I used to use store-bought charcoal to start a fire and get the heat ready for the barbecue. Today I use my method of coal production, which, by the way, also comes in handy for efficient, fast and uniform ignition of a solid fuel boiler during the startup of the heating system. In this review, I decided to highlight what this type of fuel is, what are its features, types and scope of application, as well as what are the specifics of its production technology and method of production in everyday life.
Source masterclub.online
What is charcoal
The unique properties of charcoal have been known for a long time. The fact that humanity began to use charcoal for its needs is known from archaeological excavations. Entire ancient cities and settlements used charcoal production as the main source of their income. Actually, the first environmental disasters were associated with the massive cutting down of trees to obtain this product. For example, in Crimea, in order to make amphorae for wheat, the Karaites and Genoese cut down relict forests. Because of this, some areas of Crimea are still considered unsuitable for living. This situation marked the beginning of the development of coal in England and France.
Charcoal is produced by burning wood of various species. A special feature of the process is that as a result of high-temperature exposure, the structure of wood tissue changes - chemical elements are burned out, but carbon remains. The chemical formula of the resulting product shows that its composition contains on average up to 84% non-volatile carbon. When burned, this fuel avoids the release of the most dangerous combustion product for humans - carbon monoxide. It is known from chemistry that it is this colorless and odorless gas that is released during the combustion of volatile substances without access to oxygen.
In addition, the properties of charcoal make it possible to use it in other important processes for humans - water and air purification, as a medicine, even artists have found use for this material.
But still, the composition of the material, in which carbon is the main element, has found the greatest application in industry:
- metallurgy - catalyst and reducing agent in the production of iron and steel;
- chemical industry - filters for hazardous industries;
- energy - fuel, fillers for filtration units.
Today, there are many known methods for extracting this product, from the method in which charcoal is burned in a pit, to high-tech methods for producing briquettes. In this case, not whole tracts of valuable trees are used as raw materials, but compressed sawdust of trees.
Thus, the resulting value of charcoal is:
- High content of non-volatile carbon and absence of phosphorus and sulfur;
- High heat transfer during combustion;
- Long burning period;
- Possibility of use as a renewable resource;
- Almost in its complete combustion without any residue.
Peculiarities
Like other types of coal, charcoal contains a large amount of carbon in its composition. This type of coal has a high air-absorbing capacity, which is due to the large number of pores in the substance.
After industrial preparation of such coal, in just an hour of storage in a warm room, its mass can increase by 2% due to absorbed oxygen.
At the same time, coal in large volumes can even catch fire, so enterprises specially stabilize it.
Almost all coal production methods rely on burning wood materials with a limited amount of incoming air.
Types and grades of wood fuel
The most common classification of this type of fuel divides it by type of material of origin. This classification makes it possible to select a product according to its calorific value. Depending on the color, fuel can be divided into types:
- Black – made from soft deciduous trees (alder, poplar, aspen);
- White – burned from hard wood (oak, hornbeam, birch);
- Red – obtained from coniferous trees using soft charcoal technology.
According to the state standard GOST 7657-84, charcoal is divided into three classes - A, B, C. GOST defines the highest grade as fuel grade A - in it the mass fraction of non-volatile carbon is 90% - 78%. For grade B, the mass fraction is 88-77%, grade B should contain from 77 to 67% carbon.
GOST 7657-84 Charcoal. Specifications
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In addition, there are other quality standards for charcoal, for example, the specific gravity of charcoal, weight 1 dm3, mass fraction of ash, and the presence of fractions of certain size in the volume. True, these standards apply mainly to industrial products. The production of charcoal at home is usually used to assess the quality by studying the color of the product and the presence of different fractions in the composition - the number of large pieces, medium, small and wood dust.
In the hole
At some distance from any buildings, a hole is dug in the soil for this method of charcoal burning. For a couple of bags of coal, a hole half a meter deep and 80 centimeters in diameter will be enough.
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The bottom of the pit should be thoroughly trampled manually or with a special device. After compaction, a fire of brushwood is lit at the bottom of the pit, from time to time throwing small, but not too small, firewood into it.
You should not allow tree bark to get into the fire, as its combustion produces a large amount of smoke, which will negatively affect the quality of the final product.
After placing a new portion, the contents of the pit are compacted, and the operations are repeated until the recess is filled to the brim.
The burnt firewood is covered with a layer of grass and turf and left to “simmer” for a couple of days, after which the finished charcoal can be taken out.
Properties
The beneficial properties of this fuel are determined by several indicators. First of all, they are determined by the combustion temperature of the charcoal. Thus, pressed fuel is actively used in the smelting of cast iron and steel. Reaching a high combustion temperature during melting (over 1350 degrees), the chemical composition of charcoal acts as a catalyst for the reaction in the metal. In blast furnace production during the smelting of cast iron today, the share of fuel used is small, only 7-8%, but the cast iron produced is of the highest quality. This is achieved due to the properties of charcoal - it does not contain substances that, when heated, form volatile gases, and during combustion, impurities of substances that deteriorate the characteristics and structure of the metal. The high density and specific gravity of charcoal used in metallurgy make it possible to maintain the uniformity of the smelting process without the use of additional technologies.
Among the beneficial properties of charcoal are its high combustion temperature and long-term release of high temperature heat. This is especially clearly demonstrated when preparing dishes on the grill. Once ignited, the fuel quickly reaches a high temperature and maintains combustion for several hours.
An important indicator for fuel is the ash content. According to GOST, the highest class of charcoal when burned has an ash content of 2.5 to 3%. For domestic needs, class B is usually used; it is suitable for both heating and cooking. Unlike the highest class with a higher combustion temperature, the use of class B coals poses less danger, primarily due to the lower combustion temperature - it is about 300 degrees lower. This difference between the combustion temperatures of the two types of charcoal is associated with the structure, size of the bunts and the type of fuel preparation. A higher temperature is obtained when coals from denser layers of wood are burned. In addition, storage of class A material provides for an increase of up to 20% in the presence of water in the volume of the entire mass.
An important indicator for charcoal is the homogeneity of the mass, so in the total mass of grade A, the 25 and 12 mm fractions should be no more than 12% in total, while at the same time there should be no smut in the composition of the volume at all. In the artisanal production of charcoal with your own hands, the properties are determined by the color, size of the smut and the amount of dust. It is believed that the larger the fraction and the more saturated its color, the higher its quality. In many ways, this method is justified, since it indirectly indicates the chemical composition of the fuel and the presence of a large amount of carbon in it. A more in-depth laboratory chemical analysis can show the presence or absence of sulfur, phosphorus, heavy metal salts and individual resin-based compounds in its composition. During laboratory analysis, the ash content of the material is also checked. For premium quality fuel, the ash content is 2.5-3%, for average quality it is 3.5-4%.
The density depends on the brand and type of wood from which it is made. The weight of a standard volume of fuel is 1 cubic meter. meter is:
- From spruce wood – 100-120 kg;
- Pine – 130-140 kg;
- Birch – 175-185 kg;
- Bukovogo – 187-195;
- Oak - 200-215.
The material itself is very porous; if we take the ratio of the pore volume to the total volume of the substance, then for birch charcoal it will be 72%, for spruce charcoal 80%. Because of this, the specific density of charcoal, depending on the material of origin, can be:
- Spruce – 0.26 g/cm3;
- Pine – 0.29 g/cm3;
- Birch – 0.38 g/cm3;
It is the high porosity of the material that requires special care when lighting in the grill and barbecue. First of all, before ignition, you need to treat the coals with an alcohol-containing liquid and give a little time for it to be absorbed and penetrate as deeply as possible into the pores.
Another indicator of fuel - heat capacity depends on the temperature and humidity of the material. For dry fuel (with a humidity of 7-15%) the average heat capacity is 0.18 kcal/kg; for absolutely dry fuel with a humidity of 2-4% the heat capacity is 0.2 kcal/kg.
The calorific value, that is, the ability to release heat, is about 7500-8170 kcal/kg at a temperature of 380-500 degrees.
Application
Today, the use of charcoal in everyday life mainly comes down to three main areas. First of all, you need charcoal for a grill or barbecue; a long burning period, the absence of harmful smoke components and uniform heat allow it to be used as fuel.
The second important point of its use is water and air purification. Why do you need charcoal in a kitchen hood filter? It’s all very simple; it is an excellent sorbent that absorbs all combustion products, dust and soot. Such filters are installed in circulation hoods.
No less interesting is its use as a water filter; it is effective at the fine purification stage when it comes to chemical reagents and biological pollutants.
The third use is for heating and fuel for home workshops. The fuel is highly valued by those involved in pottery and blacksmithing. This is simply an indispensable type of fuel for the forge and kiln.
True, when purchasing, you need to pay attention to the shelf life - the longer the material is stored, the more moisture it absorbs and the less its heat transfer; when burned, it may not produce the required temperature.
How much coal is needed for the winter?
In order not to be left without fuel in severe frosts and not to think about where to put coal in the summer, it is necessary to evaluate a number of parameters before purchasing this or that volume.
These include:
- room area, wall material and insulation thickness;
- type of windows, doors, degree of ventilation;
- type of fuel, boiler, coal laying scheme;
- temperature changes in the region, duration of cold weather.
As practice shows, heating a brick house requires 35% more fuel than heating a wooden or aerated concrete block building. This is due to the fact that brick, due to its characteristics, takes away some of the heat. Approximately for a house with an area of 90 square meters, built of slag concrete with a wall thickness of 45 cm, with stove heating you will need from 2.5 to 3.5 tons of coal (2/3 of the volume is “seed”, the rest is anthracite “nut”) depending on changing temperature. If such a structure does not have additional insulation, then the amount of fuel purchased will already be at least 6-7 tons. Wooden house made of timber with an area of 80 sq.m. at a minimum temperature in winter of up to -40 °C (about 1.5 months and up to -20 °C the rest of the time), you will have to heat it with 5 tons of coal and 5 tons of firewood.
Production process technology
The technology for making charcoal has not undergone much change since the inception of the industry. The main technology for producing charcoal is still kiln burning. Today, burning furnaces have changed their design, making the process more technologically advanced. But the principle of how to make charcoal remains the same - combustion of wood raw materials without access to oxygen is the main condition. The technological process consists of several cycles:
- Drying raw materials;
- Pyrolysis process;
- Cooling.
In principle, this option is similar to how charcoal is made at home. The only difference is that you can make charcoal in a home installation using improvised means, but in industrial installations each phase is strictly controlled. The result is fuel that meets the description in state standards.
Production costs
To start a charcoal production business you need about 1.5 million rubles. The bulk of the funds are needed for the purchase of equipment (650-900 thousand rubles). Among domestically produced equipment, we recommend OD-30, OD-60 furnaces; these installations are used for the production of high-quality raw materials.
The following costs must also be taken into account:
- rental of premises – up to 400 thousand rubles;
- purchase of wood – up to 100 thousand rubles;
- salaries, payment of taxes – 600 thousand rubles;
- advertising, transport – 50 thousand rubles;
- payment of utility bills - 50 thousand rubles;
- paperwork – up to 10 thousand rubles.
As a result, 1.8 million rubles are needed to confidently start industrial production of charcoal.
The sale of 1 kg of finished products brings a profit in the range from 18 to 35 rubles. The monthly net profit will be about 80 thousand rubles from 100 tons of raw materials.
Activated carbon is a product that is valuable for various areas of human life. As an environmentally friendly fuel, charcoal will occupy an increasing share of the world market, despite the prevalence of gas and oil. Raw materials can be sold, if not for the needs of the domestic market, then for export. It is useful to know the process of charcoal production at least to satisfy your own needs for raw materials, although its industrial production seems to be a promising and profitable business.
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Selection of raw materials
It is optimal to select hardwood trees for burning. Sometimes it is advised to strictly select trees of the same species. In this case, it will be possible to obtain combustion at one temperature, and the result is a homogeneous product of good quality. However, in the process of work it often happens that different types of raw materials are used in production. This is not a problem; when filling a vertical oven, the filling is first made of hardwood, and then of softwood.
Drying wood
Drying is carried out in a firing chamber at a temperature of 140-160 degrees. The use of higher temperatures leads to cracking of the smut and, as a result, the production of fine coals. Drying is carried out in an atmosphere of flue gases and at the end of it the wood with a moisture content of 4-5% should be obtained.
Pyrolysis
The second stage in the production of charcoal is pyrolysis. This stage consists of dry distillation, when the temperature rises to 150-300 degrees to remove all remaining moisture. Upon reaching 300-301 degrees, the process of exothermic pyrolysis begins. The wood begins to change color, the internal temperature rises, and for some time it exceeds the temperature in the chamber. At this moment, no additional heat is required, since the process of evaporation of volatile substances begins. Upon reaching 400 degrees, the wood finally changes color and becomes black. Wood purified by pyrolysis contains 65-70% carbon.
Calcination
After some time, when the reaction begins to fade, the temperature begins to drop and the risk of spontaneous combustion increases. In order to prevent this in industrial production, calcination is used - maintaining the required temperature by external heating. To do this, the container with wood is additionally heated from the outside, as a result of which the proportion of non-volatile carbon increases to 85-90%. Also, by regulating external heating, the temperature is reduced to a point where spontaneous combustion is no longer possible, after which the cooling process begins.
Scope of use
Wood in the absence of oxygen heats up to extreme temperatures. The result of pyrolysis is coal, which can be used in enterprises or sold in retail chains. For domestic purposes, packaged coal is purchased. It will replace firewood when you need to light the stove or cook a dish on the grill.
The finished product can be seen in the photo of charcoal. Its advantages include:
- minimum atmospheric pollution by combustion products;
- absence of sulfur and phosphorus impurities;
- slight formation of ash after combustion;
- high calorific value parameters;
- renewability of raw materials.
Charcoal, due to its advantages, can be used in various fields:
- in the manufacture of filters;
- in the technology of producing crystalline silicon;
- in the metallurgical industry and agriculture;
- for the production of food dyes and activated carbon;
- for the production of paint, glass and plastics;
- when lighting stoves and fireplaces.
Charcoal production equipment
You can make fuel at home using improvised means and even in an earthen pit. For industrial production, retort-type combustion furnaces are used. These can be either stationary or mobile installations. The main element of such installations is the combustion container. The pyrolysis barrel is the most expensive element of the installation. Today, manufacturers are offered several options for industrial installations, which include a full set of equipment for the job.
How to make charcoal at home
Making charcoal at home is done using improvised means. This is the simplest technology, although it does not guarantee the production of high-quality charcoal.
Before making charcoal with your own hands, preparatory work is carried out, which necessarily includes measures to ensure fire safety. To obtain high-quality charcoal, logs of the same type of wood are selected, they are cleared of bark and chopped into approximately equal smuts.
Before you start making charcoal with your own hands, the burning method is determined. The most popular ways to get charcoal at home is by burning wood:
- in an earthen pit;
- in a barrel;
- in the oven.
The first two are carried out outdoors, the last is carried out in two stages - the first in the stove (optimally if the stove was built outdoors), and the second on the street.
In the hole
This is the cheapest way to make charcoal at home. To do this, a hole 0.8-1.0 m deep and 0.5-0.6 m in diameter is dug in the ground. Firewood is placed at the bottom to start a fire. After the fire is lit, raw materials are placed in the pit. Firewood is stacked to the top. After the fire has engulfed the entire volume of the pit, and the wood gradually begins to burn out, the pit is covered with a metal sheet, and wet earth is poured on top, so as to completely block the access of oxygen.
12-16 hours after closing the pit, carefully open the lid. After about 1-1.5 hours, the smut can be removed. With this method of producing charcoal in a pit, the yield of the finished product is from 25 to 35% of the volume of installed firewood.
In a barrel
You can make charcoal at home in a barrel. To do this, take a metal barrel. For a large volume you will need a large 200 liter barrel; for coal with a volume of 3-4 kg, a 50 liter barrel is sufficient. For work, it is advisable to choose a barrel with thick walls, a large neck and, if possible, a lid that can be locked. To obtain charcoal in a barrel, the technology does not change much, the only thing is that it is recommended to place it on bricks in order to warm it up afterwards.
The barrel is filled with wood, ignited and after it flares up, it is closed with a lid. After about 12-18 hours for a 200 liter container, it is recommended to light a fire under the barrel and warm it up for 3-4 hours. After warming up, the barrel can be left to cool.
Remove the lid carefully so as not to inhale carbon monoxide. The material can be removed after 4-6 hours. When the barrel is fully loaded, you can get up to 40-50% of the volume of finished fuel.
In the oven
You can also make charcoal in a stove. The process consists of two stages. The first stage is burning wood in the stove. This is done until the firewood is completely burned out. Next, the firebrands are removed from the furnace firebox and placed in a bucket or ceramic container and covered with a lid. The yield of charcoal with this method is small, only 2-2.5 kg.
Step-by-step business plan: coal sales
After the entrepreneur has chosen the type of material to be produced, the production technology and has done an analysis of the competitor market, he needs to begin the step-by-step opening of his production.
Business registration
It is better to register a coal production business as an individual enterprise, choosing a simplified taxation system. This option has a positive effect on costs - you only need to pay a state fee of 800 rubles.
When choosing a simplified tax system, two options are available:
- 6% of the amount of income.
- 15% of the difference between income and expenses.
Documents required for registration of an individual entrepreneur:
- Passport, its copy.
- TIN.
- Application for registration of an enterprise.
- Receipt for payment of state duty.
- Statement on the chosen form of taxation.
You also need to select the appropriate OKVED code – 02.20 “production of charcoal”.
The time required for registration takes 3 business days.
Selecting a room
The site where charcoal will be produced must be chosen outside the city. It would be ideal to set up a workshop near sources of raw materials, thus minimizing transportation costs.
The area of the room must be at least 180-200 square meters. It is also necessary to arrange a storage room and a separate area for employees.
If your budget allows, it would be better to buy a plot of land than to rent it.
Purchase of equipment
Most of the costs will go towards purchasing all the necessary equipment. For the stable functioning of production you will need:
- Hydraulic wood chopping machine.
- Chainsaw.
- Industrial scales.
- Charcoal kilns.
- Electric generators.
- Packing block.
When choosing a charcoal kiln, choose a machine that uses multiple removable tanks to ensure continuous production.
Charcoal kilns are divided into two types:
- Stationary.
- Mobile.
The weight of the stoves ranges from 6 to 80 tons.
To start production, it will be enough to purchase one retort furnace, which produces 400-1000 kilograms of products per day. As production expands and distribution channels are established, you can think about expansion.
Purchase of raw materials, selection of suppliers
The average volume of coal production from various raw materials is 25-30%.
Wood consumption and final coal yield:
- 500 kg of birch – 140 kg of coal.
- 550 kg of oak, ash, maple - 160 kg.
- 400 kg of pine, aspen, spruce - 110 kg.
- 520 kg of larch – 150 kg.
- 420 kg alder – 120 kg.
- 380 kg poplar – 100 kg.
The consumption of raw materials depends not only on the type of wood, but also on the equipment used. For single-chamber stoves, 7 cubic meters of wood equals 1 ton of coal, and the use of a three-chamber stove will significantly reduce the consumption of raw materials.
When choosing suppliers, you should pay attention to the cost of wood waste and the quality of the raw materials offered. It is best to sign a supply agreement with:
- Woodworking factories.
- Furniture factory.
- Sawmill.
It is very important to find suppliers who will uninterruptedly supply the enterprise with the necessary raw materials
Product labeling
In industrial production, several points need to be taken into account. Before packaging, the material must be cooled and packaged (depending on customer requirements). The following information must be indicated on the packing slip or on the package itself:
- manufacturer;
- the name of the product is indicated;
- information about the origin of the fuel;
- the certificate number is indicated;
- net weight;
- there must be information about fire hazard class 4;
- storage rules and instructions for use are indicated.
