The process flow for producing powdered activated carbon using zinc chloride in a continuous process is as follows: 1. Screening and drying of wood chips – The wood chips are sent to a vibrating screen via a bucket elevator; those with a particle size of 6–40 mesh are selected, and then transported to a cyclone separator by a blower. The separated wood chips fall into a storage tank. Then air drying is carried out; the wood chips are fed in a quantitative and continuous manner from a disk feeder located below the storage bin into a spiral feeder. They are then introduced into a hot air duct, where they are carried away and dried by high-speed streams of hot air coming from a hot air furnace. The moisture content of the wood chips drops from around 40% to 15%–20%. After being separated in a cyclone separator, the dried wood chips fall into a storage bin for dried wood chips. 2. Preparation of zinc chloride solution: The preparation of zinc chloride solution involves creating a solution of the specified concentration, based on the requirements of production. During preparation, the zinc solution with a concentration of 40 degrees obtained from the recycling process is pumped into the zinc preparation tank using a pump; thereafter, fixed amounts of zinc chloride and hydrochloric acid are added to create a zinc chloride solution with the desired concentration and pH level. It is also possible to prepare the solution directly using water, after which it is pumped into the concentrated zinc tank for later use. 3. Kneading: The zinc chloride solution from the concentrated zinc tank is pumped into the high-level tank for concentrated zinc using a pump. The wood chips that have settled at the bottom of the wood chip storage bin are lifted to the metering tank using a bucket elevator. A certain amount of these wood chips is then added to the kneading machine, where they are mixed with a measured amount of concentrated zinc solution from the high-level tank; the resulting mixture is poured into the feed hopper of the rotary furnace. 4. Activation: Wood chips are fed into the rotary furnace through a disk feeder and a screw feeder located at the bottom of the hopper. Hot flue gas is introduced from the other end of the furnace, thereby carbonizing and activating the wood chips. The activated material falls into the discharge chamber, where it is taken out periodically and transported using a cart to the feed point of the bucket elevator in the recycling process. 5. Recovery and rinsing: Start the bucket elevator to add the activated material to the recovery tank for the recovery of zinc chloride. First, wash with a zinc chloride solution having a specific gravity of 25–30; the resulting concentrated zinc solution is then used to prepare another zinc chloride solution. Subsequently, wash with a weaker zinc solution, adding an appropriate amount of hydrochloric acid during the washing process, and heat the solution to above 70 degrees Celsius to convert zinc oxide into zinc chloride. Finally, the concentration of the washing solution is required to be reduced to below 1 Baumé. The recycled carbon is poured into a rinsing tank with water, and rinsed with hot water at a temperature of over 90 degrees Celsius. During the second rinse, an appropriate amount of hydrochloric acid is added and the mixture is heated to boiling point in order to remove iron from the carbon, until the rinsing solution contains no iron anymore. 6. Centrifugal dewatering, drying, and grinding: The activated carbon is dehydrated in a centrifuge, then dried in an external heat rotary dryer to a moisture content of 4–6%, and finally sent to a ball mill for grinding to produce the final product. In addition, specialized waste gas and wastewater treatment systems are installed to recover zinc chloride and hydrochloric acid from the flue gases, thereby eliminating environmental pollution. Requirements for raw materials in zinc chloride activation: The main raw material for producing powdered activated carbon using the zinc chloride method is wood chips; when producing carbon for sugar production, fir wood chips and pine wood chips are preferred, with pure fir wood chips being even better. Fresh pine sawdust contains a high amount of resin, which hinders the penetration of zinc chloride solution; it is therefore better to store it for some time to allow the volatile components to evaporate and oxidize before using it. However, it should not be stored for too long to prevent the wood shavings from rotting and deteriorating. When producing other types of activated carbon, mixed wood chips from various tree species can be used. The requirements for wood chips are: particle size of 6–40 mesh, free from bark, wood pieces, sediment, iron shavings, etc., with a moisture content of 15%–20%. To ensure stable process operation, wood chips must be screened using a vibrating screen to select those that meet the required standards and to remove impurities, thereby preventing any impact on product quality. The screened wood chips have a moisture content of about 40%. Air flow dryers are generally used for drying. It consists of a hot air furnace, a fan, and a drying tube. The drying tube is made of steel plate, with a diameter of 300 millimeters and a height of about 20 meters. The wood chips are fed into the drying tube, where hot air at 120–150 degrees Celsius, supplied by a hot air furnace, drives the chips through the drying tube at a speed of 8 meters per second. The moisture content of the dried wood chips is reduced to 15%–20%, and they are recovered using a cyclone separator. For drying wood chips, some factories use rotary kilns. The wood chips are dried indirectly by flue gas. During production, wood chips enter the cylinder through the feed port and move forward gradually as the cylinder rotates and due to the existing slope; the dried wood chips are then discharged continuously from the outlet port. The flue gas generated by burning coal in the combustion chamber first flows outside the cylinder, heating it, then enters the smoke pipes inside the cylinder to allow for thorough heat exchange, and is finally discharged through the chimney. During operation, the amount of material added should be controlled according to the furnace temperature. At the same time, the furnace temperature should not be too high to prevent the wood chips from burning. Preparation of zinc chloride solution: The concentration of the zinc chloride solution varies depending on the type of activated carbon being produced. Preparing the zinc chloride solution at the specified concentration is an important factor in ensuring an appropriate ratio of zinc shavings. Industrial zinc chloride that is white in color, readily absorbs moisture and deliquesces, and has a purity of over 96% should be used. Due to the different uses of activated carbon, varying requirements apply when using zinc chloride to produce it; these are summarized as follows: The requirements for activated carbon used in the sugar industry are that the concentration of the zinc chloride solution at 60 degrees Celsius should be between 50–57 Baumé degrees, with a pH value of 3.0–3.5. The requirements for the formula of medicinal activated carbon are as follows: the zinc chloride solution should have a concentration of 45–47 degrees Bé at 60 degrees Celsius, and its pH value should be between 1.0 and 1.5. During preparation, in the zinc preparation tank, solid zinc chloride is dissolved in the zinc chloride solution recovered from the recycling process. If the amount of zinc melt available for recycling is insufficient, water can also be used for preparation; once the desired Baumé degree is reached, hydrochloric acid is then used to adjust the pH value of the solution. The Baume concentration is a method widely used in zinc chloride production plants to indicate solution concentration. The concentration is expressed by the degree measured using a Baume hydrometer immersed in the solution. There is a certain relationship between the Baumé concentration of zinc chloride solution and temperature; when the percentage concentration remains constant, the Baumé concentration decreases as the temperature rises. Therefore, for the Baume concentration of zinc chloride solution, the temperature of the solution must be specified. For example, to prepare a zinc chloride solution with a specific gravity of 45–46 at 60 degrees Celsius, it should be prepared with a specific gravity of 46–47 at 30 degrees Celsius. The relationship between the Baumé concentration of zinc chloride solution (0Be?FONT FACE="SimSun" LANG="ZH-CN">) and temperature (in degrees Celsius), as well as the relationship between its Baumé concentration and relative density and percentage concentration, can be found in the relevant charts. Purpose and process conditions of the kneading step: The purpose of the kneading step is to mix wood chips with zinc chloride solution evenly by continuously stirring and compressing them using a pair of zigzag-shaped agitators in the kneader, thereby accelerating the penetration of the zinc chloride solution into the wood chips. Kneading is carried out in a kneader. The kneader is made of acid-resistant steel and has a horizontal semi-circular tank; it is equipped with a pair of zigzag-shaped stirrers inside. Its capacity is usually 0.5 cubic meters, and it operates in a batch mode. The kneader is equipped with a transmission mechanism; by pressing the button of this mechanism, the semi-circular groove of the kneader can be rotated by an angle, allowing the zinc shavings to be poured into the hopper of the rotary furnace. For ease of operation, the kneading process is also equipped with a wood chip metering device, as well as a high-level tank and metering device for zinc chloride solution. The wood chip metering device consists of a bucket elevator for transporting the wood chips, a scale, and a hopper, and it enables accurate control of the weight of wood chips used in each mixing process. A pipe located at the bottom of the zinc chloride solution sump is connected to the upper part of the mixer, so as to spray a precise amount of zinc chloride solution evenly into the mixer for mixing with wood chips. During mixing, the ratio of the weight of the process wood chips to the weight of the zinc chloride solution is called the slurry ratio, sometimes also referred to as the impregnation ratio. The process conditions for kneading are as follows: 1. For producing activated carbon for industrial use: Wood chip moisture content (%): 15–20; Zinc chloride solution concentration at 60 degrees Celsius (Baumé scale): 45–47; pH value of the zinc chloride solution: 1–1.5; Material-to-liquid ratio: 1:3; Kneading time (minutes): 10–15. 2. For producing activated carbon for use in sugar production: Wood chip moisture content (%): 15–20; Zinc chloride solution concentration at 60 degrees Celsius (Baumé scale): 50–57; pH value of the zinc chloride solution: 3–3.5; Material-to-liquid ratio: 1:4–5; Kneading time (minutes): 10–15. How is a rotary furnace operated? What are the process conditions for its carbonization and activation? The rotary furnace is a key equipment for the carbonization and activation of zinc shavings to produce activated carbon. The rotary furnace is horizontal, with an inner diameter of 1 meter and a length of 13 meters. The cylinder is made of steel plate and lined with refractory bricks. A large gear is installed on the outside of the middle part of the cylinder to drive its rotation. There is a pair of idler wheels at each end to support the weight of the cylinder. Both the furnace head and furnace tail are equipped with sealing devices. The installation inclination is 2–5 degrees. The rotary furnace operates continuously, with zinc scrap being fed into the rear part of the furnace via a disc feeder and a screw feeder. The material moves slowly toward the furnace head due to the rotation of the cylinder and its inclination. The burner head is equipped with a combustion chamber in which crude oil or gas is burned; the high-temperature flue gases generated flow directly into the furnace, moving from the burner head toward the furnace tail, where they come into direct contact with the material in counterflow. During the carbonization process, a viscous plastic material is formed, which adheres to the furnace walls, clumps together to form crusts, and blocks the furnace chamber. To prevent blockages, the furnace is equipped with star-shaped scrapers connected by chains, which, as the cylinder rotates, continuously strike the furnace walls to scrape off the clumped material stuck to them. The activated material is referred to as activated feed; it falls from the furnace head into the discharge chamber and is periodically removed for shipment to the recycling process. Waste flue gas enters the waste gas recovery system from the furnace tail through the flue. When starting the furnace, first activate the converter, then ignite it to raise the temperature; once the temperature at the rear of the furnace reaches around 300 degrees Celsius, feeding begins. If it is necessary to shut down the furnace, first stop feeding material while maintaining a certain furnace temperature; only after all the material inside the furnace has been removed should the fire be extinguished and the furnace shut down. Before the hot furnace has cooled down completely, rotate the cylinder every few minutes to 20 minutes to prevent it from deforming. The process conditions for carbonization and activation in the rotary furnace are as follows: Temperature of the material in the activation zone (degrees Celsius): 500–600. Carbonization and activation time (minutes): approximately 40. Filling factor of the furnace (%): 15–20. Rotational speed of the drum (revolutions per minute): 1–3. Pressure inside the furnace: slightly negative pressure. Temperature of the flue gas at the furnace outlet (degrees Celsius): 700–800. Temperature of the flue gas at the furnace inlet (degrees Celsius): 200–300. Interval between discharges (minutes): 20. The purpose of the recovery process for activated carbon produced by the zinc chloride method is to ensure that the activated material contains 70%–90% zinc chloride and zinc-containing compounds. The purpose of recycling is to recover this zinc chloride and zinc-containing compounds, thereby reducing the consumption of zinc chloride in the production of activated carbon and lowering the cost of the product. The recovery process of zinc chloride belongs to the leaching method; that is, zinc chloride and zinc oxide are dissolved in the activated material using zinc chloride solutions of different concentrations (referred to as zinc solution) along with a small amount of industrial hydrochloric acid, followed by filtration for separation. Recycling is done in a recycling bin. The recycling bin is made of steel plate and is cylindrical in shape. The interior and exterior of the barrel’s shell are coated with diabase mortar. Line the inside of the barrel with diabase slabs. The lower part of the tank has a filter plate cast with rebar and diabase powder. During the operation, the activating material is added to the recovery tank. First, a zinc solution with a higher concentration is poured into the activating material, along with hydrochloric acid in an amount equivalent to 5% of the weight of the activating material, so as to convert the zinc oxide formed during activation into zinc chloride. During the reaction, thorough stirring is required. After the reaction is complete, let it stand for a few minutes, then open the vacuum pumping valve to draw the zinc chloride solution in the recovery tank into the vacuum tank, and subsequently place it in the acid-resistant container. Generally, the concentration of the zinc chloride solution obtained in the first recovery can reach over 40 degrees Bé, and it can be used to prepare zinc chloride solutions. After the first recovery, low-concentration zinc solution is pumped into the recovery tank one after another, so that the zinc solution covers the carbon surface. This process is repeated multiple times to obtain zinc solutions of varying concentrations, which are then stored in acid-resistant tanks for use in subsequent recoveries. Until all the zinc solutions of various concentrations left from the previous time were used up, it was then washed with hot water, and the washing solution was also collected in an acid-resistant tank. Until the zinc chloride content in the carbon is below 1%. What is the purpose of rinsing? How to rinse? The purpose of rinsing is to remove various impurities from the raw materials and the processing process, so that the levels of chlorides, total iron compounds, ash, etc., as well as the pH value of the activated carbon, meet the specified standards. Rinsing is carried out in two steps: first, hydrochloric acid is added to remove iron compounds; hence it is called acid washing, or acid treatment, or also \"iron boiling\"” ; Next, alkali is added to neutralize the acid, chlorides are removed, and repeated washing with hot water is carried out, which is why it is called washing. Both rinsing steps are carried out in the same rinsing tank. The rinsing tank is made of steel plate and is cylindrical in shape. The interior and exterior of the tank’s shell are covered with several layers of glass fiber cloth bonded using epoxy resin putty, and an acid-resistant tile layer is added on the inside; a filter plate is installed at the bottom of the tank. During rinsing, the height difference between the installation positions of the recovery tank and the rinsing tank is utilized to push water with activated carbon from the recovery tank into the rinsing tank. After releasing some water, close the bottom water discharge valve, then add hydrochloric acid in an amount of about 5% of the amount of the activating material, introduce steam at the opening, and boil for 2 hours. At this point, the impurities mixed in with the carbon react with hydrochloric acid; impurities such as iron oxide and calcium oxide, which were originally insoluble in water, turn into water-soluble compounds of ferric chloride and calcium chloride, which are then removed along with the water. After acid treatment, the acidic water in the tank is drained, and the container is rinsed several times with hot water, keeping the water temperature above 60 degrees Celsius. Since excess hydrochloric acid cannot be easily washed away by water, an appropriate amount of soda ash is added to neutralize it, and the pH value of the aqueous solution in the tank is adjusted to 7–8. Heat with steam for about 15 minutes more, then drain the water. Then wash continuously with hot water until the chloride content in the carbon is less than 0.16%. The total washing time is 4–6 hours. Centrifugal dewatering, drying, and grinding? Centrifugal dewatering: The washed carbon is flushed from the rinsing tank into the carbon storage tank using water. A horizontal piston-type centrifuge is used to reduce the moisture content of activated carbon to 60%–65%. During operation, first start the sand pump to pump the rinsed carbon along with water from the carbon storage tank into the upper carbon tank. Then start the mixer in the upper carbon tank to mix the carbon with the water. Start the centrifuge again; once it is running steadily, open the valve at the bottom of the high-level tank to allow the carbonaceous material to enter the centrifuge for dehydration. The carbon is sent for drying, and the water discharged contains a lot of fine carbon; after the fine carbon is recovered through sedimentation, the wastewater is then released. Drying: The purpose of drying is to reduce the moisture content of activated carbon to below 10%. There are many methods of drying, with the rotary dryer being one of the more commonly used. The rotating body is made of steel plates; the cylinder has a diameter of about 1 meter and a length of 7 meters. It is installed inside a heating furnace and heated indirectly by flue gas. Wet carbon enters the cylinder through one end of the feed port; due to the inclination and rotation of the cylinder, the material moves forward and is continuously discharged at the discharge port. The temperature of the material inside the rotary dryer is required to be between 120 and 130 degrees Celsius. During operation, the feeding amount should be controlled according to the furnace temperature to prevent sparks from forming in the dry carbon. This type of drying furnace has a fast drying speed because the carbon particles can tumble inside the cylinder. Furthermore, the drying furnace uses indirect heating, which prevents direct contact between the carbon and the drying medium, thereby reducing the likelihood of the carbon being contaminated. Grinding: The purpose of grinding is to increase the surface area of activated carbon. It is commonly ground to 120–200 mesh using a ball mill. In a standard ball mill, feeding and discharging occur continuously, and the feed rate is generally adjusted according to the particle size of the product. To prevent activated carbon from increasing iron content during ball milling, a layer of hardwood is usually installed inside the mill, and crushing is carried out using pebbles or ceramic balls. Some factories also use Raymond mills for grinding. The process flow for the intermittent production of powdered activated carbon using zinc chloride is as follows, taking a certain manufacturing plant as an example: The raw material in the form of wood chips is fed into a vibrating screen via a belt conveyor, where it is screened through 8–16 mesh screens. The qualified wood chips then fall into a feed hopper, from where they are sent to a rotary dryer via another belt conveyor for drying; after drying, the moisture content of the wood chips is 10%–15%. The dry wood chips are conveyed to the cyclone separator by a feeding fan, where they fall into a storage bin for later use. Solid zinc chloride is placed in an underground zinc preparation tank, where it is dissolved using recycled concentrated zinc solution or water to produce a zinc chloride solution that meets the required standards. This solution is then pumped into a leaching tank to be mixed with wood chips. The wood chips are fed from the storage bin into the dipping tank, where they are then pumped into the prepared zinc chloride solution and stirred evenly for impregnation. The impregnated zinc shavings are conveyed by a belt conveyor to the carbonization furnace, where they are fed into the furnace for carbonization. Zinc scrap, after carbonization, is called carbonized material, which is pushed by a trolley to an activation furnace for activation; the material after activation is known as activated material. After the activated material is loaded into the feeding hopper and weighed, it is lifted by a winch and poured into a recovery tank, where hot water and hydrochloric acid are added for recovery. The concentration of the first recovery liquid is high; it is sent to the zinc concentrate tank, from where it flows through underground channels to the underground zinc tank in the process for preparing zinc chloride solution, to be used as a component. The low-concentration zinc chloride solutions obtained in the subsequent recoveries were placed in zinc bath tanks of different concentrations for use in the next recovery process. The recovered carbon is poured into a soaking tank with water, heated, and steam is introduced for steaming – a process known as \"iron boiling\" – to remove iron salts. After boiling, the waste acidic water is discharged into underground drains. The carbon is then poured into a rinsing tank, heated, and steam is used for washing it. The activated carbon that has passed the rinsing test is placed in a three-legged centrifuge to be dried. After drying, the carbon is collected in a feed hopper and transported by a belt conveyor to a rotary dryer for further drying. The dried carbon is lifted by a winch and poured into a ball mill for grinding. Finally, it is packaged and stored. What is the purpose of the impregnation process? How to operate it? In the intermittent production of powdered activated carbon using the zinc chloride method, in order to reduce investment in mechanical equipment, the mixing of wood chips with the zinc chloride solution is not carried out using a kneader; instead, an impregnation tank is used to allow zinc chloride to penetrate the wood chips, thereby serving the same purpose as that of a kneader. The method of impregnation varies slightly among different manufacturers, but it remains largely the same. Impregnation is generally carried out using an impregnation tank, also known as a dipping tank. It is a pool on the ground, built with bricks and acid-resistant cement; the pool is 3 meters long, 2 meters wide, and 1 meter deep. Acid-resistant ceramic tiles are applied to the outer surface of the tank to prevent corrosion, and a drainage pipe is installed at the bottom of the tank to remove excess zinc chloride solution after immersion. During the impregnation process, the wood chips that meet the requirements are placed into the impregnation tank. Then, the zinc water pump is activated to pour the prepared and tested zinc chloride solution evenly over the wood chips, until the solution covers them completely. After 8–12 hours of impregnation, the drain at the bottom of the impregnation tank is opened to allow any excess zinc chloride solution to flow into the zinc tank. Two hours later, the zinc chips can be taken to the carbonization process for carbonization. In some factories, the materials are mixed using a certain solid-to-liquid ratio; after thorough mixing, they are left to soak for 8–10 hours, with occasional stirring to ensure that the zinc shavings are evenly distributed. The mixture of zinc shavings and zinc melt should not contain too much zinc; it should be able to be shaped into a lump by hand without any dripping of liquid. For producing activated carbon for various purposes, the process conditions for mixing the materials are as follows: For activated carbon used in sugar production, the concentration of the zinc chloride solution (Bé) is 53–54; the temperature at which the zinc chloride solution is prepared (in degrees Celsius) is above 40; the pH value of the zinc chloride solution is 3–3.2. The weight ratio of wood chips to zinc chloride solution is 1:4, and the soaking time is 8 hours or more. For activated carbon used in pharmaceutical applications, the concentration of the zinc chloride solution (Bé) is 46–47; the temperature at which the zinc chloride solution is prepared (in degrees Celsius) is above 50; the pH value of the zinc chloride solution is 1–1.5. The weight ratio of wood chips to zinc chloride solution is 1:3, with a soaking time of 8 hours or more. The carbonization of zinc shavings is carried out in an open-bottom carbonization furnace. This carbonization furnace operates intermittently. A carbonization furnace uses cast iron plates or 6.5-cm-thick refractory ceramic plates assembled to form a flat carbonization bed, which is why it is called a flat-plate furnace. Beneath the carbonization bed, there is a wall of refractory bricks evenly distributed to provide support, on which cast iron plates or refractory ceramic plates are mounted. At the lower front part of the flat carbonization bed, there is a combustion chamber where the fuel burns. The flue gases generated as a result of this combustion are distributed evenly beneath the flat carbonization bed to heat the cast iron plate or heat-resistant ceramic plate, and then flow through the rear flue ducts to the chimney. Directly above the flat carbonization bed, an exhaust gas hood is installed, through which the exhaust gases generated during the carbonization process are directed outside. During carbonization, zinc shavings are placed in the carbonization furnace; the furnace temperature should be between 400–600 degrees Celsius, while the temperature of the material itself should be between 200–300 degrees Celsius. It is necessary to maintain a uniform flame in the furnace and turn the material around at regular intervals to prevent clumping. When the carbonized material becomes loose, does not clump together, and is black and shiny, it can be removed, and all the carbon in the furnace should be swiftly taken out. The carbonization time is 30–60 minutes. Flat-plate furnaces are simple to construct, but when the cast iron plates come into contact with zinc chloride, corrosion occurs easily; this leads to uneven surfaces, warping, and even burn-through of the plates, resulting in a short service life. At the same time, the contact between zinc shavings and iron plates has the drawback of increasing the iron content in the material. To avoid the aforementioned drawbacks, some manufacturers use refractory ceramic plates in place of cast iron plates. Furthermore, since the carbonization furnace is open, toxic zinc chloride gas leaks out and fills the workshop, severely affecting the working environment.