Charcoal Production - Revision history

Lisafeldmann at 06:46, 30 March 2022

2022-03-30T06:46:08Z

Show changes

Chris Adam at 07:31, 24 March 2022

2022-03-24T07:31:46Z

Chris Adam at 07:28, 24 March 2022

2022-03-24T07:28:53Z

Chris Adam at 07:26, 24 March 2022

2022-03-24T07:26:22Z

Chris Adam at 07:07, 24 March 2022

2022-03-24T07:07:19Z

Chris Adam at 06:36, 24 March 2022

2022-03-24T06:36:21Z

Johanna at 07:45, 24 July 2019

2019-07-24T07:45:26Z

Lisafeldmann: /* Charcoal Briquetting */

2019-07-23T08:55:55Z

Charcoal Briquetting

Lisafeldmann: /* Challenges and Potentials to Sustainable Charcoal Production */

2019-07-23T08:53:15Z

Challenges and Potentials to Sustainable Charcoal Production

Lisafeldmann: /* Basics on Charcoal */

2019-07-23T08:52:34Z

Basics on Charcoal

@@ Line 217: / Line 217: @@
 A '''"Box-Kiln"''' has been developed by Dr.Chris ADAM in 2019. This kiln works as an improvment to the round steel kilns (MARK II) . For more information search this "Box-Kiln" via Youtube.
-[[File:Box-Kiln m Vida 2021 sml.jpg|none|thumb|"Box-Kiln" Ghana 2021 (giz project)]]
+[[File:Box-Kiln m Vida 2021 sml.jpg|thumb|"Box-Kiln" Ghana 2021 (giz project)|alt=]]
 <br />

@@ Line 211: / Line 211: @@
 === Steel Kiln<br/> ===
-Many different types of steel kilns have been developed which are considered as one basis of modern charcoal production. They are capable to carbonize even poor quality wood and can easily be transported when necessary. However, as the annual output of a typical demountable steel kiln is about 100 – 150 t, they are not suitable for high-volume production. Furthermore, the investment costs may be as high as 1,000 US$, which limits the use of steel kilns considerably. Nevertheless, since efficiency is high (27 – 35&nbsp;%) and carbonization is quick (16 to 24 hours after ignition), steel kilns have been promoted as community kilns in Kenya. There are also steel [[File:Engery Uhuru (Freedom) - The Green Cap Kiln.PNG|thumb|right|325px|Energy Uhuru (Freedom)]]drum kilns on the market - designed by Dr. M. Kinyanjui to facilitate access to sustianably made charcoal, (using twigs, branches, maize cobs, coconuts etc. for feedstock) these kilns are low cost, portable and easy to use. They can also have a wood oil trap installed to condense some of the smoke into wood tar/oil for home use. They come in two sizes - domestic for 40$ and business for 130$.<br/><br/>Marketing materials promoting these kilns.
+Many different types of steel kilns have been developed which are considered as one basis of modern charcoal production. They are capable to carbonize even poor quality wood and can easily be transported when necessary. However, as the annual output of a typical demountable steel kiln is about 100 – 150 t, they are not suitable for high-volume production. Furthermore, the investment costs may be as high as 1,000 US$, which limits the use of steel kilns considerably. Nevertheless, since efficiency is high (27 – 35&nbsp;%) and carbonization is quick (16 to 24 hours after ignition), steel kilns have been promoted as community kilns in Kenya. There are also steel [[File:Engery Uhuru (Freedom) - The Green Cap Kiln.PNG|thumb|right|325px|Energy Uhuru (Freedom)]]drum kilns on the market - designed by Dr. M. Kinyanjui to facilitate access to sustianably made charcoal, (using twigs, branches, maize cobs, coconuts etc. for feedstock) these kilns are low cost, portable and easy to use. They can also have a wood oil trap installed to condense some of the smoke into wood tar/oil for home use. They come in two sizes - domestic for 40$ and business for 130$.<br/>Marketing materials promoting these kilns.
 A '''"Box-Kiln"''' has been developed by Dr.Chris ADAM in 2019. This kiln works as an improvment to the round steel kilns (MARK II) . For more information search this "Box-Kiln" via Youtube.<br />
 === Adam Retort<br/> ===

@@ Line 211: / Line 211: @@
 === Steel Kiln<br/> ===
-Many different types of steel kilns have been developed which are considered as one basis of modern charcoal production. They are capable to carbonize even poor quality wood and can easily be transported when necessary. However, as the annual output of a typical demountable steel kiln is about 100 – 150 t, they are not suitable for high-volume production. Furthermore, the investment costs may be as high as 1,000 US$, which limits the use of steel kilns considerably. Nevertheless, since efficiency is high (27 – 35&nbsp;%) and carbonization is quick (16 to 24 hours after ignition), steel kilns have been promoted as community kilns in Kenya. There are also steel [[File:Engery Uhuru (Freedom) - The Green Cap Kiln.PNG|thumb|right|325px|Energy Uhuru (Freedom)]]drum kilns on the market - designed by Dr. M. Kinyanjui to facilitate access to sustianably made charcoal, (using twigs, branches, maize cobs, coconuts etc. for feedstock) these kilns are low cost, portable and easy to use. They can also have a wood oil trap installed to condense some of the smoke into wood tar/oil for home use. They come in two sizes - domestic for 40$ and business for 130$.<br/><br/>Marketing materials promoting these kilns.<br/>
+Many different types of steel kilns have been developed which are considered as one basis of modern charcoal production. They are capable to carbonize even poor quality wood and can easily be transported when necessary. However, as the annual output of a typical demountable steel kiln is about 100 – 150 t, they are not suitable for high-volume production. Furthermore, the investment costs may be as high as 1,000 US$, which limits the use of steel kilns considerably. Nevertheless, since efficiency is high (27 – 35&nbsp;%) and carbonization is quick (16 to 24 hours after ignition), steel kilns have been promoted as community kilns in Kenya. There are also steel [[File:Engery Uhuru (Freedom) - The Green Cap Kiln.PNG|thumb|right|325px|Energy Uhuru (Freedom)]]drum kilns on the market - designed by Dr. M. Kinyanjui to facilitate access to sustianably made charcoal, (using twigs, branches, maize cobs, coconuts etc. for feedstock) these kilns are low cost, portable and easy to use. They can also have a wood oil trap installed to condense some of the smoke into wood tar/oil for home use. They come in two sizes - domestic for 40$ and business for 130$.<br/><br/>Marketing materials promoting these kilns.
-<br/>
+A '''"Box-Kiln"''' has been developed by Dr.Chris ADAM in 2019. This kiln works as an improvment to the round steel kilns (MARK II) . For more information search this "Box-Kiln" via Youtube.<br />
 === Adam Retort<br/> ===
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 '''Carbonizer-1''' (drum open pit carbonizer)  The unit works by adding the coffee husks continously into a barrel (oil drum). <gallery>
 File:Carbonizer-1 zen.png
-</gallery>'''Carbonizer-2''' (drum rotary carbonizer)
+</gallery>'''Carbonizer-2''' (drum rotary retort carbonizer)   The unit works by adding the coffee husks by batch into a turning barrel
-'''Carbonizer-3''' (drum carbonizer)
+'''Carbonizer-3''' (drum retort carbonizer)  The unit works by adding the coffee husks by batch into a  barrel
 = Industrial Process<br/> =

@@ Line 217: / Line 217: @@
 === Adam Retort<br/> ===
-[[File:Adam retort.jpg|thumb|right|200px|Adam retort]]The retort kiln is one of the most efficient means of producing good quality charcoal. The kiln returns the wood gases from the carbonisation chamber back to the external fire-box, burns the volatile a higher proportion of the tar components almost completely and uses the heat for the carbonisation process. The Improved Charcoal Production System (ICPS), also called "adam-retort", may be presented as a modern example of retort technology. Efficiency can be as high as 35&nbsp;% and noxious emission can be reduced by 70&nbsp;%. In addition, the production cycle is completed within 12 hours or 24 to 30 hours included cooling. The retort kiln is suitable for rural and semi-industrial charcoal production. Volume of wood chamber is about 3m³ and ~250kg or more of charcoal can produced per batch. Wood chamber can be loaded with about 1 ton of wet wood or ~750kg of ofen dry wood.<br/>
+[[File:Adam retort.jpg|thumb|right|200px|Adam retort]]The retort kiln is one of the most efficient means of producing good quality charcoal. The kiln returns the wood gases from the carbonisation chamber back to the external fire-box, burns the volatile a higher proportion of the tar components almost completely and uses the heat for the carbonisation process. The Improved Charcoal Production System (ICPS), also called "adam-retort", may be presented as a modern example of retort technology. Efficiency can be as high as 35&nbsp;% and noxious emission can be reduced by 70&nbsp;%. In addition, the production cycle is completed within 12 hours or 24 to 30 hours included cooling. The retort kiln is suitable for rural and semi-industrial charcoal production. Volume of wood chamber is about 3m³ and ~250kg or more of charcoal can produced per batch. Wood chamber can be loaded with about 1 ton of wet wood or ~750kg of ofen dry wood. (www.biocoal.org)<br/>
 [[File:Adam retort India Puja initiation 2014 small.jpg|right|207px|alt=Adam retort India Puja initiation 2014 small.jpg]]<br/>Disadvantges include that it’s a stationary kiln, investment costs exceed 1,200 US$ and special skills are required for construction and operation. Nevertheless, the Adam-retort has been introduced in several countries (Senegal, Tanzania, Mali, Angola, Madagascar, Peru, Costa Rica, Mexico, India, Cambodia, etc.) on a pilot basis. Currently, the method is being further refined for up-scaling. A construction manual with drawings is available on a license basis by dr.Chris ADAM.<br/>(Photo up: Madagascar, Photo down: "Puja initiation" of a retort in South India/Kumta, 2014)<br/>
@@ Line 229: / Line 229: @@
 == The "mobile adam-retort" ==
-[[File:Mobile Adam Retort Testrun Trailer Small.JPG|thumb|right|200px|alt=Mobile Adam Retort Testrun Trailer Small.JPG]]This lately developed '''mobile retort''' by Dr.Chris Adam is available since 2015 and its design is based on 2 oil drums. These oil drums are replacable.
+[[File:Mobile Adam Retort Testrun Trailer Small.JPG|thumb|right|200px|alt=Mobile Adam Retort Testrun Trailer Small.JPG]]This lately developed '''mobile retort''' by Dr.Chris ADAM is available since 2015 and its design is based on 2 oil drums. These oil drums are replacable.
-The mobile retort burns most of the smoke and works with high efficiency of about 30% referring to the dry mass of the wood. About 140kg of wet wood (corresponding to about 120kg of wood without water) can be loaded and about 35kg of charcoal (high temperature burnt) can be harvested.<br/>
+The mobile retort burns most of the smoke and works with high efficiency of about 30% referring to the dry mass of the wood. About 140kg of wet wood (corresponding to about 120kg of wood without water) can be loaded and about 35kg of charcoal (high temperature burnt) can be harvested. This mobile retort is not yet smoke free and some modifications will be done in 2022.<br/>
 == Unit to carbonize coffee husks to make briquetts ==
-<br />In 2022 CARiTAS-SUISSE is lancing a briquetting project in Ethiopia. The briquettes are made from carbonized coffee husks. 3 differnt carbonizing units are currently be developed and tested. All units are low-cost systems:
+<br />In 2022 CARiTAS-SUISSE is lancing a briquetting project in Ethiopia. The briquettes are made from carbonized coffee husks. 3 differnt carbonizing units are currently be developed and tested. All units are low-cost systems and they have been designed by Dr.Chris ADAM (www.biocoal.org) :
-'''Carbonizer-1''' (drum open pit carbonizer)
+'''Carbonizer-1''' (drum open pit carbonizer)  The unit works by adding the coffee husks continously into a barrel (oil drum). <gallery>
-'''Carbonizer-2''' (drum rotary carbonizer)
+'''Carbonizer-3''' (drum carbonizer)
 = Industrial Process<br/> =

@@ Line 233: / Line 233: @@
 The mobile retort burns most of the smoke and works with high efficiency of about 30% referring to the dry mass of the wood. About 140kg of wet wood (corresponding to about 120kg of wood without water) can be loaded and about 35kg of charcoal (high temperature burnt) can be harvested.<br/>
-Operation time is about 5 hours (3 hrs drying of wood, 2 hours of carbonization).
+== Unit to carbonize coffee husks to make briquetts ==
-<br/>
+'''Carbonizer-1''' (drum open pit carbonizer)
-<br/>
+'''Carbonizer-2''' (drum rotary carbonizer)
 = Industrial Process<br/> =

@@ Line 24: / Line 24: @@
 Charcoal is a prime source of energy in most African countries, and is a driving force in their economies. Worldwide charcoal production has increased, rising by an annual 3.7% from 1990 to reach 44 million tones in 2000 (see: [[:File:FAO 154-Forests and energy-2008.pdf|FAO (2008), Forests and Energy]] (pdf))
 = Challenges and Potentials to Sustainable Charcoal Production<br/> =
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 <br/>
 = Basics on Charcoal<br/> =
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 <br/>
 = Technological Aspects<br/> =
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 <br/>
 = Charcoal Briquetting<br/> =
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 [[File:Briquetting process.jpg|right|215px|Briquetting process.jpg|alt=Briquetting process.jpg]]
-A briquette is a block of flammable matter used as fuel to start and maintain a fire. Residues from agriculture and forestry e.g. bagasse, coffee husks, saw-dust, and coconut husks are a valuable source of raw material and can be used for producing briquettes.The briquetting process entails many steps. After collection, the wood or agro-industrial waste is dried before it is converted to charcoal in a charring kiln. The carbonised biomass is then mixed with water and locally-available binders such as starch, gum arabic, molasses, clay and others. Finally, the mixture (powdered charcoal + binder mixture) is pressed into briquettes. Piston and screw presses are the most widely used technologies where as in the developed countries roll presses are more here[[Biomass_Briquettes_–_Production_and_Marketing|here]]common. The production capacity of screw presses is around 40 to 70 kg per hour. After a subsequent drying step, the briquettes will develop the required strength and stability.Forest and agricultural waste charcoal briquettes, with about 20% of clay, produce about 12 MJ/kg depending on the composition of charcoal.
+A briquette is a block of flammable matter used as fuel to start and maintain a fire. Residues from agriculture and forestry e.g. bagasse, coffee husks, saw-dust, and coconut husks are a valuable source of raw material and can be used for producing briquettes.The briquetting process entails many steps. After collection, the wood or agro-industrial waste is dried before it is converted to charcoal in a charring kiln. The carbonised biomass is then mixed with water and locally-available binders such as starch, gum arabic, molasses, clay and others. Finally, the mixture (powdered charcoal + binder mixture) is pressed into briquettes. Piston and screw presses are the most widely used technologies where as in the developed countries roll presses are more common. The production capacity of screw presses is around 40 to 70 kg per hour. After a subsequent drying step, the briquettes will develop the required strength and stability. Forest and agricultural waste charcoal briquettes, with about 20% of clay, produce about 12 MJ/kg depending on the composition of charcoal.
 Further information on biomass charcoal briquetting for energy based income generation in rural areas can be found in the booklet [http://www.amm-mcrc.org/publications/BiomassCharcoalBriquetting_English.pdf Biomass Charcoal Briquetting].<br/>The GIZ Program to promote rural electrification and a sustainable supply of domestic fuel (PERACOD) in Senegal documented their experience at the [http://www.peracod.sn/?lang=en Peracod website].
-More information about production and marketing of briquettes can also be found [[Biomass_Briquettes_–_Production_and_Marketing|here]] on energypedia.<br/>
+More information about production and marketing of briquettes can also be found [[Biomass Briquettes – Production and Marketing|here]] on energypedia.<br/>
 = Transport and Marketing<br/> =
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 {{#set: Hera category=Woodfuel Supply}}
 [[Category:Cooking_Energy]]

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 Charcoal is a prime source of energy in most African countries, and is a driving force in their economies. Worldwide charcoal production has increased, rising by an annual 3.7% from 1990 to reach 44 million tones in 2000 (see: [[:File:FAO 154-Forests and energy-2008.pdf|FAO (2008), Forests and Energy]] (pdf))
 = Challenges and Potentials to Sustainable Charcoal Production<br/> =
@@ Line 67: / Line 68: @@
 <br/>
-*the supra-regional Chaposa project (1998-2002) investigating the charcoal potential for Southern Africa:
+*the supra-regional Chaposa project (1998-2002) investigating the charcoal potential for Southern Africa: -> [http://sei-international.org/mediamanager/documents/Publications/Climate/chaposa.pdf Charcoal Potential in Southern Africa CHAPOSA]
 *the National Charcoal Survey:Exploring the potential for a sustainable charcoal industry in Kenya (ESD 2005)
 *the study initiated by the Forest Governance Learning Group (FGLG) for Malawi: [http://pubs.iied.org/13544IIED.html Charcoal - the reality: A study of charcoal consumption, trade and production in Malawi]
-*a policy note prepared by Worldbank staff for decision makers in Tanzania summarizing the fundamental characteristics of charcoal use in the country and presenting policy options along the entire value chain of charcoal production and consumption (2010):
+*a policy note prepared by Worldbank staff for decision makers in Tanzania summarizing the fundamental characteristics of charcoal use in the country and presenting policy options along the entire value chain of charcoal production and consumption (2010): [http://siteresources.worldbank.org/EXTCC/Resources/PolicyNote_Charcoal_TZ_08-09.pdf ENVIRONMENTAL CRISIS OR SUSTAINABLE DEVELOPMENT OPPORTUNITY? Transforming the charcoal sector in Tanzania]
 <br/>

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 <br/>
 = Basics on Charcoal<br/> =
-Charcoal is produced following several processes, artisanal and industrial. The best known industrial processes are '''slow pyrolysis''' and '''supra-carbonization'''.<br/>
+Charcoal is produced following several processes, artisanal and industrial. The best known industrial processes are slow pyrolysis and supra-carbonization.<br/>
-During combustion, the wood will undergo 2 to 3 different chemical reactions: 2 for pyrolysis with endothermic and exothermic; we must add a third for supra-carbonization, that is, <span style="background-color: rgb(255, 255, 255)">endothermic</span> again. Because of this, charcoal has a higher fixed carbon content.
+During combustion, the wood will undergo 2 to 3 different chemical reactions: 2 for pyrolysis with endothermic and exothermic; we must add a third for supra-carbonization, that is, <span style="background-color: rgb(255, 255, 255)">endothermic</span> again. Because of this, charcoal has a higher fixed carbon content.<br/>
-#Pyrolysis consists of heating wood or other substances, in the absence of oxygen, with external energy.&nbsp;<span style="background-color: rgb(255, 255, 255)">Pyrolysis is initiated by heating a pile of wood under controlled conditions in a closed space such as a charcoal kiln with a very limited supply of air triggering endothermic and exothermic reactions. The biomass produces a a result of the pyrolysis process, a mixture of gas, liquid and charcoal.</span>
+#Pyrolysis consists of heating wood or other substances, in the absence of oxygen, with external energy.&nbsp;<span style="background-color: rgb(255, 255, 255)">Pyrolysis is initiated by heating a pile of wood under controlled conditions in a closed space such as a charcoal kiln with a very limited supply of air triggering endothermic and exothermic reactions. The biomass produces, as a result of the pyrolysis process, a mixture of gas, liquid and charcoal.</span><br/>
 #Supra-carbonisation ("MAGE" technology) does not require external energy, unlike pyrolysis, since it is the wood itself which serves as ignition for the furnaces and is done by the upper part; and with the help of high chimneys, this allows to control the process during the carbonization phase. As the fresh air intake is located below the furnaces, the carbonization front goes downhill because the air at the top of the furnaces is consumed first. The combustion phase is followed by a carbonizer, in order to avoid the total ignition of the wood inside the oven, as well as the evaporation of the water present in the raw material (up to 100 ° C). The energy required for this step comes from the partial combustion of the wood, giving CO, CO2, acetic acid and methanol (up to 270 ° C). Then, the exothermic decomposition of the wood begins, between 270 and 300 ° C, causing an increase in the temperature inside the furnace up to 400 ° C, with the production of charcoal, plant tar and pyroligneous extracts. At this stage, the charcoal still contains a large amount of volatile compounds (about 30%), with a fixed carbon content of 60 to 65%. At + 800 ° C, the fixed carbon content reaches 82 to 84% for 3 to 7% of volatile compounds.<br/>
-Charcoal is first of all characterized by its density which can vary between 0.2 and 0.6 t/m<sup>3</sup> depending on the density of wood used as raw material. Charcoal produced from hardwood is heavy and strong, whereas produced from softwood is soft and light. The coefficient of transformation is about half (example: eucalyptus with a density of about 0.6 gives charcoal with a density of around 0.25 to 0.35).<br/>The bulk density of charcoal does not only depend on the apparent density but also on the size distribution, and is in the range of 180 - 220 kg/m<sup>3</sup>.<br/>Charcoal has a relatively low moisture content of around 3 to 10%. The gross calorific value of charcoal is linked to the amount of fixed carbon and depends strongly on the carbonization temperature varying from 27 to 33 MJ/kg. Low carbonization temperatures give a higher yield of charcoal but this charcoal is low grade, is corrosive due to its content of acidic tars, and does not burn with a clean smoke-free flame. Good commercial charcoal should have a fixed carbon content of about 75% and a final carbonization temperature of around 500°C.
+Charcoal is first of all characterized by its density which can vary between 0.2 and 0.6 t/m<sup>3</sup> depending on the density of wood used as raw material. Charcoal produced from hardwood is heavy and strong, whereas produced from softwood is soft and light. The coefficient of transformation is about half (example: eucalyptus with a density of about 0.6 gives charcoal with a density of around 0.25 to 0.35).<br/>The bulk density of charcoal does not only depend on the apparent density but also on the size distribution, and is in the range of 180 - 220 kg/m<sup>3</sup>.<br/>Charcoal has a relatively low moisture content of around 3 to 10%. The gross calorific value of charcoal is linked to the amount of fixed carbon and depends strongly on the carbonization temperature varying from 27 to 33 MJ/kg. Low carbonization temperatures give a higher yield of charcoal but this charcoal is low grade, is corrosive due to its content of acidic tars, and does not burn with a clean smoke-free flame. Good commercial charcoal should have a fixed carbon content of about 75% and a final carbonization temperature of around 500°C.<br/>
 <br/>
 = Technological Aspects<br/> =