Wood pyrolysis

In order for wood to become coal, it needs to undergo a process of pyrolysis, decomposition without access to air.
Wood decomposes in an oxygen-free gas atmosphere, in a retort, under the influence of heat. A retort is a closed vessel; heating is carried out through its walls. Vapor gases that are formed during the pyrolysis process are removed through a pipe in the retort. Next, in the condensation device, the gas is separated from the liquid.
The technical process begins with the wood being placed in a retort, the loading hole is closed and the apparatus is heated to 400-500°C. A pyrometer located in the recreational hole helps regulate the temperature.

The pyrolysis process consists of three main stages, which differ from each other in control measurements and external signs.
The first stage is drying the wood. At temperatures up to 150°C, moisture is released from the raw material.
The second stage is the actual pyrolysis, dry distillation. At a temperature of 150-350°C, gas is released and organic products are formed in the distillate. At this stage, an important period for the entire process occurs, called exothermic. It lies in the fact that pyrolysis proceeds vigorously, reaction heat is released, and this occurs at a temperature of about 280°C.
The third stage, calcination. If coal was formed at the previous stage, then at this stage resins in a small amount and many non-condensable gases are separated from it. The temperature at this stage starts at 350°C and reaches 550°C.
The process of wood decomposition is very complex, since it consists of a whole complex of organic compounds. They have different molecular weights, so the chemical reactions that occur between them are also different. It will be difficult to calculate or describe in detail all these reactions. However, in general outline it's possible. The decomposition of xylan begins first, at a temperature of 150°C, and the process continues at 250°C or more. As a result, substances such as acetic acid, furfulol and gases are formed. At a temperature of 200°C, lignin begins to decompose, which leads to the release of volatile low molecular weight compounds. And at 300°C cellulose decomposes.
During the process of pyrolysis, chemical reactions occur, sequential and parallel, which are accompanied by the appearance of new and breaking of old bonds that existed before heat treatment. The resulting new substances begin mutual reactions. Years of laboratory research and experience gained in production have made it possible to establish a connection between ongoing processes, between the chemical components of wood and the products resulting from its decomposition. And also to establish the factors that influence these processes. The main indicators that determine the progress of the pyrolysis process are the raw materials and the technical conditions for its processing.

Requirements for devices for wood pyrolysis

There are many devices for thermal decomposition of wood. Some of them were popular in the past, but have now lost their relevance. Others are still functioning. There is a category of devices that were not implemented and remained on paper, at the level of design developments.

Today it has become possible to build a device based on the knowledge accumulated over several generations, without inventing new technologies. You can proceed solely from the wishes of the customer and the characteristics of demand and raw materials, their quantity and composition. The most optimal solutions for charcoal burning in production conditions today are those that can be used on the territory of a forestry enterprise and are able to process waste. Necessary conditions for such equipment:
1. Liquid processed products must be burned because there is no need to use them for other purposes.
2. The volume of equipment productivity for raw materials must correspond to the volume of the enterprise for waste. In this case, the transportation of raw materials is eliminated as unnecessary, and money is saved on transportation.
3. Simple installation design. In case of moving logging, it must be transportable and easy to move
4. Environmental friendliness of equipment is necessary in order to minimize pollution environment
5. Ease of operation, compliance with fire safety standards.
For many years, charcoal burning was environmentally unsafe. And given the fact that coal consumption was constantly growing, the cleanliness of the environment was in question. Both industry and the population benefited from the work of charcoal pits and barrels. Demand for products and goods made using coal grew. A little later, furnaces for the production of coal were invented; they required enormous labor costs and investments of raw materials. At the same time, they produced a lot of emissions into the atmosphere. Without insulation, these ovens heat up to 300°C, which is a violation of safety regulations and puts the health and lives of people servicing the equipment at risk.
In 1992, a furnace was invented in which the processes of drying, pyrolysis and calcination of coal occur simultaneously in different sections. Vapor gases formed during the process burn out inside the stove. As a result, the need for additional heat is satisfied if the firewood has low humidity. This installation is able to process not only raw materials from wood, but also various waste and agricultural residues. The efficiency of this furnace lies in the fact that heat loss is reduced. To cool the coal, you do not need to cool the entire installation; you just need to remove the retort, in which the process has already completed.
Along with these revolutionary ovens, compact ones that can be transported to the place of production or accumulation of raw materials are also in demand. For example, they can be used for processing waste from forestry enterprises, when laying roads in densely forested areas. Sawdust is an unused raw material in many sawmills. Their processing requires large energy costs, incommensurate with the profit. For these purposes, you can use the method of producing coal from sawdust compressed into briquettes.

Manufacturing charcoal

One of ancient technologies production in the history of mankind is the production of wood combustion products. Judging by the results of archaeological excavations, cavemen already knew what charcoal was. It could have been made specially or collected at fire sites. In the Bronze Age, charcoal became one of the pillars of developing culture. It was made from smoldering brands and used as fuel that does not cause combustion.
In ancient times, every Russian village had its own forge. Only in the forge could many items be made, such as horseshoes, plows, and scythes. And the forges worked on charcoal. Malleable and ductile cast iron of excellent quality can be made exclusively using charcoal.
Another historical use of wood is the production of pine resin and tar as a product of thermal processing of wood.
Charcoal is one of the important industrial products. It is environmentally friendly because it does not contain sulfur, phosphorus, or heavy metals. The production of sorbents is another option for using coal.
Today, about 9 million tons of charcoal are produced worldwide per year. The lion's share of production comes from Brazil, about 7.5 million tons. Russia, despite the large amount of timber, produces about 350 thousand tons per year. Supply does not cover demand, so coal is imported into Russia from Ukraine, China, and Belarus.
Charcoal consumption per capita in Russia is less than 100 grams per year. At the same time, the average European consumes more than 20 kg of coal per year, the Japanese - more than 60 kg per year.
When producing charcoal, preference is given to raw materials from hardwood trees. The coal they produce is dense and durable. However, in modern conditions Coal is also made from waste from softwood, brush and aspen. You can also make good quality coal from them, if you do not deviate from proven technology and briquet the products.
Due to the fact that there are different raw materials and manufacturing technologies, several varieties of charcoal are obtained as a result of processing. For example, there is a type of fuel for grills and fireplaces called “red coal.” It is produced by soft charcoaling at low temperature. “White coal” is popular in Japan; it is burned from Far Eastern white oak.
During the heat treatment of wood, its decomposition produces charcoal and other products - liquid and gaseous.
Liquid combustion products come out in the droplet phase, and partially in vapor form. Together with non-condensable gases they form a vapor-gas mixture. These products were as in demand as coal until the mid-twentieth century. Later they were supplanted by new generation products, cheaper, made from natural gas and petroleum products.
An important condition for obtaining high-quality charcoal is compliance with the subtleties of production technology. It is quite simple, but if you neglect its conditions, the coal will turn out to be small, cracked, unburned, and there will be less of it at the output.

Benefits of charcoal

Today it becomes obvious that the scale of charcoal use is growing every year. This is not surprising; charcoal is the most environmentally friendly type of fuel and meets the highest requirements, unlike firewood, peat and coal. The main advantages of charcoal are as follows:
— ready fuel high quality, environmentally friendly and safe;
— when burning does not form smoke or flame, while giving the required temperature;
— high heat transfer – 31000 kJ/kg;
— absence of any harmful substances;
- inability to spontaneous combustion;
— good frying of food due to even burning and long-term heat retention;
- Can be used for grills, barbecues, fireplaces and open fires.
If coal is pressed into briquettes, this gives it a convenient shape, as a result of which 1.5 times more heat is released during combustion, and the combustion itself lasts much longer, which makes it possible to cook more food.

The advantage of using charcoal for cooking meat is that it is not exposed to open fire, but to heat, which makes such cooking the safest and most harmless to health. The best raw materials for such coal are birch or oak wood.
Charcoal is a low-ash material due to the absence of foreign chemical impurities in it. It has high thermal stability and electrical resistivity. If the coal is pierced, its electrical conductivity increases and due to this it is possible to obtain products with established dielectric properties. For the manufacture of secondary products, waste from charcoal production such as coal dust and fine coal is often used, which cannot be used everywhere.
Today, in Europe and Asian countries, coal production using briquette sawdust is becoming increasingly popular. A large amount of such sawdust is generated in any production, and turning them into commercial products allows the enterprise to receive additional profit. The density of briquettes reaches 1100-1200 kg/m, which makes it possible to use them as high-quality fuel.
Recently, Japanese scientists made another discovery in favor of charcoal. It turns out that it is able to absorb unpleasant odors and harmful elements in the room, thereby improving a person’s well-being.

Charcoal in industrial production

Charcoal is a fuel that people have used since ancient times. Later it began to be used in forges, smelting furnaces and medicine. Currently, coal is increasingly being used in industry and other areas of production.
In industry, charcoal plays the role of a reducing agent. Due to its unique composition, it began to be used in this area at the beginning of the twentieth century. For example, in Brazil, cast iron is produced using charcoal. Such cast iron does not contain the elements of phosphorus and sulfur, which enter it when using coal coke, and coal consumption is only 0.5 tons per ton of cast iron. Cast iron produced using charcoal is stronger and indestructible. These advantages are widely used today in Russia, where lattices, sculptures and tabletop figures are made from cast iron.
Charcoal is widely popular as a coating flux for smelting bronze, brass, nickel alloys, manganese and other valuable metals. In the electronics industry, charcoal is indispensable in the creation of crystalline silicon and the smelting of silicon alloys.
Charcoal from soft-leaved wood is successfully used in instrument making and printing production for grinding and polishing parts. Due to its low content of ash and impurities, coal is used to produce solid lubricants, which are in great need of mechanical engineering enterprises.
Coal from alder wood has found its application in the production of black powder. The carbon content of this type of coal ranges from 72 to 80 percent, which gives a high burning rate, unlike coal based on other types of wood, which takes too long to ignite.
Nowadays in many industries National economy Electrocarbon products have found application. They are made from pure carbon materials such as charcoal, petroleum coke and pitch coke. Such products operate in electrical equipment of various engines, electric machines, etc.
In plastic production, charcoal can replace expensive and scarce granite. Here it is used as a filler for plastics.
In Western Europe, charcoal can be found on sale in almost any store. Gradually, this innovation comes to us. It is most often purchased by summer residents, lovers of country holidays, kebab shops, and restaurants. The dish cooked on charcoal has a pleasant smoky aroma and a crispy crust, which makes its taste unforgettable.

Recycling

The problem of recycling door waste has been and remains one of the most pressing for logging and processing enterprises. During wood harvesting alone, up to 25% of the biomass that remains in the forest is lost. With further processing of waste, no less is formed: sawdust, shavings, cuttings, slabs.
One of the main trends in this direction now is combustion to produce thermal and electrical energy. However, the inconvenience of transporting and storing a number of wastes makes this process quite expensive. But the increasing use of charcoal as an alternative to traditional fuels is prompting people to look for new ways to combat forest waste. The latest achievement in this area is the production of so-called raw charcoal. With this method, waste from logging is processed and the forest is cleared, and most importantly, the wood of soft-leaved trees is recycled.
According to GOST requirements, there are several grades of charcoal: “A”, “B” and “C”. They differ in the type of wood that decomposes without access to air in special devices. Thus, grade “A” is obtained from hardwood, “B” - from a mixture of hardwood and softwood, “B” - from a mixture of hardwood, softwood and softwood.
It is coal grades “B” and “C” that make it possible to produce charcoal briquettes, which are among the most effective methods preparing coal for disposal. At enterprises engaged in the production of charcoal, a fairly large amount of small waste is generated, which has no further use, but which can be formed into briquettes. Such charcoal briquettes are a fairly high-quality type of fuel; they have high mechanical strength and density. Fuel briquettes are an ideal type of biofuel produced from clean wood waste without the use of any chemical additives. In Europe, such briquettes have become commonplace and one of the cheapest and most environmentally friendly types of fuel. They are used at home for stoves and fireplaces, as well as in boiler houses and thermal power plants. There is no sulfur in fuel briquettes, because of this, no oxides are formed during combustion, and the carbon content is minimal.
Waste disposal is not a cheap business and requires high capital investments for the removal of waste as garbage, and also causes great damage to the environment. Therefore, the best option is waste recycling. It brings additional profit to the company and does not cause pollution to the environment.

Applications of charcoal

Charcoal is a carbon mass consisting of large quantity coal materials. Charcoal has been produced for many millennia, and today it is a major source of energy throughout the world. It is made from natural materials such as oak, maple and fruit trees. They give best variety charcoal.
Nowadays, the area of ​​application of charcoal is increasing. It is used to filter organic compounds of chlorine, gasoline, pesticides and other toxic chemicals. As a fuel, it can be used for cooking steaks, hamburgers, and in general, for any picnic, charcoal will be very useful. Charcoal is completely safe for cooking over an open fire. In this case, only 30% of the temperature released during combustion goes directly to cooking, while the remaining 70% turns out to be unusable. In countries with cold climates, to maximize the use of heat released during combustion, this unusable 70% is used to heat the room.
However, it must be used very rationally, then charcoal will retain its value for many centuries. The effectiveness of using charcoal is to transfer as much as possible high temperature object that needs to be heated and depends on how rationally the coal is used.
The quality of charcoal is determined by different methods and techniques. To obtain high quality charcoal, sometimes you have to raise the price. Burning charcoal at home gives very good results, which allows us to talk about its rational use at home. Therefore, it is believed that the domestic market is less demanding on the quality of coal than the external market. Coal is exported to the foreign market for use in the steel and chemical industries. It should be noted that charcoal is also used in cooking and barbecuing.
Thanks to its beneficial physical and chemical properties Coal began to be used in the steelmaking industry. It is the most expensive raw material for blast furnaces and therefore must be highly compressed.
Not only charcoal itself has beneficial properties, but also the ash that is formed after its combustion. Ash is the same mineral as clay, quartz and calcium oxide, so it has found its use in forestry and agriculture as a fertilizer.

Charcoal burning devices

Currently, several types of charcoal are known, which are associated with different production technologies and characteristics of raw materials. So in Japan, so-called “white” coal is very popular. It is burned from Far Eastern oak. For fireplaces and grills abroad, they use “red” coal, made by soft charcoaling at a low temperature.
As a raw material for charcoaling, the main advantage is given to hardwood. The coal it produces is strong and dense. Recently, much attention has been paid to the use of coniferous waste for the production of charcoal, but in order to produce high-quality charcoal from it, it must be briquetted.
To date, a huge number of devices have been created for the thermal decomposition of wood. These charcoal burning devices must meet the following conditions:
— the productivity of raw materials is equal to the volume of waste at the enterprise, usually 3-20 thousand m3 per year, which eliminates long-distance transportation of raw materials, which increases the cost of production;
— at low productivity, liquid products must be burned rather than processed. In this way, the heat needs of the process are covered;
— the device must be environmentally friendly and not produce emissions into the atmosphere;
— the device must be easy to manufacture and transportable;
— the device must be easy to operate, explosion- and fire-proof.
Historically, charcoal has always been an environmentally unfriendly process. And the fact that over the past hundred years the demand for goods that require charcoal has increased is having an increasing impact on the environment, threatening the survival of nature itself. But the demand for charcoal continues to increase. Entrepreneurs are only interested in profit, so cheap UVP-5 stoves came into their field of vision. They do not require much manual labor, but they emit too much gas vapor into the atmosphere. The stoves have no insulation, so there is huge heat loss. The temperature on the surface of the furnace during exotherm reaches 300 0C, which violates safety standards. One cubic meter of firewood produces two times less coal than rationally designed installations, but thanks to the dense stacking of firewood, these stoves are highly efficient in terms of coal output per unit volume of the installation and per ton of metal consumed. The use of the UVP-5 stove dates back to the Soviet system, in which the destruction of nature was justified by production needs.
An alternative was the stove developed in 1992. In 1997, she received Russian patent No. 2115689. In this furnace, the retorts are installed in such a way that if drying takes place in one, pyrolysis occurs in another, and coal is calcined in the third. Gas vapors are discharged through special channels into the combustion volume and burn out there. The heat requirement is met when the moisture content of the wood is less than 50%; if the humidity is higher, then more wood is added to the firebox. The furnace operates without interruption, and at the end of the process, the retorts are removed and placed in special stands for cooling. The next retort filled with new firewood is inserted into the free hole. As a result, the combustion chamber is not cooled, and heat loss is reduced.

Production of charcoal using traditional and industrial methods

People began producing and using charcoal back in the Stone Age. It was then used in agriculture and also as a cooking fuel. In developing countries, nothing has changed in the use of charcoal today. It still continues to be used for cooking because as a fuel it has a high calorific value. IN developed countries The direction of using charcoal has changed somewhat. Currently, it is used in copper and zinc production, as well as barbecue fuel.
Charcoal is produced by heating wood, which releases resin and a mixture of gases. An important indicator for the quality of wood is the level of moisture content. The more it is, the less coal can be produced. All currently known methods of producing charcoal are divided into traditional and industrial.

Coal was produced using traditional methods until the early twentieth century. The wood was piled into holes, which were dug in the shape of boats. Holes were made in the earthen pits through which the wood was set on fire. Due to its low cost, this method is used before today in developing countries, however, productivity is very low: only 1 kg of charcoal from 10-12 kg of wood. In the 70s of the last century, people began to improve traditional production methods. The first step in this direction was to equip earthen ovens with chimneys made from oil drums. This causes partial combustion of the wood frame to provide the high temperature required for coking. As a result, 1 kg of charcoal can be obtained from 8 kg of wood.
At the end of the twentieth century, industrial technologies were discovered that made it possible to improve the results and quality of charcoal production, which could not be achieved with traditional methods. New types of furnaces with automatic and semi-automatic controls were created, which increased productivity to 1 kg of charcoal from 5-7 kg of wood. However, factories with this production method emit too much smoke, soot and dirty air into the environment, which is unsafe for human health. Therefore, the latest trend in industrial charcoal production is to improve equipment to minimize the environmental impact of its operation, while maintaining the quality and quantity of charcoal at high level. To do this, steel containers are filled with dried timber and placed in a brick-lined oven, which is preheated to 900 0C. The resins and gas heated together with the wood enter a special high-temperature combustion chamber. The gas in this chamber is used to heat coking ovens and pre-dry the wood. With proper temperature control, in such modern equipment, 1 kg of charcoal can be obtained from 3-4 kg of wood.

Charcoal is a completely organic material used as fuel. Its high environmental properties are known for the fact that when smoldering it does not emit poisonous and toxic fumes, since it consists entirely of carbon.

In industry, it is widely used by metallurgical complexes and chemical plants; in agriculture, it is used as a mineral additive. Such a high demand for carbon fuel, combined with its unique qualities, contributed to the development of technological processes for its production.

Charcoal is produced using a soft charcoal system, which is characterized by a low temperature regime. There are three main types of charcoal:

1. Black, obtained from the processing of soft wood.
2. White, made from hardwood.
3. Red, produced from coniferous trees.

When producing coal, any wood waste (paper waste, furniture industry waste, stumps, twigs) is used as a consumable material. Moreover, white coal is valued in Japan, and red coal is valued for private use.

This universal product has found adequate application in almost all spheres of human activity. Being an alternative type of fuel, it is still actively used in households. The industrial dimensions of its application are huge and multifaceted, they affect the following areas of its active use:

• metal smelting;
• water purification;
• as a trap of harmful and toxic gases;
• in medicine for poisoning;
• feed for animals and birds;
• in public catering systems;
• as a fertilizer.

Depending on the quality, it is divided into three grades, assigning letter designations A, B, C.
The technological process for obtaining this product is simple, but requires additional knowledge and skills. Therefore, this type of activity is often used as profitable business. But it should be borne in mind that with a clear understanding of the role of correct compliance with all stages of the process, the percentage of yield of a quality product increases.

The charcoal production technology typically includes 4 main stages: drying, pyrolysis, calcination, cooling. Until recently, its production caused serious harm to the environment. But modern technologies solved this problem by introducing new unique equipment.

Equipment for the production of

The basis of the production process for the production of charcoal is the following mechanisms:

1. Device for splitting firewood using hydraulics.
2. Chainsaws.
3. Scales.
4. Charcoal kiln.
5. Electricity generator.

To construct the furnace, an open and level area should be equipped; the furnace itself must be of high quality, ensuring that oxygen cannot penetrate. Otherwise, some of the raw materials will not be processed, but will burn.

Video: furnace for making charcoal.

A good furnace is designed in such a way that the gases produced during oxidation are fed into the firebox, burned there and directed to maintain the required temperature. This energy saving is environmentally friendly and economical.

There is also equipment in which it is possible to use only one container. In this case, the process of continuity of technological production of charcoal is disrupted and downtime occurs. This situation is solved by the presence of removable containers in which you can separately dry, oxidize firewood and leave it to burn out.

Modern technologies used to make charcoal are waste-free, environmentally friendly and ergonomic. The equipment does not require additional or specific maintenance. In production, as a rule, 3 people work, responsible for the continuity of the process and the automatic adjustment of machines.

The equipment differs in its variability, but they can be grouped into 3 main types:

1. Mobile installations;
2. Stationary mechanisms;
3. Auxiliary equipment.

The first and second groups of equipment differ from each other in the presence and absence of the ability to transfer it. Moreover, some types of equipment have a single function for performing drying and pyrolysis.

Charcoal kilns weigh from 6 to 80 tons. When choosing mobile equipment, you should choose small models that will allow you to change their location. The choice in their favor is due to the lack of opportunity to systematically supply consumables to a specific place. Mobile units consist of modules and are quickly assembled and dismantled. They can be located without creating additional canopies and protective spaces.

Stationary installations, on the contrary, require the allocation of a separate adapted room, which can be used simultaneously as a storage facility for finished products.

Installation of equipment must be carried out by specialists and comply with the provisions of GOST. All installations must meet safety and environmental requirements, since waste and carbon residues are burned in the furnaces.

Auxiliary equipment is desirable to purchase because it significantly reduces costs, primarily of a temporary nature. These types of mechanisms include a weighing and filling dispenser and a separator.

Using the oven

The central mechanism of the entire process is the oven. A modern charcoal kiln, or, as it is also called, a retort kiln, differs significantly from its predecessor at the beginning of the twentieth century. Its transformations took place against the backdrop of growing scientific and technical knowledge, as a result of which the equipment used now is excellent both in terms of external characteristics, and in terms of the quality of product output.

Various modifications of furnaces are used, differing from each other in the way the coolant is supplied to the raw materials. Since it is located in an isolated chamber, contact with the flue gas is leveled. The material supply process is carried out through the loading hopper and the activation compartment. To supply raw materials, a trolley is used as an auxiliary mechanism.

Loading depends on the type of equipment selected and may involve manual or automatic feeding. In automatic mode, it is produced using a mechanical conveyor. After being fully loaded, the trolley is driven into a chamber for drying-pyrolysis.

The chambers, equipped with separate furnaces, can accommodate three trolleys at a time.
After laying, the raw materials are dried, the gases released during the process are transported to a separate chamber and burned there.

In order to increase production efficiency, the heat remaining from the pyrolysis compartment is directed to the drying chamber. Next, the chambers change roles and drying performs the functions of pyrolysis. All condensate is discharged through specially equipped pipes. Thus, the dual functioning of these cameras saves time and energy resources. After this technological stage is completed, the trolleys leave the chambers with the finished product.

The separator helps sort the finished product into piece sizes. Using a weighing dispenser, you can quickly package large coal into bags. If the production involves the use of a packaging dispenser, then fine coal is used for packaging and it is carried out in an open package.

The finished material can also be briquetted, for which auxiliary equipment is used.

The production of charcoal briquettes also consists of the order of following stages - grinding coal, creating briquette mass, pressing briquettes, drying and calcination.

Charcoal- a unique product, with its highest efficiency it is completely in a safe way fuel in terms of environmental impact.

It is widely used not only for industrial purposes, but also in household activities.

In addition to heating homes, it is successfully used as energy source for cooking.

When using it no carcinogenic substances are released, poisoning food, which cannot be said about ordinary firewood and coal.

Construction companies also do not ignore its use as an excellent thermal insulation material. In agriculture, it is used as a biologically valuable feed component for poultry and livestock, as well as in the form of soil fertilizers.

Charcoal comes in three types:

• red, produced using the soft firing method, mainly from conifers;
• white, made by firing hardwood (oak, birch, hornbeam, etc.);
• black, obtained by firing soft wood (poplar, aspen, alder, etc.).

In terms of quality, it is divided into three grades (according to GOST):

Production technology

Basis of production – pyrolysis process.

Pyrolysis is the burning of wood in the absence of oxygen.

To perform pyrolysis, you need retort charcoal kilns. They can be:

• stationary;
• mobile.

Retort furnaces– these are the chambers where the raw materials are fired and dried.

The main principle of operation of the stove is that the gases and vapors that are released when wood burns flow directly into the firebox.

There they are burned, thereby not harming the environment and providing the combustion process with additional heat.

Work on coal production proceeds in the following order:

1. The wood is placed in the retort oven chamber.
2. As soon as a sensor signal is received about the burning and drying of charcoal, it is unloaded and left to cool.
3. After this, the product is crushed into pieces and packaged in bags and bags (paper or plastic). Coal for domestic purposes is crushed more finely, for industrial purposes the crushing is coarser.

Raw materials

As for raw materials, absolutely any are suitable for coal production:

• knotty pieces of wood;
• sawdust;
• fragments of wooden cloth;
• branch;
• furniture production waste;
• paper industry, etc.

Suppliers may be:

• woodworking industries;
• furniture factories;
• sawmills;
• organizations that cut trees.

Can be installed business contacts with workers of nearby forestry enterprises engaged in logging.

Peat can also be used in this production.

Even your dacha neighbors can become your suppliers, because many of them trim trees every year.

The consumption of raw materials per ton of charcoal approximately looks like this: about 8 m3 - birch wood, about 12 m3 - soft varieties.

Equipment

Charcoal production requires the purchase of the following equipment:

• charcoal kiln. Price from 100 thousand rubles;
• scales. Cost – approximately 5 thousand rubles;
• electricity generator. Costs are approximately 20 thousand rubles;
• chainsaw. Cost – from 5 thousand rubles;
• hydraulic device, used for chopping wood. Average prices are around 55 thousand rubles.

Personnel

As for workers, no more than 2-3 people are needed; no professionalism is required from them. Workers are needed to:

• load the production line;
• unload raw materials;
• load finished products.

In addition to workers, you will need to hire:

• watchman;
• sales and purchasing manager (if you do not plan to engage in sales yourself);
• perhaps an accountant.

Permitting documentation

Any commercial activity requires the creation of an LLC or individual entrepreneur.

In the case of charcoal production, it is better to give preference to the individual entrepreneur form, since in this case tax rates are much more preferential.

In addition, you will not have to waste time on complex paperwork.

Unlike many other types of commercial activities, no special permits or licenses not required.

Registration ends with the usual entry of data into the general state database.

Total costs and payback

When talking about overall business costs, in addition to the cost of equipment, you should consider the following:

• rent (if you do not have your own premises, you will have to pay about 200 thousand rubles per year);
• salaries to employees (about 200 thousand rubles annually);
• advertising, marketing, transport (approximately 50 thousand rubles).

Thus, the cost of starting a business will be about 635 thousand rubles. (or less if using your own site).

With the cost of charcoal ranging from 18 to 25 rubles. for 1 kg, monthly income from product sales will be from 80 to 100 thousand rubles. This will allow you to recoup your investment in at least six months, and if you don’t need to pay rent for the premises, then even less. Cafes and restaurants alone burn, on average, about 4-5 tons of charcoal every month.

With proper commercial sales, the circle of buyers will grow, which, accordingly, will entail increase in turnover and profit.

The workshop premises may be located outside the city. An excellent solution to the problem of premises can be the use of a summer house. The main thing is that suppliers of raw materials are as close as possible.

Sales of charcoal

As for the sale of charcoal on the domestic market, this type of commerce can become cost-effective and very profitable.

The main consumers of charcoal are catering facilities (restaurants, cafes), which use about 5 million tons of this product in one season.

This should include other enterprises and vital infrastructure such as:

• kindergartens;
• schools;
• higher educational establishments and etc.

Private consumers also purchase coal when traveling to:

• fishing;
• dacha;
• hunting.

Production shops that produce varnishes and paints are constantly in need of coal.

With an abundance of opportunities for selling products, this business does not require costly and high-tech forms of production.

conclusions

Speaking about a business based on the production of charcoal from wood waste, it is worth noting a number of points that encourage the choice of this particular type of commercial activity. All over the world in last decades trends in preserving and maintaining the ecological balance of nature are noted.

This is about:

• preservation of green areas and ecosystems untouched by human activity;
• maintaining a clean environment by creating production facilities that do not produce harmful emissions.

The active work of environmental organizations has led to the fact that many governments Western countries, setting an example for the whole world, have a significant government subsidies business based on processing wood (and other) waste.

Russia does not remain aloof from new trends in the field of resource conservation and the environment. Under development Russian state small and medium business support programs in this area should be regarded as a favorable factor for opening a wood waste processing enterprise.

You may also be interested in: an article about, a short article about the prospects for waste recycling in Russia, or material about turning plastic bottles into recyclable materials

Let us note that modern technologies do not stand still. If just a few years ago it took about 5 tons of wood to create 1 ton of charcoal, now, with the use of new technical means, 1.5 tons less wood waste is required.

The most important positive aspects when assessing the prospects of this business are free or almost free raw materials, low cost of equipment, no need to search for highly professional personnel, ample opportunities for marketing manufactured products.

The process of charcoal production is clearly presented in the video:

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Demand for charcoal remains consistently high over a long period of time. It is used not only in everyday life, but also in the metallurgical and chemical industries, and also as a feed additive for animals. The popularity of charcoal as an essential commodity during the period summer holiday and picnics need no proof. According to some data, the profitability of a charcoal production business ranges from 20 to 30%. The total investment in a mini-enterprise for the production of charcoal is at least 1.5 million rubles. This amount, as a rule, includes the purchase of equipment, arrangement of a production site, purchase of raw materials, registration of activities and other unforeseen expenses...

Most experts are of the same opinion - the domestic charcoal market is unsaturated. The volume of charcoal production in Russia is just over 100 thousand tons per year. Although back in the days Soviet Union this figure was at least 350 thousand tons per year. For example, in Brazil, a little bit is produced annually - 7.5 million tons of coal. Our country, which has disproportionate reserves of raw materials for the production of charcoal, is forced to be an importer of these products, instead of exporting charcoal. The main countries exporting coal to Russia are Belarus, China and Ukraine.

If you decide to open your own charcoal production, then you should consider one very important point. It is easier to open such a business for those who already have a business in the forestry industry. This helps to significantly reduce the entrance fee to business. In addition, wood processing enterprises have free raw materials for the production of charcoal, which ultimately reduces the cost of finished products, and therefore allows them to sell products at a more competitive price. If this is not possible, then significant start-up investments will be required.

Selecting a room

Charcoal production is not considered environmentally harmful. However, it is more advisable to locate the enterprise outside the city or village, at a distance of at least 300 meters from the nearest residential complexes. The ideal option is to locate production near wood processing plants and sawmills, as well as wood harvesting sites. This is due not only to legal requirements, but also to a logistical component.

As for the sizes land plot, then its area must be at least 200 square meters. meters. The main part of the equipment (furnace) is located on an open plot of land. A separate part of the territory is allocated for a warehouse for raw materials and a warehouse for finished products. You should also install a small room (cabin) to accommodate production personnel and security guards. In addition, it is worth taking care of the presence of a product sales and accounting department. The arrangement of the production and office area will require financial investments in the amount of 700 thousand rubles.

Renting a plot of such area, depending on the region, will cost an entrepreneur 50 - 150 thousand rubles per month. According to experts, high rent can have a detrimental effect on business development. Therefore, depending on the availability of starting funds, it is more expedient to acquire ownership of a land plot and the buildings and structures located on it.

What equipment to choose for charcoal production

Equipment for organizing a small workshop for the production of charcoal includes: charcoal kiln (~ 120 thousand rubles), weighing dispenser (~ 20 thousand rubles), electric generator (~ 30 thousand rubles), hydraulic wood splitter (~ 90 thousand . rub.), packaging machine (~ 100 thousand rubles), chainsaws (~ 30 thousand rubles for 2 pieces). The cost of the entire set will be about 350 - 400 thousand rubles.

In addition to purchasing production equipment, you should also think about purchasing truck, which will transport raw materials and finished products. About 300 - 700 thousand rubles (used cars) should be provided for this expense item.

The main component for the production of charcoal is a charcoal kiln (or pyrolysis plant). The purpose of the furnace is to process non-commercial wood and wood processing waste into environmentally friendly charcoal. Charcoal kilns, according to their purpose, are divided into stationary and mobile. Mobile furnaces are used primarily by logging organizations and serve for recycling waste from the forestry industry. Mobile kilns are moved to the processing site, thereby reducing the cost of delivering raw materials, plus, wood waste serves as additional fuel.

Stationary furnaces are located on a permanent basis and, as a rule, have big sizes. The cost of stationary ovens is several times higher than their mobile options. Such stoves are used by large woodworking enterprises that need to dispose of wood waste. Coal production in such companies is often an additional source of income, and also allows them to get rid of the remains of non-commercial wood.

Raw materials for charcoal production

Hardwood trees are used as raw materials for the production of charcoal. Wood must comply with regulatory documents in accordance with GOST 24260-80 “Raw materials for pyrolysis and charcoalization”. By technical specifications contained in this regulatory document raw materials are divided into three groups. The first group includes oak, elm, ash, beech, maple and birch. These tree species are most suitable for pyrolysis and charcoalization. The second group contains species suitable for pyrolysis - alder, linden, aspen, poplar, and willow. And conifers- spruce, pine, fir, cedar, larch. And finally, the third group includes soft-leaved trees and other tree species that are least suitable for charcoaling: aspen, poplar, apple, pear, cherry, plum, acacia and others.

The yield of charcoal by wood type can be seen in the table below:

When producing charcoal, not only the type of wood is important, but the size of the raw material. The criteria for the size of wood raw materials are as follows: thickness from 3 to 18 centimeters, length from 75 to 125 centimeters.

Which OKVED code to indicate when registering a charcoal production business

A license is not required to produce charcoal. The organizational and legal form of a business can be either an individual entrepreneurship or a limited liability company. When registering a business, you can indicate in your application OKVED code 20 “Wood processing and production of wood and cork products, except furniture.”

Which tax system to choose for charcoal production

The most suitable taxation system is the simplified taxation system (USN). You can choose two options for paying tax: 6% of revenue (gross income), or 15% of the organization’s profit. The second option is more profitable if there are high costs for the production of charcoal. Thus, the tax base will be reduced, which means the tax will be less.

How much can you earn if you produce charcoal?

The average wholesale selling price of charcoal by region is 25 rubles/kg. Thus, the potential monthly revenue of an enterprise with a production volume of 40 tons can be 1,000,000 rubles. Naturally, subject to 100% sales of all manufactured products. In reality, you can count on selling 60-70% of the entire production batch, that is, receiving 600 - 700 thousand rubles in income.

As for expenses, the main ones include: rent of land and premises ~ 80 thousand rubles, wages (5 people) and insurance contributions ~ 150 thousand rubles, raw materials (chopped firewood 1500 rubles/ m3) ~ 100 thousand rubles, transportation costs ~ 40 thousand rubles, utility bills (electricity, water) ~ 30 thousand rubles, other costs ~ 50 thousand rubles. In total, total monthly expenses are about 450 thousand rubles.

Hence, the potential profit of the enterprise, minus taxes, is 130 - 170 thousand rubles per month. The payback of the project, with an initial investment of 1.5 - 2.0 million rubles, occurs in 12 - 16 months.

Step-by-step plan for starting a charcoal business

1. Market analysis.
2. Searching for wood suppliers, signing supply contracts.
3. Registration of an individual entrepreneur or LLC with the tax service.
4. Selection of premises for production with an area of ​​more than 100 square meters. m. Ideal place It is considered a warehouse near the city, close to the location of the raw material base.
5. Purchase and installation of equipment.
6. Organization of product sales.
7. Start of production.

How much money do you need to start?

• Equipment (charcoal kiln) - 75-100 thousand rubles.
• Packaging equipment - 50 thousand rubles.
• Devices for splitting wood - about 100 thousand rubles.
• Chainsaw - 10 thousand rubles.
• Scales for weighing coal - 5 thousand rubles.
• Electric generator - 20 thousand rubles.
• Purchase of raw materials - 200-300 thousand rubles. (depending on the type of wood).
• Registering a business, obtaining permits - 15 thousand rubles.
• Other expenses - 20 thousand rubles.

In total, 600 - 700 thousand rubles are needed. You can reduce costs at the initial stages by using used equipment and manually packaging products.

Do I need permission to open?

The production of charcoal does not require licensing or certification. The enterprise may be located within the boundaries of a populated area, since it does not emit harmful substances.

Business opening technology

The technology of the activity is to convert wood into coal. Production involves going through the process of pyrolysis - roasting wood in a special oven without access to oxygen. The process itself is as follows: wood is fed into the loading chamber and its burning begins. Special sensors indicate the readiness of the coal, after which it is unloaded and allowed to cool. Any wood can be used in the production process: waste from forestry, furniture companies, fallen trees.

Charcoal is a natural biofuel that you can make yourself.

Making charcoal in a pit

You can make it yourself in a pit. Used this method a long time ago. 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 burning, you can start making coal. 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 imply compliance fire safety. The lid must be kept closed until the coal cools completely. Once it is cold, it can be considered ready for use.