Design ManualTertiary & Reuse › Activated Carbon
FREE ENGINEERING TOOL · TERTIARY

Granular Activated Carbon Adsorber

GAC is the simplest way to take the last slice of dissolved organic matter out of a secondary effluent — and the easiest unit to get wrong, because the two numbers that matter are not the ones on the vessel drawing. This tool sizes the bed from empty bed contact time, derives the loading rate the geometry actually produces, then turns the COD you remove into a carbon usage rate, a bed life and an annual tonnage.

1Duty — what has to come out

Carbon is consumed by the mass it adsorbs. The more you ask it to remove, the more it costs — so the influent and target concentrations are the whole economic question.

2Contact time & vessel geometry

Empty bed contact time is the design intent; the loading rate is what the geometry then gives you. Choose the EBCT, choose the bed depth, and the vessel diameter follows — along with the velocity, which is the number that actually has a limit.

3Carbon & backwash

Adsorption capacity is the number most often taken from a datasheet and applied to a completely different water. Measure it on your own effluent if the tonnage matters.

Results — bed, carbon & run time

Carbon bed volume
Vessel diameter
m
Carbon usage rate
g/m³
ItemValueBasis

4Vessel & hydraulics

The geometry check. EBCT is what you asked for; the loading rate is what you got.
ItemValueBasis

5Carbon consumption & bed life

This is the operating cost line. Bed life is what tells you whether the plant is maintainable or whether you will be changing carbon every fortnight.
ItemValueBasis

6Backwash & head loss

GAC beds collect biomass and solids. Clean-bed head loss is small; the fouled bed is what the structure and the backwash system have to survive.
ItemValueBasis

GAC vs PAC vs BAC

ItemGACPAC

7Instrument schedule

The one measurement that matters is the one that tells you the bed is exhausted before the effluent does. Differential pressure and effluent turbidity between them catch most of it.
PointInstrumentWhy here

Quote the adsorber instruments at factory price

Flow, differential pressure, level and effluent turbidity — all mappable to our catalogue and supplied at the manufacturer's ex-works price (our margin is the export rebate, not a markup on the device).

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Sources & parameter basis

[1]METCALF & EDDY / AECOM — tertiary adsorption: secondary effluent COD typically 20–60 mg/L; granular carbon can polish to 10–20 mg/L. The mass removed sets the carbon consumption.
[2]Empty bed contact time: 20–40 min for COD and colour polishing, 10–20 min for trace organic (micropollutant) control, 10–20 min ahead of RO as a membrane protection step. More contact time is not free — it buys vessel volume.
[3]Loading rate 5–15 m/h (2–6 gpm/ft²); bed depth 1.5–3.5 m; two or three vessels in series in lead-lag operation so the lead vessel is fully exhausted before it is taken out of service. EBCT = n·H/v.
[4]Adsorption capacity for wastewater dissolved organics at low concentration is typically 0.05–0.40 kg COD per kg carbon — an order of magnitude below the values quoted for high-strength industrial wastes. Measure it on your own water.
[5]Regeneration: thermal reactivation loses 5–12 % of the carbon per cycle as fines and burn-off. On-site regeneration is normally justified above roughly 50–100 t/yr of spent carbon.
[6]Backwash 20–40 m/h for 10–20 min to release trapped biomass and solids. Clean-bed head loss ≈0.35 m per metre of bed at 10 m/h, scaling with velocity; design allowance 2–3 m before backwash or changeout.
Full derivation and worked example: Activated-Carbon-Calculation-Sheet.md. Drop the capacity from 0.20 to 0.05 kg/kg and watch the annual tonnage quadruple — that single input is worth more measurement effort than every other number on the page.
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