The Importance of Activated Carbon Filters in Industrial Applications

Industrial activated carbon filter

Water filters that use activated carbon to remove impurities from the water are known as activated carbon filters. Carbon that has undergone processing to increase its surface area is known as “activated carbon.” As water flows through it, pollutants are effectively trapped as a result. Activated carbon is made from a variety of materials, including coal, wood, and coconut shells. The carbon is first activated by heating it to a high temperature in the absence of oxygen. This process creates a porous structure in the carbon, which gives it a large surface area suitable to attract and retain contaminants. When water flows through an activated carbon filter, the contaminants in the water are attracted to the surface of the carbon and are retained. The contaminants can then be removed from the water by backwashing the filter or by replacing the filter cartridge. Activated carbon filters are effective at removing a variety of contaminants from water, including Chlorine VOCs (volatile organic compounds) Pesticides Heavy metals Taste and odour compounds. This blog aims to offer readers valuable insights and suggestions on how Activated Carbon Filters play a crucial role in Industrial Applications, contributing to environmental preservation.

Why do Industrial Applications Require Activated Carbon Filters?

Activated carbon filters are essential in industrial applications for various reasons. They effectively remove contaminants like chlorine, pesticides, heavy metals, and taste/odour compounds from water and air. They also safeguard workers from hazardous chemicals like benzene and formaldehyde. Moreover, these filters prevent environmental contamination by treating industrial wastewater, and protecting ecosystems. Furthermore, they enhance air quality by eliminating pollutants such as VOCs and particulate matter, reducing respiratory risks not only for workers but also for the local community.

How can activated carbon filters purify water in an industrial setting?

Activated carbon filter in wastewater treatment plays a vital role in industries. Activated carbon filtration is a straightforward process where water passes through activated carbon, attracting and retaining contaminants on its surface. Filter effectiveness relies on carbon type, pore size, and water flow rate. The choice of activated carbon filter depends on specific contaminants, like chlorine removal. Filter size corresponds to water volume, while flow rate impacts filter size. Periodic cleaning or backwashing removes accumulated contaminants, and regeneration may be necessary if saturation occurs. 

The Importance of Activated Carbon Filters in Industrial Applications

Activated carbon filter in water treatment plants play a vital role in industrial applications due to their effectiveness in removing a wide range of contaminants. 

Here are a few compelling reasons for its growing importance:

1. Removal of contaminants

Activated Carbon Filters are used in various industrial applications to remove impurities from fluids using adsorption where the substrate has a large surface area within which contaminants can be trapped. 

Some of the industrial applications of activated carbon filters include: 

  • Potable water: Removal of dissolved organic matter, control of taste and odour, removal of lead, chlorine & colour. 
  • Food industry: Decolorization of liquid sugars (glucose, maltose), removal of chlorine and dissolved organic contaminants from potable water after disinfection with chlorine. 
  • Petrochemical: Removal of oil and hydrocarbon contaminations from recycled steam condensate for boiler feed water. 
  • Groundwater treatment: Reduction of total organic halogens and adsorbable organic halogens in industrial reserves of contaminated groundwater. 

2. Protection of equipment and processes

Industrial activated carbon filters provides a cost-effective and efficient solution for eliminating various impurities found in water. Its utilization proves invaluable in safeguarding equipment and processes against potential harm caused by contaminants. ACF finds practical applications across diverse sectors. 

  • In Water treatment plants, ACF shields equipment against corrosion and fouling. 
  • In metal finishing plants, it guards metal surfaces against oxidation and contamination. 
  • Power plants can deploy ACF to safeguard turbines and equipment from corrosion and fouling. 
  • ACF effectively eliminates contaminants like oil, grease, organic compounds, and heavy metals from wastewater safeguarding metal surfaces. 

The versatility and reliability of activated carbon water filters make them an indispensable technology for protecting equipment and enhancing efficiency and longevity.

3. Compliance with regulations and standards

Activated carbon filtration (ACF) offers multiple benefits for achieving water treatment compliance in industrial plants. It aids compliance by: 

Removing regulated contaminants: ACF effectively eliminates substances like chlorine, taste, and odour from process water, meeting organizational regulations with vary with geography. It also removes organic compounds, such as pesticides and herbicides, from wastewater, complying with relevant regulations. 

Enhancing treatment process efficiency: ACF improves the efficiency of other water treatment methods like ion exchange and reverse osmosis. This leads to reduced chemical and energy usage, facilitating compliance with environmental regulations. 

Providing secondary protection: ACF acts as a supplementary layer of defence in water treatment systems. It removes contaminants that may not be eliminated by other processes, ensuring compliance with all applicable regulations and standards. 

By leveraging the best activated carbon water filter, industrial plants can effectively comply with water treatment requirements while achieving efficient and reliable results.

4. Efficiency and Cost-Effectiveness

Activated carbon filters (ACFs) are highly efficient because of their unique and well-developed structural properties. They have a high specific surface area (reaching up to 3000 m2 g−1) and uniform microporosity. This means that they have a large number of tiny pores that can trap contaminants. In addition, the pores in activated carbon are negatively charged, which means that they can attract and hold positively charged contaminants. This is known as adsorption. The efficiency of ACFs can be further improved by using a combination of different types of activated carbon.

ACF water filters provide significant cost savings through various means. Firstly, they eliminate the need for expensive chemical treatments, as the activated carbon efficiently adsorbs contaminants without requiring additional chemicals. Secondly, by removing impurities, ACF water filters prevent equipment and process damage, resulting in reduced maintenance and replacement expenses. Moreover, the use of ACF can prolong the lifespan of downstream treatment systems like ion exchange or reverse osmosis by reducing fouling and improving their efficiency. 

To summarize, among the key benefits of activated carbon filter water filters are their efficiency and cost-effectiveness, making them a worthwhile investment for industries, guaranteeing the delivery of high-quality water while minimizing operational costs.

5. Environmental Benefits

Activated carbon filters (ACFs) offer significant environmental benefits, encompassing reduced water and air pollution, waste reduction, and energy efficiency. ACFs contribute to curbing water pollution by effectively eliminating contaminants prior to their discharge, thereby safeguarding aquatic ecosystems and human well-being. 

Similarly, ACFs aid in removing contaminants from the air, such as volatile organic compounds (VOCs), leading to improved air quality and a decreased risk of respiratory issues. ACFs also play a role in waste reduction by facilitating the recovery and recycling of contaminants, conserving resources and minimizing landfill waste. 

Additionally, ACFs demonstrate energy efficiency in purifying water and air, resulting in reduced greenhouse gas emissions and improved environmental impact within industrial processes. ACFs are a versatile and effective technology applicable across diverse industrial sectors. 

Specific examples include the textile industry, where ACFs remove dyes and pollutants from wastewater, and the metal finishing industry, where ACFs extract heavy metals to prevent environmental accumulation and potential risks to human health.

Wipro Water Approach

Wipro Water is a division of Wipro Infrastructure Engineering that provides integrates highly customized water and wastewater treatment solutions for diverse and largescale industrial water requirements and provides integrated service and spares management. With over 40+ years of experience in the water treatment industry, Wipro Water has served over 500+ customers in 25 different industry segments. The company offers end-to-end, custom-designed integrated plants for a variety of sectors. Their extensive knowledge in activated carbon filters, coupled with a wide array of water treatment offerings, positions them as a valuable resource for meeting diverse industrial needs.

Wipro Water’s activated carbon filters (ACFs) are designed with utmost precision and efficiency to meet various treatment requirements. These filters consist of different grades of carbon granules, supported by gravel, pebble, and sand. The choice of carbon grades is based on the specific treatment needs. The activated carbon used in these filters possesses an optimal iodine value, ensuring effective removal of contaminants. The Activated Carbon Filters (ACFs) play a vital role as the second stage of filtration following Multi-Grade Filters (MGFs) or Pressure Sand Filters (PSFs) in various industrial applications including Effluent Treatment Plants (ETPs), Sewage Treatment Plants (STPs), Water Treatment Plants (WTPs), and Effluent Treatment Processes (ETPs). Noteworthy features of Wipro Water’s ACFs include long-life activated carbon with a high adsorption capacity (900 Iodine value) for efficient dechlorination, removal of organic contaminants, and color. The filters deliver consistent treated water quality, and their pressure vessels are constructed with non-corrosive FRP material and UPVC front piping. They are designed to operate within a pressure range of 3.5 – 5.0 Kg/cm2 and are capable of handling feed Total Suspended Solids (TSS) levels of less than 5 ppm. The ACFs are available in both manual and auto operation modes and are offered in MSEP/MSRL material (IS2062). The capacity range of these filters spans from 0.4 m3/hr to 55 m3/hr source water flow, catering to a wide range of industrial needs.

With an unwavering commitment to delivering top-notch water treatment solutions, Wipro Water stands out as a trusted partner for industrial companies.