GREENPOWER CK-3 EURO CHARCOAL KILN PRESENTATION

GREENPOWER CK-3 EURO CHARCOAL KILN PRESENTATION 2014

Contents Introduction 1. Charcoal of the future..4 2. Construction of CK-3 EURO charcoal kiln.7 3. Description of kiln elements.8 4. Description of CK-3 EURO operation..12 5. Carbonization area and material balance...16 Conclusion 2

Introduction This material is devoted to the new charcoal-burning kiln of EURO generation produced by GREENPOWER Company since 2009. The main goals of the company realized in our equipment: High coefficient of efficiency Environmental safety Absence of human factor influence Maximal control of the production process Automation of the production process Remote control Reliability and durability of all elements Simple and cheap maintenance in case of breakdown Minimal physical efforts during maintenance Favorable working conditions for the maintenance staff The main purpose of CK EURO is production of charcoal from phytogenic materials and heat energy. While developing the great consideration was given to the orientation of the kiln for wood briquettes processing into high-grade charcoal, there is separate chapter devoted to this. CK-3 EURO is based on the proved and patent operating principle of charcoalburning kilns of EURO type: We don t move raw material from one chamber in to another, we move the process, i.e. we switch necessary mode in the drying or pyrolysis chamber. We are able to control the amount of supplied heat into the chamber; it ensures 100% process control, which is a guarantee of high yield and grade of charcoal. There is no need to use crane, telpher etc. when operating the kiln. Minimal heat losses of the kiln and uniform heating of raw material provide high coefficient of efficiency that enable generation of additional heat energy. The main advantage of CK-3 EURO is overall elimination of all constructional shortcomings of the first generation of EURO -type kilns. 3

1. Charcoal of the future Pillow formed briquette is widespread in the countries of EC as well as in the North and South America. It gained its popularity due to its properties: 1. High density that influences duration of burning 2. Similar fraction even heat distribution 3. High mechanical strength minimal quantity of siftings by physical influence (transportation, loading works etc.) Fig. 1 Pillow charcoal briquette Despite these positive properties of BBQ briquette, there is a range of shortcomings, which are not seen by the average man, namely: high content of ash (up to 20%), low content of carbon (less than 70%), in compliance with GOST 7657-84(94). Charcoal is of B mark, which is of the lowest grade. Low content of carbon influences the quantity of volatile matters, high content of which causes flame appearance during the burning and partial burn-out of carbon, that significantly decreases period of burning in the industry, where the carbon content is of key importance. The main point of the above listed shortcomings consists of materials used for its production, which are: Charcoal dust (small fraction of charcoal or low grade crushed charcoal) is the reason of low content of carbon, high content of volatile matters. Binding material (starch or others), amount of volatile matters increases during the process of burning. 4

parasite material (sand etc.). It is used in order to increase the nominal weight of the produced briquette. In fact the buyer pays the cost of charcoal for the sand. Why the average man prefers charcoal briquette more than usual charcoal? Because people don t see good charcoal, there is only 5% of charcoal in the world obtained technologically by means of industrial equipment, the rest 95% produced by traditional methods without adherence to the main requirements of wood drying and pyrolysis. From the above-listed one can conclude that perfect charcoal should possess the next characteristics: A. High density B. Resistance to mechanical effect C. Homogeneous fraction content D. High content of nonvolatile carbon (not less than 85%) E. Low ash content Nowadays it is impossible to produce from wood growing in the most regions of the world. Thus, perfect and approximate to it charcoal can be made from black, red and iron wood also far eastern oak, coconut, mango and other exotic trees of high density. Is it possible to produce charcoal from usual wood birch, poplar etc. which would correspond to the characteristics of the exotic species? Yes, it is. Even from straw or sunflower husks. By means of artificial changing the density of raw material used for pyrolysis. It is feasible today. Many faced the next product. This is a fuel briquette Pini kay. Today it is used everywhere. There are different materials and methods of its production. But its properties are practically always the same: Caloricity 4400-4800 kcal/kg Ash content up to 4% Moisture up to 8% Density 1,1 1,3 According to its characteristics, this artificially formed product is an ideal raw material for charcoal production. Pini Kay briquettes are the perfect material for pyrolysis with modern technology giving us the perfect charcoal. Such charcoal may burn up to 7 hours, comparing to 5

beech charcoal that burns up to 3 hours and iron tree up to 5 hours. Besides due to high density this charcoal takes far less volume that positively influences logistics. The above listed properties significantly reduce charcoal consumption and enable production of more qualitative products due to its application. An opportunity appears to use subquality products as raw material: sawdust (wood chips), straw, buckwheat husks, cake, lignin, rice or sunflower husks etc. Fig. 2 Pini Kay briquette and charcoal Besides production of charcoal with new charcoal kiln CK-3 EURO permit: Usage of production spaces as much effective as possible Excluding of harmful emissions into the atmosphere Increase of percentage charcoal yield from 1 ton of raw material Application of waste from wood procurement, woodworking and agricultural industries Reduction of cutting of valuable species for charcoal production. Generation of heat or electric energy Generation of valuable products of pyrolysis CK-3 EURO is the most suitable for the processing of Pini kay into charcoal as in the result of pyrolysis: Amount of siftings does not exceed 1 % The briquette structure is maximally preserved Charcoal yield is 35-40% of the dry weight Processes of loading and unloading are maximum convenient It is possible to derive heat or electric energy Efficiency of the kiln reaches 80 tons of charcoal per month. 6

Nowadays, pyrolysis of Pini Kay briquette for charcoal production is a promising sector of processing industry. Thus such charcoal is better than usual charcoal for a score of characteristics. Charcoal has a wider application than a fuel briquette. Besides, the cost of the produced charcoal is significantly higher than usual and several times higher than the cost of fuel briquette. 2. Construction of CK-3 EURO charcoal kiln Overall dimensions of the kiln correspond to the dimensions of 20 container. The kiln consists of 2 chambers which are connected to the fire chamber. Each chamber has a loading hatch to load/unload the trolleys. The chambers are equipped with gas-escape channels used to withdraw gas emitted during the process of pyrolysis into the furnace. It provides support of drying/pyrolysis and ecological cleanness of the process. The kiln construction supports the modes of drying and pyrolysis. The upper parts of the chambers equipped with discharging pipes of steam emitted during the process of wood drying. There is a waterlock attached to the chamber to stabilize pressure inside the chamber and to drain a condensate from the steam discharging pipe. The kiln is equipped with a chimney. All the operating controls are mechanized. Fig. 3 The first-experimental CK-3 EURO charcoal kiln 7

The construction of CK-3 EURO corresponds to the next requirements: Temperature inside the chamber can reach 550 o C Temperature of pyrolysis products burning is up to 1300 o C Temperature of coolant supply into the heating channels of the pyrolysis chambers can reach 800 o C The medium of the process is aggressive because there are steam, acids and other products of pyrolysis Wood waste can be used as fuel Heating of raw material must be as much uniform as possible The process must be maximally controlled The process must be controlled both manually and automatically The residual heat after going through pyrolysis chamber must be used for drying of raw material. The operation must be least dependent on external factors: human, weather conditions etc. The operation must be mechanized as much as possible. Excess heat produced upon the process must be used to generate heat energy or electricity. 3. Description of kiln elements 1. The fire chamber. Wood waste, natural gas or pyrolysis products can be used as fuel. It consists of two parts, one part is used to heat the chamber and the other one to burn the excess products of pyrolysis. 2. Drying/pyrolysis chamber to the number of two pieces with a general wall. 3. The trolleys, in which loading, drying, pyrolysis of raw material, then cooling of charcoal up to the environmental temperature take place. There is a collector in the trolleys used to discharge steam out of the drying mode chamber and products of carbonization during the pyrolysis mode. 4. The heating flues of drying/pyrolysis chambers. The coolant heats the raw material up to the necessary temperature moving through the heating flues. 5 and 6. Fire chamber Damper and chimney damper. Gate valves of the fire chamber and chimney that provide process control, change of drying/pyrolysis modes. 8

7. Gas collector, for pyrolysis gas (pyrolysis mode) and steam (drying mode). 8. Gas pipes, for pyrolysis gas (chamber-furnace connection). 9. Chimney (stationary part). 10. System of process control and operation which turns the activating mechanism on. 11. Furnace-chamber connection (special material). 12. Platform to transfer the trolleys. Platforms to transfer the trolleys along the area. It simplifies loading/unloading of trolleys in/out of the chamber. It is used to transfer 3 or 4 trolleys at once. 13. Steam pipe (drying mode). Fig. 4 9

Fig.5 afterburning plug afterb urnin forced air blower Fig.6 10

2300 2250 Main parameters and dimensions of CK-3 EURO Item Unit of measure EURO EURO-m Productivity: on wood* / on briquette t/month 25-45 / 80 28-55 / 100 Power consumption, not more kw/hour 1,5 1,5 Consumption of firewood for furnace* m 3 /24 hours 0,5 0,5 5980 6980 Overall dimensions: length, width, height mm 2300 2300 2250 2250 Duration of the complete cycle hours 18-30 20-32 Weight t 10 11,5 * The value depends on: humidity, age and type of wood; size of piece; season; Fig. 8 5980/6980 11

4. Description of CK-3 EURO operation The kiln is of a pyrolysis type with the way of heat supply through the wall at the same time heat carrier goes through the pipes, the products emitted during the pyrolysis process are burnt up, and this ensures absence of harmful emissions during kiln operation. The principle used since 2009 in the CK EURO kiln was taken as a basis. The kiln belongs to the facilities operated by 2 working shifts 12 hours each under control, i.e. continuously. The kiln operates by the following principle: the heat from the fire chamber required for pyrolysis mode is supplied to one chamber. The residual heat from the pyrolysis mode chamber is supplied to the other chamber, which provides operation of the drying mode. Cooling of charcoal and loading of raw material in the trolleys take place beyond the chamber. Upon completion of the set mode, the chamber is switched to the necessary drying or pyrolysis mode with the help of dampers. Scheme CK-3 EURO charcoal kiln FURNACE FURNACE CHAMBER A CHAMBER B 1. Damper of collant supply into the chamber А 2. Damper of collant supply into the chamber B 3. Damper of the chamber A chimney 4. Damper of the chamber B chimney 5. Steam dump valve of the chamber A 6. Steam dump valve of the chamber B 7. Valve of pyrolysis gas channel of the chamber A 8. Valve of pyrolysis gas channel of the chamber A 9. Valve of pyrolysis gas channel of the chamber B 10. Valve of pyrolysis gas channel of the chamber B 11. Valve of the air supply underneath the furnace bar 13. Damper of the afterburning plug 14. Furnace snail -type blower T1 temperature of heat supply into the chamber A T2 temperature of steam-gas mixture of the chamber A T3 temperature inside the chamber A T4 temperature of heat supply into the chamber B T5 temperature of steam-gas mixture of the chamber B T6 temperature inside the chamber B К1 liquid level sensor in the water lock of the chamber A К2 liquid level sensor in the water lock of the chamber B 12

Duration of drying and pyrolysis processes depend on density and chemical properties of initial wood. The influence of wood humidity on the process of drying is shown in the table below if environment temperature >10 o C, atmospheric pressure is normal and air humidity doesn t exceed 60% Influence of humidity on duration of drying No Relative humidity Duration, hours 1 <20% <4 2 <40% <10 3 <55% <14 4 <70% <20 The temperature of coolant influences duration of the processes of drying and pyrolysis as well, the higher the temperature the shorter the process is. However the process rate influences the final properties of charcoal. Raw material for pyrolysis is hardwood or PINI-KAY briquette is to be loaded into the trolleys. Each chamber can be loaded with 3 or 4 trolleys depending on the kiln model, volume of trolley is 1,5 m 3, capacity of each trolley is about 1m 3 or up to 1 t of briquette. Fig.8 CK-3 EURO and platforms to transfer the trolleys 13

There are platforms used for convenient motion of trolleys, loading and unloading in and out of the chambers. Trolleys fit the platform which moves perpendicular along the drying/pyrolysis chambers, from the place of trolleys loading to the place of trolleys cooling and unloading. Electric winch is used to transfer the platform and trolleys. The trolleys are moved into drying/pyrolysis chamber switched to the drying mode. When the loaded wood is completely dried that is indicated by readings of thermocouples, this chamber is switched to the Pyrolysis mode by means of valves. At the same time the produced pyrolysis gases are directed into the fire chamber where they are burnt in order to maintain the process. Kiln operating principle («chamber B pyrolysis/chamber А drying») DAMPER 3 OF THE CHIMNEY OPENED FURNACE DAMPER 1 CLOSED DAMPER 4 OF THE CHIMNEY CLOSED FURNACE DAMPER 2 OPENED Primary coolant from furnace Products of pyrolysis Secondary coolant of pyrolysis chamber Steam 14

Coolant produced due to the burning of firewood or (and) products of pyrolysis moves through the firetubes through the opened damper into the chamber B set to the pyrolysis mode, then to chamber A set to the drying mode and then in to the chimney through the opened damper. At the same time products of pyrolysis are delivered to the furnace from the chamber B. Raw material in the trolleys staying in drying or pyrolysis mode is heated indirectly by the firetubes. Upon indirect heating of raw material the pressure is produced in the chamber that leads to the motion of pyrolysis products in the steam pipe or furnace, respectively. The temperature of coolant is controlled by means of thermocouples. If the excess products of pyrolysis appear that leads to rise of coolant temperature getting to the chamber B, a part of coolant is burnt by means of the 2 nd part of furnace and gets in to the waste-heat boiler. That means excess heat doesn t take part in the process, and heat necessary for the flow of reaction in the chambers B and A gets in to the chamber. Readings of thermocouples in the chambers B and A show when the process starts or comes to an end. Then drying mode chamber A is switched to the pyrolysis mode, and pyrolysis mode chamber B is switched to the drying mode. Then trolleys with produced charcoal are taken out of chamber B. The hatch of chamber is closed in order to avoid heat losses. Trolleys with produced charcoal are placed for cooling. The empty chamber is loaded with a new portion of raw material. The process is repeated. 15

5. Carbonization site and material balance Intermediate quality control will take place at every step of manufacture. Special attention will be given to fulfillment of the next manufacturing operations: 1. Primary mechanical processing of wood. Absence of damages caused by rot or mould. 2. Quality analysis of the produced material after pyrolysis. When organizing the area, the factor of raw material motion at all production stages was taken into account. Empty trolleys are installed onto the rails at the place of raw material loading (A. trolley loading area). After the filling of raw material the trolley is placed onto the platform which is moved along the rails closer to charcoal kilns (B. pyrolysis area). Empty platform is moved to the chamber where the pyrolysis process is over. The trolleys are taken out of the chambers on the platform. Empty chamber is loaded with trolleys filled with raw material. When the trolleys are cooled (C. Trolleys cooling area) down to the ambient air temperature they are to be unloaded. Empty trolleys are moved to the place of raw material loading by means of platform (A. trolley loading area). Scheme of carbonization site 16

The data regarding hardwood and Pini Kay briquette are given in the Table 5. Generally qualitative characteristics of the produced charcoal depend on density of the wood used for the process. The denser wood is the higher density of charcoal. Charcoal output depending on the types of wood No Type of wood Weight of absolutely dry wood, kg/m 3 Charcoal output*, kg 1 Hornbeam 630 220 2 Beech 580 200 3 Oak, maple, ash 550 190 4 Larch, elm 520 180 5 Birch 500 170 6 Pini Kay briquette 1 100 385 The given data must be considered as approximate because output of charcoal depends not only on the process temperature but also on rate of heat supply, size of piece, conditions of growth, age of wood and other factors. 17

Conclusion By 2014 GREENPOWER Company had produced more than 200 units of charcoal burning kilns of CK EURO type. The main principle followed by GRENPOWER Company is constant improvement of all produced equipment. During a 5-year period of CK EURO production invaluable experience was received. Construction of the kiln has come to its logical conclusion. Development of CK-3 EURO is necessary in the conditions of technological progress. We hope that CK-3 EURO will become a good continuation of charcoal kilns of the EURO type. 18