Charcoal Production for Activated Carbon Raw Material

Charcoal characteristics are influenced by the raw materials used and the conditions of the production process. The use of charcoal for certain applications or industries also requires certain specifications or characteristics. For example, charcoal used for fuel can have different specification requirements from charcoal specifications for agriculture (biochar), or charcoal used as raw material for activated carbon. A number of parameters that are acceptable in certain applications may not be acceptable in other applications.

Charcoal products used as raw materials for activated carbon production are also the same. Parameters in the form of high fixed carbon (~80%), high hardness, low ash content (~3%) and low volatile matter (<10%) are prerequisites for the specifications or quality of charcoal as a raw material for activated carbon. As a comparison, charcoal for agriculture (soil amendment) or commonly called biochar has a wide range of quality or specifications, namely lower fixed carbon (FC), higher ash content and higher volatile matter, especially in agro type biochar according to WBC (World Biochar Certificate), while premium type biochar according to WBC has a higher or highest quality and can be used for various purposes. While the material type biochar according to WBC has the lowest quality with use mainly in certain industries such as cement, asphalt, plastic, electronics, and composite materials or cannot be used for agriculture, soil applications and consumer products.

Raw materials for charcoal production for activated carbon production because it requires stricter parameters, especially high fixed carbon, low ash content and high hardness so that raw materials suitable for this purpose are more limited or not all biomass can be used for charcoal production for activated carbon raw materials. This is what makes coconut shells the best and most popular raw material for charcoal production as activated carbon raw materials today. And palm kernel shell raw materials (especially from dura variety) are expected to be the next candidate. The availability of abundant palm kernel shells (PKS) is a special attraction. But indeed with this palm kernel shell (PKS) charcoal raw material, there is still the smell of palm oil, so it is a challenge for activated carbon producers.

Reviving the Integrated Coconut Industry Part 3

When continuous pyrolysis is used for processing coconut shells and producing charcoal and is not processed further into activated carbon, excess syngas and biooil can be used as energy sources for processing fruit flesh and coconut water. Fruit flesh and coconut water can be processed into a variety of products needed by the market. The production costs of various processed coconut products have become very competitive because energy costs are very minimal or even zero. In addition, energy needs can also be added from coconut fiber which is used as fuel as well. The energy source can be used for electricity or heat or both depending on industry needs.

If gliricidae is planted as a crop between coconut plantations, wood products will also be obtained. The wood can be used as raw material for wood pellets as an export commodity which is predicted to continue to increase demand in line with awareness of environmental problems and climate change. Gliricidae leaf waste can also be used as animal feed such as goats, sheep and cattle. Maintenance of gliricidae is very easy and planting patterns as intercropping with coconut plantations are also common in Sri Lanka. Land optimization can also be done by using land between coconut plantation and gliricidae as pasture fields such as goats, sheep and cattle and for beekeeping.

To make the business profitable and sustainable, professional management certainly needs to be applied in the business. Management of the upstream sector namely plantations and livestock should be separated from the downstream sector namely factory or plant as a processing unit. This is similar to the organization in the palm oil company which separates the plantation division from the factory or mill division. In addition to facilitating business operations, the business will become efficient and competitive.

Reviving the Integrated Coconut Industries in Indonesia

The absence of a market causes the coconut industry to not develop, stagnate and even tend to die. Although various products can be produced from coconut fruit but with a small product uptake is not able to turn on the coconut industry. When the products that the demanded by market are already obtained, such as CPO in the palm oil industry, it is possible for the coconut industry to stretch and rise and be taken into account. Modernization of technology also needs to be done so that the coconut industry becomes a modern industry even though the production capacity is not as big as the palm oil industry. Another factor needed to revive the integrated coconut industry and this is almost the same experienced by all industries in general that is the availability of energy. So that to meet the energy needs, not all coconut fruit should be processed, but some are used to produce energy, for example coconut fiber, because the economic value is the lowest.

Activated carbon is a product that has a very good market potential and with continuous pyrolysis technology followed by activation, the product can be produced without the need for additional external energy. Thus the activated carbon plant can stand on its own using its coconut shell waste. But to get the coconut shell, someone must process the coconut fruit. Products such as VCO, dedicated coconut, and coconut milk can be the main products so that the processing of the coconut fruit. The coconut water can be processed into isotonic drinks or nata de coco. The use of coir-fired boilers (if in a palm oil mill, high efficient boilers only use the fiber) or even fronds and leaves can be used for electricity and steam production. Similar to operations in palm oil mills as well, namely electricity can be used to move a variety of mechanical equipment for processing coconut and steam as well as a source of heat, especially if the processing of the coconut fruit does need it.

With the above pattern, the coconut industry can be operated even though the location is in a remote area and there is no electricity network there, a place where coconut plantations are located. Indonesia as a seduction country of coconut islands with the plantation area of almost 4 million hectares and the widest in the world today or the equivalent of 1/3 of palm oil plantations should be also the leader in the world coconut industry. 

Continuous Pyrolysis Unit for Activated Carbon Production

Production of activated carbon requires charcoal as raw material. Charcoal production will be more effective and efficient by continuous pyrolysis (carbonization). In addition to the high quality charcoal produced can also produce electricity and steam production for the activation process. Of course this makes high efficiency of the production process. Whereas in terms of environmental aspects, it is also very environmentally friendly because of smoke pollution during the process of pyrolysis (carbonisation) can be minimized below the threshold. Methane emissions that are very damaging to the ozone layer also did not occur.

The process of pyrolysis (carbonization) with a temperature of around 400 C with a product in the form of charcoal can immediately proceed with activation. Activation with 700-1000 C operating conditions can be done directly by raising the temperature. If the excess syngas is used for electricity production, then biooil from pyrolysis can be used to fuel in steam production. Excess electricity can also be sold to industries or to electricity companies. Whereas if all sources of energy are used for the production of activated charcoal (activated carbon), the consumption of heating oil can be minimized and even eliminated. Activated carbon production with all the energy can be supplied by itself is certainly very interesting and economical.

The problem with traditional charcoal production is the problem of smoke pollution and the amount of energy lost. Smoke pollution can be directly identified and can be easily felt, but the problem of energy loss is usually not noticed and generally do not know. Of course this is very unfortunate, let alone energy is one component of high costs in a production process. Is there really an energy loss? And how much energy is lost? Of course we need to look in detail at the carbonization process (pyrolysis) to answer these questions.

 Conversion from raw materials to charcoal is only 20-25% in the process of traditional carbonization / pyrolysis. For example, we take a conversion of 25%, with a raw material of 10 tons of coconut shell, 2.5 tons of charcoal are produced. Coconut shell with a heating value of around 4,500 kcal / kg, meaning that 10 tons of raw material is 45,000,000 kcal. While coconut shell charcoal with a heating value of around 8,000 kcal / kg, then 2.5 tons of charcoal will have a heating value of 20,000,000 kcal / kg. Based on these calculations more than 50% of energy is lost or is only wasted, ie 25,000,000 kcal. If the conversion to charcoal is lower or 20%, the energy loss is even greater, namely 29,000,000 kcal or more than 60%. Of course it is very inefficient and should be avoided. This can also happen for carbonization of various other raw materials for activated carbon, such as palm kernel shells, wood, and so on.

Continuous pyrolysis is the best solution for charcoal production and also the production of energy that can be used for the activated carbon production process itself. The activated carbon factories that have been established can upgrade the technology especially on the side of charcoal production and energy fulfillment. The more efficient of a production will be the more economical the business. While the pyrolysis or carbonization process is also still produced by-products namely biomass vinegar (pyroligneous acid / liquid smoke) which can be used as plant fertilizer, biopesticides to raw materials for chemicals, especially biophenol and wood adhesive.

We Will Produce Charcoal As You Wish

Charcoal has widespread uses include metallurgy, tobbaco curing, water purification (activated carbon), poultry and animal feeds, soil Amendment, and other miscellaneous uses. Charcoal is made by a certain process conditions to achieve the specifications according to their usefulness.

The amounts of moisture (2 to 4 percent), volatiles (18 to 23 percent), ash (1 to 4 percent), and fixed carbon (74 to 81 percent) in charcoal provide an average index of quality for general market acceptance either in lump or briquette form. Charcoal with relatively low volatile content and correspondingly higher amounts of fixed carbon is desirable for specialized industrial uses. Temperatures somewhat higher than the normal kiln operating temperatures of 850° to 950° F (454°  to 510° C) are required to produce it. The volatiles, when present in proportions greater than about 24 percent, will cause smoking when charcoal is burned and will give product degrade in some areas of recreational use.

 

In a continuous process raw organic material of any kind is passed through the retorts and cooked into marketable products. While some of the biogas is used to fuel its own process, on site gas turbines or steam boilers can be fueled by the same gas. Variable speed drives give the operator total control on product quality by altering the residence time of the feed stock. The operator can also vary the percentage split between the bio-oil and charcoal by changing the temperature.

 

Chemical properties can be precisely determined only with analytical equipment. A rough quality test for volatiles can be made, however, by burning samples of charcoal and observing the absence or extent of smoking. A metallic ring when a piece of charcoal is dropped onto a hard surface provides a further rough test for good quality. Too rapid coaling at high temperature usually results in the formation of crumbly charcoal easily broken into small pieces and fines. The species of wood does not influence the chemical quality of charcoal; the physical properties, however, are influenced by wood density and structure. For example, the low-density woods produce charcoal in greater bulk, while some woods will produce brittle charcoal. In general, the lump charcoal obtained from the medium-dense to dense hardwoods is considered a cleaner product because of less breakage and dusting with handling.

GENERAL OVERVIEW OF CHARCOAL PROPERTIES

The quality of charcoal depends on both wood species used as a raw material and of the proper application of the carbonisation technology. Charcoal produced from hardwood like beech or oak is heavy and strong. Charcoal made from softwood, on the other hand, is soft and light. The density of beech charcoal is 0.45 t/m3a, that of pine charcoal 0.28 t/m3. 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/m3. The gross calorific value (GCV) is usually in the range of 29-33 GJ/t.

Good quality charcoal was characterized by Chaturvedi as follows: “[It] retains the grain of the wood; it is jet black in colour with a shining luster in a fresh cross-section. It is sonorous with a metallic ring, and does not crush, nor does it soil the fingers. It floats in water, is a bad conductor of heat and electricity, and burns without flame.”

Charcoal intended for barbecue typically contains 20-30%mass of volatiles, whereas metallurgical charcoal often contains 10-15%m (or even less) volatile matter. Hence, taking ash contents into account, the fixed carbon content is 78-90 %mass.

This carbon is a finely crystalline and practically free of sulfur. Charcoal also contains volatiles that may escape at elevated temperatures (obviously above the charcoal manufacturing process of approximately 400 C), consisting of hydrogen, oxygen, and nitrogen. Ash content is approximately 1.5-5%mass. Charcoal also contains water, the amount being dependent on ambient temperature and humidity. Moisture content varies between 5 %m-8 %mass.

Standards for barbecue charcoal and charcoal briquettes, according to EN 1860.

Charcoal: Carbon (fix), dry basis > 75% Ash, dry basis < 8% Moisture, wet basis < 8% Granulation [d > 80 mm] < 10% [d > 20 mm] > 80% [0 mm < d < 10 mm] < 7% Bulk density > 130 kg/m3

Charcoal briquettes: Carbon (fix), dry basis > 60% Ash, dry basis < 18% Moisture, wet basis < 8% Granulation Suitable for BBQ equipment of EN 1860-1 [d < 20 mm] < 10% Binder Combustion gases cause no health hazards in contact with food. Binder is of food grade quality.

Source : INDUSTRIAL CHARCOAL PRODUCTION, A Development of a sustainable charcoal industry,Presented by FAO

COCONUT SHELLS AND PALM SHELL USED AS WATER PURIFIERS IN TOKYO

Granulated charcoal, made of shells of coconuts and palm kernels, is being used by treatment plants in Tokyo and neighboring regions to filter tap water supplies and protect the city’s water from radiations leaked by a damaged nuclear power plant, according to a report last month from www.bloomberg.com. Prices for the absorbent carbon material have risen as much as 44 percent since the March 11 earthquake and tsunami that triggered the radiation threat, said Yoshio Toi, a spokesman for the municipal government in Chiba, a prefecture neighboring Tokyo.



Treatment plants are trying to remove any traces of radioactive matter, such as iodine-131, known to cause thyroid cancer, and convince customers that water supplies are safe. Some Tokyo facilities more than quadrupled the amount of activated charcoal used in filtration after a March 21 sample contained iodine-131 that exceeded the safe limit for infants. “Tokyo is ordering more activated charcoal as we deplete our stocks,” said Gen Ozeki, a spokesman for the city’s Bureau of Waterworks. “It’s not just Tokyo doing this, others are taking extraordinary measures for their water, too, so charcoal is becoming scarce.” Kuraray Co., which produces about 24,500 tons of a year of activated charcoal, is receiving orders for “several hundred tons” daily from utilities in and around Tokyo, said Takeshi Hasegawa, a spokesman for the Tokyo-based company. He declined to comment on prices.