Product · Steam activation

Rotary activation furnace — 0.5 to 3 t/h at 850–950 °C

A three-zone refractory shell, variable-speed drive and indirect hot-gas jacket that hold iodine value within ±30 mg/g across a full shift, on shell char from 2 mm to 12 mm.

Capacity

0.5–3t/h

Activation temp.

850–950°C

Iodine value

900–1,100mg/g

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Refractory-lined rotary kiln shell during assembly in our workshop — HL series · Henan, ChinaHL SERIES

180+lines supplied0.5–3 t/hfinished carbon, five models15–25 don-site commissioning2 yrmechanical warrantyEngineer-written answers, not sales copy

Key specifications

Mechanical and process data, HL-1200 (1 t/h) as reference.
Parameter	Value
Finished capacity	1.0 t/h · 24 t/day
Char feed rate	1.65–1.75 t/h
Shell diameter × length	1.2 m × 18 m
Rotation speed	0.3–1.2 rpm, VFD
Installation slope	2.5°
Activation temperature	850–950 °C, 3 zones
Residence time	45–90 min
Steam consumption	1.8 t/h at 0.8 MPa
Heat consumption	2,800–3,500 kJ/kg carbon
Fuel	Natural gas / LPG / diesel / biomass gas
Refractory	High-alumina castable + 65 mm insulation
Shell material	Q345R plate, 16 mm, stress-relieved
Installed power	75 kW
Discharge temperature	≤ 80 °C after water jacket
Instrumentation	PLC + 3-zone thermocouple + O₂ trim
Design life	Lining 3–5 years, shell 12+ years

What happens inside the shell

Zone 1 — feed and dry (200–400 °C)

Wet char enters through a double flap valve that keeps air out. Residual moisture flashes off; the zone is deliberately long so water leaves before the material reaches activation temperature.

Zone 2 — heat to reaction temperature (400–850 °C)

Indirect hot gas from the combustion chamber passes through the jacket. Volatiles still bound in the char are driven off and burned in the chamber, which is why fuel consumption drops once the line is stable.

Zone 3 — steam activation (850–950 °C)

Superheated steam enters through a distribution pipe running the length of the kiln. The endothermic reaction C + H₂O → CO + H₂ opens pores. Residence time and steam ratio here decide the iodine value.

Discharge and cool

Carbon drops into a water-jacketed screw cooler and reaches below 80 °C before contact with air — above that, hot carbon burns off the surface area you just paid for.

Gas handling

Off-gas passes a cyclone, a waste-heat boiler if fitted, a scrubber and an ID fan. Particulate and CO are controlled here, not at the stack.

Where iodine value is actually lost

Iodine value is set in the last 8 metres of the kiln, and most of the losses we are called in to fix come from four mechanical causes rather than process chemistry.

First, a lining that has spalled in zone 3 creates a cold patch; carbon passing that patch is under-activated and blends into the good product. Second, a steam pipe with blocked or oversized holes delivers uneven steam along the length — the kiln average looks correct while half the cross-section is starved. Third, feed rate creep: operators push tonnage up 10% to hit a shipment, residence time falls, and iodine value drops 40 mg/g before anyone checks. Fourth, discharge temperature above 100 °C, which burns off surface area after the fact.

Our control philosophy addresses each one directly: three independent thermocouples with trend alarms, a removable steam distribution pipe with a documented hole pattern, feed rate interlocked to kiln speed rather than set independently, and a discharge cooler sized with 30% margin.

Model range

All figures on a finished-carbon basis. Intermediate sizes are available but standard models keep spare parts and lining schedules simple.
Model	Capacity	Char feed	Steam	Power	Footprint
HL-800	0.5 t/h · 12 t/d	0.85 t/h	1.0 t/h	55 kW	18 × 8 m
HL-1200	1.0 t/h · 24 t/d	1.70 t/h	1.8 t/h	75 kW	24 × 10 m
HL-1500	1.5 t/h · 36 t/d	2.50 t/h	2.6 t/h	95 kW	26 × 10 m
HL-1800	2.0 t/h · 48 t/d	3.35 t/h	3.2 t/h	110 kW	28 × 11 m
HL-2200	3.0 t/h · 72 t/d	5.00 t/h	4.8 t/h	160 kW	34 × 12 m

Scope of supply

Rotary shell with refractory lining, cast and cured on a logged curve before dispatch.
Combustion chamber, burner and fuel train for gas, LPG, diesel or biomass gas.
Steam distribution pipe, superheater and feed-water pump set (steam boiler optional).
Variable-speed drive with auxiliary motor for maintenance rotation.
Water-jacketed discharge cooler and screw conveyor.
PLC cabinet with three-zone temperature control, trend recording and alarm log.
Cyclone, scrubber, ID fan and ducting to the stack flange.
Foundation drawings, utility schedule, O&M manual and spare parts list for two years.

A note on quoted capacity

Ask whether a quoted tonnage refers to finished carbon or to char feed. The two differ by roughly 40%, and a quotation that does not state the basis cannot be compared with one that does. Ours are always finished carbon, dry basis, at the stated iodine value.

Questions buyers ask before ordering

Straight answers with numbers. If yours is missing, send it over.

What iodine value can a rotary furnace reach?

900–1,100 mg/g from coconut shell char, 900–1,050 mg/g from hazelnut shell char and 900–1,000 mg/g from palm kernel shell char. Above 1,100 mg/g requires either a longer residence time at reduced throughput or a two-stage activation, which we quote separately.

How much steam does the furnace need?

1.2–2.0 kg of steam per kg of char, so a 1 t/h line needs about 1.8 t/h of steam at 0.8 MPa. Steam quality matters more than quantity: wet steam cools zone 3 and shows up as a 30–50 mg/g iodine drop.

Gas, diesel or biomass — which fuel should I choose?

Natural gas is the cheapest to control and gives the tightest temperature profile. Diesel is common where gas is unavailable but costs more per tonne. Biomass gas works if the calorific value is stable; we size the combustion chamber for the lower heating value you actually have, not a laboratory figure.

How is the lining maintained?

Inspect zone 3 every 6 months through the inspection door. Typical lining life is 3–5 years depending on thermal cycling. We supply a patch kit and a cure schedule, and a relining crew can be on site in about 10 days.

Can the furnace run at partial load?

Yes, down to about 60% of design capacity by reducing feed and kiln speed together. Below that, temperature uniformity suffers and iodine value becomes unstable — for very low tonnage, the 0.5 t/h model running intermittently is a better answer than a large kiln at 20% load.

Sizing a line? Start with the mass balance.

Send the raw material, target tonnage and finished spec. You get a configuration, a utility schedule and a budget range — not a brochure.

Get a quotation +86 180 3911 8358