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DUCON Activated Carbon Filters

DUCON Activated Carbon Filters

DUCON activated carbon filters for VOC, odor and gaseous pollutant control: compact round design, easy maintenance and high performance with pre-filtration.

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DUCON Activated Carbon Filters

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DUCON Activated Carbon Filters

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DUCON Activated Carbon Filters

DUCON activated carbon filters use a dimensionally stable round design and can be safely integrated into dust extraction and ventilation systems. They remove harmful gaseous air pollutants effectively from industrial exhaust streams.

The activated carbon is selected and adapted according to the substances to be filtered. It adsorbs harmful gases, reduces odors, and cleans exhaust air. By using these filters, plants can minimize negative impacts on employees, the environment, and nearby residents.

Operating Principle

Raw gas enters the filter through the inlet manholes. The air to be cleaned is distributed evenly in the inlet chamber and then passes uniformly through the activated carbon bed. The carbon filling is held inside circular perforated sheet-metal cassettes.

As the gas passes through these cassettes, pollutants are adsorbed by the activated carbon; the cleaned gas is directed upward through the central tube. Activated carbon saturation progresses from the outside toward the inside over time. Once full saturation is reached, the carbon filling is replaced.

The clean gas is discharged through the stack installed at the top of the filter. To maintain optimum function and performance, pre-filtration is recommended before feeding raw gas into the activated carbon filter.

Technical Specifications

  • Nominal air flow: 1,500-90,000 m³/h per filter unit
  • Solids content: Solid matter in the gas stream should not exceed 5 mg/Nm³.

Equipment Features

  • Robust construction with separate filling and discharge manholes
  • Vertical ladder and access hatches suitable for easy maintenance operations
  • Membrane-type explosion relief panels mounted on the body for pressure relief
  • High-quality paint system for comprehensive corrosion protection
  • Full stainless-steel version available for aggressive exhaust gases
  • Impregnated activated carbon option for specific gas-filtration requirements

Advantages

  • Maximum dimensional stability: Vibration-free body structure independent of low or high pressure conditions
  • Safety: Pressure-resistant design can be implemented easily for explosion-risk applications
  • Compact design: Vertical installation requires a small footprint
  • Integrated stack: The filter body can also serve as the stack base, saving additional floor area
  • Easy maintenance: Fast filling and discharge with big-bag handling without dismantling
  • Flexibility: Easy integration into existing plants
  • Efficiency: Low pressure drop thanks to a large surface area and optimized bed thickness

Operating Principle (Adsorption)

  • The gas stream passes through an activated-carbon bed (adsorber column) with a very high internal surface area; pollutant molecules are physically retained in the carbon micropores (adsorption).
  • The internal surface area of activated carbon is typically on the order of 500-1500 m²/g; this large surface provides the sites needed to capture even trace pollutants at low concentration.
  • Capture efficiency depends on contact time (bed depth / superficial velocity - EBCT) and gas temperature; because adsorption is exothermic, capacity falls as temperature rises.
  • When the carbon saturates, pollutant appears at the outlet (breakthrough / saturation); at this point the carbon is replaced or regenerated.
  • This stage is usually placed after a dust filter or scrubber; incoming dust and moisture must be controlled, since dust blinds the pores and excess moisture weakens adsorption.

Technical Specifications and Design Parameters

  • Carbon type: granular activated carbon (GAC) as standard; impregnated carbon per target (e.g. sulfur/iodide-impregnated for mercury, caustic/alkaline-impregnated for H2S).
  • Operating temperature: typically preferred below 40-50°C; adsorption capacity is higher at lower temperature. For safety the carbon bed is generally kept below ~60°C (hot carbon carries a self-ignition / bed-fire risk).
  • Superficial gas velocity: typically in the 0.2-0.6 m/s range; bed depth and empty-bed contact time (EBCT) are sized to the target efficiency.
  • Pressure drop (ΔP): depends on bed depth and particle size, typically a few hundred Pa to a few mbar.
  • Target efficiency: with correct sizing, typically 90-99+% removal of the target compound; depends on inlet concentration and contact time.
  • Configuration: fixed-bed adsorber columns/beds; parallel modules at high flow, with replaceable cartridge/bed layout for continuous duty.

Carbon Types and Regeneration

  • Standard granular activated carbon (GAC) - the most common choice for general VOC and odor removal.
  • Sulfur (S) impregnated carbon - chemical capture of mercury (Hg) vapor; in waste incineration and flue-gas lines.
  • Iodide/KI impregnated carbon - enhanced capture of elemental mercury and certain acidic gases.
  • Alkaline/caustic impregnated carbon - for hydrogen sulfide (H2S) and acidic odor components.
  • After breakthrough: carbon changeout (disposal/recovery of spent carbon) or thermal/steam regeneration to restore activity.
  • Regeneration feasibility depends on the pollutant; on impregnated carbon, chemically bound species are usually not regenerated and the carbon is replaced.

Applications (Final Polishing)

  • Odor control - wastewater treatment plants, composting and solid-waste lines, food processing.
  • VOC removal - paint/coating, solvent-using lines, chemical and petrochemical flue gases.
  • Mercury (Hg) capture - final stage in waste-to-energy, cement, and some metallurgical flue gases.
  • Dioxin/furan capture - final polishing of trace organic pollutants on waste-incineration lines.
  • H2S and sulfur compounds - odor/corrosion control in biogas, sewage, and refinery lines.
  • Trace-pollutant polishing - pulling residual gas-phase pollutants at a scrubber or baghouse outlet below the emission limit.

Frequently Asked Questions

What is an activated carbon filter?

An activated carbon filter is a treatment stage that retains (adsorbs) gas-phase pollutants such as VOCs, odor, H2S, mercury (Hg), and dioxins/furans onto the porous carbon surface. It is typically used as a final polishing stage after a dust filter or scrubber. It is not a wet filter.

How does activated carbon adsorption work?

The gas passes through an activated-carbon bed with a very high internal surface area (typically 500-1500 m²/g), and pollutant molecules physically attach to the carbon micropores. This physical attachment is called adsorption; it can capture even trace pollutants at low concentration.

Which pollutants does an activated carbon filter remove?

Mainly volatile organic compounds (VOCs), odors, hydrogen sulfide (H2S), mercury (Hg) vapor, dioxins/furans, and other trace gas-phase pollutants. Standard granular carbon (GAC) or impregnated carbon is selected according to the target compound.

What is the difference between GAC and impregnated carbon?

GAC (granular activated carbon) is the standard carbon used for general VOC and odor removal. Impregnated carbon is dosed to chemically capture a specific pollutant: sulfur/iodide-impregnated carbon is preferred for mercury, and caustic/alkaline-impregnated carbon for H2S and acidic odors.

When is the carbon replaced (what is breakthrough)?

When the carbon saturates, pollutant concentration starts to rise at the outlet; this is called breakthrough (saturation). At this point the carbon is replaced or, where feasible, its activity is restored by thermal/steam regeneration. Change frequency depends on inlet load, contact time, and carbon quantity.

At what temperature does an activated carbon bed operate?

Because adsorption capacity is higher at lower temperature, operation below 40-50°C is typically preferred. Since adsorption is exothermic and hot carbon carries a self-ignition / bed-fire risk, the bed is generally kept below ~60°C with a safe margin.

What efficiency does an activated carbon filter achieve?

With correct sizing (adequate bed depth and contact time), removal of the target compound is typically 90-99+%. Efficiency depends on inlet concentration, empty-bed contact time (EBCT), gas temperature, and moisture level.

Why is an activated carbon filter placed after a scrubber or baghouse?

Activated carbon is a polishing stage; incoming dust and moisture must be controlled. Dust blinds the carbon pores and excess moisture weakens adsorption. The carbon bed is therefore placed at the outlet of a filter or scrubber that has already removed the dust and/or soluble gases.

Who manufactures activated carbon adsorption systems in Turkey?

MDSJ Process designs, manufactures, installs, and commissions activated-carbon adsorber systems in Turkey under the DUCON brand (MDSJ holds the DUCON trademark rights for Europe, Asia, and Turkey). It has produced turnkey air-pollution-control equipment since 1986.

Quick Info

Adsorbs gas-phase pollutants such as VOCs, odor, H2S, mercury (Hg), and dioxins/furans onto the porous carbon surface
Operates as a final polishing stage after a filter or scrubber - it is not a wet filter
Granular (GAC) and impregnated carbon options let the bed be tailored to the target pollutant

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