GB2495038A - Manufacture of charcoal - Google Patents

Manufacture of charcoal Download PDF

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Publication number
GB2495038A
GB2495038A GB1223362.3A GB201223362A GB2495038A GB 2495038 A GB2495038 A GB 2495038A GB 201223362 A GB201223362 A GB 201223362A GB 2495038 A GB2495038 A GB 2495038A
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United Kingdom
Prior art keywords
text
trough
combustion chamber
inlet
primary combustion
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Granted
Application number
GB1223362.3A
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GB2495038B (en
GB201223362D0 (en
Inventor
Andrew Mark Elliott
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Individual
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Individual
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Priority to GB1223362.3A priority Critical patent/GB2495038B/en
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Classifications

    • CCHEMISTRY; METALLURGY
    • C10PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10BDESTRUCTIVE DISTILLATION OF CARBONACEOUS MATERIALS FOR PRODUCTION OF GAS, COKE, TAR, OR SIMILAR MATERIALS
    • C10B49/00Destructive distillation of solid carbonaceous materials by direct heating with heat-carrying agents including the partial combustion of the solid material to be treated
    • C10B49/02Destructive distillation of solid carbonaceous materials by direct heating with heat-carrying agents including the partial combustion of the solid material to be treated with hot gases or vapours, e.g. hot gases obtained by partial combustion of the charge
    • C10B49/04Destructive distillation of solid carbonaceous materials by direct heating with heat-carrying agents including the partial combustion of the solid material to be treated with hot gases or vapours, e.g. hot gases obtained by partial combustion of the charge while moving the solid material to be treated
    • C10B49/06Destructive distillation of solid carbonaceous materials by direct heating with heat-carrying agents including the partial combustion of the solid material to be treated with hot gases or vapours, e.g. hot gases obtained by partial combustion of the charge while moving the solid material to be treated according to the moving bed type
    • CCHEMISTRY; METALLURGY
    • C10PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10BDESTRUCTIVE DISTILLATION OF CARBONACEOUS MATERIALS FOR PRODUCTION OF GAS, COKE, TAR, OR SIMILAR MATERIALS
    • C10B53/00Destructive distillation, specially adapted for particular solid raw materials or solid raw materials in special form
    • C10B53/02Destructive distillation, specially adapted for particular solid raw materials or solid raw materials in special form of cellulose-containing material
    • CCHEMISTRY; METALLURGY
    • C10PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10LFUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G, C10K; LIQUEFIED PETROLEUM GAS; ADDING MATERIALS TO FUELS OR FIRES TO REDUCE SMOKE OR UNDESIRABLE DEPOSITS OR TO FACILITATE SOOT REMOVAL; FIRELIGHTERS
    • C10L5/00Solid fuels
    • C10L5/40Solid fuels essentially based on materials of non-mineral origin
    • C10L5/44Solid fuels essentially based on materials of non-mineral origin on vegetable substances
    • C10L5/442Wood or forestry waste
    • CCHEMISTRY; METALLURGY
    • C10PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10LFUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G, C10K; LIQUEFIED PETROLEUM GAS; ADDING MATERIALS TO FUELS OR FIRES TO REDUCE SMOKE OR UNDESIRABLE DEPOSITS OR TO FACILITATE SOOT REMOVAL; FIRELIGHTERS
    • C10L5/00Solid fuels
    • C10L5/40Solid fuels essentially based on materials of non-mineral origin
    • C10L5/44Solid fuels essentially based on materials of non-mineral origin on vegetable substances
    • C10L5/447Carbonized vegetable substances, e.g. charcoal, or produced by hydrothermal carbonization of biomass
    • CCHEMISTRY; METALLURGY
    • C10PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10LFUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G, C10K; LIQUEFIED PETROLEUM GAS; ADDING MATERIALS TO FUELS OR FIRES TO REDUCE SMOKE OR UNDESIRABLE DEPOSITS OR TO FACILITATE SOOT REMOVAL; FIRELIGHTERS
    • C10L9/00Treating solid fuels to improve their combustion
    • C10L9/08Treating solid fuels to improve their combustion by heat treatments, e.g. calcining
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23BMETHODS OR APPARATUS FOR COMBUSTION USING ONLY SOLID FUEL
    • F23B5/00Combustion apparatus with arrangements for burning uncombusted material from primary combustion
    • F23B5/04Combustion apparatus with arrangements for burning uncombusted material from primary combustion in separate combustion chamber; on separate grate
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23CMETHODS OR APPARATUS FOR COMBUSTION USING FLUID FUEL OR SOLID FUEL SUSPENDED IN  A CARRIER GAS OR AIR 
    • F23C7/00Combustion apparatus characterised by arrangements for air supply
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23GCREMATION FURNACES; CONSUMING WASTE PRODUCTS BY COMBUSTION
    • F23G5/00Incineration of waste; Incinerator constructions; Details, accessories or control therefor
    • F23G5/02Incineration of waste; Incinerator constructions; Details, accessories or control therefor with pretreatment
    • F23G5/027Incineration of waste; Incinerator constructions; Details, accessories or control therefor with pretreatment pyrolising or gasifying stage
    • F23G5/0276Incineration of waste; Incinerator constructions; Details, accessories or control therefor with pretreatment pyrolising or gasifying stage using direct heating
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23GCREMATION FURNACES; CONSUMING WASTE PRODUCTS BY COMBUSTION
    • F23G5/00Incineration of waste; Incinerator constructions; Details, accessories or control therefor
    • F23G5/24Incineration of waste; Incinerator constructions; Details, accessories or control therefor having a vertical, substantially cylindrical, combustion chamber
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23GCREMATION FURNACES; CONSUMING WASTE PRODUCTS BY COMBUSTION
    • F23G5/00Incineration of waste; Incinerator constructions; Details, accessories or control therefor
    • F23G5/44Details; Accessories
    • F23G5/46Recuperation of heat
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23GCREMATION FURNACES; CONSUMING WASTE PRODUCTS BY COMBUSTION
    • F23G7/00Incinerators or other apparatus for consuming industrial waste, e.g. chemicals
    • F23G7/10Incinerators or other apparatus for consuming industrial waste, e.g. chemicals of field or garden waste or biomasses
    • F23G7/105Incinerators or other apparatus for consuming industrial waste, e.g. chemicals of field or garden waste or biomasses of wood waste
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23JREMOVAL OR TREATMENT OF COMBUSTION PRODUCTS OR COMBUSTION RESIDUES; FLUES 
    • F23J1/00Removing ash, clinker, or slag from combustion chambers
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23MCASINGS, LININGS, WALLS OR DOORS SPECIALLY ADAPTED FOR COMBUSTION CHAMBERS, e.g. FIREBRIDGES; DEVICES FOR DEFLECTING AIR, FLAMES OR COMBUSTION PRODUCTS IN COMBUSTION CHAMBERS; SAFETY ARRANGEMENTS SPECIALLY ADAPTED FOR COMBUSTION APPARATUS; DETAILS OF COMBUSTION CHAMBERS, NOT OTHERWISE PROVIDED FOR
    • F23M9/00Baffles or deflectors for air or combustion products; Flame shields
    • F23M9/06Baffles or deflectors for air or combustion products; Flame shields in fire-boxes
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23GCREMATION FURNACES; CONSUMING WASTE PRODUCTS BY COMBUSTION
    • F23G2201/00Pretreatment
    • F23G2201/30Pyrolysing
    • F23G2201/302Treating pyrosolids
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23GCREMATION FURNACES; CONSUMING WASTE PRODUCTS BY COMBUSTION
    • F23G2201/00Pretreatment
    • F23G2201/30Pyrolysing
    • F23G2201/303Burning pyrogases
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23GCREMATION FURNACES; CONSUMING WASTE PRODUCTS BY COMBUSTION
    • F23G2203/00Furnace arrangements
    • F23G2203/30Cyclonic combustion furnace
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23GCREMATION FURNACES; CONSUMING WASTE PRODUCTS BY COMBUSTION
    • F23G2206/00Waste heat recuperation
    • F23G2206/20Waste heat recuperation using the heat in association with another installation
    • F23G2206/203Waste heat recuperation using the heat in association with another installation with a power/heat generating installation
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23GCREMATION FURNACES; CONSUMING WASTE PRODUCTS BY COMBUSTION
    • F23G2900/00Special features of, or arrangements for incinerators
    • F23G2900/55Controlling; Monitoring or measuring
    • F23G2900/55007Sensors arranged in waste loading zone, e.g. feed hopper level
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23JREMOVAL OR TREATMENT OF COMBUSTION PRODUCTS OR COMBUSTION RESIDUES; FLUES 
    • F23J2900/00Special arrangements for conducting or purifying combustion fumes; Treatment of fumes or ashes
    • F23J2900/01007Thermal treatments of ash, e.g. temper or shock-cooling for granulation
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02EREDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E20/00Combustion technologies with mitigation potential
    • Y02E20/12Heat utilisation in combustion or incineration of waste
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02EREDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E50/00Technologies for the production of fuel of non-fossil origin
    • Y02E50/10Biofuels, e.g. bio-diesel
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02EREDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E50/00Technologies for the production of fuel of non-fossil origin
    • Y02E50/30Fuel from waste, e.g. synthetic alcohol or diesel
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02PCLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P20/00Technologies relating to chemical industry
    • Y02P20/141Feedstock
    • Y02P20/145Feedstock the feedstock being materials of biological origin

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Oil, Petroleum & Natural Gas (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Combustion & Propulsion (AREA)
  • Organic Chemistry (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Environmental & Geological Engineering (AREA)
  • Sustainable Development (AREA)
  • Materials Engineering (AREA)
  • Wood Science & Technology (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Sustainable Energy (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • Biodiversity & Conservation Biology (AREA)
  • Ecology (AREA)
  • Forests & Forestry (AREA)
  • Solid Fuels And Fuel-Associated Substances (AREA)
  • Coke Industry (AREA)
  • Processing Of Solid Wastes (AREA)

Abstract

Apparatus (102) for the manufacture of charcoal, comprising a unit (201) having walls (204, 206, 207, 208) defining a primary combustion chamber (209), and a material inlet (107) for allowing a feed of wood chips (103) through said material inlet into said apparatus. A trough (219) is located at a lower height than said material inlet such that material (103) passing through said material inlet is able to fall into the trough. An air inlet (228) is located below the material inlet such that, when wood chips are located within the trough piled up to said material inlet, air passing from said air inlet passes through said wood-chips and into the primary combustion chamber (209).

Description

Manufacture Of Charcoal
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method and apparatus for continuous manufacture of charcoal
2. Description of the Related Art
Methods for manufacturing charcoal are known in which pieces of wood are heated within a container that is deficient of air. A problem with such methods is that the material is processed in batches, involving loading each io batch of material into a container that is processed before being unloaded for re-use. in addition, processing time is prohibitively long, being typically one or mare days.
BRIEF SUMMARY OF THE INVENTION
According to a first aspect of the present invention, there is provided apparatus for continuous manufacture of charcoal as claimed in claim 1
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
Figure 1 shows a system 101 including apparatus 102 for manufacturing charcoal; Figure 2 shows a simplified cross-sectional view of the apparatus 102; Figure 3 shows again the cross-sectional view of the apparatus 102 shown in Figure 2, illustrating a plane 301; * Figure 4 shows a cross-sectional perspective view of a front portion of the apparatus 102, also showing the plane 301; and Figure 5 shows the apparatus 102 illustrating the operation of the S.....
apparatus.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Figure 1 A system 101 including apparatus 102 for manufacturing charcoal is shown in Figure 1.
The charcoal manufactured by the apparatus 102 is made from wood chips 103 that are initially stored in a container 104. The wood chips 103 may be produced on the same site as the system 101 are alternatively transported in from a separate production site. For reasons explained below, the wood chips are manufactured such that they comprise particles of wood having a largest dimension between fifty millimetres (50mm) and one hundred and fifty millimetres (150mm).
The wood chips are typically formed from waste wood, either used wood, such as old furniture, doors, etc. or freshly cut wood. The wood chips are formed using conventional equipment, for example comprising rotating blades, or flailing hammers, which progressively reduces the material particle size until it is small enough to fall through a screen. Thus, the dimensions of the apertures in the screen determine the sizes of wood chips produced. In the present embodiment the screen has square apertures having a width of approximately 75mm (seventy-five millimetres).
The system 101 comprises a conveyor 105 for conveying wood chips from the container 104 into a hopper 106 positioned at a material inlet 107 of the apparatus 102.
The apparatus 102 processes the wood chips 103 to produce charcoal 108 that is experled from the apparatus 102 at its material outlet 109. The charcoal emerging from the outlet has a temperature of typically 200t, and is a.....
* deposited onto a conveyor 110 where it air-cools down to typically 40'C before * being deposited into a container 111 for temporary storage or transportation.
The charcoal 108 may then be further processed depending upon its intended usa For example, it may be ground to a powder and formed into * briquettes in accordance with known methods.
: Operation of the apparatus 102 generates excess heat, which is carried from the apparatus in the form of hot waste gases through its gas outlet 112.
The waste gases are passed through a waste heat boiler in which heat from the hot gases is used to generate steam. The steam is then used to drive a turbine 114 and thereby generate electricity.
S After passing through the waste heat boiler the waste gases are drawn through a bag filter 115 by an exhaust fan 116 before being expelled to atmosphere through a stack 117.
The exhaust fan creates negative pressures (i.e. air pressures below ambient atmospheric pressure), not only in the exhaust pipework 118, connecting the apparatus 102, boiler 113 bag filter 115 and fan 116, but also within combustion chambers located within the apparatus 102. A pressure sensor (not shown) in the gas outlet 112 of the apparatus 102 provides a measure of pressure within the outlet, and the speed of the fan 116 is adjusted in response to the pressure measurement.
Figure 2 A simplified cross-sectional view of the apparatus 102 is shown in Figure 2. In the present embodiment the apparatus 102 comprises a unit having the general form of a rectangular box 201 with a length of approximately five metres (5m), a height (shown by arrow 202) of approximately two metres (2m), and a width (into the page) of approximately one point seven metres (1.7m).
The box 201 comprises a floor 203. front wall 204, a rear wall 205, two side waIls 206 and a horizontal upper wall 207. The box 201 is formed of steel sheet material and lined with refractory blocks (in the present embodiment comprising calcium silicate) capable of withstanding the temperatures of up to *:-. 1200cc that are reached during operation of the apparatus 102.
The apparatus comprises an interior baffle wall 208 which extends downwards from the ceiling created by the upper wall 207 and from one side :. * wall 206 to the other side wall. The baffle wall 208 divides a primary combustion chamber 209 from a secondary combustion chamber 210.
However a rectangular shaped gap 211 is formed between the bottom edge 212 of the baffle wall 208 and the floor 203 such that gases in primary combustion chamber 209 are able to escape into the secondary combustion chamber 210.
In the present embodiment, the secondary combustion chamber also has two horizontal baffle walls 213 which divide up the secondary combustion chamber to provide an elongated meandering path, which waste gases must traverse between the gap 211 and the gas outlet 112. During operation, this meandering path ensures that the gases passing through secondary combustion chamber 210 have sufficient time to fully combust before leaving the apparatus through outlet 112.
A trough wall 214 extends upwards from the floor 203 to a height of approximately one hundred and ten centimetres (1.lm) and from one side wall 206 to the other side wall. The trough wall 214 extends parallel to, and between, the front wall 204 and the baffle wall 208 The trough wall is tapered such that its top edge 215 is narrower than its base portion, and such that its face 216 that faces the front wall 204 slopes downwards towards it.
The front wall 204 is provided with a lower portion 217 of similar height to the trough wall 214, and which has a sloping face 218 that slopes downwards towards the trough wall. A trough 219 is therefore defined by the lower portion 217 of the front wall and the trough wall 214, and due to the sloping faces 216 and 218 of the trough wall 214 and front wall 204 the trough is relatively wider at its top than its bottom. in the present embodiment the top of the trough has a width of approximately one metre (im) while a bottom * 25 portion of the trough has a width of a half of one metre (0.5m).
* A conveyor mechanism 220 has a first end 221 located within the bottom portion of the trough 219 just above its bottom surface 222. The *:" conveyor mechanism extends through a horizontaSly extending enclosure 223 from the trough 219 at one end of the enclosure to the material outlet 109 at *e*.
* * 30 the opposite end of the enclosure. In the present embodiment the conveyor ** mechanism comprises a screw-type conveyor configured to continuously transport particles of charcoal 108 from the bottom of the trough to the material outlet 109.
The enclosure 223 has an extended space 224 above the conveyor 220 which contains a water jet arrangement 225 for spraying jets of water onto the charcoal during transportation by the conveyor mechanism 220. During operation, charcoal received by the conveyor 220 at the bottom of the trough 219 is typically at a temperature of approximately 600CC. Consequently, the charcoal is quenched by the water jets produced by the arrangement 225 to ensure that the charcoal does not burn when exposed to air after leaving the outlet 109. The rate of water provided by the water jet arrangement 225 is calculated and arranged to be sufficient to reduce the temperature of the charcoal leaving the outlet 109 to approximately 200t. It may be noted that the temperature of the charcoal leaving the material outlet 109 is kept above 1 OUt to prevent water remaining in liquid form on the charcoal.
An inlet waIl 226 extends downwards from the upper wall 207, parallel to the front wall 204 and from one side wall 206 to the other side wall. A gap is provided in the upper wall 207 between the inlet wall 226 and the front wall 204. Consequently the inlet wall 226, the front wall 204 and the two side walls 206 form a downwardly extending passageway which provides the material inlet 107.
The inlet wall 226 has a bottom edge 227 located above the top end of the trough 219 and the hopper 106 is fixed to the upper end of the material inlet 107. Consequently, when the apparatus is empty of wood/charcoal material, it is possible for wood chip particles dropped into the hopper 106 to passes through the material inlet 107 and drop into the trough 219.
* .. *..
* The apparatus 102 also comprises an air inlet 228 provided in the front wall 204, which supplies air to the apparatus via a valve 228V. The air inlet 228 has an elongated rectangular opening such that it extends horizontally across the inner face of the front waIl 204 substantially from one side wall 206 to the * 30 other side wall. * S
A secondary air inlet 229 is provided in the upper wall 207 to allow air to be drawn into, or blown into the primary combustion chamber 209, via a valve 229V. In the present embodiment the secondary air inlet is one of an array of air inlets 230 located in the ceiling of the primary combustion chamber 209.
During operation, of the apparatus it is necessary to maintain a stock of material in the hopper 106. For this reason, a position sensor 231 is provided for detecting the level of the upper surface 232 of wood chip material 103 in the hopper 106. When signals from the position sensor indicate that the level has dropped below a threshold level, the conveyor mechanism 105 is energised to drop wood chip material into the hopper. When an upper threshold level is reached the conveyor 105 is stopped. In the present embodiment, the position sensor is a position sensor of known type that detects the material surface by radar. However, other embodiments employ other remote sensing position sensors, such as those using ultrasonic signals for detecting a material surface. Stilt further other embodiments use a pair of sensors that detect the presence or absence of material at an upper and at a lower level. In these latter embodiments, detection of material at the upper sensor causes the conveyor 105 to stop, while the absence of material detected at the lower sensing causes the conveyor to restart.
During normal operation of the apparatus 102, the process converting wood chip to particles of charcoal generates an excess of heat. However, at times it is necessary to provide additional heat to the primary combustion chamber 209. Consequently, an auxiliary burner 233 is provided on the floor 203 in the primary combustion chamber 209. The burner 233 is supplied with **. : fuel and air from corresponding supplies 234 and 235 via control valves 236. A o 25 temperature sensor (not shown) is located in the primary combustion chamber 0***e* * 209, and, during operation of the apparatus, when the detected temperature is * less than a required lower threshold value the valves 236 are operated to ignite the burner 233. *
In the present embodiment, the burner is an oil burner, but other fluid * S *.*.
so fuel burners, such as gas burners are used in other embodiments.
Figures 3 and 4 The cross-sectional view of the apparatus 102 shown in Figure 2 is shown again in Figure 3, illustrating a plane 301, and a cross-sectional perspective view of a front portion of the apparatus 102 is shown in Figure 3, also showing the plane 301.
As previously mentioned, the trough 219 has inwardly sloping sides 216 and 218 such that a lower portion of the trough 302 is narrower than the top end of the trough. The lower portion 302 of the trough has substantially parallel surfaces 303 and 304 that extend vertically downwards.
The plane 301 is a vertical plane extending parallel to each of the two surfaces 303 and 304, and equidistant from said surfaces. Now, as illustrated in Figures 3 and 4, the material inlet 107 is located to one side of the plane 301, while the primary combustion chamber is located on the other side of the plane. As described bejow, when wood chips are supplied to the apparatus 102, this arrangement leads to a pile of material of a desired shape.
It should also be noted that the lower edge 227 of the inlet wall 226 is higher than the top edge 215 of the trough wall 214. Furthermore, the air iri?et 226 is positioned at a height between that of the tap edge 215 of the trough wall 214 and the lower edge 227 of the inlet wall 226. Consequently, air flowing into the apparatus 102 through the air inlet 228 generally passes below the lower edge 227 and above the top edge 215.
As illustrated in Figure 4, the array of air inlets 230 comprises three rows of three air inlets.
Figure 5 The cross-sectional view of the apparatus 102 shown in Figure 2 is shown again in FigureS, illustrating the operation of the apparatus.
Before production of charcoal commences, it is necessary to bring the interior of the combustion chamber 209 up to operating temperatura * Consequently, before any wood chip material is supplied to the apparatus 102, ao the material inlet 107 and outlet 109 are closed, and the burner 233 is ignited. a
The valves such as valve 228V and 229V providing air to the inlets 228, 229, 230 are also partially closed, but provide air for the burner at a restricted flow rate.
When the temperature within the primary combustion chamber reaches a minimum operating temperature, (of 850°C in the present embodiment), the material inlet 107 is opened and wood chip material is supplied to the inlet. As a result, wood chip material piles up in the trough 219 to create a pile 501 that extends back up through the material inlet 107. The upper surface level 232 of material is subsequently maintained within the hopper 106 by operation of the conveyor 105 in accordance with signals received from the position sensor 231 (as described previously). Meanwhile the conveyor 220 is continuously operated to remove material from the pile 501 at the bottom of the trough 219.
As illustrated in Figure 5, the positioning of the material inlet 107 to one side of the trough 219 causes the wood chip particles to pile up in the trough adjacent to the front wall 204. Consequently, the wood chip particles form a pile 501, such that from the lower edge 227 of the inlet wall 226 down to the trough wall 214, the pile has a sloping surface 502 generally facing toward the primary combustion chamber 209. The surface 502 of the pile 501 is therefore subjected to direct radiant heat from the primary combustion chamber 209.
It should also be noted that the pile 501 has a relatively steeply sloping surface 502. Such a steep slope is possible due to the general resistance to flow due to intermeshing of the relatively large wood chips.
Heat from the primary combustion chamber 209 causes the wood chip ". : material to give off various volatile components, some of which are flammable.
Consequently, such flammable components mix with air provided through air inlets 230 and combust within the primary combustion chamber 209. This * :* : combustion causes the temperature within the combustion chamber 209 to rise further and so increase the heat applied to the wood chip material.
It may be noted that, when normal stable operating conditions are * 30 established, the quantity of flammable components given off from the pile 501 : * and combusted in the primary combustion chamber 209 is sufficient to maintain a temperature of between 1100°C and 1200°C in the chamber 209, without operation of the burner 233. In such conditions, the combustion within the chamber 209, along with the air flows provided by the air inlets 229, 230, and the presence of the baffle wall 208, cause the burning gases to rotate around the primary combustion chamber 209 as indicated by arrows 550.
Thus, the majority of the combustion takes place in the primary combustion chamber, close to the pile 501 of material. Any gases not combusted in the primary combustion chamber are combusted in the secondary combustion chamber before the gases leave through the outlet 112.
With the wood chip material supplied to the apparatus 102, the valve 22W is opened such that air is also supplied via the air inlet 228. In the present embodiment air is drawn in through the inlet 228 by the negative pressure present in the primary combustion chamber 209, caused by the operation of the exhaust fan 116 (shown in Figure 1). However, when a higher rate of flow of air is required, an inlet fan also may be used to force in air through the inlet 228.
Due to the relatively large dimensions of the wood chip particles, the pile 501 contains sufficiently large gaps between the wood chip particles to allow the air provided at the inlet 228 to flow through the pile. Consequently, a substantially horizontal layer 503 of the pile 501 adjacent to the air inlet 228 contains wood chip particles that are surrounded by air. Particles in this layer 503 are also subjected to direct radiation from the combustion chamber 209 and so they give off volatile components including flammable components.
Consequently, the flammable components combust in the air flowing from the air inlet 228, in close proximity to the wood chip particles and within the layer * a...
* 503 itself. Thus the layer 503 of the pile 501 is effectively a layer of burning It should be understood that the pile 501 is not static, but comprises a pile of particles that travel from the inlet 107 to the bottom of the trough 219 due to the action of the conveyor 220, and gravity. Thus, wood chip particles pass through the layer 503, within a period of typically 5 to 10 minutes, as they travel downwards.
While in the layer 503, the wood chip particles reach temperatures of approximately 600°C, within a few minutes, and begin to carbonise. This initial carbonising stage is essential to the process, as it ensures that alt of the particles, across the full width of the pile, are brought to a sufficiently high temperature to start the carbonisation process.
As the particles travel further downwards, into the trough, the partially carbonised particles continue to be heated by the heat generated in the combustion chamber 209. Consequently, they remain at a temperature of approximately 600C for up to an hour, and they continue to give off gases ari to carbonise. However, as there is no oxygen supplied to the trough itself, the gases that are given off generally emerge from the surface 502 of the pile 501 and become mixed with the burning gases in the primary combustion chamber 209. Furthermore, due to the lack of oxygen below the layer 503, the particles below the layer 503 carbonise but cannot oxidise. (If any oxygen is present in this part of the pile, it preferentially causes combustion of the emitted gases rather than the particles themselves.) As a result, the particles reaching the bottom of the trough 219 comprise charcoal.
When the process is first started, wood chip material supplied to the apparatus 102 passes through without being completely carbonised. (Such material may be reprocessed by the apparatus and fully carbonised.) However, when the apparatus 102 reaches its normal steady-state operating mode, wood chip particles passing through the material inlet 107 emerge as charcoal * from the outlet 109 within a matter of a few hours.
It should be understood that the rate at which material passes through the apparatus is determined by the rate at which the conveyor 220 expels material from the outlet 109. Thus, this rate is set at a value that ensures that the wood particles supplied at the material inlet 107 are fully carbonised during the transit through the apparatus.
As mentioned previously, the material inlet 107 is a downwardly extending passageway, that is formed between the front wall 204 and the internal inlet wall 228. During operation, wood chip material travels through the passageway in approximately 10 to 15 minutes. As the passageway is only separated from the primary combustion chamber 209 by the inlet wall 226, heat from the chamber 209 passes through the inlet wail 226 and raises the temperature of wood chip material in the passageway to between 1 OUt and 200°C. Consequently, material emerging at the bottom of the passageway is pre-heated, and at least partially dried.
It should also be noted that the wood chip material in the passageway partially plugs the material inlet 107, and prevents air from being drawn in through the material inlet 107 without it passing through the wood chip material in the layer 503.
The intermeshing of the wood chips can potentially cause problems in the mate!ial inlet, as the wood chips form bridges, stopping the material above from falling under gravity. However, the present embodiment includes reciprocating pokers (not shown) which extend into the inlet passageway and mechanically disturb the wood chips within their vicinity to prevent such bridges forming.
In the present embodiment, clean fresh air is supplied to the air inlet 228. However, in alternative embodiments, at least a portion of the air that is provided to the air inlet 228 comprises hot air previously expelled through the gas outlet 112. Air within the outlet 112 comprises approximately 6% to 7% of oxygen and therefore it is still usable for combustion purposes.
*.: Advantageously, as the air from the outlet 112 is hot, when it is supplied through the inlet 228 it assists with heating the wood chips inlayer 503.
In a further alternative embodiment, hot air from the outlet 112 is passed through a heat exchanger used to heat fresh air supplied to the air inlet * * * * . * *.

Claims (2)

  1. <claim-text>Claims 1. Apparatus for continuous manufacture of charcoal, comprising a unit having: chamber walls defining a primary combustion chamber, in which an upper one of said chamber walls defines a ceiling for said chamber; a trough wall located within said chamber, such that a trough is to one side of said trough wall and a primary combustion space of said chamber is to the other side of said trough wall, said trough being located at a lower height than said material inlet such that material passing through said material inlet is io able to fall into the trough; a material inlet for allowing a feed of wood chips through said material inlet into said apparatus; a first air inlet located below the material inlet such that, when wood chips are located within the trough and piled up to said material inlet, air passing from said first air inlet passes through said wood-chips and into the primary combustion chamber1 and a second air inlet located in said upper one of said chamber walls configured to provide a flow of air from said ceiling and into said primary combustion space, wherein said material inlet comprises a downwardly extending passageway defined by an inlet wall that separates said passageway from said primary combustion chamber, such that heat generated within said primary *". combustion chamber is able to pass through said inlet wall into said * passageway. a. * S *</claim-text> <claim-text>*
  2. 2. The apparatus of claim 1, wherein said trough extends along a * verfica) plane, said material inlet extends along said trough to one side of said a:...: vertical plane and said primary combustion chamber extends along said trough to the other side of said vertical plane, such that when particulate material is located within said trough piled up to said material inlet said particulate material defines a surface exposed to said primary combustion chamber.</claim-text> <claim-text>3. The apparatus according to claim 1 or claim 2, further comprising a fluid fuel burner Located within said primary combustion space for increasing the temperature of gases within said primary combustion chamber.</claim-text> <claim-text>4. The apparatus according to any one of claims I to 3, wherein said unit comprises a secondary combustion chamber having a gas outlet, said secondary combustion chamber being in communication with said primary combustion chamber such that gases are allowed to pass from said primary combustion chamber through said secondary combustion chamber to said outlet.</claim-text> <claim-text>5. The apparatus according to any one of claims 1 to 4, further comprising a conveyor mechanism arranged to transport particulate matter from a bottom end of said trough.</claim-text> <claim-text>6. The apparatus of claim 5, wherein said conveyor is located within an enclosure and said apparatus further comprises a water jet arrangement within said enclosure for spraying jets of water onto mailer transported by said conveyor.</claim-text> <claim-text>7'. The apparatus according to any one of claims 1 to 6, wherein: said trough is defined by said trough wall and one of said chamber walls, which extend along said trough,; and said material inlet is located closer to said one of said chamber walls * * S * than the tough wall. *</claim-text> <claim-text>3. The apparatus according to any one of claims ito 7, wherein said material inlet is arranged to alfow gravity feed of wood chips though said material inlet.</claim-text> <claim-text>9. The apparatus of any one of claims ito 8 further comprising: a hopper fixed to the material inlet; a position sensor for sensing a level of an upper surface of wood chip material; and an inlet conveyor mechanism for dropping wood chip material into said hopper in response to signals from the position sensor indicating that the level has dropped below a threshold level.</claim-text> <claim-text>10. A method of manufacturing charcoal, comprising: obtaining an apparatus in accordance with any one of claims ito 9; obtaining a supply of material comprising particles of wood; feeding said material through a material inlet such that said material is located within the trough and forms a pile up into the material inlet; passing a flow of air from the first air inlet through the pile of material and into the primary combustion space; and providing a second flow of air downwards from the second air inlet; and within the primary combustion space, combusting flammable components given off by the material to generate heat, a portion of said heat passing through the inlet wall into the passageway and pie-heating the material located within said passageway before said material is subjected to radiant heat generated by the combustion of said flammabie components in said primary combustion space. a. * S * *5</claim-text> <claim-text>11. A method of manufacturing charcoal according to claim 10 further comprising removing charcoal material from said pile such that particulate a...: material within said pile moves past said flow of air from the first air inlet. S *</claim-text> <claim-text>* 12. A method of manufacturing charcoal as claimed in claim 11, a * wherein particulate material comprising charcoal is continuously removed from a bottom portion of said pile so that particulate material within said pile continuously moves downwards past said flow of air from said first air inlet.</claim-text> <claim-text>13. A method of manufacturing charcoal as claimed in claim ilor claim 12, wherein said particulate material comprises particles having a largest dimension between 50mm and 150mm.</claim-text> <claim-text>14. A method of manufacturing charcoal as claimed in any one of claims 11 to 13, wherein hot air generated by said combusting flammable components is used to provide at least a portion of said flow of air through said layer.</claim-text> <claim-text>45. A method of manufacturing charcoal as claimed in any one of claims 11 to 14, wherein hot air generated by said combusting flammable components is used to provide heat to said flow of air through said layer.</claim-text> <claim-text>16. Apparatus for continuous manufacture of charcoal substantially as herein described with reference to the accompanying figures.</claim-text> <claim-text>17. Apparatus for continuous manufacture of charcoal, comprising a unit having: walls defining a primary combustion chamber; a material inlet for allowing a feed of wood chips through said material inlet into said apparatus; a trough located at a tower height than said material inlet such that ". : 25 materiat passing through said material inlet is able to fall into the trough; and * ** an air inlet located below the material inlet such that, when wood chips are located within the trough piled up to said material inlet, air passing from said air inlet passes through said wood-chips and into the primary combustion * chamber. * . * *</claim-text> <claim-text>18. The apparatus of claim 17, wherein said trough extends along a vertical plane, said material inlet extends along said trough to one side of said vertical plane and said primary combustion chamber extends along said trough to the other side of said vertical plane, such that when particulate material is located within said trough piled up to said material inlet said particulate material defines a surface exposed to said primary combustion chamber.</claim-text> <claim-text>19 The apparatus of claim 17 or claim 18, wherein said material inlet comprises a downwardly extending passageway defined by a wall that separates said passageway from said primary combustion chamber such that heat generated within said primary combustion chamber passes through said wall into said passageway.</claim-text> <claim-text>20. The apparatus according to any one of claims 17 to 19 further comprising a fluid fuel burner located within said primary combustion chamber for increasing the temperature of gases within said primary combustion chamber.</claim-text> <claim-text>21. The apparatus according to any one of claims 17 to 20, wherein said unit comprises a secondary combustion chamber having a gas outlet, said secondary combustion chamber being in communication with said primary combustion chamber such that gases are allowed to pass from said primary combustion chamber through said secondary combustion chamber to said *. outlet. * *</claim-text> <claim-text>22. The apparatus according to any one of claims 17 to 21, further comprising a conveyor mechanism arranged to transport particulate matter from a bottom end of said trough.* *...</claim-text> <claim-text>23. The apparatus according to any one of claims 17 to 22, wherein said unit comprises a second air inlet located within a wall defining said primary combustion chamber for supplying air directly into said primary combustion chamber.</claim-text> <claim-text>24. The apparatus according to any one of claims 1? to 23, wherein said unit comprises a horizontal upper wall providing a ceiling for said primary combustion chamber, and a second air inlet located within said horizontal upper wall for supplying air into said primary combustion chamber.</claim-text> <claim-text>25. The apparatus according to any one of claims 17 to 24, wherein: said trough is defined by a pair of walls extending along said trough said pair of walls comprising a rear wall and a front wall, said rear wall being positioned adjacent to said primary combustion chamber between said primary combustion chamber and said front wall; and said material inlet is located closer to said front wall than the rear wall.</claim-text> <claim-text>-15 26. The apparatus according to any one of claims 18 to25, wherein said material inlet is arranged to alJow gravity feed of wood chips though said material inlet.</claim-text> <claim-text>27. A method of manufacturing charcoal comprising: obtaining a supply of material comprising particles of wood; feeding said material through a material inlet to maintain a height of a pile comprising particulate material; in a chamber adjacent to said pile, combusting flammable components i:..,; given off by said particulate material to generate heat such that said heat causes further flammable components to be given off by said particulate *". : * * material; providing a flow of air through a layer of said pile, such that within said layer flammable components given off by said particulate material are combusted within said pile; and removing charcoal material from said pile such that particulate material within said pfle moves past said flow of air.</claim-text> <claim-text>28. A method of manufacturing charcoal as claimed in claim 27, wherein said method comprises pre-heating said material comprising particles of wood before subjecting said material to radiant heat generated by the combustion of said flammable components in said chamber.</claim-text> <claim-text>29. A method of manufacturing charcoal as claimed in claim 28, wherein said material inlet comprises a downwardly extending passageway, said pile of particulate material has an upper portion extending up into said passageway and said pre-heating is performed within said passageway.</claim-text> <claim-text>30. A method of manufacturing charcoal as claimed in claim 27, wherein said material inlet comprises a downwardly extending passageway and the height of said pile is maintained such that an upper part of said pile extends into said passageway.</claim-text> <claim-text>31. A method of manufacturing charcoal as claimed in any one of claims 27 to 30, wherein particulate material comprising charcoal is continuously removed from a bottom portion of said pile so that particulate material within said pile continuously moves downwards past said flow of air.</claim-text> <claim-text>32. A method of manufacturing charcoal as claimed in any one of claims 27 to 31, wherein a lower portion of said pile resides within a trough, and particulate material comprising charcoal is continuously removed from a bottom portion of said trough so that particulate material within said pile continuously moves downwards past said flow of air. *</claim-text> <claim-text>33. A method of manufacturing charcoal as claimed in any one of claim 27 to 32, wherein said particulate material comprises particles having a largest dimension between 50mm and 150mm.</claim-text> <claim-text>34. A method of manufacturing charcoal as claimed in any one of claims 27 to 33, wherein: said pile has a lower portion located within a trough defined by a pair of walls extending along said trough, said pair of walls comprising a front wall and a trough wall, said trough wall being positioned adjacent to said primary combustion chamber between said primary combustion chamber and said front wail; and said material inlet is located closer to said front wall than the trough wall so that said pile defines a sloping surface extending from said material inlet to said trough wall.</claim-text> <claim-text>35. A method of manufacturing charcoal as claimed in any one of claims 27 to 34 wherein hot air generated by said combusting flammable components is used to provide at least a portion of said flow of air through said layer.</claim-text> <claim-text>36. A method of manufacturing charcoal as claimed in any one of claims 27 to 35, wherein hot air generated by said combusting flammable components is used to provide heat to said flow of air through said layer. * ** * ** tS.. ** e * a* * 0*S * * * *5 S * S* *</claim-text>
GB1223362.3A 2012-12-21 2012-12-21 Manufacture of charcoal Expired - Fee Related GB2495038B (en)

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP3018406A1 (en) * 2014-11-04 2016-05-11 Harmanus Tapken Solid fuel burner for burning and gasifying animal manure

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB191104935A (en) * 1911-02-27 1912-02-27 Louis Felizat Improvements in Furnaces for Burning the Commercial Residues of Different Industries, especially in Oil Works, for the purpose of Obtaining Wood-charcoal.
US5279234A (en) * 1992-10-05 1994-01-18 Chiptec Wood Energy Systems Controlled clean-emission biomass gasification heating system/method
JP2004189788A (en) * 2002-12-09 2004-07-08 Tokan:Kk Preparation method of pyrolignous acid or bamboo vinegar and carbonizing furnace
EP1508607A1 (en) * 2003-08-20 2005-02-23 Bruno Henzi Reactor for the preparation of charcoal
US20060278141A1 (en) * 2005-06-09 2006-12-14 Edmondson Jerry M Versatile rapid thermal process oven

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB191104935A (en) * 1911-02-27 1912-02-27 Louis Felizat Improvements in Furnaces for Burning the Commercial Residues of Different Industries, especially in Oil Works, for the purpose of Obtaining Wood-charcoal.
US5279234A (en) * 1992-10-05 1994-01-18 Chiptec Wood Energy Systems Controlled clean-emission biomass gasification heating system/method
JP2004189788A (en) * 2002-12-09 2004-07-08 Tokan:Kk Preparation method of pyrolignous acid or bamboo vinegar and carbonizing furnace
EP1508607A1 (en) * 2003-08-20 2005-02-23 Bruno Henzi Reactor for the preparation of charcoal
US20060278141A1 (en) * 2005-06-09 2006-12-14 Edmondson Jerry M Versatile rapid thermal process oven

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP3018406A1 (en) * 2014-11-04 2016-05-11 Harmanus Tapken Solid fuel burner for burning and gasifying animal manure

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