Carbonization Furnace
GEMCO carbonization furnace features the indirect rotary kiln design and can be applied in the material carbonization section of both coal-based and wood-based activated carbon production. It can also be used for the continuous carbonization of other granular materials and debris materials, with a wide range of applications and high compatibility.
Long service life
Continuous Production
High carbonization efficiency
High automation degree
The Carbonization Furnace Designed for Continuous Production
The rotary kiln drum of the carbonization furnace is made of stainless steel No. 304 material, ensuring durability and resistance to wear and tear. The furnace’s heating system features a gas combustion unit with high-frequency welding, and the outer shell is lined with high-temperature refractory fiber. The equipment adopts a stable horizontal structure and can operate continuously for 24 hours, achieving the goal of continuous production and overcoming the disadvantages of traditional intermittent kilns. This combination guarantees a long service life and minimizes maintenance needs, providing a hassle-free experience for our users.
Uniform Heating for Superior Material Quality
GEMCO Energy’s externally heated carbonization kiln features a combustion chamber created by an insulating cover and the outer wall of the kiln. The burner flame is directed at the kiln’s shell, allowing heat to be conducted through the shell to the material inside. This method ensures more uniform heating of the material. The materials inside the kiln chamber will not come into contact with oxygen or open flames, and there will be no erosion on the surface of the materials and the surface strength will not be damaged. As a result, the carbonized material produced by our furnace boasts superior quality, with a smooth surface and high strength.
Low-Temperature Carbonization Principle
The carbonization process in our furnace involves low-temperature dry distillation of the material. During this process, the material is gradually heated under low-temperature conditions and in an oxygen-free environment. The slow heating allows for orderly thermal decomposition of the material’s colloidal substances, maximizing the formation of fixed carbon that forms the skeleton structure. The low final carbonization temperature prevents graphitization of the carbonized material, resulting in a product with a higher content of C-H chemical bonds, which is beneficial for subsequent activation reactions.
Energy-Efficient Counter-Current Process
Our externally heated rotary kiln carbonization furnace utilizes a counter-current principle. As the material is heated and carbonized inside the kiln, a large amount of volatile gases are released. These gases move in the opposite direction to the material flow, creating a counterflow effect. The volatile gases, which exceed 120°C, are directed into a secondary combustion chamber where they undergo excess-air combustion, releasing substantial heat. The high-temperature exhaust gases produced are then routed through a pipe into the heating jacket of the carbonization furnace, providing heat for the material carbonization through thermal radiation. This innovative counterflow process ensures higher energy efficiency and optimal utilization of the released heat.
Carbonization in Activated Carbon Preparation
Carbonization is a significant step in the preparation of activated carbon. This process involves the thermal treatment of raw materials. Within the carbonization equipment, under appropriate temperatures, the raw materials undergo a reaction where most of the non-carbon elements—hydrogen and oxygen—are expelled as gases due to high-temperature decomposition. This process removes volatile matter and moisture from the raw materials. The released carbon atoms combine to form ordered crystalline structures known as basic graphite microcrystals. This causes the carbon particles to develop initial pores, giving them the original structure of activated carbon. The material obtained after carbonization is called carbonized material. Although it possesses some adsorption capacity, this capacity is very low and requires further activation processes to become qualified activated carbon.
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Composition of the Carbonization Furnace
The carbonization furnace is a comprehensive system composed of a cylinder, kiln tyres, a girth gear, support rollers, thrust wheels, a feeding device, and a secondary combustion chamber. Using the preparation of wood-based activated carbon as an example, the crushed and screened raw materials are fed into the furnace via a screw conveyor. The furnace’s carbonization process is divided into several sections: a preheating section (temperature: 300°C), a high-temperature carbonization section (600°C), and a final cooling section (300-350°C).
Initially, the materials enter the preheating section for preliminary heating. As the furnace rotates, the materials move towards the high-temperature carbonization section, where the main purpose is to release ash and volatiles from the materials, thereby enhancing the strength and hardness of the carbonized material.
After carbonization, the materials proceed to the cooling section at the end of the furnace. This section is equipped with a spiral coil for preliminary cooling, followed by a water cooling unit for further cooling. The end product is high-quality carbonized material.
GEMCO Carbonization Furnace Parameters
| Equipment specification (m) | Auxiliary power (kW) | Carbonization capacity (t/d) | Kiln size (mm) |
| Φ1.2m×15m | 18.5 | 8 | 15000*1500*4000 |
| Φ1.5m×15m | 25 | 10 | 18000*1500*4000 |
GEMCO Carbonization Furnace Working Principle
The externally heated rotary kiln carbonization furnace is one of the most commonly used carbonization devices, characterized by its independently distributed kiln chamber. During operation, each independent kiln chamber performs carbonization and decomposition internally. Upon completion, the decomposed material is discharged from the end of the kiln cylinder, operating in a parallel flow manner.
The carbonization decomposition products are conveyed through volatile matter pipes into the incinerator for combustion. With adequate air distribution via air allocation pipes, the volatile gases undergo excess oxygen combustion. This thorough combustion in the incineration chamber releases a significant amount of heat, and the resulting high-temperature exhaust gas is expelled through high-temperature exhaust pipes.
The heat is then transferred back into the furnace body through heat radiation, providing the necessary heat for the materials. The low-temperature exhaust gas exiting the furnace body is directed through exhaust pipes to the tail gas treatment device.
One of the key advantages of this workflow is the efficient reuse of energy. It can be output as a thermal power source and also provide heat for steam boilers, thereby maximizing energy utilization.
Carbonization Furnace Applications
Coal-Based Activated Carbon
Biomass Carbonization
Coconut Shell Activated Carbon
