Front-End Engineering Design (FEED)
Part 1: Project Overview & Design
Basis
1.1 Project Description
The project aims to
develop a Low Temperature Activated Carbon (LTAC) production facility with an
initial capacity of 5,000 metric tons per annum (TPA). The facility is
designed to be modular and scalable, enabling expansion up to 30,000
TPA in phases. The plant will process biomass-based feedstocks (such as coconut
shells, wood chips, palm kernel shells) through drying, pyrolysis,
low-temperature steam activation, and final finishing to produce high-quality
activated carbon.
1.2 Project Objectives
- Develop a sustainable and
modular activated carbon production facility.
- Use low-temperature activation
technology to reduce energy consumption and emissions.
- Ensure high quality of the final
product, compliant with international standards.
- Allow for future expansion
without major infrastructure overhaul.
1.3 Plant Location and Site
Considerations
- Location Type: Semi-rural/peri-urban zone with
access to plantation/agro-waste sources.
- Site Area Requirement (Initial
5,000 TPA):
~6,000–8,000 m².
- Site Area (Full 30,000 TPA): ~30,000 m².
- Nearby Resources: Biomass plantations, water
supply, and power grid.
- Climate Considerations: Tropical/humid, average ambient
temperature 25–35°C, rainfall 2,000 mm/year.
1.4 Plant Capacity
Phase |
Installed
Capacity |
Expansion
Capability |
Operation
Mode |
Phase 1 |
5,000 TPA |
Modular block-based |
Single shift |
Final Phase |
30,000 TPA |
6 x 5,000 TPA lines |
Continuous (24/7) |
1.5 Feedstock and Input Requirements
Parameter |
Value |
Biomass Type |
Coconut Shells, Palm Kernel Shells,
Wood Chips |
Feedstock Requirement |
~15,000 tons/year for 5,000 TPA
output |
Moisture Content |
≤ 12% (after drying) |
Transport Mode |
Truck delivery from plantations |
1.6 Product Specifications
Parameter |
Target
Value |
Iodine Number |
≥ 900 mg/g |
Moisture |
≤ 5% |
Ash Content |
≤ 8% |
Hardness |
≥ 95% |
Particle Size |
As per
application (mesh 8x30, 12x40, etc.) |
1.7 Utility Requirements (Initial
5,000 TPA)
Utility |
Estimated
Load/Consumption |
Source |
Electrical Power |
~250 kW
connected load |
Local grid or diesel genset backup |
Steam |
~1,200
kg/hr |
Biomass-fired steam boiler |
Cooling Water |
~5 m³/hr |
Recycled loop (cooling tower) |
Compressed Air |
6 bar, 30
Nm³/hr |
Screw compressor |
Fuel (Startup) |
Diesel for
burner startup only |
Local supplier |
1.8 Design Life and Operation
Philosophy
- Design
Life: 20 years
(with regular maintenance)
- Operation
Mode:
Semi-continuous with potential shift-based operation
- Manpower
Requirement (5,000 TPA):
~20–25 persons (operators, engineers, maintenance, logistics)
1.9 Environmental and Regulatory
Basis
- Compliance
with:
- ISO 14001 (Environmental Management)
- ISO 45001 (Occupational Health & Safety)
- National environmental emissions and effluent
standards
- EIA/AMDAL
required for >10,000 TPA capacity
- Dust
control and gas scrubbing system required
1.10 Key Assumptions
- Feedstock
is available within a 100 km radius
- Grid
power is stable or reliable diesel backup is provided
- Land
is owned or long-leased with no legal conflict
- Steam
boiler license and emission permits can be secured
- Final
product is packed and sold in bulk (bagged or super sack)
1.11 Deliverables from FEED – Part 1
- Design
Basis Document (this file)
- Site
Layout (to be included in Part 3)
- Initial
Utility Load List
- Equipment
List (in next part)
- Process
Description (next part)
Part 2: Process Design
2.1 Process Flow Description
The Low Temperature Activated Carbon
(LTAC) production process comprises the following major steps:
- Biomass
Reception & Preprocessing
- Biomass (e.g., coconut shells) is received,
sorted, and crushed.
- Oversized or contaminated materials are removed.
- Crushed material is stored in covered bunkers.
- Drying
- Moisture reduction to <12% using rotary dryer
or belt dryer.
- Heat source: biomass hot gas generator or steam
heat exchanger.
- Pyrolysis
(Carbonization)
- Biomass is carbonized at 400–500°C in a rotary
kiln or multi-hearth furnace.
- Oxygen is restricted to prevent combustion.
- Volatile gases are collected and used as fuel or
flared.
- Low-Temperature
Activation
- Carbonized char is exposed to steam at ~700°C.
- Activation increases surface area and porosity.
- Residence time: 30–60 minutes depending on product
grade.
- Cooling
- Activated carbon is cooled in inert or air-cooled
screw coolers to below 50°C.
- Screening
and Grinding
- The product is sized (e.g., 8x30 mesh, 12x40) or
ground to powder.
- Packing
and Storage
- Packed in 25–50 kg bags or jumbo bags.
- Stored in moisture-controlled warehouse.
2.2 Simplified Process Flow Diagram
(PFD)
2.3 Mass and Energy Balance (5,000
TPA Basis)
Input Materials:
- Biomass
Feedstock: ~15,000 tons/year (dry basis)
- Water
(for cooling & steam): ~10,000 m³/year
- Electricity:
~500,000 kWh/year
- Biomass
fuel for dryer/boiler: ~1,000 tons/year
Output:
- Activated
Carbon: 5,000 tons/year
- By-products:
Ash, Char dust (100–300 tons/year)
- Flue
Gases: To scrubbing unit
Energy Use:
- Thermal:
~2.5–3.5 GJ/ton of product
- Electrical:
~100 kWh/ton of product
2.4 Process Equipment Summary (Main
Units)
Equipment |
Type |
Quantity |
Crusher |
Hammer Mill |
1 |
Dryer |
Rotary/Belt |
1 |
Carbonization Kiln |
Rotary or Multi-Hearth |
1 |
Activation Reactor |
Rotary with steam inlet |
1 |
Cooling Screw |
Jacketed / water-cooled |
1 |
Screening Machine |
Vibratory |
1–2 |
Packing Machine |
Semi-auto bagging |
1 |
2.5 Process Control Philosophy (To be
detailed in Part 4)
- Local
PLC with SCADA interface
- Temperature
and flow monitoring in each stage
- Gas
analyzer for flue control
- Manual
override and alarm system
2.6 P&ID (Summary Functional
Description)
P&ID to be developed in Part 3
- All
units will be equipped with:
- Temperature sensors (RTD or thermocouple)
- Flow sensors for steam, air, biomass
- Pressure indicators on steam lines
- Interlock system to prevent unsafe operations
2.7 Process Safety Features
- Emergency
vent for kiln and reactor
- Flame
arrestors on gas outlets
- Fire
suppression in dryer and carbon storage
- Temperature
interlocks and shutdown systems
2.8 Compliance and Standards
- NFPA
86 (Ovens and Furnaces)
- ISO
9001 for product quality
- ISO
14001 for emissions
- EN
746-2 for thermal processing safety
Part 3: Mechanical & Equipment
Design
3.1 Major Process Equipment List
Equipment |
Description |
Qty |
Material
of Construction (MOC) |
Biomass Crusher |
Hammer or knife mill |
1 |
Mild Steel (MS) with SS liners |
Rotary Dryer |
Direct-fired or steam indirect |
1 |
Carbon Steel with refractory lining |
Carbonization Kiln |
Low-temperature rotary kiln |
1 |
Alloy Steel, refracted |
Steam Activation Reactor |
Insulated rotary type |
1 |
Stainless Steel 310/316 |
Cooling Conveyor |
Water-jacketed screw conveyor |
1 |
SS contact parts + MS outer shell |
Screening Machine |
Vibrating screen |
1 |
SS304 in contact areas |
Pulverizer / Grinder |
Impact or hammer mill |
1 |
SS304 |
Bagging Machine |
Semi-automatic with scale |
1 |
MS frame, SS hopper |
3.2 Equipment Datasheet Summary
(Example)
Equipment Name: Rotary Kiln
- Type: Horizontal rotary, direct
heating
- Capacity: ~1 TPH char production
- Length
x Diameter: 10
m x 1.5 m
- Rotation
Speed: 0.5–1
rpm
- MOC
(Shell): Carbon
Steel with 3-layer refractory lining
- Drive
System: Gear
reducer with VFD
- Temperature
Range:
400–600°C
- Insulation: Ceramic fiber + castable
refractory
3.3 Equipment Layout Principles
- Linear
Process Flow:
From raw material to product, minimizing cross-traffic.
- Modular
Blocks: Each
5,000 TPA line occupies ~1,200 m²
- Isolation
Zone: Thermal
equipment (kiln, dryer) in separated fire-safe zone
- Green
Belt Buffer:
10% of site area for emission barrier and natural cooling
3.4 Materials of Construction (MOC)
Service
Area |
MOC
Recommendation |
Reason |
Wet Biomass Handling |
MS with epoxy or SS304 liners |
Corrosion resistance |
High Temp Kiln |
Alloy Steel, Refractory Lined |
Thermal and mechanical strength |
Steam Lines |
SS304 or Carbon Steel SCH 40 |
Pressure and corrosion resistance |
Product Contact Area |
SS304 |
Prevent contamination |
Exhaust Ducts |
Carbon Steel + paint |
Non-corrosive flue gas |
3.5 Civil/Structural Load Data
(Preliminary)
Equipment |
Operating
Weight (ton) |
Foundation
Type |
Rotary Kiln |
~15 tons |
RCC with vibration pads |
Dryer |
~10 tons |
RCC slab |
Steam Boiler |
~20 tons |
Deep RCC footing |
Bagging Machine |
~2 tons |
Steel pedestal |
3.6 Mechanical Safety Features
- Explosion
vents on drying
and pyrolysis units
- Emergency
Stop Buttons at
all operator points
- Insulated
and guarded rotating parts
- Temperature
interlocks on
all combustion and heating systems
- Smoke/CO
detectors near
pyrolysis chamber
3.7 Codes and Standards Applied
Component |
Standard
Applied |
Pressure Vessels |
ASME Sec VIII Div 1 |
Structural Steel |
AISC / ASTM A36 |
Refractory Materials |
API 936 |
Lifting Equipment |
OSHA 1910, ISO 9927 |
General Fabrication |
ISO 9001, ISO 3834 (Welding) |
Part 4: Instrumentation, Electrical
& Automation
4.1 Electrical Power Demand &
Distribution
4.1.1 Power Load Estimation (5000 TPA
Capacity)
Equipment |
Rated
Power (kW) |
Qty |
Total
(kW) |
Biomass Crusher |
30 |
1 |
30 |
Dryer Blower & Drive |
45 |
1 |
45 |
Rotary Kiln Drive |
15 |
1 |
15 |
Activation Reactor Drive |
22 |
1 |
22 |
Cooling Screw Drive |
15 |
1 |
15 |
Screening + Pulverizer |
30 |
1 |
30 |
Bagging System |
5 |
1 |
5 |
Lighting & Auxiliaries |
— |
— |
20 |
Total Installed Load (Approx.) |
— |
— |
182 kW |
4.1.2 Electrical System Architecture
- Main
Power Source:
415V, 3-phase, 50Hz (or site-specific)
- Backup
Power: Diesel
Genset 250 kVA
- Distribution: MCCs located in control room;
underground armored cables
- Protection: MCBs, MCCBs, Earth leakage
detection, Surge protection
4.2 Instrumentation Architecture
4.2.1 Key Instruments by Area
Area |
Instruments |
Purpose |
Dryer |
Temp sensor, flow switch, RTD |
Moisture control, safety shutdown |
Kiln |
Thermocouple, gas analyzer (CO,
CH4) |
Process monitoring, safety |
Activation Reactor |
Steam flowmeter, pressure switch |
Process control, interlock |
Cooling |
Temp sensor, motor current relay |
Cooling confirmation |
Product Area |
Weighing sensor, level switch |
Packing control |
General |
Smoke & fire detector,
emergency push |
Safety |
4.2.2 Instrument Specification Sample
Instrument Type: Thermocouple
- Type: K Type, sheathed
- Range: 0–1000°C
- Mounting: Flanged or threaded
- Signal
Output: 4–20 mA
via transmitter
- Protection: IP65, SS304 sheath
4.3 Automation Philosophy
4.3.1 Control System Overview
- Architecture:
- Local PLC-based system (Siemens S7-1200 or Allen
Bradley CompactLogix)
- SCADA HMI interface (optional remote monitoring
via web dashboard)
- Hardwired ESD loop for critical interlocks
- Control
Mode:
- Semi-automatic with operator setpoints
- Auto-purge & startup sequences for kiln &
dryer
- Alarm management (visual + audible)
4.3.2 Sample PLC I/O List
I/O
Type |
Description |
Qty |
AI (Analog In) |
Temperature, Flow, Pressure |
20 |
AO (Analog Out) |
Control valves (steam, air) |
5 |
DI (Digital In) |
Limit switches, emergency stop |
30 |
DO (Digital Out) |
Motor start, alarm indicators |
30 |
4.4 Safety Interlocks and System
Integration
4.4.1 Interlock Matrix (Sample)
Condition |
Action |
Dryer temp > 180°C |
Dryer shutdown, alarm |
Kiln gas leak detected |
Fuel cutoff, ventilation on |
Steam pressure drop in reactor |
Reactor shutdown |
Emergency stop pressed |
All motors off, vents open |
Fire detected in control room |
Power cut to non-essential |
4.4.2 Fire & Gas Safety
- CO/CH4
detection in activation area
- Flameproof
junction boxes near hot zones
- Fire
alarm panel + smoke detector network
- Integration
to plant-wide alarm horn/siren
4.5 Relevant Standards and Codes
Category |
Applicable
Standards |
Instrumentation |
ISA S5.1, IEC 61508, IEC 61131-3 |
Electrical Panels |
IEC 61439-1, IEC 60204-1 |
Automation |
IEC 61131, Modbus/Profibus
standards |
Safety Systems |
NFPA 70E, ISO 13849, IEC 61511 |
Part 5: Health, Safety, and
Environment (HSE) & Risk Mitigation
5.1 HSE Philosophy
The HSE strategy focuses on proactive
prevention of incidents through:
- Inherently
safe plant design
- Environmental
compliance with national and international regulations
- Occupational
health protection
- Continuous
risk assessment and mitigation
- Emergency
preparedness
5.2 Occupational Health & Process
Safety Hazards
Hazard
Area |
Potential
Risk |
Mitigation
Measures |
High Temperature Units |
Burns, fires, explosion |
Thermal insulation, explosion
vents, PPE |
Steam System |
Scalding, pipe bursts |
Pressure relief valves, leak
detection |
Dust from Charcoal |
Respiratory hazards, dust explosion |
Dust collectors, ATEX-rated motors |
Noise from Crushers |
Hearing damage |
Ear protection, acoustic enclosure |
Slippery Floors |
Falls/slips |
Anti-slip coating, proper drainage |
Handling Chemicals |
Skin, eye irritation |
SDS availability, PPE, eyewash
stations |
5.3 Fire and Explosion Prevention
Fire Sources
- Biomass
dust
- Volatile
gases from pyrolysis
- Hot
surfaces
Preventive Measures
- Grounding
and bonding of equipment
- Flame
arrestors and gas vents
- Automatic
fire detection system with smoke and CO sensors
- Fire
extinguishers (ABC, CO₂) located every 15 meters
- Fire
hydrant and sprinkler system in storage areas
5.4 Environmental Impact Assessment
(EIA)
5.4.1 Air Emission Sources
- Kiln
flue gas (CO₂, CO, VOCs)
- Dust
from grinding and screening
Control Systems:
- Multi-cyclone
and bag filter systems
- Scrubber
for VOC neutralization
- Chimney
stack height ≥12 meters for dispersion
5.4.2 Water & Wastewater
- No
process water consumption (closed steam loop)
- Only
sanitary wastewater (treated via STP or septic)
- No
liquid effluents from production line
5.4.3 Solid Waste
Type |
Source |
Disposal/Reuse
Method |
Ash |
From dryer combustion |
Used as soil amendment |
Reject Carbon |
Oversized or under-burnt |
Recycled to kiln feed |
Filter Dust |
Baghouse unit |
Compacted and landfilled |
5.5 Green Design Integration
- Green
Belt: 10–15% of
site area for buffer and carbon sequestration
- Rainwater
Harvesting: For
utility use and firewater storage
- Natural
Lighting and Ventilation:
Reduces energy footprint
- Low-NOx
Burner Selection:
For reduced air pollution
5.6 Risk Assessment (HAZOP Summary)
Node |
Deviation |
Consequence |
Safeguards |
Kiln Temperature |
High Temp |
Fire, equipment damage |
Temp Interlock, Alarm |
Steam Pressure |
Low Pressure |
Incomplete activation |
Pressure switch, backup line |
Dust Collector |
Blockage |
Explosion risk |
DP Switch, Auto-shaking |
Conveyor Motor |
Overcurrent |
Fire risk, shutdown |
OLR, MCC trip |
CO Level |
Above threshold |
Toxic inhalation |
Gas Detector + Ventilation |
5.7 Compliance Standards and
References
Regulation
/ Standard |
Area
Covered |
OSHA 29 CFR 1910 |
General workplace safety |
NFPA 654, 68, 69 |
Dust explosion prevention |
ISO 14001 |
Environmental management |
ISO 45001 |
Occupational health & safety |
IFC / World Bank EHS Guidelines |
Air emissions, wastewater |
5.8 Emergency Preparedness
- Assembly
Point: Clearly
marked zones with route signage
- Mock
Drills:
Quarterly simulations of fire, chemical spill, and blackout
- Trained
Response Team:
Fire marshals, first aid officers
- Emergency
Shutdown Procedure:
PLC logic + manual override
Part 6: Existing Reference Plants
& Performance Benchmarks
6.1 Objective
This section presents
validated reference plants that have successfully operated using
low-temperature activation technology for biomass-based activated carbon. The
aim is to benchmark operational feasibility, product quality, scalability, and
sustainability.
6.2 Reference Plant #1 – EcoCarb Pvt
Ltd (India)
- Location: Gujarat, India
- Capacity: 6,000 TPA
- Feedstock: Coconut shell, wood chips
- Technology: Indirect rotary kiln at
450–550°C with steam activation
- Operation
Since: 2016
- Key
Highlights:
- Modular expansion achieved in 2021 to 12,000 TPA
- Achieved Iodine Number: 900–1100 mg/g
- Ash Content: <5%
- Utilized baghouse and scrubber for emissions
control
- Carbonization and activation in same continuous
unit
6.3 Reference Plant #2 – GreenCarbon
Ltd (Thailand)
- Location: Surat Thani, Thailand
- Capacity: 10,000 TPA
- Feedstock: Palm kernel shell (PKS)
- Technology: Rotary reactor with low-O₂
atmosphere and steam injection
- Operation
Since: 2017
- Key
Features:
- Integrated biomass drying using waste heat
- Digital SCADA system controlling temperature zones
- Product used in water filtration and gold recovery
- Reduced CO₂ emissions by 30% using biomass-fueled
boiler
6.4 Reference Plant #3 – EnviroCarb
USA
- Location: Louisiana, USA
- Capacity: 5,000 TPA
- Feedstock: Hardwood sawdust
- Technology: Low-temperature
microwave-assisted activation
- Operation
Since: 2018
- Highlights:
- Batch-based operation
- Focus on ultra-low ash activated carbon
- Fully automated with Modbus integration
- Compliant with EPA emission norms
6.5 Key Performance Benchmarks
Parameter |
Industry
Range |
Reference
Target (Project) |
Iodine Number |
800–1200 mg/g |
950–1100 mg/g |
BET Surface Area |
600–1200 m²/g |
>1000 m²/g |
Ash Content |
<8% |
<5% |
Bulk Density |
350–600 kg/m³ |
400–500 kg/m³ |
Moisture Content |
<10% |
<7% |
VOC Emissions |
<50 mg/Nm³ |
<30 mg/Nm³ |
Plant Availability |
>90% |
Target 92–95% |
Specific Energy Use |
0.7–1.2 kWh/kg |
~0.95 kWh/kg |
6.6 Lessons Learned from Operational
Plants
- Steam
quality
significantly impacts activation consistency; use of saturated steam >4
bar is optimal.
- Modular
design (multi-kiln) supports easier maintenance and staggered production.
- Dust
control and fugitive emissions require rigorous filter maintenance.
- Automation
reduces labor costs and enhances product repeatability.
- Use
of waste heat recovery improves thermal efficiency and plant economics.
6.7 Takeaways for FEED Development
- Proven
technology with more than 5 years of operation in tropical and industrial
settings
- Viability
of multiple biomass types as feedstock
- Effective
scalability from 5,000 to 30,000 TPA via parallel line expansion
- Compliance
with environmental and product quality standards achievable with current
systems
If desired, a field visit or virtual
benchmarking with these plants can be arranged as part of the detailed
engineering phase or investor due diligence.
7.1 Reference Standards Utilized
Standard
Organization |
Standard
Name / Number |
Scope
of Application |
ASTM International |
ASTM D2866, D4607, D1762-84 |
Moisture, Iodine Number, Activation
Specs |
ISO |
ISO 14001, 45001 |
Environmental & Occupational
Safety Mgmt. |
ASME |
ASME B31.3 |
Process Piping |
API |
API 650, 661 |
Storage Tanks, Heat Exchangers |
NFPA |
NFPA 68, 69 |
Dust Explosion Prevention |
IEC |
IEC 61511 |
Safety Instrumented Systems (SIS) |
IFC / World Bank |
EHS Guidelines |
Emission, Effluent, and Worker
Safety |
7.2 Scientific Literature and
Engineering Data
- Activated
Carbon: Production, Properties and Applications
- Marsh, H., & Rodriguez-Reinoso, F. (Elsevier
Science)
- Technical foundation of carbon microstructure and
pore development.
- Biomass-Based
Activated Carbon: A Review
- ScienceDirect - Elsevier
- Covers the impact of feedstock and activation
methods.
- Design
Considerations for Steam Activation Process
- International Journal of Chemical Reactor
Engineering
- Thermodynamics of low-temp activation and steam
reactivity.
- Charcoal
& Carbonization Handbook (FAO Document)
- FAO.org
- Guidelines on biomass selection and conversion
techniques.
7.3 Engineering Tools & Software
Used
Tool |
Purpose |
Aspen Plus |
Process simulation and material
balance |
AutoCAD & Plant 3D |
2D/3D layout and P&ID
development |
Microsoft Excel |
Heat & mass balance
calculations |
HAZOP Manager |
Safety and operability studies |
COMSOL Multiphysics |
Heat transfer simulation (Kiln
zone) |
SketchUp & Photoshop |
Plant visualization and cover
rendering |
7.4 Industrial Supplier and
Technology Benchmark Sources
- Jacobi
Carbons (Sweden)
- https://www.jacobi.net
- Global leader in activated carbon products.
- Carbon
Activated Corp (USA)
- https://www.carbonactivated.com
- Technology partner for process design.
- ECOMAX
Carbon (India)
- https://ecomaxcarbon.com
- Plant EPC and modular activation kilns.
- EnviroSorb
Technologies (USA)
- https://envirosorb.com
- Turnkey carbon plants and emission control
systems.
7.5 Government Regulations Consulted
- Indonesia
Ministry of Environment & Forestry (KLHK)
- Regulation No. P.12/Menlhk/Setjen/Kum.1/4/2019 –
Emission standards
- Regulation No. 56/M-IND/PER/11/2006 – Industrial
Safety and Health
- EPA
USA
- Title 40 – Protection of Environment
- ILO
& WHO
- Industrial hygiene and chemical exposure
guidelines
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