Building a Prototype Carbonizer for Biocharcoal Poduction

Catalino, Gayaso, Pacsay, Palsiyeng, Alagon, Dacquias, and Panit

INTRODUCTION

Background of the Study

Energy resources have been more and more extensively used throughout the years

that sustainable energy has become much more of a worldwide essential necessity. The

effects that sustainable energy have on the environment, however, has led to a more

inclusive notion of sustainability as well as the impacts it has for civilization. These have

been specifically perceived in energy resources that operates a large entity of the world’s

economic measures in different economic sectors. Thus, either being Carbon-based or

renewable, energy resources are gathered from all of what is available within our reach,

which mostly comes from the environment. The accumulated waste from undergoing the

process of producing such energy, however, will nevertheless be set loose into the

atmosphere. The issue then, with regards to producing sustainable energy, is largely

concerned on the harmful by-products that come along with the process of operating such

power plants that aids in the production of sustainable energy.

In order to accommodate the agricultural demand while at the same time

establishing resilience to environmental issues caused by the emission of harmful gases

into the atmosphere along with greenhouse concentrations, the obligation to manufacture

alternative solutions are to be administered. One of which is through the production of

biocharcoal (biochar), charcoal produced from plant matter and stored in the soil as a

means of removing carbon dioxide from the atmosphere. Through the process of

pyrolysis (burning) where biomass heated to a temperature from 300°C to 700°C in an

oxygen-limited environment (Gezae & Chandraratne, 2018). According to a research

conducted by Lehmann and Joseph (2015), biochar is useful for two main reasons. First is

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that it further enhances soil capacity which can bear better crops and second is that it

further eliminates carbon footprints instilled in other processes of producing commercial

charcoal (Hertsgaard, 2014).

Biochar can either be produced with the help of a biological charcoal kiln or a

200L metal drum with vents at the bottom for primary air and a chimney where smoke

escapes. This 200L metal drum is sometimes termed as a carbonizer as it separates the

biomass material with its Carbon dioxide component and releases it into the atmosphere.

This Carbon dioxide emission is then considered to negatively affect the Earth’s

atmosphere as to result to higher chances and development of global warming and

climate change as it was observed that this carbonizer still emits a very high

concentration of Carbon dioxide (Atonen et al., 2019).

Several models and designs of a charcoal kilns include mechanisms that minimize

operator exposures to harmful gases, smoke and particulates, as producing biochar can be

hazardous if carbonizers are improperly designed, maintained or used. One of existing

models of a carbonizer with such conventions was published in an article of Agiculture

Management for Climate and Change, a carbonizer designed and made by Orge,

McHenry, and Qiros (2015). Their version of a cabonizer aimed to be as simple as

possible, using only locally available materials from the community, and incorporate it

only for passive draft air flow; in contrast to most other alternative carbonizers which

require active electric fans.

Other designs for carbonizers focus more on the properties of biological wastes

that speeds up the process of carbonization. A study by Saravanakumar (2013) identified

three main and important factors of biological wastes that affect the time it takes to fully

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carbonize a material. The study identified species, moisture content, and dimensions of

the wood itself as the important factors. A high-volume increment may correspond to low

density and hence low yield of charcoal per unit volume of wood. Also, denser wood

usually produces a denser, less friable charcoal. Moisture in wood charged to the kiln has

to be evaporated by burning extra wood and this lowers overall yield. It is necessary to

strike the optimum time balance in drying so that the maximum amount of moisture is

lost in the early period when water loss is rapid. Carbonization rate is closely related to

wood size. Large wood pieces carbonize slowly since the transfer of heat into the interior

of the wood is a relatively slow process.

With this, the researchers intend to construct a modified version of a carbonizer

that is more efficient, effective, and economical. Wherein the carbonizer still utilizes

biomass materials to produce biochar, but instead of producing carbon dioxide and

dispersing it into the atmosphere, the researchers plan to trap this gas into an exhaust

chamber or chimney where it undergoes the process of condensation that thereon results

into a product which is aqueous carbon dioxide or liquid smoke. In this way, the smoke

emissions can easily be disposed and/or it can be used in chemical processes, storage of

carbon powder, and in fire extinguishers.

Figure 1 presents the flow of the study. The materials will be collected. The

materials that will be used are agricultural wastes (grass and pine wood), metal pipes, a

metal drum, and welding and cutting materials. The agricultural wastes will be dried and

the other materials will be used in constructing the carbonizer. After the drying and

construction of the carbonizer, carbonization will now take place. Carbonization is the

conversion of materials into carbon or a carbonic residue. By the process of pyrolysis, the

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agricultural waste will produce smoke and biochar. The smoke is then condensed in the

exhaust pipe forming liquid smoke.

Figure 1. Paradigm of the study

Statement of the Problem

Generally, the study aims to test the capability of a modified carbonizer that will

produce charcoal from bio-wastes.

Specifically, the study aims to address the following questions:

1. What are the carbonization rates of the following:

 Grass; and

 Pine Wood?

i. (diameter≤ 0.9in)

ii. (1in ≤ diameter ≤ 1.9in)

iii. (diameter ≥ 2in)

2. How much carbonized material was produced for the bio-waste (percentage

yield)? How much was not carbonized?

3. What are the bulk densities of the produced biocharcoal?

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Significance of the Study

The disposal of agricultural wastes has been a problem for some people. Due to

this, the device that would be created will help since biological charcoal would be

produced by burning the agricultural wastes and the smoke produced would be

condensed, turning it to liquid smoke that may also be used as a fungicide or pesticide.

Other than that, the biological charcoal produced can help people financially.

Specifically, this study would be beneficial to:

a. Farmers. The study could be beneficial to farmers because it will give them a

way to dispose their wastes while having the chance on earning money by

selling the biological charcoal produced.

b. Community. Not only will it be beneficial top farmers, the people of the

community can also benefit from the creation of the device. It may serve as a

way to gain profit and a way to dispose their agricultural wastes without

posing threat to the environment.

c. Department of Environment and Natural Resources (DENR). The DENR may

also use the design of the device as a model for creating their own closed type

carbonizer.

Scope and Delimitation

The research was conducted at the vicinity of the school. The collected materials

were gathered near the area of Cordillera Regional Science High School. The materials

were cut by a local auto shop and several other people. The study was done in the second

semester of the academic year 2019-2020. The study only focuses on the construction and

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testing of the modified carbonizer. The materials used were purely commercialized

materials.

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METHODOLOGY

Research design

The research design used in this study is a one-shot research design. A one-shot

research design is a type of pre-experimental design wherein a single group is used in a

treatment and only a single measurement is only taken afterwards. This design only

measures the post-test results and there is no control group (Insights Association, n.d.).

Design of the experiment

Essentially, the carbonizer is divided into two parts: the body, and the exhaust

pipe or chimney. The body is a hollow drum (35in length and 23in diameter) with two

doors: one at the top (for putting the agricultural waste) and one at the bottom (for the

fire). There are also 2in holes at the back of the drum in order for oxygen to enter the

drum; however the holes above were covered with mud to limit the entrance of oxygen.

Attached to the drum is a 15.69in exhaust pipe or chimney. This was used in order to

divert the smoke into one pathway only. The exhaust pipe was connected to a 90° metal

elbow and was connected to another elongated pipe with a length of 19.69in (with the

coupling). Afterwards, a metal tee was connected. The bottom part of the tee is for the

liquid smoke to flow down while the upper part is for the smoke to go up. A 45° elbow

was attached above to direct the smoke to an 87.5in pipe that was sealed using tape. The

smoke will then condense in the upper part of the chimney, forming now liquid smoke

(pyroligneous acid). The idea of condensing smoke was adopted from Atonen, Cachin,

Diano, and Lagasca’s (2019) model of carbonizer. Figure 2 shows the design of the

carbonizer.

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Figure 2. Design of the carbonizer and its dimensions

Data Gathering

First, the carbonizer was made by different auto shops and was assembled in the

school. While the carbonizer was being done, the gathered agricultural wastes were dried

to reduce moisture content (below 15%) and were weighed. The pine woods were

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categorized into three groups depending on its diameter. Afterwards, the dried materials

were put inside the carbonizer and firewood and kerosene was used to start the fire. The

holes above the upper chamber were covered with mud to control the flow of oxygen

inside the drum. The carbonizer was closed while the materials are being carbonized. The

waste materials were checked at an interval to see if the materials are already carbonized.

The produced biocharcoal is then measured for its bulk density afterwards.

Testing of Parameters

Carbonization Rate. Carbonization rate is the amount of time it took the materials to be

carbonized. The rates of carbonization for each material were collected using a

stopwatch.

Percentage Yield. The percentage yield is the amount of materials carbonized over the

dried weight (Food and Agriculture Organization, 1985). This can be solved using the

formula:

mass of carbonized material( g)

percentage yield= ×100
mass of material before carbonizing ( g)

Bulk Density. This is defined as the mass of the carbonized material per unit volume

(g/mL) (Lopez-Cordoba & Goyanes, 2017). This can be solved by using the formula:

mass of carbonized material ( g)

bulk density ( ρ)=
volume of the carbonized material(mL)

Data analysis

A descriptive analysis was used in the study. This deals with describing a

phenomena and it attempts to examine situations in order to describe the norm

(Walliman, 2011). Since there is no control group, the data gathered were described and

were linked with other researches relating to the topic at hand.

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Risk and Ethical considerations

Due to the nature of the research, the researchers can be exposed to different

hazards from the study. Starting off, the construction of the carbonizer is a hazard due to

the usage of many tools and apparatuses to use (such as metal cutters and welding tools).

With this, the researchers sought help from experts who are inclined with metal cutting,

mainly smiths, who are in the vicinity. Another hazard is the burning of the agricultural

waste. The latter can expose the researchers with burns from the metal and from the fire

itself. As a way to combat it, insulation of hands (such as using cloth) can help in the

problem.

Finally, the researchers upheld truth and honesty, especially in the collection of

data and interpretation of it. The researchers followed the rules of the Intel International

Science and Engineering Fair (Intel ISEF) when conducting the experiment.

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RESULTS AND DISCUSSION

This section shows the findings from the data gathered in the experiment.

Descriptions, discussions, and interpretations are included in the analysis of the results.

Carbonization Rate of Materials

The different materials were carbonized and the rate of carbonization was taken

into account. Table 1 shows the carbonization time of the different materials.

Table 1. Carbonization time of the different materials

Materials Mass (in grams) Carbonization time (in minutes)

Grass 250 10

Pine Wood 750 40

(diameter≤ 0.9in)

Pine Wood 1750 50

(1in ≤ diameter ≤ 1.9in)

Pine Wood 3250 60

(diameter ≥ 2in)

As presented in the table, the grass was carbonized faster compared to the other

materials. This may be due to the thinness of the leaves of the grass, making it catch fire

easily. Also, the more the mass of the material is, the more time it needs for it to

carbonize. That is why the pine wood with a weight of 2.25kg had the highest

carbonization time. Carbonization rate is closely related to wood size. Large wood pieces

carbonize slowly since the transfer of heat into the interior of the wood is a relatively

slow process (Saravanakumar, 2013).

Another factor that could affect the carbonization time is the moisture content.

The moisture content of the materials directly affect the carbonization time (Huang, Jhan,

Cheng, & Cheng, 2014). The amount of oxygen or airflow can also affect the rate of

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carbonization (Rivas, Yuan, Wang, & Boyette, 2017). Moisture in wood charged to the

kiln has to be evaporated by burning extra wood and this lowers overall yield. It is

necessary to strike the optimum time balance in drying so that the maximum amount of

moisture is lost in the early period when water loss is rapid (Saravanakumar, 2013).

Percentage Yield of Carbonized Materials

The percentage yields of the different materials are shown in the table below.

Table 2. Percentage yield of the different materials

Carbonized
Uncarbonized Percentage yield
Materials material (in
material (in grams) (wt%)
grams)

Grass 38 32 15.2

Pine Wood 214 108 28.53

(diameter≤ 0.9in)

Pine Wood 244 434 13.94

(1in≤diameter≤1.9in)

Pine Wood 470 2013 14.46

(diameter ≥ 2in)

In the efficiency of carbonization, it is expressed as the yield of charcoal and is

expressed as a percentage (actual percentage yield). However, the unburnt materials

represent the inefficiency of the design of the carbonizer (Food and Agriculture

Organization, 1985). The reason as to why there were unburnt materials was due to the

uneven distribution of air going inside. The carbonizer’s doors cannot close properly,

which have a small gap that increases the intake of oxygen. The mud covering the holes

may have also affected the oxygen distribution. The coverings fell at times, especially

when it dries. The uneven oxygen distribution also increases the ash yield. This has

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happened in the second trial of the pine wood. The second trial was not that given much

attention as compared to the other trials (Rivas, Yuan, Wang, & Boyette, 2017).

For the percentage yield, it has a range of 13.94% to 28.53%. In normal

circumstances, the average percentage yield is at least 30% (Ronsse, Hecke, Dickinson,

& Prins, 2012). The yield of the produced charcoal did not account for the average

percentage yield. Once again, the uneven distribution of oxygen greatly affects the yield

of biocharcoal as it has a tendency to turn into ash as oxygen increases.

Bulk Density of the Carbonized Materials

The following table shows the bulk density of the different materials.

Table 3. Bulk density of the different materials

Bulk Density
Materials Mass (in grams) Volume (in mL)
(g/mL)

Grass 38 75 0.51

Pine Wood 72 200 0.36

(diameter≤ 0.9in)

Pine Wood 86 200 0.43

(1in ≤ diameter ≤ 1.9in)

Pine Wood 90 200 0.45

(diameter ≥ 2in)

Basing from the table, the range of bulk density for the carbonized materials is

0.36g/mL to 0.51g/mL. The table above shows that the carbonized grass is denser than

that with the pinewood of different diameters. This may be due to the compressibility of

the grass in char form. The grass is finer and has smaller particles creating fewer spaces

in between when it was put in the beaker and compressed. The pinewood, on the other

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hand, has bigger particles because of the way it was pulverized hence, this created spaces

that are not filled when it was put in the beaker and compressed.

In the case of the pinewood with different diameters, it can be inferred that the

greater the diameter of the pinewood, the denser it is. Since the sample that was gathered

from the pinewoods was set to 200ml for all, they varied in weight and it is implied that

the heavier the pinewood, the denser it is.

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CONCLUSIONS AND RECOMMENDATIONS

Conclusions

Based from the results of the study, the following conclusions were drawn:

 The carbonization rate of grass, pinewood (diameter≤ 0.9in), pinewood (1in ≤

diameter ≤ 1.9in), and pinewood (diameter ≥ 2in) in minutes is 10, 40, 50, and 60,

respectively.

 15.2%, 28.53%, 13.94%, and 14.46% of grass, pinewood (diameter≤ 0.9in),

pinewood (1in ≤ diameter ≤ 1.9in), and pinewood (diameter ≥ 2in), respectively

are carbonized. On the other hand, 32g to 2013g from the grass, pinewood

(diameter≤ 0.9in), pinewood (1in ≤ diameter ≤ 1.9in), and pinewood (diameter ≥

2in) were not carbonized.

 The mass per unit volume (g/mL) of the grass, pinewood (diameter≤ 0.9in),

pinewood (1in ≤ diameter ≤ 1.9in), and pinewood (diameter ≥ 2in) is 0.51, 0.36,

0.43, and 0.45, respectively.

Recommendations

It is then recommended to others that:

 Different bio-wastes should be tested such as corn cobs, coconut husks, etc.

 A cooling system in the condenser should be added to further enhance the

condensation of pyroligneous acid.

 A division on the drum should be added to reduce the ash content in the charcoal.

The upper portion would be for the bio-wastes and the lower portion is for the

fire.

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 A cone-like structure can be implemented in the chimney to diverge the pathway

of the smoke easier.

 The quality of the produced biocharcoal should be assessed using other

parameters such as proximate analysis, soil improvement, and heating value.

 A briquetting machine can also be added to create charcoal used in cooking.

 Find for ways to easily dispose the liquid smoke.

 Compare the data gathered to the standardized carbonizer of the Department of

Science and Technology (DOST).

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REFERENCE LIST

Atonen, Cachin, Diano, &Lagasca (2019). Building an economic carbonizer. An

unpublished thesis.

Food and Agriculture Organization (1995). Industrial Charcoal Making. Retrieved

February 2020 from http://www.fao.org/3/X5555E/X5555E00.htm

Gezae, A. & Chandraratne, M. (2018). Biochar Production from Biomass Waste-Derived

Material. doi: 10.1016/B978-0-12-803581-8.11249-4.

Hertsgaard, M. (2014). As Uses of Biochar Expand, Climate Benefits Still Uncertain.

Retrieved November 2019 from e360.yale.edu/features/as_uses_of_biochar_
expand_climate_benefits_still_uncertain.

Huang, P., Jhan, J., Cheng, Y., & Cheng, H. (2014). Effects of Carbonization Parameters
of Mose-Bamboo-Based Porous Charcoal on Capturing Carbon Dioxide, The
Scientific World Journal, vol. 2014.

Insights Association (n.d.). One-shot Case Study. Retrieved November 2019 from
https://www.insightsassociation.org/issues-policies/glossary/one-shot-case-study

Lehmann, J. & Joseph, S. (2015). Biochar for Environmental Management: An

Introduction. Retrieved November 2020 from https://www.taylorfrancis.com/
books/e/9780203762264/chapters/10.4324/97802 03762264-8

Lopez-Cordoba, A., & Goyanes, S. (2017). Food Powder Properties, Reference Module in
Food Science. doi: 10.1016/B978-0-08-100596-5.211980. Retrieved February 27,
2020.

Orge, R.F., McHenry, M.P. & Quiros, E.N. (2015). Waste rice husk continuous
carbonizers for carbon sequestration and energy in rural Philippine Regions. In:
McHenry, M.P., Kulshreshtha, S.N. and Lac, S., (eds.) Agriculture Management
for Climate Change. Nova Science Publishers, pp. 109122.

Rivas, A., Yuan, W., Wang, D., & Boyette, M. (2014). In-Chamber Thermocatalytic Tar
Cracking and Syngas Reforming Using Char-Supported Nio Catalyst in an
Updraft Biomass Gasifier, International Journal of Agricultural and Biological
Engineering, 7(6):91.

Ronsse, F., Hecke, D., & Prins, W. (2012). Production and Characterization of Slow
Pyrolysis Biochar: Influence of Feedstock Type and Pyrolysis Conditions, GCB
Bioenergy, 5(2).

Rosen, M. (2009) Energy Sustainability: A Pragmatic Approach and Illustrations.

Retrieved from https://www.mdpi.com/journal/sustainability (ISSN 2071-1050)

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Saravanakumar, T. M. (2013). A novel performance study of kiln using long stick wood
pyrolytic conversion for charcoal production. Energy Education Science and
Technology Part A: Energy Science and Research, 31(2), 711-722.

Walliman, N. (2010). Research Methods: The Basics, Roultledge, London and New
York.

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APPENDICES

Appendix A: Plates

Plate 1. Pre-testing

Plate 2. Collection and Drying of Grass

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Plate 3. Collection of Pine Wood

Plate 4. Classifying the Pine Wood by Diameter

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Plate 5. Covering of Holes during Carbonization

Plate 6. Final Design and Carbonization Process

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Plate 7. Condensation of Pyroligneous Acid

Plate 8. Carbonized Grass

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Plate 9. Carbonized Pine Wood (below 0.9in)

Plate 10. Carbonized Pine Wood (between 1in to 1.9in)

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Plate 11. Carbonized Pine Wood (above 2in)

Plate 12. Uncarbonized Materials

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Plate 13. Measuring Bulk Density

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Appendix B: Letter of Communication

CORDILLERA REGIONAL SCIENCE HIGH SCHOOL

Wangal, La Trinidad, Benguet
(074)-422-5662

November 6, 2019

DENVER P. DOKEY
Teacher

S I R:

We are planning to conduct a study regarding our model of a prototype carbonizer and
the produced biocharcoal. This is in partial fulfillment of the requirements for the subject
Inquiries, Investigation, and Immersion.

Part of this research requires us to (reason). With this, we would like to (aim). In
addition, may we ask for (additional request). Rest assured that all information given by
your institution will solely be for research purposes.

Your positive feedback will go a long way in contributing to good research practices as
well as in accomplishing the objectives of this study.

Thank you very much and God bless!

Sincerely yours,

ALVIN N. PALSIYENG
Team Leader

NOTED:

AMETHYST JOY B. TAQUED

Subject Teacher

APPROVED:

MERLYN CONCHITA D. DE GUZMAN

School Principal I

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Republic of the Philippines

Cordillera Administrative Region
Schools Division of Benguet
La Trinidad, Benguet
CORDILLERA REGIONAL SCIENCE HIGH SCHOOL
Wangal, La Trinidad, Benguet
(074) 422-5662

February 02, 2020

RHANDY TUBAL
Senior Research Specialist
Department of Environmental and Natural Resources
Loakan, Baguio City

S I R:

We are Grade 12 students currently conducting a quantitative study entitled “Building

Prototype Carbonizer for Biocharcoal Production” as a requirement for our Inquiries,
Investigations, and Immersion (III) subject. During the week (January 26-January 30), we
attempted to gather our data, however problems arose such as the smoke not condensing
and the agricultural wastes not being fully carbonized. In line with this, we would like to
seek for your advice once again on the design of the carbonizer.

Your positive response will greatly contribute to the success of this endeavor.

Thank you very much

Respectfully yours,

ALVIN N. PALSIYENG
Team Leader
(09299883108)

NOTED:

AMETHYST JOY E. TAQUED

Adviser

MERLYN CONCHITA O. de GUZMAN

School Principal I

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Appendix C: Tables

Table 1. Carbonization time of the different materials

Materials Mass (in grams) Carbonization time (in minutes)

Grass 250 10

Pine Wood 750 40

(diameter≤ 0.9in)

Pine Wood 1750 50

(1in ≤ diameter ≤ 1.9in)

Pine Wood 3250 60

(diameter ≥ 2in)

Table 2. Percentage yield of the different materials

Carbonized
Uncarbonized Percentage yield
Materials material (in
material (in grams) (wt%)
grams)

Grass 38 32 15.2

Pine Wood 214 108 28.53

(diameter≤ 0.9in)

Pine Wood 244 434 13.94

(1in≤diameter≤1.9in)

Pine Wood 470 2013 14.46

(diameter ≥ 2in)

Table 3. Bulk density of the different materials

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Bulk Density
Materials Mass (in grams) Volume (in mL)
(g/mL)

Grass 38 75 0.51

Pine Wood 72 200 0.36

(diameter≤ 0.9in)

Pine Wood 86 200 0.43

(1in ≤ diameter ≤ 1.9in)

Pine Wood 90 200 0.45

(diameter ≥ 2in)

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