Do-it-yourself charcoal – production technology. How to make charcoal at home How to make your own charcoal

How charcoal is made: distinctive chemical and physical properties + 3 types of substance + 8 areas of application + technological aspects + production conditions + cost accounting + 2 traditional methods of production at home.

Charcoal has been around since ancient times. It was made using primitive technologies in small quantities, and the process itself was cumbersome and took a long time. Over time, when the need for the substance increased, many people wondered how charcoal was made and opened their own production.

Today, a more simplified methodology is used, modern equipment is used, new developments have been introduced and knowledge has been accumulated, so it is easier to obtain high-quality material.

Since charcoal is in high demand, the business of its production is quite profitable and promising.

Distinctive properties of charcoal

Charcoal, in accordance with State Standard 7657-84, is understood as a solid, porous substance that can release energy during combustion. The material contains mostly carbon.

In many ways, charcoal resembles stone, because... The main element of both is carbon.

Both substances are essentially made from wood. However, coal is made from wood that has been decomposing in conditions of limited oxygen for several centuries. Charcoal is made from charred wood. First, it is partially burned with a low oxygen content.

The material is known for its environmental friendliness. It does not pollute the environment with acrid smoke despite being a good type of fuel.

The substance also acts as an adsorbent. The porous structure allows you to purify water, gases, and alcohol. Due to its unique chemical and physical properties, such coal is prone to spontaneous combustion, having an increased calorific value, practically not inferior to stone.

When manufacturers make high-quality wood products, the output is black coal with a clearly visible shiny, blue tint. If the material is broken, it is clear that the structure of the wood is preserved, but the surface is cracked. Thanks to them, they determine how long the substance has been charred.

Worldwide, annual charcoal production reaches 9 million tons. Brazil is the leader. Russia accounts for about 100 thousand tons. Products are imported into the country from China, Belarus, and Ukraine.

The lead in consumption belongs to Japan (60 kg per year per citizen), in European countries the amount of coal consumed per capita is approximately 20 kg. In the Russian Federation this figure is 100 grams.

Types and uses of charcoal.

Coal is classified into 3 types:

• Red, the wood raw materials of which are coniferous species. Its production is achieved through soft charcoaling.
• Black, it is made from willow, aspen and other soft-leaved trees.
• White, obtained from oak, beech, birch, ash, hornbeam, etc. First, the charring process occurs at low temperatures, and then there is a sharp jump to 1000°C. White coal does not retain its bark, unlike black coal.

Wood material is widely used in various areas of the national economy. Coal is made for further use in the creation of pure ferroalloys in non-ferrous/ferrous metallurgy.

Metal products undergo carbon cementation in order to improve their properties and prevent oxidation as a result of saturation with carbon. Most coal from wood is required by enterprises producing carbon disulfide and crystalline silicon.

In addition, the substance is made for:

• chemical industry(production of colorful solutions, artificial fiber, glass, pesticides, plastic, filters, cellophane, antiseptic);
• construction (as an absorber of moisture and unpleasant odors);
• electrical engineering (due to radiation resistance and non-toxicity, it is used in the creation of radio components, electrodes, conductors, etc.);
• medicine (in the form of tablets, as a medicinal drug);
• Agriculture, in particular livestock farming (addition to the normal diet of birds, cattle and small cattle, fertilization of the top layer of soil);
• floriculture (organic terra preta element);
• food industry (food coloring, which can be found on product packaging under the brand name E153);
• cosmetic industry(one of the components of products designed to provide care for the skin of the face, body, and hair).

In Japan, the wood product has even more diverse uses. Coal is used in laying foundations, baking cookies, and making toothbrushes and soap. Our people are accustomed to using it in everyday life, as fuel and in cooking.

How coal is made from wood in factories: technological aspects

Charcoal is made from wood through pyrolysis. This is a process involving the dry distillation of raw materials. In other words, during production, decomposition of organic carbon compounds occurs under the influence of high temperatures (with limited or no oxygen at all).

For pyrolysis, retort furnaces (pyrolysis boilers) of a stationary or mobile type are used, which have a pyrometer that allows you to regulate the temperature. Raw materials are placed into the loading space manually or automatically.

However, first the wood is unloaded into a designated area and sorted. If wood raw materials are purchased not crushed, they are chopped into firewood.

1. The first stage involves drying. Then the temperature is not raised above 150°C.
2. When excess moisture leaves the wood material, the temperature is increased and proceed to the next step. Heat is generated in the upper chamber of the oven. Under its action, wood is burned, wood gas is generated, which moves to the nozzle to mix with secondary air. As a result of these processes, burnt, dry coal is formed.
3. Next you need to calcinate it. This will remove resin and unnecessary gases.
4. The wood product is then unloaded and allowed to cool.
5. Then it is made into crushed .

A diagram of the technological process that takes place over 16-20 hours, during which coal is made, is shown in the figure:

The raw materials are:

• decks;
• hemp;
• branches;
• measles;
• wood chips;
• whips;
• waste generated during the manufacture of furniture,
• logs;
• sawdust;
• wood preparations;
• mouthguards;
• peat.

The purchase of consumables is organized from forestry departments.

To produce 1 ton of coal, you will have to spend up to 8 cubic meters. m. birch. If soft hardwoods are used, the consumption is higher - up to 12 cubic meters. m. The factories produce 3 grades of coal: A, B, C.

Safety rules for making charcoal.

According to safety rules, only produced coal, the volume of which exceeds 100 cubic meters. dm, may spontaneously ignite. Because of this, it is necessary to take measures to prevent spontaneous combustion.

Many entrepreneurs who understand how charcoal is made, unfortunately, do not comply with these requirements and do not protect their products from contact with the oxidizing agent. Allowing the accumulation of coal dust is also considered a big mistake.

When workers make charcoal, labor safety rules R O-00-97 must be observed, which you can read here - https://ohranatruda.ru/ot_biblio/norma/252437

To transport wood products, you need to use steel barrels, craft, paper, and polypropylene bags. Coal is stored in closed warehouses and special bunkers to prevent the ingress of precipitation.

Delivery of goods is carried out in bulk or in packaged form using trucks and covered wagons.

Necessary conditions for charcoal production

Charcoal is made by first creating the appropriate conditions for this:

• Firstly, this is a workshop room located outside the city, an open plot of land required for the boiler. The area, including a separate storage room, must be at least 200 square meters. m.
• Secondly, staff is required, usually 2-3 workers. They must be provided with a work uniform (overalls, goggles, mask, gloves). In addition to production workers, you need to hire an accountant, a cleaner, a watchman, a sales manager, a driver and several laborers or loaders.
• Thirdly, equipment.

The technological equipment of the workshop where charcoal is made includes:

You need to choose a good installation for making charcoal, then the production will be complete. How to determine it?

Does not emit a burnt, suffocating smell into the atmosphere. It is released, but remains in the firebox, which is used for thermal decomposition of the next batch of wood and drying. Also, high-quality retort furnaces minimize energy losses.

On the market there are:

• large stationary complexes that produce coal in large volumes;
• mobile machines;
• auxiliary equipment.

The choice of equipment is significantly influenced by the planned production volume and the following parameters:

If the process is automated, the computer program will regulate the temperature in retorts, drying chambers, set commands for making amendments, reduce worker errors by reducing their number, and report the onset of the next stage of the production process.

In the photo you can see the industrial site and working retort furnaces. Their total capacity reaches 20 barrels. This is more than 200 tons of woody matter per month (about 1.5 cubic meters of raw materials). Such equipment pays for itself within 1-2 years.

Another important condition for production is a certain amount of raw materials. When 25-30 tons of coal are produced per month, an average of 225-250 cubic meters is consumed. m. of wood (depending on the species). And you will also need additional containers for packaging.

Direct and indirect costs for the production of coal from wood.

Charcoal is made at a cost of at least 1.5 million rubles. Business is a very expensive direction. The most money will have to be spent on powerful equipment, the price of which on average is 800 thousand rubles.

Among domestically produced units, pay attention to the Zarya units. The Fantastika complexes also showed good performance. High-quality charcoal is produced by the OD-30, OD-60 furnaces, the prices of which are in the range of 680-890 thousand rubles.

Expect that renting a premises and industrial site may cost about 200-400 thousand rubles. , the cost of purchasing raw materials will cost 100 thousand rubles. The wage fund and taxes will amount to 600 thousand rubles. In addition, take into account the costs of advertising, transport - 50 thousand rubles. Registration of necessary documents - about 10 thousand rubles. , utilities - 50 thousand rubles.

Total the total notional amount of initial investment at which wood products are produced in mass quantities is 1.8 million rubles.

Sales of 1 kg of coal cost 18-35 rubles. Net profit every month from the production of 100 tons of finished products will be 70-80 thousand rubles.

2 Traditional Ways to Make Charcoal at Home

Using a simple old-fashioned method, charcoal is made on a smaller scale than in full-scale production. Since standard equipment for home charcoal burning is not suitable due to its bulkiness and high cost, many have adapted to burning raw materials in pits and barrels.

First way.

Involves making coal in a barrel. This method is more convenient than the one described below.

The woody substance is made in a container with a volume of at least 200 liters. A hole is drilled at the bottom of the barrel to insert the pipe. You need to attach a vacuum hose to it, which will supply primary oxygen to the combustion zone. The metal container must be sealed tightly, so you should find a suitable lid.

An auxiliary tool will be a poker for mixing firewood. Performers need to find a longer steel rod.

The wood material is processed to remove the bark before being placed in the barrel. It will emit a lot of smoke, and the output from it will be small. The logging is then cut into 30 cm long logs.

The firewood is laid out in such a way that it fits tightly against each other. Make a small fire at the bottom of the tank, then start the vacuum cleaner. It is imperative to control the process in order to place the next portion on time.

Charcoal should not be allowed to turn into ash. During operation, the entire barrel will be filled. Then cover it tightly with a lid, turn off the air supply, and close the pipe.

All you have to do is wait until the charcoaling ends. The container opens only when its walls have completely cooled. If unfired lumps are found, they are calmly sent in the next batch.

Now it’s time to sift the resulting coal and pack it into bags.

Methods for producing charcoal.

How is charcoal made? Main stages of production.

Second way.

Charcoal is made in another way - in a pit. It is dug out in the shape of a cylinder. You can make two bags of products from a pit with the following parameters: 50 cm – depth, 80 cm – diameter.

The bottom is trampled down, and the vertical walls are cleaned a little, so the soil will not mix with the wood. A fire is made from dry wood 30-40 cm in length. Gradually, the people who make the material must add wood chips and thin branches.

When the fire burns to the desired level, you can proceed directly to charcoaling. Wood raw materials are gradually added, periodically stirring the burning wood. As with a barrel, the hole must be filled completely.

This is done for 3-6 hours. The duration depends on many factors: air humidity, wood size, density. Burning firewood from hardwood takes longer, but the result of the work will be excellent.

Once filled, the hole is covered with leaves, grass, and a small layer of soil. All this is compacted. Coal should remain in such conditions for 48 hours. Once cooled, it is ready for sifting.

Charcoal is a very valuable product. Despite the “gas revolution”, it will continue to be a good biofuel in the future, an indispensable assistant in many areas.
Even if demand in the domestic market drops a little, it is always possible to export products.

So why not learn thoroughly in practice how charcoal is made in order to produce a quality product and make a profit from it? Or, at a minimum, provide for their own needs.

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The Village, with the help of experts, answers a variety of questions from Kiev residents about the life of the city. This time we learned how charcoal is made for barbecue.

• The Village Kiev 30 April 2013
• 27823
• 0

Even if a picnic is planned in the forest, many people prefer not to search for firewood on the spot and buy logs or special charcoal for barbecuing at the supermarket. Charcoal looks like burnt wood, which begs the question: why does it burn? For an answer, we turned to the founder of the company Grillbon, which produces charcoal and coal briquettes.

How is charcoal made for barbecue?

Ivan Bondarchuk

founder of Grillbon

To produce charcoal, hardwood trees are used - birch, oak, hornbeam, ash, cherry, and apple. The strongest and densest is obtained from birch and hornbeam. Barbecue charcoal is made using two technologies - lump and briquette.

Coal production from lump wood has several

stages. First, the raw materials are prepared: cut, crushed and dried. Then they are placed in a charcoal kiln, the temperature of which reaches 450°C. Here the process of wood pyrolysis occurs, that is, its thermal decomposition in a vacuum. After this, the coal must cool in the furnace, also without access to oxygen. Then it is taken out and left to cool for another 30 hours. If you do not do this, the coal may spontaneously ignite. The cooling process is called stabilization. Finally, the lump charcoal is packed into bags.

If you do not follow the production technology, the yield of coal decreases; it turns out fine, smelling of tar, and unburnt. The most common reason for a decrease in the amount of coal at the output is oxygen entering the furnace, which causes part of the mass to burn out.

If you produce coal using briquette technology, then you need to use ready-made fine charcoal as a raw material. It is mixed with paste and starch, and briquettes are formed from the resulting mass using a press. The main advantage of charcoal briquettes is that they are denser, therefore they burn longer, 4–5 hours (regular charcoal - 1.5–3 hours). Transporting briquettes is also more convenient: they are heavier, but take up less space. Plus, they provide even heat.

Charcoal is a natural biofuel that you can make yourself.

Making charcoal in a pit

You can make it yourself in a pit. This method has been used for a long time. This way you can make coal quite simply. To do this, it will be necessary to prepare a small pit, which should have the shape of a cylinder, while the walls should remain vertical. Its diameter should be 80 cm, while the depth should be 50 cm. Using this technology, you can get two bags of biofuel.

Features of making a pit for producing coal

If you decide to make it yourself, you first need to prepare a hole. After its bottom is thoroughly compacted, you can use the method of pressing with your feet. This is necessary in order to prevent mixing of the finished product with the soil. After this, you need to make a fire using birch bark and small branches. Gradually you need to start adding wood and thin branches to the fire. You need to ensure that everything is covered with burning wood. Once the fire is lit, you can begin making charcoal. To do this, you will need to prepare firewood.

Requirements for raw materials for the production of coal

Do-it-yourself charcoal will turn out to be of high quality if you throw firewood that does not have bark into the pit. This is due to the fact that it smokes a lot. Whereas coal using such firewood is of very low quality. In order to use fuel more comfortably, the raw materials must first be cut into individual elements.

You can choose the dimensions of the workpieces yourself, but the size of one element should not exceed 30 cm. New firewood must be laid on top, and the mass must be moved with the help of a long pole. The beams should be laid in layers as densely as possible. Thus, the hole should be filled to the top. The duration of burning will also depend on air humidity.

When you make charcoal with your own hands, it will be possible to fill a pit of the size mentioned in about 3 hours.

Final works

After the hole is filled, it needs to be covered with grass and also leaves. Everything is sprinkled with a layer of soil on top and compacted. In such conditions, charcoal should remain for two days, after which it can be sifted and then packaged. As soon as this work can be completed, it can be considered ready for use.

Making charcoal in a barrel

You can use equipment for the production of charcoal according to the type of container. To do this, it will be necessary to prepare a thick-walled steel barrel. Its dimensions should be selected depending on the amount of coal expected to be received.

If the barrel is large, it will take much longer to fill it. If the container has ever been filled with chemicals, such containers cannot be used. If petroleum products were stored in a barrel, it must first be prepared by burning, and then used, but only in its pure form.

Options for making coal in a barrel

Pyrolysis of wood will make it possible to obtain coal using one of the technologies, each of which involves the use of a barrel. The first method involves lighting a fire inside the container. In this case, the process will not differ from the production of coal in a pit. The container should have a large capacity (about 200 liters) - this is necessary so that the wood does not clog the fire.

It is also necessary to install 6 bricks; it is advisable to use fire-resistant products. A fire will have to be lit between them. If you use such equipment for the production of charcoal, then the firewood must be immersed carefully until it covers the bricks. Afterwards, a grate must be installed on the product so that the next batch of firewood can be placed on it.

The wood should be laid in rows fairly tightly. After the barrel is filled to the top, you need to wait until the flame appears from above. Afterwards, you need to cover everything with a steel sheet and leave a small gap. In order to speed up this process, you need to make a hole in the bottom of the container through which air will flow. While the wood is burning, you will need to monitor the color of the smoke. As soon as it acquires a bluish tint, the barrel will need to be closed as tightly as possible and left until it cools completely. Afterwards, the lid is removed from the container, and the finished coals are removed from the inside.

An alternative option for making coals in a barrel

Pyrolysis of wood can make it possible to obtain coal using a slightly different technology. To do this, it will be necessary to fill the container to the top with wood. Afterwards everything should be covered with a non-flammable lid. The barrel must be closed almost hermetically. It is necessary to leave a hole for the gases to escape (it must be large), the temperature inside will need to be brought to 350 degrees.

In order for the production of charcoal to become possible, the container must be installed on a platform. This way it will be possible to isolate it from the soil. The easiest way to implement this is with the help of bricks, which must be laid on a sheet of steel. A fire should be lit between them, which will warm the barrel.

After a certain time, the process of oxidation of the wood will begin and gas will begin to escape. As soon as the gas output stops, the barrel will need to be left on the fire for some time. Thus, it will take about 2.5 hours to burn a 200-liter container. After this, the barrel must be removed from the heat and the remaining holes in the lid must be sealed. In this condition, the container must be stopped until it cools down. Charcoal at home will be ready after the barrel is opened. The coal can be used immediately.

Making charcoal using a stove

If you're wondering how charcoal is made, another method you can consider is using a stove. After the firewood burns out, you will need to select the burned, but not yet collapsed, coals. They should be red. They will need to be placed in a container with a well-sealed lid. It is preferable to use a ceramic container, but you can also use a small bucket or barrel. It is worth remembering that the use of steel containers must involve compliance with fire safety. The lid must be kept closed until the coal cools completely. Once it is cold, it can be considered ready for use.

For those who don't know, you can make your own charcoal if you have the right stove. The process is quite labor-intensive and dirty, but it will allow you to prepare high-quality fuel for the winter or even open your own small business producing coal. This technology will be especially interesting for those who live near a forest and have access to an unlimited amount of firewood, which will allow them to produce charcoal for free and then sell it. Of course, this type of coal is most in demand for those who like to have a barbecue.

Let's take a closer look at how charcoal is mined.

Materials and tools:
- wood (any kind will do);
- partially burnt wood;
- a special stove with chimneys;
- overalls for this type of work;
- mask;
- gloves;
- protective glasses.

Charcoal mining process:

Step one. Preparing the oven
First of all, you need to prepare for work. For these purposes, you need to wear protective overalls, gloves, rubber boots, a mask and goggles. All this is necessary in order not to get dirty during work and not to inhale harmful dust particles from coal. Now you can climb into the oven and clean it. Particular attention should be paid to the ventilation openings, they must be clean.

Step two. Installation of the first tier of logs
When the lower part of the stove is cleaned, short logs are laid on it according to a special pattern, their length is about one meter. They need to be laid in the same way as the spokes on a bicycle wheel are installed, in which case the necessary ventilation corridors are formed.

Step three. Filling the stove with logs
Then you can put all the remaining logs in the oven. They are placed in a circle on top of the base of those logs that were laid out in the form of wheel spokes. A chimney is made in the center of the stove; it consists entirely of partially burnt wood, which remains from the previous production process.

Step four. Installing the stove cover and chimneys
The stove is filled with logs to the very top, but a gap must be left so that the lid can be installed. The height of this gap should be about 75 centimeters. When the installation is completely done, the oven is set on fire, and then it is covered with a lid. It is best to do all this early in the morning, for example at 5-6 o’clock, since it takes about 8-12 hours to burn the logs. The combustion time depends on the type of wood, for example, birch or pine will burn much faster than oak.

Also now you need to install chimneys around the stove. They are installed vertically in special holes. There should be three chimneys in total. They should be located at the same distance from each other. Otherwise, the air circulation will be incorrect and the logs will burn unevenly, which is a waste of raw materials.

Step six. Final stage of firing
When the required time has passed, the stove is given time to go out naturally. Now, to continue further work, you need to wait until the oven and its contents have cooled completely.

Step seven. Sorting of received raw materials
At this stage, you need to put on your entire protective uniform again, since the work ahead is dirty. All burnt wood is taken out of the oven and sorted. If you come across logs that are not completely burned, they are set aside and will be used to create a chimney the next time the stove is refueled.

What remains is then sifted from dust and placed in paper bags and other containers.

People who do blacksmithing usually use coal in their furnaces, others use gas, and still others use charcoal.

I read that the good thing about charcoal is that it is environmentally friendly, cheap, and you can make charcoal at home.

I read several tutorials on how to make your own charcoal and chose the easiest and cheapest method.

Step 1: Tools and Materials

Basic materials and tools:

• wood for ignition and wood for charcoal
• tool for cutting and separating wood
• metal container and a way to seal it

What I used:

• Chainsaw (any saw will do)
• A strong carving knife, a steel wedge and sled, or a long ax
• A block of wood for driving a knife
• Large coffee can
• Aluminum foil for sealing jar

Step 2: Pierce, cut, fill

I haven’t attached any photos of the wood preparation process, but I think you’ll understand what needs to be done.

First, I sawed the tree trunk into stumps, the length of which was slightly shorter than the height of a metal can, then I divided them into firewood about 2-3 cm thick.

The thickness of the firewood is a purely personal matter, and since this was my first experiment, I decided not to make it too thick. I filled the jar as much as possible with logs and covered it with aluminum foil. I made a small hole in the foil to allow moisture and wood gas to escape.

When wood is heated in the absence of oxygen, it releases wood gas, which is actually a very useful thing if you can collect it. Even engines run on it! If you make a completely sealed container with wood, you will practically create a bomb - nothing like that will happen with foil, of course, but completely sealed containers... I think you can imagine what can happen.

Step 3: Build a Fire

Safety first! So make sure you have a bucket of water or a water hose handy.

I also have a fairly large beard and I just recently lost half of it. So guys with beards, braid your beard or tuck it into your shirt. People with long hair can tie a braid or tie their hair up. The main thing is just don’t burn them, because it will take you a long time to regrow everything again.

I started a fire using pine chips and small pieces of wood. After the fire flared up, I added oak wood to it. The traditional method of making charcoal requires patience, but I wanted to make it this evening, so I put a fan on the fire. After about half an hour, the jar with the foil lid was placed on the fire and the next step could begin.

Step 4: Wait and watch

I lined the can with firewood and pointed a fan at it. After 20 minutes, steam came out of the can. About an hour passed and gas began to come out of the hole in the foil instead of steam. This meant that the method was working and the wood began to char. After about another hour, the flame on top of the can went out, which meant the wood gas had escaped and the process was almost complete.

Using a couple of sticks, I pulled the canister out of the fire and laid a layer of wet mud on top - this finally sealed the lid. At this stage, the air would cause the wood to burn, which we need to avoid. I waited about another hour, opened the jar and assessed the result.

Step 5: Open the jar, draw conclusions

I unpacked the chilled canister, removed the soil, took out the coal and broke it into pieces. I was almost sure that the wood was charred and that’s exactly what it turned out to be! In the end, I ended up with about 3 liters of coal.

My thoughts:

• I was pleasantly surprised by the amount of charcoal I got as I thought the can would be about half full when I opened it
• If you don't have a coffee can, you can buy a paint can or use a bucket.
• Make sure to use hardwood to make charcoal, as it has a higher energy density than softwood.

I hope you liked the instructions on how to make charcoal for barbecue and use it!