- Site Area: Approx. 6,000 – 10,000 m² (for
5,000 TPA); expandable to 18,000 m² for 30,000 TPA.
- Preferred Location: Near coconut/palm plantation;
proximity <10 km from raw material source.
- Topography: Flat to slightly sloped;
elevation control required.
- Utilities Required: Water supply (bore well or
industrial), Electricity (300–500 kW min), Drainage, Access road.
1.2 Plant Layout
(Zone Division)
- Zone A – Raw Material Receiving and
Crushing
- Zone B – Drying and Carbonization Area
- Zone C – Steam Activation and Cooling
Area
- Zone D – Screening, Pulverizing, and
Packing
- Zone E – Utilities: Boiler House,
Genset Room, Compressor Area
- Zone F – Control Room, Laboratory,
Admin Office, Workshop
- Zone G – Storage & Warehouse (Raw and Finished)
|
Facility |
Min
Distance from Property Line |
|
Kiln/Activation Unit |
15 m |
|
Crusher and Dryer |
10 m |
|
Control Room |
8 m |
|
Warehouse |
5 m |
|
Fuel Storage (if
any) |
20 m |
1.4 Material Flow
Arrangement
- Linear Flow: From biomass reception →
drying → carbonization → activation → product handling → packing.
- Avoids cross-contamination and minimizes backtracking.
- Includes dust control zoning
and natural ventilation optimization.
1.5 Safety Setbacks
and Access
- Fire Access Lane: 4.5 m minimum width all
around.
- Fire Hydrant Points: Every 50 m.
- Access for loading/unloading: 12 m wide road near warehouse.
📘
DED – Part 2: Mechanical Equipment Sizing & Layout
2.1 Main Equipment
List and Description (Capacity: 5,000 TPA)
|
No |
Equipment |
Capacity/Spec |
Qty |
Material
of Construction |
|
1 |
Biomass Crusher |
5–8 TPH |
1 |
Mild Steel / SS-304
(wear area) |
|
2 |
Storage Hopper |
5 m³ |
1 |
Carbon Steel |
|
3 |
Rotary Dryer |
1.5 ton/hr
drying capacity |
1 |
SS-304 Inner Shell |
|
4 |
Biomass Burner (Hot Gas Source) |
0.5 MMKcal/hr |
1 |
Firebrick Lined
Steel |
|
5 |
Carbonization Kiln (Rotary) |
0.5 TPH |
1 |
SS 310/316 (Inner) +
CS Jacket |
|
6 |
Steam Activation Chamber |
Batch or
Continuous (1–2 T/day) |
1 |
SS-316 |
|
7 |
Cooling Screw Conveyor |
0.5 TPH |
1 |
SS-304 |
|
8 |
Vibratory Screener |
2 deck –
10, 30 mesh |
1 |
SS-304 |
|
9 |
Pulverizer/Mill |
250–500
kg/hr |
1 |
Hardened Steel/SS |
|
10 |
Packing Machine (Semi-auto) |
5–10
bags/min (25 kg) |
1 |
Mild Steel/SS Hopper |
|
11 |
Conveyor Systems |
Belt/Screw |
- |
Galvanized
Steel/SS-304 |
|
12 |
Boiler for Steam Activation |
500 kg/hr @
6 bar |
1 |
Water Tube / Fire
Tube |
|
13 |
Dust Collector / Bag Filter |
10,000
m³/hr air handling |
1 |
CS with filter bags |
|
14 |
Cyclone Separator |
For dryer
flue gas |
1 |
Carbon Steel |
2.2 Equipment
Layout Considerations
- Linear Flow from crusher → dryer → kiln →
activation → screener → packing.
- Dryer & Burner close-coupled with dust
collection system.
- Steam line from boiler routed to
activation chamber with safety relief valve and condensate trap.
- Pulverizer and screener area enclosed to control dust.
- Overhead clearance: 4–6 m for rotary and cyclone
systems.
- Material Handling: gravity-assisted chutes where
possible.
- 300 days/year operation.
- 2 shifts/day (8 hours/shift).
- Design factor: 1.2 on continuous
load.
- Future expansion to 30,000 TPA
by replication in modules (x6 line).
📘
DED – Part 3: Electrical System Design & SLD Overview
3.1 Electrical Load
Summary (Initial Capacity: 5,000 TPA)
|
System
/ Equipment |
Estimated
Load (kW) |
|
Crusher |
15 kW |
|
Rotary Dryer Motor |
10 kW |
|
Induced Draft Fan
(Dryer) |
7.5 kW |
|
Kiln Drive + ID Fan |
10 kW |
|
Steam Boiler
(Auxiliary) |
15 kW |
|
Activation Chamber
Fans |
7.5 kW |
|
Pulverizer / Grinder |
22 kW |
|
Screw Conveyor
Motors |
5 kW |
|
Screener / Vibrator |
3 kW |
|
Packing Line |
5 kW |
|
Lighting + Office
Loads |
10 kW |
|
Instrumentation
& Control |
2.5 kW |
|
Total Connected
Load |
≈ 112.5
kW |
|
Demand Factor (0.75) |
≈ 85 kW |
3.2 Power Source
and Distribution
- Primary Supply: PLN 3-phase, 400V, 50Hz.
- Backup Generator: 125 kVA Silent Type Diesel
Genset.
- Main Panel (MDB): In Control Room with MCCs.
- Distribution:
- MCC-1: Crusher, Dryer, Kiln
- MCC-2: Boiler, Activation,
Pulverizer
- Lighting DB: Office, Workshop, Perimeter
- Control Panel: Local + Remote I/O, PLC, HMI
3.3 Cable &
Trunking Layout
- Underground armored cable for main power.
- Cable trays for above-ground motor supply.
- Separate conduit for signal
cables
(instrumentation).
- Earthing system: 1 ohm or less resistance, with
chemical earthing pit.
3.4 Lightning and
Surge Protection
- Lightning Arrestor Mast: ≥2 points based on coverage.
- SPD: Surge Protection Device on MDB
and PLC power supply.
3.5 Single Line
Diagram (SLD) – Simplified Overview
[PLN 400V] -----+
|
[ATS Panel] ----- [125 kVA Genset]
|
[MDB Panel]
|
+-----------+------------+
|
| |
[MCC-1]
[MCC-2] [Lighting DB]
|
| |
Motors 1-5 Motors 6-10
Office, Yard, Lab
📘
DED – Part 4: Instrumentation & Control System Design
4.1 Control
Philosophy Overview
The plant will operate
in semi-automatic mode with central control through PLC-HMI
system. Operators can monitor, start/stop equipment, and receive alarms via HMI
touchscreen located in the Main Control Room.
Key Control Modes:
- Manual Local (maintenance mode)
- Remote Start/Stop (normal ops)
- Auto Batch Timing (activation, drying, screening)
4.2 Major
Instrumentation and Sensors
|
Location |
Instrument
Type |
Signal
Type |
Remarks |
|
|
Biomass Hopper |
Level Sensor (Ultrasonic) |
4-20 mA |
Material presence monitoring |
|
|
Dryer Outlet |
Temperature Sensor (RTD / TC) |
4-20 mA |
Heat control |
|
|
Burner Flue Gas |
Temp. + Oxygen Analyzer (optional) |
4-20 mA |
Combustion efficiency |
|
|
Rotary Kiln |
Speed Encoder + Thermocouple |
Pulse /
4-20 mA |
Rotational monitoring |
|
|
Activation Steam Inlet |
Pressure Transmitter + Flow Meter |
4-20 mA |
Steam pressure control |
|
|
Cooling Conveyor Outlet |
Temp Sensor |
4-20 mA |
Material readiness |
|
|
Bag Filter Dust Chamber |
Differential Pressure Transmitter |
4-20 mA |
Bag health monitoring |
|
|
Packing Line Hopper |
Weight Cell / Load Cell |
4-20 mA |
Bag filling automation |
|
4.3 PLC & HMI
Specification
- PLC: Siemens S7-1200 / Allen
Bradley MicroLogix (as per vendor availability)
- HMI: 7” or 10” Touchscreen with
multi-page navigation
- I/O Capacity:
- Digital Input: 24
- Digital Output: 16
- Analog Input: 16
- Analog Output: 4
4.4 Communication
and Protocol
- Internal Communication: Modbus RTU or Ethernet/IP
- Expandable I/O Modules for future 30,000 TPA upgrade.
- Optional SCADA Interface via PC with data logging
features (CSV export).
4.5 Alarm &
Safety Interlocks
|
Alarm
/ Interlock |
Action |
|
Over temperature in Dryer/Kiln |
Auto shutdown burner, activate
cooling fan |
|
Steam pressure low in Activation |
Delay in cycle start, send alarm |
|
Power Failure |
Auto restart delay and safe
shutdown |
|
Bag Filter Pressure High |
Warn operator to clean filter |
|
Emergency Stop |
Total plant trip, manual reset
required |
📘
DED – Part 5: Safety & Environmental Engineering
5.1 Process Safety
Overview
The Low Temperature
Activated Carbon Plant operates with thermal units, rotating machinery,
combustible materials, and pressurized steam, requiring a detailed
safety and environmental engineering approach.
Key Safety
Objectives:
- Prevent fire/explosion due to
fine carbon dust and high temperatures.
- Ensure safe handling of biomass
and hot equipment.
- Protect personnel and
environment from emissions and physical hazards.
5.2 HAZOP &
Risk Assessment Summary
|
Process
Node |
Potential
Hazard |
Cause |
Mitigation |
|
Dryer + Kiln |
Overheating, Fire |
Burner malfunction |
Temp sensor + shutdown interlock |
|
Activation Chamber |
Overpressure |
Valve stuck, steam surge |
Relief valve + pressure switch |
|
Pulverizer |
Dust explosion |
Static build-up, spark |
Grounding, dust extraction |
|
Bagging Unit |
Repetitive strain |
Manual handling |
Ergonomic design, semi-auto packer |
|
Boiler Room |
Steam burst, fire |
Poor maintenance |
Certified operator + safety valve |
5.3 Fire Protection
System
- Fire Extinguishers: Dry chemical + CO₂ units near
thermal zones.
- Hydrant System: Around fuel storage and
biomass dryer.
- Smoke Detectors: In control room and packaging
area.
- Spark Arrestor: Installed on flue gas exhaust
line.
5.4 Dust &
Emission Control
- Cyclone Separator: Captures >70% of
particulates from dryer.
- Bag Filter / Dust Collector: Captures fine carbon &
biomass dust.
- Chimney Stack Height: Minimum 12 m for proper
dispersion.
- Air Emission Limit Compliance: PM < 150 mg/Nm³ (based on
WHO/local standard).
5.5 Noise Control
Measures
- Enclosures for crusher, dryer fan, and
grinder.
- Silencers on boiler exhaust and pneumatic
line.
- PPE: Mandatory ear protection in
high noise zones.
5.6 Waste &
Effluent Management
- Solid Waste: Collected char fines → reused
as fuel.
- Ash: From burner → collected in
sealed container.
- Wastewater: Minimal; condensate reused;
floor wash directed to soak pit.
- Oil & Grease: Stored in spill-proof
containers, sent to recycling vendor.
5.7 Occupational
Health & Safety (OHS)
- Daily Toolbox Meeting
- Permit to Work (PTW) for maintenance jobs
- PPE Requirements:
- Safety shoes
- Heat-resistant gloves
- Dust mask / Respirator
- Face shield (pulverizer area)
📘
DED – Part 6: Utility & Facility Engineering
6.1 Utility Requirement
Summary (for 5,000 TPA Capacity)
|
Utility
Type |
Estimated
Consumption |
Source |
|
Water |
~10 m³/day |
Deep well / local supply |
|
Electric Power |
~85 kW
average |
PLN + 125 kVA genset |
|
Steam |
~400–500
kg/hr |
Biomass-fired steam boiler |
|
Fuel (Biomass) |
~4,500 tons/year |
Supplied from plantation |
|
Compressed Air |
4–6 bar, 10
Nm³/hr |
For actuator & cleaning |
6.2 Water System
- Sources: Borewell with submersible
pump.
- Storage Tank: 20 m³ elevated tank.
- Distribution: For steam generation, floor
cleaning, and cooling.
Note: No wastewater treatment required
due to dry process.
6.3 Steam
Generation System
- Boiler Type: Biomass-fired package boiler,
600 kg/hr @ 7 bar
- Fuel: Biomass waste (coconut shell,
wood chips)
- Water Treatment: Softener + blowdown tank
- Safety: Pressure gauge, relief valve,
level indicator
6.4 Air Compressor
System
- Compressor Type: Screw type, 10 HP
- Air Receiver Tank: 500 liters
- Dryer & Filters: Installed for clean air
- Applications: Instrumentation valves, bag
filter pulse jet
6.5 Storage and
Logistics
|
Facility |
Capacity
/ Area |
Notes |
|
Raw Biomass Yard |
~500 tons
(10 days stock) |
Open yard with roof |
|
Finished Goods WH |
~50 tons
(10 days stock) |
Ventilated building |
|
Packing Area |
2–3 MT/day
capacity |
Manual + semi-auto filler |
|
Boiler Room |
20 m² |
With heat-resistant coating |
|
Control Room |
12–15 m² |
Air-conditioned, HMI + PC |
|
Office/Rest Room |
30 m² |
Toilets, pantry, small meeting room |
6.6 Site Layout
Suggestions
- Wind Direction: Boiler stack downwind of
office.
- Traffic Flow: One-way truck path
(delivery–loading).
- Fire Access: 3m-wide clearance all around.
- Green Buffer: 10% area for landscaping &
dust control.
📘
DED – Part 7: Expansion Engineering for 30,000 TPA Capacity
7.1 Design
Considerations for Scalability
The plant is
originally designed for 5,000 TPA, but several engineering allowances
are embedded to enable smooth expansion to 30,000 TPA (6× increase). Key
considerations include:
❖
Modular Layout:
- Each processing line (crusher →
dryer → kiln → activation → cooling) sized for ~5,000 TPA.
- Plant layout accommodates up to
6 parallel modules.
❖
Utility Scalability:
- Boiler Room: Reserved area for up to 3
additional boilers.
- Compressor System: Expandable manifold with
additional air dryers.
- Main Electrical Panel: Built with 40% spare I/O and
50% spare MCC slots.
7.2 Expansion
Equipment Sizing (Per 5,000 TPA Unit)
|
Equipment |
Base
(1 Line) |
Expanded
(6 Lines) |
|
Crusher |
1 Unit |
6 Units |
|
Dryer |
1 Unit |
6 Units |
|
Kiln |
1 Unit |
6 Units |
|
Activation Chamber |
1 Unit |
6 Units |
|
Cooling Conveyor |
1 Unit |
6 Units |
|
Screening + Packing |
1 Line |
6 Lines |
|
Boiler (500 kg/hr) |
1 Unit |
6 Units or
1×3 TPH |
Automation can be centralized with 1 main PLC
system and 6 distributed Remote I/O stations.
7.3 Site Expansion
Layout (Conceptual)
- Centralized Utility Core: Boiler, air compressor,
electrical control remain shared.
- Parallel Process Lines: Each with its own biomass
input and product output.
- Integrated Conveyor System: Optional for common raw
material feeding.
- Separate Product Silos or
Bagging:
Depending on market packaging format.
7.4 Manpower &
Logistics Adjustment
|
Parameter |
5,000
TPA |
30,000
TPA |
|
Total Workers
(Shifts) |
~15 |
~45 |
|
Truck Movements/Day |
2–3 |
12–15 |
|
Water Consumption |
10 m³ |
~60 m³ |
|
Power Consumption |
~85 kW |
~500 kW |
Automation Level increase will reduce proportional
manpower requirement.
7.5 Financial
Feasibility Checkpoint (Indicative)
|
Description |
5,000
TPA |
30,000
TPA |
|
Capex Estimate (USD) |
$450,000 –
$600,000 |
~$2.5 –
$3.0 Million |
|
Product Sale Price (per ton) |
$700 –
$1,200 |
Same
(volume discount) |
|
Break-even Period (Estimate) |
2–3 Years |
3–4 Years |
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