Modernization Charcoal Production with Continuous Pyrolysis

Charcoal production and charcoal marketing have not been treated by strict rules such as wood pellets. This is mainly due to the large number of charcoal producers, with a small average production and traditional production technology. In addition, the market or buyer also does not require large volumes and long-term contracts. The quality factor remains an important standard, especially for the export market. But it could be that more stringent rules will also apply to production and marketing, given the potential damage caused. The low conversion of traditional charcoal kiln, which is an average of 15%, makes the need for wood raw materials extra, so that to produce 1 million tons of raw materials is needed about 6.5 million tons of wood. The approach to using efficient technology is increasingly urgent especially to serve large and continuous needs. Pyrolysis or continuous carbonization is the solution to this, with a conversion rate to charcoal reaching 30% or almost one third. With this efficient technology, only 3 million tons of wood is needed, or only half that means saving about 3 million tons of wood raw material.

Another motivation for using continuous pyrolysis technology is the high efficiency of energy savings that can be obtained. In charcoal production traditionally more than 60% of energy is lost during the production process. This can be illustrated in making charcoal from coconut shells. Conversion from raw materials to charcoal is only 15-25% in the process of traditional carbonization / pyrolysis. For example, we take a conversion of 25% (the best estimate), with a raw material of 10 tons of coconut shell, then 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 a lot of energy waste.

Whereas in the continuous pyrolysis process almost all energy can be utilized. Syngas and biooil are two types of by-products from pyrolysis that can be used as energy sources. Based on this, not only is conversion increasing, resulting in a reduction in raw materials which are also used by side products that can be used as energy sources. At present there are very few people who are thinking of utilizing the energy lost during the carbonization / pyrolysis process, this is because most people only think about how to increase the conversion to the charcoal. The loss of energy during the carbonization process is unknown or not realized by mostly charcoal producers in particular.

The use of 'lost energy' when the carbonization / pyrolysis process becomes another form of energy is certainly very good and adds value to its benefits. Electricity and heat are the two most needed forms of energy, so the conversion of 'lost energy' or pyrolysis / carbonization byproducts to become electric and heat energy is the best use scenario today. A number of regions or regions in the world still have low levels of electricity access. Africa, for example, on average has a low level of access to electricity, which is less than 30%, whereas in this region is the largest charcoal producer in the world which reaches 50% of global global production. By using continuous pyrolysis, this area, in addition to being the largest charcoal producer and even with a higher conversion, will also have access to electricity with the construction of a power plant fueled by the pyrolysis / carbonization by-products.

Charcoal is an energy product from biomass processing, especially wood. Wood charcoal has been known for a long time and is produced in a number of places. The process of producing wood charcoal is generally traditional, takes a long time and the quality is not uniform. According to FAO, global wood charcoal production in 2015 was recorded at more than 50 million tons and about half of it was produced in Africa. That means with the assumption that the conversion rate of 15% requires biomass, especially wood as raw material, as much as 333 million tons every year with 167 million tons coming from Africa. If the conversion rate to charcoal can be increased to 30% or two times, then the need for raw materials will decrease drastically or only half, namely 167 million tons globally and 83.5 million tons from Africa. What a very significant savings effort.

Every year Europe imports 1 million tons of charcoal, as well as Saudi Arabia and Middle Eastern countries import more than 1 million tons of charcoal. Saudi Arabia and the Middle East mainly use charcoal to roast lamb, a favorite food there. The use of charcoal in general is mostly the household sector with retail distribution. In addition charcoal is also used for metallurgy, agriculture (biochar) and activated charcoal (activated carbon) raw materials.

Activated Carbon Production From Palm Kernel Shell

Besides being able to be directly used as fuel, for charcoal production and torrified products, palm kernel shells can also be processed for higher added value which is activated carbon. One of the advantages of activated carbon from palm kernel shells is that the majority of micropore is more than 80%. This makes it suitable for recovering gold and silver from the solution. Another thing that makes it suitable for the application is because of the level of its hardness. Activated carbon from palm kernel shells will have characteristics similar to activated carbon from coconut shell. The form of granule is activated carbon which is commonly used for recovery of gold and silver. The granule shape is made by crushing both coconut shells and palm kernel shells to a certain size.

Rotating Kiln For Steam (Physical) Activation

Indonesian and Malaysian palm kernel shell production is huge, which is more than 15 million tons per year from palm oil mills waste. There are around 17 million hectares of palm oil plantations from both countries as palm oil sources and are the largest in the world today. The use of palm kernel shells can be optimized for the production of activated carbon. Activated carbon demand is predicted to increase by about 10% per year and the demand reaches nearly 4 million tons in 2021 valued at 8.12 billion USD (while data in 2015 recorded global production of 2.7 million tons of of activated carbon valued at USD 4.74 billion). Powdered activated carbon (PAC) has the largest market share followed by granular activated carbon (GAC) .The high demand for PAC is mainly driven by the needs in a number of industries such as chemicals, petrochemicals, food and beverages for decolorizarion and deodorization applications. Liquid phase application have the largest portion for usage of activated carbon. Asia Pacific region is the largest market location for activated carbon, and the location of Indonesia and Malaysia which are rich in palm kernel shells is also in the Asia Pacific region, meaning that producers and markets can be in one region, so they should also be the main players of this commodity .

As awareness of sustainability increasing, the production of activated carbon from renewable raw materials will be expanded. It should be noted that world activated carbon production is currently dominated by activated carbon from non-renewable raw materials which reach up to 80% and partly produced in western countries. Activated carbon production can be carried out by chemical or physical activation. Chemical activation is not so much done on an industrial scale because of the associated environmental pollution, although the yield is higher and the operating temperature used is lower. Physical activation, especially with the steam, is the type of activation that is suitable for palm kernel shells and mostly operated today. Rotary kilns are the most widely used equipment for steam or physical activation.

Before being activated, the palm kernel shell is made into charcoal. The charcoal production process is still largely traditional, which makes a lot of air pollution, small yields and large energy losses. Modernization of technology for charcoal production needs to be done to overcome the above. Pyrolysis or continuous carbonization is a technology for charcoal production which is the activated carbon raw material. The pyrolysis or continuous carbonization will also make the activated carbon production process very efficient. This is because one of the highest cost components for the activated carbon production process can be fulfilled from the side products of continuous pyrolysis namely syngas and biooil. For more details can be read here.

Continuous Pyrolysis for the Activated Carbon Production Part 2

Activated carbon production can be done in two ways, namely physical and chemical activation. Both physical and chemical activation require pyrolysis (carbonization) in the activated carbon production process. The difference about the sequence, in the use of the pyrolysis unit (carbonization) in the activation process is the physical activation of the pyrolysis unit (carbonization) for charcoal production which is then activated using steam or CO2, while the chemical activation of the pyrolysis unit (carbonization) is used for charcoal production from raw materials previously chemically activated like with H3PO4, ZnCl2, KOH. Other differences in physical activation using temperature for activation are higher, namely the range of 800-1000 C while the chemical activation uses a lower temperature, which is around 150-200 C only. Activated carbon products or yield that are produced chemically are more than those produced physically, which are around 3: 1.

The advantage of using a continuous pyrolysis unit for activated carbon production primarily increases the efficiency of the production process and the quality of the products. Efficiency is very important for a production activity. The efficiency of the production process is derived from the use of pyrolysis by-products that can be used to produce heat and even electricity. As an example of physical activation that uses a high operating temperature, excess syngas can be used to reach that temperature. Biooil produced can produce steam. Charcoal products produced from a continuous pyrolysis (carbonization) unit also do not need to be cooled and can be activated directly, so that their energy needs can be minimized. So that the activated carbon production should be an integration between the pyrolysis unit (carbonization) and its activation unit.

While in the chemical activation process, pyrolysis (carbonization) byproducts can also be used for the production of activated carbon. The activation process that uses a temperature that is quite low at 150-200 C can use excess heat from the pyrolysis process for its heat source. While excess syngas can be used to produce electricity for the production of activated carbon or sold to other parties such as other industries or PLN. Biooil can also be used for burner fuel or purified again for the production of vehicle fuel and so on. Continuous use of pyrolysis (carbonization) will also produce high quality, standard and stable product quality, this is because the operating conditions in the unit can be easily and accurately controlled, such as heating rate, residence time and temperature.

While in charcoal production (carbonization) traditionally operating in batches, in addition to a lot of energy loss also produces a lot of smoke which causes air pollution. The loss of energy during the traditional process of carbonization (pyrolysis) can even reach more than 60% meaning that more than half of the energy is only wasted, for more details can be read here. Of course this is very unfortunate, the activated carbon plant which should be able to operate very efficiently and economically, becomes wasteful and expensive. The effect of this is of course on the depletion of the profits obtained by the business. Within a short time it is expected that activated carbon factories will use continuous pyrolysis (carbonization) to increase efficiency, environmental and economic aspects.

Continuous Pyrolysis for Palm Oil Mills

A number of regions have been over-supplied with electricity so it is not possible to add or build new power plants. Making a new plant will only be in vain because the electricity production cannot be utilized or absorbed by the user. Based on this, electricity production in a number of areas must be limited and diversified into other products needed. These other products are products whose needs are still not met. Another thing that can be done is to increase the efficiency of a production process. When the efficiency of a production process is improved and produces the products needed, of course the business benefits increase. Besides that, when all the waste can be processed, it becomes a production unit that is zero waste and environmentally friendly.

Palm oil mills are very numerous in Indonesia and Malaysia, the number reaches more than 1000 units, while Thailand also begins to follow the planting of oil palm. At present some of the palm oil mill effluents have not been processed such as empty palm bunches, palm shells and fronds. The palm oil mill that has been operating can be increased efficiency and the production of by-products that provide additional income. This can be done by using a continuous pyrolysis unit for both electrical and heat energy sources and the production of various by-products in the form of charcoal, biooil and biomass vinegar. The three by-products can be sold or marketed and become an additional income for the palm oil mill which is quite attractive.

Conventional Energy System in Palm Oil Mill

Improved Palm Oil Mill with Continous Pyrolysis System

Palm oil mills also do not need to be bothered with the problem of waste, especially solid waste if everything can be processed and very profitable. Meanwhile, from the environmental aspect of a palm oil mill that is zero waste and environmentally friendly, it is certainly the dream of all the palm oil mill owners. The community and the surrounding environment which is not disturbed by the palm oil mill that is because of its pollution is also a condition desired by the palm oil entrepreneurs. By using the continuous pyrolysis, the air pollution generated is very minimal or far from the required threshold, so that the environment and the surrounding community can be accepted. If the palm oil mills have used continuous pyrolysis, it will also be economically attractive.

Charcoal produced also has many benefits. Technically, charcoal is a stable fuel so it is easy to store and does not decay or is eaten by termites. Charcoal can be used for energy sources directly easily, or converted to other fuels, for example converted into liquid or gas fuel. The condition of fossil fuels, especially petroleum which is increasingly depleted, demands the diversification of energy, such as Indonesia which is predicted to run out of oil in 10 years or in 2028. Likewise, biooil can be used immediately, or upgraded to better fuels, such as vehicle fuel. While biomass vinegar can be used for fertilizer, biopesticides and upgraded to biophenol and wood adhesive.

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.

Production of Biophenol, Bioformaldehyde and Wood Adhesive from Pyrolysis Liquid Products

The byproducts of biomass (slow) pyrolysis are liquid and gas products. The liquid products consist of biooil and biomass vinegar (pyroligneous acid). Biooils can be directly used as fuel with a particular burner, or can also be upgraded to the vehicle fuel. Meanwhile, if used for non-energy products, can be used for the production of green chemical or renewable chemicals such as BioFormaldehyde and wood adhesive. While the aqueous phase of pyrolysis liquid product that is biomass vinegar (pyroligneous acid) can be used for feedstock biophenol production. Previously biomass vinegar has been known for various uses such as latex coagulant, anti-termite and fertilizer. While the biophenol production process scheme of biomass vinegar as follows.

Global consumption for phenol currently reaches 20 million tons or worth 20 billion US dollars (280 trillion rupiah). Renewable phenol or biophenol can substitute phenol which has been produced based on petroleum. Excess heat and excess syngas from the pyrolysis process can be used for the production process of the biophenol as energy sources. An integrated and efficient production unit will produce highly competitive products, such as the pyrolysis process which is primarily charcoal, and from its by-products made derivative products that are desperately needed today.

Biochar and IOT

The availability of nutrients for crops, especially food crops, to always produce maximum productivity is important for farmers. This is where biochar will help provide nutrients for the plant by making the soil microbials homes with pores, then with pores will also retain nutrients or fertilizers from leaching so that fertilization becomes effective and efficient. Biochar will also keep the organic moisture and carbon (C) needed for the plant. Organic farming that is currently widely developed will be in line with the use of biochar. The use of biochar with compost (solid organic fertilizer) is an application commonly used in organic farming and has been proven to give maximum results for the productivity of these plants. While the use of chemical fertilizers on the contrary will kill the soil microbes that will damage the chemical structure of the soil. Good soil should be like a fresh bread that expands with lots of pores in it, instead of like solid, hard bread.

Then what to do with IOT (InternetOf Things)? This IOT can later be used to measure and monitor the availability of nutrients or fertilizers for these plants, as well as various variables that affect plant growth such as air humidity, sunlight availability for photosynthesis, the presence of pests and so on. Parameter parameters will be displayed with the IOT app, which can be viewed with a personal computer (PC) or even with a smartphone or gadget in real time. With this IOT the soil conditions and nutritional availability can be measured and monitored. So the use of biochar can also be known how effective and efficient compared with not using biochar. 

The more measurable the condition and availability of nutrients or fertilizers in the soil, the easier it is for farmers to manage their farms. Fertilizers also need not be added again if known to be sufficient or otherwise. A number of studies with various experiments have shown that the use of biochar in agricultural land can reduce the use of  fertilizer up to 50%. Of course it is very interesting for farmers. With the IOT technology makes the existence of biochar increasingly known benefits so it will also be more widely used. For large biochar requirements, production with continuous pyrolysis technology is the best way.