reactors is the formation of concentration gradients along the length of the reactor, which may cause considerable temperature gradients. In industry, gradients catalysts often eliminate these gradients. The proposed catalytic activity is somewhat complex and lacks the research to be replicated for this process.

Good temperature distribution eliminates hot spots and improves heat exchange contributing to the high thermal efficiency displayed by fluidized bed reactors.  Although CFB reactors exhibit high heat transfer, it is found to increase with increased fluid superficial velocity, as well as solid circulation rate. Thus, increasing fixed cost is a major drawback of using this technique. Furthermore, CFB are generally much larger than BFB in industry. Findings of a wall – to-suspension heat transfer investigation by figure1suggests, that assuming the same material is used for both reactors, the influence of increased reactor length increases surface area. Subsequently, leading to higher energy requirement.

CFB’s are more expensive to install and maintain than BFB. Assuming of identical conversion in both beds, the relatively small feedstock promotes BFB usage. But, future scale up would advocate usage of a circulating fluidized bed because the low velocities adopted in the bubbling regime will not be able to fluidize large masses efficiently.

How Do You Meet Prof Standards?

We stick to your rubric like glue—nailing the structure, depth, and tone your professor wants—then polish it with edits for that extra shine. Our writers know what profs look for, and we double-check every detail to make sure it’s submission-ready and grade-worthy.