KWS Manufacturing

Special Thermal Processor for Cooling Activated Carbon

Download PDF Brochure Special Thermal Processor for Cooling Activated Carbon: ADA Carbon Solutions, LLC

Plant Name and Location

ADA Carbon Solutions, LLC
Coushatta, LA

Consulting Engineer

BE& K Engineering
Birmingham, AL

General Description

ADA Carbon Solutions needed a solution for conveying and cooling high temperature activated carbon. The existing vibratory coolers were not providing adequate cooling and could not meet the desired capacity requirements. ADA Carbon Solutions is a leader in clean coal technology and associated specialty chemicals. The company develops and implements proprietary environmental technology and specialty chemicals that enable coal-fueled power plants to enhance existing air pollution control equipment, maximize capacity and improve operating efficiencies. Activated carbon is used in Activated Carbon Injection (ACI) systems at coal-fired power plants to reduce emissions of mercury and sulfuric, hydrochloric and other acid gases.

Engineers from KWS worked closely with BE&K, the engineering firm hired by ADA Carbon Solutions. BE&K is a division of KBR Inc. and offers a full spectrum of construction, engineering, and maintenance services to clients around the world. Together, KWS and BE&K designed thermal processors able to achieve both the cooling and the conveying requirements of this extremely demanding application.

Design Parameters

  1. Product Type: Activated Carbon
  2. Product Inlet Temperature: 1,450°F
  3. Product Outlet Temperature: 250°F
  4. Activated carbon is calcined and enters the thermal processor at 1,450-degrees F. It is somewhat sluggish and particle size can range from powdery fines to random pieces up to one inch.
  5. Material Density: 30 Lbs. per Cubic Foot
  6. Thermal Processor Capacity: 200 Cubic feet per Hour
  7. Duty: 24 Hours per Day, 7 Days per Week

KWS Advantages

KWS designed thermal processors with the ability to handle the enormous heat load while meeting capacity requirements and staying within the space constraints of the customer’s existing plant layout. KWS provided a full range of engineering expertise on the project including structural supports, access platforms, screening equipment, instrumentation as well as chute work to connect to existing upstream and downstream equipment.

Special Features

The KWS thermal processor utilized independent twin drive reducers and motors for complete redundancy and lower stresses on individual components. Each thermal process was designed in strict accordance with the ASME Boiler and Pressure Vessel Code. Special plate, pipe, and sheet steel alloys were used to meet the demands of the extreme product temperatures as well as the internal pressures of the cooling medium within the processor’s cooling jacket and hollow flight screws.


"The KWS thermal processors are performing above expectations. The units have been in service now for over four years with minimal downtime and maintenance."

Victor Tingle – ADA Carbon Solutions, LLC (2012)


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