Activated carbon and energy production system

Abstract

The invention provides a system, which enables the uninterrupted single-step production of high quality activated carbon from apricot kernel shells, olive pits, almond kernels and shells, walnut shells, peach kernels and shells, hazelnut shells, pistachio shells, sour cherry pits, cherry pits, date pits or olive pomace, etc, and which can also produce more energy compared to the energy it consumes through energy recovery, does not harm the environment and nature as it performs the carbonization process in a controlled manner and provides negative carbon emission.

Description

[0001] ACTIVATED CARBON AND ENERGY PRODUCTION SYSTEM

[0002] Technical Field

[0003] The invention relates to a system for producing activated carbon using woody biomass.

[0004] State of the Art

[0005] Activated carbon is a structure obtained by carbonization of fossil-derived and biomass structures, then increasing the surface area and performing activation. Activated carbon is an adsorbent structure due to the high surface area thereof. For this reason, activated carbon is used in various fields, particularly in filtering applications.

[0006] Activated carbon structures are also prone to react with different substances as they contain activated carbon. For this reason, not only physical filtration but also chemical filtration processes can be performed using activated carbon structures. Therefore, activated carbon is used in various fields such as pharmaceutical and food industry, particularly in liquid and gas treatments. In order to produce activated carbon, biomass structures must first be heated and carbonized. Then, the obtained carbon form must be chemically or physically activated.

[0007] In the applications in the present art, said activation process is carried out physically with steam and by using various chemicals. However, in case of chemical activation, due to the adsorbent structure of activated carbon, some of the chemicals used in the activation process may remain in the activated carbon after the activation process. This reduces the reliability as well as the absorbing performance of the resulting activated carbon. On the other hand, activated carbon manufacturing from biomass is generally carried out using coconut shells in current applications, and uninterrupted / single-step production cannot be achieved. Activated carbon is obtained by batch production in stages, firstly by a carbonization process and then by an activation process in split processes. This increases the total production time, reduces the product output efficiency, and increases the energy production costs. Therefore, in the state of the art, there is a need for a system that enables the activation process for activated carbon without any chemicals by uninterrupted production, with increased output and minimized energy costs. Another example of the state of the art is the document No. CN 101962184. Said document relates to a method for the preparation of activated carbon by a mechanicalchemical method. Said method comprises the process steps of placing a dried carbon source material in a pure auxiliary solution to be uniformly mixed and wetted, grinding the material in grinding equipment, subjecting it to thermal treatment, and washing the treated material with hydrochloric acid solution and deionized water, and transferring the material to a drying furnace to be dried after water washing.

[0008] As a result, the aforementioned problems and the shortcomings of the existing solutions have made it necessary to make a development in the relevant technical field.

[0009] Object of the Invention

[0010] The present invention relates to an activated carbon and energy production system for eliminating the aforementioned disadvantages and providing new advantages to the relevant technical field.

[0011] The main object of the invention is to provide a system for the carbonization of woody biomass without the use of chemicals, followed by activation with water vapor in the same furnace without interruptions.

[0012] The objective of the invention is to provide a system which enables the production of high quality activated carbon without interruptions in a single-step process as the activation process is carried out without the use of chemicals, which can produce more than the energy it consumes through energy recovery, which does not harm the environment and nature as it carries out the carbonization process in a controlled manner and which provides negative carbon emission.

[0013] Another objective of the invention is to provide a system for transforming any woody biomass into activated carbon.

[0014] Another objective of the invention is to provide a system which ensures energy efficiency as it produces its own energy by collecting the gases generated in the pyrolysis stage, in which woody biomass is transformed into carbon in the rotary kiln, to be used in steam production and using the obtained steam for the activation of the carbon obtained in the rotary kiln and also for the production of electricity.

[0015] Another object of the invention is to provide a system in which woody biomass is fed into the system in a continuous production cycle and the carbonization and activation processes are performed for 24 hours within the same production line in a single uninterrupted step to produce activated carbon and electrical energy.

[0016] Another objective of the invention is to provide a system which enables production in three integrated atmospheric environments, including carbonization in the rotary kiln, activation with steam in the rotary kiln and cooling processes within the same system.

[0017] The structural and characteristic features and all advantages of the invention will be more apparent from the following figures and the detailed description with reference to these figures. Therefore, the interpretation should be based on these figures and the detailed description.

[0018] Figures to Understand the Invention

[0019] Fig. 1 : A perspective view of the activated carbon production system according to the invention.

[0020] Description of Part References

[0021] 10. Raw material inlet unit

[0022] 20. Conveyor

[0023] 30. Separator

[0024] 40. Crusher

[0025] 50. Pipe conveyor

[0026] 60. Raw material silo

[0027] 70. Rotary kiln

[0028] 80. Combustion chamber

[0029] 90. Gas transmission pipe

[0030] 100. Steam generator

[0031] 110. First steam transmission pipe 120. Second steam transmission pipe

[0032] 130. Steam turbine

[0033] 140. Cooling unit

[0034] 150. Product outlet conveyor

[0035] 160. Product silo

[0036] 170. Sieving conveyor

[0037] 180. Sieve

[0038] 190. Packaging unit

[0039] 200. PLC control unit

[0040] Detailed Description of the Invention

[0041] In this detailed description, the preferred alternatives of the activated carbon and energy production system according to the invention are described solely for the purpose of a better understanding of the subject matter and without any limiting effect.

[0042] Fig. 1 shows a perspective view of the activated carbon and energy production system according to the invention. Accordingly, the activated carbon and energy production system essentially comprises: a raw material inlet unit (10) allowing woody biomass to enter the system, a conveyor (20) for conveying the woody biomass entering the raw material inlet unit (10), a separator (30) located on the conveyor (20) and separating the foreign matter in the woody biomass, a crusher (40) located at the end of the conveyor (20) and crushing the woody biomass conveyed by the conveyor (20) to the desired size, a pipe conveyor (50) for conveying the woody biomass sized by crushing in the crusher (40), a raw material silo (60) storing woody biomass conveyed by the pipe conveyor (50), a rotary kiln (70) for transforming the woody biomass stored in the raw material silo (60) into carbon without burning at high temperature and producing activated carbon by the activation process using water vapor after the carbonization process, a combustion chamber (80) connected to the rotary kiln (70) by means of a gas transmission pipe (90), and collecting the syngas generated during the carbonization process carried out in the rotary kiln (70), a steam generator (100) for generating water vapor with syngas collected in the combustion chamber (80) and transmitting water vapor to the rotary kiln (70) via a first steam transmission pipe (110) for the activation process, a steam turbine (130) connected to the steam generator (100) via a second steam transmission pipe (120) and generating electrical energy with the excess water vapor generated in the steam generator (100) and delivering part of this energy to the electricity grid and part to the rotary kiln (70), a cooling unit (140) connected to the rotary kiln (70) and cooling the activated carbon in the rotary kiln (70), a product outlet conveyor (150) conveying the activated carbon cooled in the cooling unit (140), a product silo (160) storing the activated carbon conveyed by the product outlet conveyor (150), a sieving conveyor (170) conveying the activated carbon in the product silo (160), a sieve (180) for separating the activated carbon in the sieving conveyor (170) by size, a packaging unit (190) for packaging the activated carbon separated by size by the sieve (180), a PLC control unit (200) for controlling and managing the operating regime of the activated carbon production system.

[0043] The woody biomass transformed into activated carbon in the activated carbon and energy production system according to the invention may be biomass with hard structures such as apricot kernel shells, olive pits, almond kernels and shells, walnut shells, peach kernels and shells, hazelnut shells, pistachio shells, sour cherry pits, cherry pits, date pits or olive pomace.

[0044] The woody biomass enters the system through the raw material inlet unit (10) located at the inlet of the activated carbon production system. At least one conveyor (20) is connected to the raw material inlet unit (10). Said conveyor (20) conveys the woody biomass entering the raw material inlet unit (10). On the conveyor (20), there is provided at least one separator (30) for separating foreign matter in the woody biomass. Said separator (30) may preferably be a magnet for separating metal foreign matter.

[0045] At least one crusher (40) is provided at the end of the conveyor (20). Said crusher (40) crushes the woody biomass conveyed by the conveyor (20) to the desired size. The crusher (40) includes removable blades for crushing different types of woody biomass to the desired size.

[0046] At least one pipe conveyor (50) is connected to the end of the crusher (40). Said pipe conveyor (50) conveys the woody biomass which is crushed and sized in the crusher (40). The other end of the pipe conveyor (50) is secured to at least one raw material silo (60). The raw material silo (60) stores the woody biomass, which is conveyed by the pipe conveyor (50). A rotary kiln (70) with rotary movement is associated with the raw material silo (60). Said rotary kiln (70) is heated to a temperature of 650-1000 °C by means of an electric heater. The rotary kiln (70) enables transforming the woody biomass stored in the raw material silo (60) into carbon by heating at high temperature without burning and producing activated carbon by the activation process using water vapor after the carbonization process.

[0047] In the activated carbon and energy production system according to the invention, firstly, the woody biomass stored in the raw material silo (60) is heated to be transformed into carbon at a high temperature without burning in the rotary kiln (70), which is brought to a temperature of 650-1000 °C by means of an electric heater. During this process (carbonization) syngas is released. At least one combustion chamber (80) is connected to the rotary kiln (70) by means of a gas transmission pipe (90) so that said syngas can be directly used in generating water vapor without being discharged into the atmosphere. The syngas released during the carbonization process in the rotary kiln (70) is transmitted to the combustion chamber (80) via the gas transmission pipe (90) and collected in the combustion chamber (80).

[0048] A steam generator (100) is placed on the rotary kiln (70) for producing water vapor with the syngas collected in the combustion chamber (80), and said steam generator (100) is connected to the rotary kiln (70) by means of a first steam transmission pipe (110). The steam generator (100) generates water vapor at a temperature of 150-300 °C with the syngas collected in the combustion chamber (80) and transmits the water vapor to the rotary kiln (70) for the activation process via the first steam transmission pipe (110). After the carbonization process, the activation process is applied by means of the water vapor transmitted to the rotary kiln (70) and the woody biomass is transformed into activated carbon.

[0049] The steam generator (100) has to generate water vapor for the activation process in the rotary kiln (70). Here, only a part of the generated water vapor is sufficient for the activation process. The remaining water vapor is used to generate electrical energy in the system according to the invention. Accordingly, a steam turbine (130) is connected to the steam generator (100) by means of a second steam transmission pipe (120). The steam turbine (130) generates electrical energy with the excess water vapor generated in the steam generator (100) and delivers part of this energy to the electricity grid and part to the rotary kiln (70). The electrical energy transmitted to the electricity grid is used in the facility in which the activated carbon and energy production system according to the invention is located or elsewhere. The electrical energy transmitted to the rotary kiln (70) is used in the electric heater for heating the rotary kiln (70) and the electrical energy requirement of the total system is completely met.

[0050] At least one cooling unit (140) is connected to the rotary kiln (70) for cooling the activated carbon obtained after the carbonization process by high temperature combustion in the rotary kiln (70) followed by the activation process by water vapor. Said cooling unit (140) cools the activated carbon in the rotary kiln (70) to a temperature of 60-120 °C with cold water. The cooling unit (140) is tubular and cold water is passed through the outer wall of the pipe to cool the activated carbon.

[0051] At least one product outlet conveyor (150) is connected to the cooling unit (140) for conveying the activated carbon cooled in the cooling unit (140). The product outlet conveyor (150) conveys the activated carbon cooled in the cooling unit (140) to the product silo (160). The product silo (160), located at the outlet end of the product outlet conveyor (150), stores the activated carbon. The activated carbon stored in the product silo (150) is conveyed to the packaging unit (190) by means of at least one sieving conveyor (170) connected to the product silo (160). The sieving conveyor (170) is provided with at least one sieve (180) for separating the activated carbon by size. Activated carbon, which is separated by size with the sieve (180), is packaged in the packaging unit (190) positioned below the sieve (180).

[0052] The activated carbon production system according to the invention is controlled and managed via the PLC control unit (200). By means of said PLC control unit (200), the temperature and rotation speed of the rotary kiln (70) and the steam pressure parameters in the steam generator (100) are adjusted in the system.

[0053] In the activated carbon and energy production system according to the invention, the processes of feeding woody biomass to the rotary kiln (70) to transform the woody biomass into carbon without burning at high temperature and applying the activation process by means of water vapor are carried out without interruptions in a continuous cycle. At the same time, with the activated carbon production system according to the invention, the syngas released in the rotary kiln (70) during the production of activated carbon is burned in the combustion chamber to obtain heat, and water vapor is produced in the steam generator (100) with this heat, and electrical energy is produced in the steam turbine (130) from the water vapor produced. Part of the steam produced in the steam turbine (130) is delivered to the electricity grid and part to the rotary kiln (70). The electrical energy transmitted to the electricity grid is used in the facility in which the activated carbon and energy production system according to the invention is located or elsewhere. The electrical energy transmitted to the rotary kiln (70) is used in the electric heater for heating the rotary kiln (70). Therefore, energy efficiency is also ensured by generating all of the electrical energy required for the operation of the system.

Claims

CLAIMS1. An activated carbon and energy production system for producing activated carbon using woody biomass, characterized in that it comprises:- a raw material inlet unit (10) allowing the woody biomass to enter the system,- a conveyor (20) connected to the raw material inlet unit (10) and conveying the woody biomass entering the raw material inlet unit (10),- a crusher (40) located at the end of the conveyor (20) and crushing the woody biomass conveyed by the conveyor (20) to the desired size,- a pipe conveyor (50) connected to the crusher (40) and conveying the woody biomass sized by crushing in the crusher (40),- a raw material silo (60) connected to the pipe conveyor (50) and storing the woody biomass conveyed by the pipe conveyor (50),- a rotary kiln (70) with a rotary movement heated by an electric heater, associated with the raw material silo (60) and transforming the woody biomass stored in the raw material silo (60) into carbon without burning at high temperature and producing activated carbon by the activation process using water vapor after the carbonization process,- a combustion chamber (80) connected to the rotary kiln (70) by means of a gas transmission pipe (90), and collecting the syngas generated during the carbonization process carried out in the rotary kiln (70),- a steam generator (100) for generating water vapor with syngas collected in the combustion chamber (80) and transmitting water vapor to the rotary kiln (70) via a first steam transmission pipe (110) for the activation process,- a steam turbine (130) connected to the steam generator (100) via a second steam transmission pipe (120), generating electrical energy with the excess water vapor generated in the steam generator (100) and delivering part of this energy to the electricity grid and part to the rotary kiln (70) to be used in the electric heater,- a cooling unit (140) connected to the rotary kiln (70) and cooling the activated carbon in the rotary kiln (70),- a product outlet conveyor (150) connected to the cooling unit (140) and conveying the activated carbon cooled in the cooling unit (140),- a product silo (160) connected to the product outlet conveyor (150) and storing the activated carbon conveyed by the product outlet conveyor (150),- a PLC control unit (200) for controlling and managing the operating regime of the activated carbon production system.

2. An activated carbon and energy production system according to claim 1 , characterized in that it comprises a separator (30) located on said conveyor (20) and separating the foreign matter in the woody biomass.

3. An activated carbon and energy production system according to claim 2, characterized in that said separator (30) comprises a magnet for separating metal foreign matter in the woody biomass.

4. An activated carbon and energy production system according to claim 1 , characterized in that it comprises a sieving conveyor (170) connected to said product silo (160) and conveying the activated carbon in the product silo (160).

5. An activated carbon and energy production system according to claim 4, characterized in that it comprises a sieve (180) located in said sieving conveyor (170) and separating the activated carbon in the sieving conveyor (170) by size.

6. An activated carbon and energy production system according to claim 5, characterized in that it comprises a packaging unit (190) positioned below said sieve (180) and enabling the packaging of the activated carbon separated with said sieve (180) by size.

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