{"id":29587,"date":"2025-09-26T14:42:00","date_gmt":"2025-09-26T09:12:00","guid":{"rendered":"https:\/\/www.haycarb.com\/resources\/activated-carbon-development-for-a-powered-air-purifying-respirator-copy\/"},"modified":"2025-10-14T17:30:25","modified_gmt":"2025-10-14T12:00:25","slug":"resolving-operational-risks-due-to-carbon-fine-generation-in-activated-carbon-for-de-chlorination-at-a-beverage-bottling-plant-in-europe","status":"publish","type":"page","link":"https:\/\/www.haycarb.com\/de\/resources\/resolving-operational-risks-due-to-carbon-fine-generation-in-activated-carbon-for-de-chlorination-at-a-beverage-bottling-plant-in-europe\/","title":{"rendered":"Resolving Operational Risks due to Carbon Fine Generation in Activated Carbon for De-Chlorination at a Beverage Bottling Plant in Europe"},"content":{"rendered":"<div data-elementor-type=\"wp-page\" data-elementor-id=\"29587\" class=\"elementor elementor-29587\" 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data-elementor-post-type=\"page\">\n\t\t\t\t<div class=\"elementor-element elementor-element-b9926ef animated-slow e-flex e-con-boxed elementor-invisible e-con e-parent\" data-id=\"b9926ef\" data-element_type=\"container\" data-settings=\"{&quot;background_background&quot;:&quot;classic&quot;,&quot;animation&quot;:&quot;fadeIn&quot;}\">\n\t\t\t\t\t<div class=\"e-con-inner\">\n\t\t\t\t<div class=\"elementor-element elementor-element-93f7de9 elementor-widget elementor-widget-heading\" data-id=\"93f7de9\" data-element_type=\"widget\" data-widget_type=\"heading.default\">\n\t\t\t\t\t<h1 class=\"elementor-heading-title elementor-size-default\">Resolving Operational Risks due to Carbon Fine Generation in Activated Carbon for Dechlorination at a Beverage Bottling Plant in Europe <\/h1>\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-8cce9d4 elementor-hidden-widescreen elementor-hidden-desktop elementor-hidden-laptop elementor-hidden-tablet_extra elementor-hidden-tablet elementor-hidden-mobile_extra elementor-hidden-mobile elementor-widget elementor-widget-bdt-breadcrumbs\" data-id=\"8cce9d4\" data-element_type=\"widget\" data-widget_type=\"bdt-breadcrumbs.default\">\n\t\t\t\t\t<div class='bdt-ep-breadcrumbs-wrapper'><ul class=\"bdt-ep-breadcrumb breadcrumb-align-left\"><li><a href=\"https:\/\/www.haycarb.com\/de\/\">Haycarb<\/a><\/li>\n<li><span> Seite<\/span><\/li>\n<\/ul><\/div>\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-20bd23e text-left elementor-widget elementor-widget-tp-breadcrumbs-bar\" data-id=\"20bd23e\" data-element_type=\"widget\" data-widget_type=\"tp-breadcrumbs-bar.default\">\n\t\t\t\t\t<div id=\"bread69dc33197c34f\" class=\"pt_plus_breadcrumbs_bar\"  \"><div class=\"pt_plus_breadcrumbs_bar_inner bred_style_1\"><nav id=\"breadcrumbs\"><span class=\"bc_home\"><a class=\"home_bread_tab\" href=\"https:\/\/www.haycarb.com\/de\/\">Haycarb<i class=\"fa fa-chevron-right bread-sep-icon\" ><\/i><\/a><\/span> <span class=\"del\"><\/span> <span class=\"current on-off-current\"><div class=\"current_tab_sec\">Seite<\/div><\/span><\/nav><\/div><\/div>\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t<div data-bdt-parallax=\"border-color: #D11111,#AFAFAF;\" class=\"elementor-element elementor-element-b109734 e-flex e-con-boxed e-con e-parent\" data-id=\"b109734\" data-element_type=\"container\" data-settings=\"{&quot;background_background&quot;:&quot;classic&quot;}\">\n\t\t\t\t\t<div class=\"e-con-inner\">\n\t\t\t\t<div class=\"elementor-element elementor-element-6511be0 elementor-widget elementor-widget-spacer\" data-id=\"6511be0\" data-element_type=\"widget\" data-widget_type=\"spacer.default\">\n\t\t\t\t\t\t\t<div class=\"elementor-spacer\">\n\t\t\t<div class=\"elementor-spacer-inner\"><\/div>\n\t\t<\/div>\n\t\t\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t<div class=\"elementor-element elementor-element-99fff56 animated-slow e-flex e-con-boxed elementor-invisible e-con e-parent\" data-id=\"99fff56\" data-element_type=\"container\" data-settings=\"{&quot;animation&quot;:&quot;fadeIn&quot;}\">\n\t\t\t\t\t<div class=\"e-con-inner\">\n\t\t<div class=\"elementor-element elementor-element-51e2b48 e-con-full e-flex e-con e-child\" data-id=\"51e2b48\" data-element_type=\"container\">\n\t\t\t\t<div class=\"elementor-element elementor-element-e2ac3da elementor-widget__width-initial animated-slow elementor-invisible elementor-widget elementor-widget-heading\" data-id=\"e2ac3da\" data-element_type=\"widget\" data-settings=\"{&quot;_animation&quot;:&quot;fadeIn&quot;}\" data-widget_type=\"heading.default\">\n\t\t\t\t\t<h2 class=\"elementor-heading-title elementor-size-default\">Einf\u00fchrung<\/h2>\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-9568a1e elementor-widget__width-initial elementor-widget-laptop__width-initial elementor-widget-tablet__width-inherit elementor-widget-mobile__width-inherit elementor-widget elementor-widget-text-editor\" data-id=\"9568a1e\" data-element_type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t\t\t\t\t\t<p>Haycarb has long been recognized for delivering specialized industrial activated carbon filtration solutions that ensure excellence in water treatment and purification. Among our core offerings is specialized <a style=\"color: #424242; font-weight: 400; line-height: 24px; text-decoration: underline;\" href=\"https:\/\/www.haycarb.com\/de\/activated-carbon\/\">Aktivkohle<\/a> for dechlorination in beverage water treatment, engineered to effectively remove residual disinfectant agents generated by chlorine gas, sodium hypochlorite (NaOCl), and calcium hypochlorite [Ca(OCl)\u2082]. These carbons are specifically designed to adsorb raw water containing organic compounds (VOCs) and residual contaminants responsible for undesirable taste and odor, thereby enhancing overall water quality.<\/p><p>In water treatment applications, two primary grades of activated carbon are widely used:<\/p><p>\u2022\u00a0 <strong>Standard Carbon<\/strong> \u2013 optimized for de-chlorination and removal of free chlorine.<br \/>\u2022\u00a0 <strong>Catalytic Carbon<\/strong> \u2013 designed for the more complex removal of chloramine species.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-9218db0 elementor-widget elementor-widget-image\" data-id=\"9218db0\" data-element_type=\"widget\" data-widget_type=\"image.default\">\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<img fetchpriority=\"high\" decoding=\"async\" width=\"768\" height=\"432\" src=\"https:\/\/www.haycarb.com\/wp-content\/uploads\/2025\/10\/Standard-Catalytic-Carbon-768x432.webp\" class=\"attachment-medium_large size-medium_large wp-image-29838\" alt=\"\" srcset=\"https:\/\/www.haycarb.com\/wp-content\/uploads\/2025\/10\/Standard-Catalytic-Carbon-768x432.webp 768w, https:\/\/www.haycarb.com\/wp-content\/uploads\/2025\/10\/Standard-Catalytic-Carbon-300x169.webp 300w, https:\/\/www.haycarb.com\/wp-content\/uploads\/2025\/10\/Standard-Catalytic-Carbon-1024x576.webp 1024w, https:\/\/www.haycarb.com\/wp-content\/uploads\/2025\/10\/Standard-Catalytic-Carbon-1536x864.webp 1536w, https:\/\/www.haycarb.com\/wp-content\/uploads\/2025\/10\/Standard-Catalytic-Carbon-2048x1152.webp 2048w\" sizes=\"(max-width: 768px) 100vw, 768px\" \/>\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t<div class=\"elementor-element elementor-element-e84e121 animated-slow e-flex e-con-boxed elementor-invisible e-con e-parent\" data-id=\"e84e121\" data-element_type=\"container\" data-settings=\"{&quot;animation&quot;:&quot;fadeIn&quot;}\">\n\t\t\t\t\t<div class=\"e-con-inner\">\n\t\t<div class=\"elementor-element elementor-element-55e0b1a e-con-full e-flex e-con e-child\" data-id=\"55e0b1a\" data-element_type=\"container\">\n\t\t\t\t<div class=\"elementor-element elementor-element-ca1ab5f elementor-widget__width-initial elementor-widget-laptop__width-initial elementor-widget-tablet__width-inherit elementor-widget-mobile__width-inherit elementor-widget elementor-widget-text-editor\" data-id=\"ca1ab5f\" data-element_type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t\t\t\t\t\t<p>For one of the largest beverage producers in Europe, Haycarb supplied a standard Activated Carbon grade PHO 14&#215;45 AW for de-chlorination carbon to meet chlorine removal requirements, as part of their comprehensive approach to drinking water treatment.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t<div class=\"elementor-element elementor-element-b038575 e-con-full e-flex e-con e-child\" data-id=\"b038575\" data-element_type=\"container\">\n\t\t\t\t<div class=\"elementor-element elementor-element-6aa2575 elementor-widget__width-initial animated-slow elementor-invisible elementor-widget elementor-widget-heading\" data-id=\"6aa2575\" data-element_type=\"widget\" data-settings=\"{&quot;_animation&quot;:&quot;fadeIn&quot;}\" data-widget_type=\"heading.default\">\n\t\t\t\t\t<h2 class=\"elementor-heading-title elementor-size-default\">Problem Identification<\/h2>\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-3625ffd elementor-widget__width-initial elementor-widget-laptop__width-initial elementor-widget-tablet__width-inherit elementor-widget-mobile__width-inherit elementor-widget elementor-widget-text-editor\" data-id=\"3625ffd\" data-element_type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t\t\t\t\t\t<p>The customer had been facing performance limitations with their previous activated carbon supplier and decided to switch to Haycarb. Following successful laboratory-scale validation of our PHO 14&#215;45 AW grade, they proceeded with a commercial order for use in their large-scale carbon filtration system.<\/p><p>During the initial filter operation, however, the customer observed excessive dust generation from the new carbon. This resulted in an increased pressure drop across the system and had an adverse impact on treated water clarity and quality.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t<div class=\"elementor-element elementor-element-2838824 e-con-full e-flex e-con e-child\" data-id=\"2838824\" data-element_type=\"container\">\n\t\t\t\t<div class=\"elementor-element elementor-element-e58b158 elementor-widget__width-initial animated-slow elementor-invisible elementor-widget elementor-widget-heading\" data-id=\"e58b158\" data-element_type=\"widget\" data-settings=\"{&quot;_animation&quot;:&quot;fadeIn&quot;}\" data-widget_type=\"heading.default\">\n\t\t\t\t\t<h2 class=\"elementor-heading-title elementor-size-default\">Root Causes Identified:\n<\/h2>\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-1fd343a elementor-widget__width-initial elementor-widget-laptop__width-initial elementor-widget-tablet__width-inherit elementor-widget-mobile__width-inherit elementor-widget elementor-widget-text-editor\" data-id=\"1fd343a\" data-element_type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t\t\t\t\t\t<p><strong>1.<\/strong> <strong>Abrasion of Carbon by Pump Impeller<\/strong><\/p><ul><li>\u00a0The client had used a submersible pump to feed PHO 14&#215;45 AW into the filter. This method forced carbon particles through the rotating impeller, causing attrition and breakdown into fine dust. The effect was more pronounced during continuous operation cycles, making the feeding method a significant contributor to carbon attrition &amp; dust generation.<\/li><\/ul><p><strong>2.<\/strong> <strong>Improper Backwashing Conditions<\/strong><\/p><ul><li>\u00a0The backwashing process, designed to clean the filter media by reversing water flow, was not optimized for Haycarb\u2019s carbon. The client applied the same backwash flow rate used for pellet carbon, which has larger particle size and higher bulk density. For PHO 14&#215;45 AW, with its lower bulk density and smaller particle size, this excessive flow expanded the bed by nearly 50%. The resulting turbulence accelerated attrition and dust release. For optimal operation, backwashing optimization for carbon filters requires bed expansion to be maintained at around 30%.<\/li><\/ul><p><strong>3.<\/strong> <strong>System Configuration Mismatch<\/strong><\/p><ul><li>Critical operating parameters including linear velocity, pump design, and backwash settings had been calibrated for the previous supplier\u2019s carbon. Since Haycarb\u2019s PHO 14&#215;45 AW has different bulk density and hydraulic characteristics, these parameters were not fully aligned. This mismatch led to system instability and dust formation until corrective adjustments were made.<\/li><\/ul>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t<div class=\"elementor-element elementor-element-d141613 e-con-full e-flex e-con e-child\" data-id=\"d141613\" data-element_type=\"container\">\n\t\t\t\t<div class=\"elementor-element elementor-element-5a4367f elementor-widget__width-initial animated-slow elementor-invisible elementor-widget elementor-widget-heading\" data-id=\"5a4367f\" data-element_type=\"widget\" data-settings=\"{&quot;_animation&quot;:&quot;fadeIn&quot;}\" data-widget_type=\"heading.default\">\n\t\t\t\t\t<h2 class=\"elementor-heading-title elementor-size-default\">Solutions Implemented\n<\/h2>\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-d997caa elementor-widget__width-initial elementor-widget-laptop__width-initial elementor-widget-tablet__width-inherit elementor-widget-mobile__width-inherit elementor-widget elementor-widget-text-editor\" data-id=\"d997caa\" data-element_type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t\t\t\t\t\t<p>Haycarb\u2019s technical team carried out a site audit and implemented the following corrective measures:<\/p><p><strong>Adjusted Linear Velocity<\/strong><\/p><ul><li>Reduced linear velocity to achieve 30% bed expansion, enabling effective cleaning without excessive shear stress.<\/li><\/ul>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-516135f elementor-widget elementor-widget-image\" data-id=\"516135f\" data-element_type=\"widget\" data-widget_type=\"image.default\">\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<img decoding=\"async\" width=\"768\" height=\"546\" src=\"https:\/\/www.haycarb.com\/wp-content\/uploads\/2025\/10\/Beyond-Growth-Building-Agility-for-Lasting-Success-6-768x546.png\" class=\"attachment-medium_large size-medium_large wp-image-29737\" alt=\"\" srcset=\"https:\/\/www.haycarb.com\/wp-content\/uploads\/2025\/10\/Beyond-Growth-Building-Agility-for-Lasting-Success-6-768x546.png 768w, https:\/\/www.haycarb.com\/wp-content\/uploads\/2025\/10\/Beyond-Growth-Building-Agility-for-Lasting-Success-6-300x213.png 300w, https:\/\/www.haycarb.com\/wp-content\/uploads\/2025\/10\/Beyond-Growth-Building-Agility-for-Lasting-Success-6-1024x728.png 1024w, https:\/\/www.haycarb.com\/wp-content\/uploads\/2025\/10\/Beyond-Growth-Building-Agility-for-Lasting-Success-6-1536x1092.png 1536w, https:\/\/www.haycarb.com\/wp-content\/uploads\/2025\/10\/Beyond-Growth-Building-Agility-for-Lasting-Success-6-2048x1456.png 2048w\" sizes=\"(max-width: 768px) 100vw, 768px\" \/>\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<\/div>\n\t\t<div class=\"elementor-element elementor-element-bbbb12b e-con-full e-flex e-con e-child\" data-id=\"bbbb12b\" data-element_type=\"container\">\n\t\t\t\t<div class=\"elementor-element elementor-element-fc59071 elementor-widget__width-initial elementor-widget-laptop__width-initial elementor-widget-tablet__width-inherit elementor-widget-mobile__width-inherit elementor-widget elementor-widget-text-editor\" data-id=\"fc59071\" data-element_type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t\t\t\t\t\t<p><strong>Optimized Bed Expansion Parameters<\/strong>\u00a0<\/p><ul><li>Introduced bed expansion graphs tailored to the density and physical properties of PHO 14&#215;45 AW, ensuring uniform backwashing while minimizing carbon breakage.<\/li><\/ul><p><strong>Enhanced Backwashing Procedures<\/strong>\u00a0<\/p><ul><li>Standardized flow rates, duration, and frequency of backwash cycles, significantly reducing dust generation.<\/li><\/ul><p><strong>Sterilization Practices<\/strong>\u00a0<\/p><ul><li>Recommended periodic sterilization protocols to prevent microbial growth, safeguarding against filter fouling and performance losses.<\/li><\/ul><p>As a result of these adjustments, system efficiency and carbon stability were restored, leading to improved water quality and customer satisfaction.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t<div class=\"elementor-element elementor-element-0c9f44d e-con-full e-flex e-con e-child\" data-id=\"0c9f44d\" data-element_type=\"container\">\n\t\t\t\t<div class=\"elementor-element elementor-element-8337841 elementor-widget__width-initial animated-slow elementor-invisible elementor-widget elementor-widget-heading\" data-id=\"8337841\" data-element_type=\"widget\" data-settings=\"{&quot;_animation&quot;:&quot;fadeIn&quot;}\" data-widget_type=\"heading.default\">\n\t\t\t\t\t<h2 class=\"elementor-heading-title elementor-size-default\">General Recommendations<\/h2>\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-3a7b8d6 elementor-widget__width-initial elementor-widget-laptop__width-initial elementor-widget-tablet__width-inherit elementor-widget-mobile__width-inherit elementor-widget elementor-widget-text-editor\" data-id=\"3a7b8d6\" data-element_type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t\t\t\t\t\t<p>This case highlights the importance of aligning operational parameters with the physical and hydraulic characteristics of the activated carbon in use. For similar applications, Haycarb\u2019s experts recommend:<\/p><p><strong>1.<\/strong> <strong>Comprehensive System Assessment<\/strong><\/p><ul><li>Evaluate source water chemistry, system hydraulics, and pump design prior to carbon replacement.<\/li><\/ul><p><strong>2.<\/strong> <strong>Appropriate Carbon Selection<\/strong><\/p><ul><li>Choose between standard and catalytic carbons depending on whether the target contaminant is free chlorine or chloramine.<\/li><\/ul><p><strong>3.<\/strong> <strong>Optimized Operational Settings<\/strong>\u00a0<\/p><ul><li>Match linear velocity, bed expansion height, and pump configuration with the density and mechanical properties of the carbon.<\/li><\/ul><p><strong>4.<\/strong> <strong>Preventive Maintenance &amp; Sterilization<\/strong>\u00a0<\/p><ul><li>Implement sterilization protocols to prevent biofouling, and schedule periodic monitoring and backwash adjustments to maintain long-term carbon integrity.<\/li><\/ul>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t<div class=\"elementor-element elementor-element-5d945ad e-con-full animated-slow e-flex elementor-invisible e-con e-child\" data-id=\"5d945ad\" data-element_type=\"container\" data-settings=\"{&quot;background_background&quot;:&quot;classic&quot;,&quot;animation&quot;:&quot;fadeIn&quot;}\">\n\t\t<div class=\"elementor-element elementor-element-eed48df e-con-full e-flex e-con e-child\" data-id=\"eed48df\" data-element_type=\"container\">\n\t\t\t\t<div class=\"elementor-element elementor-element-e36ecea elementor-widget elementor-widget-heading\" data-id=\"e36ecea\" data-element_type=\"widget\" data-widget_type=\"heading.default\">\n\t\t\t\t\t<h2 class=\"elementor-heading-title elementor-size-default\">Werden Sie noch heute Partner von Haycarb!<\/h2>\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-828f751 elementor-widget__width-initial 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value=\"Saint Lucia\">St. Lucia<\/option><option value=\"Saint Vincent and the Grenadines\">St. Vincent und die Grenadinen<\/option><option value=\"Samoa\">Samoa<\/option><option value=\"San Marino\">San Marino<\/option><option value=\"Sao Tome and Principe\">S\u00e3o Tom\u00e9 und Pr\u00edncipe<\/option><option value=\"Saudi Arabia\">Saudi-Arabien<\/option><option value=\"Senegal\">Senegal<\/option><option value=\"Serbia\">Serbien<\/option><option value=\"Seychelles\">Seychellen<\/option><option value=\"Sierra Leone\">Sierra Leone<\/option><option value=\"Singapore\">Singapur<\/option><option value=\"Slovakia\">Slowakei<\/option><option value=\"Slovenia\">Slowenien<\/option><option value=\"Solomon Islands\">Salomonen<\/option><option value=\"Somalia\">Somalia<\/option><option value=\"South Africa\">S\u00fcdafrika<\/option><option value=\"South Sudan\">S\u00fcdsudan<\/option><option value=\"Spain\">Spanien<\/option><option value=\"Sri Lanka\">Sri Lanka<\/option><option 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Among our core offerings is specialized Activated Carbon for [&hellip;]<\/p>","protected":false},"author":24,"featured_media":11111,"parent":10674,"menu_order":0,"comment_status":"closed","ping_status":"closed","template":"","meta":{"_acf_changed":false,"footnotes":""},"class_list":["post-29587","page","type-page","status-publish","has-post-thumbnail","hentry"],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v25.6 - https:\/\/yoast.com\/wordpress\/plugins\/seo\/ -->\n<title>Activated Carbon for Air Purification | Haycarb Activated Carbon<\/title>\n<meta name=\"description\" content=\"Explore how Haycarb\u2019s activated carbon for air purification enhances respirator performance and safety in industrial applications.\" \/>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" 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