Yes, I did not have a tripod for my camera so I just fed in a little to show how it worked. A day later I did it without videoing and I ground up 40 gallons by feeding it as fast as it would take it with the hopper filled to the top. which took about a half an hour. I now have about 170 gallons of engine grade charcoal in air tight plastic containers along with about 20 gallons of garden biochar.
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Hey Don. You sound like gasoline is only needed by the wife at your household. I was curious as to how important it is to prevent atmosphere moisture from affecting charcoal. I thought that similar to popped popcorn, you would have to soak it in water to really make a temporary mess.
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Charcoal Grinder Finished
Finished up the charcoal grinder.
Here it is with the motor and the upper throat installed.
This motor is from the scooter pictured above. As far as I can tell by looking around on the Internet, it is a 225 watt motor (around 1/3 HP ?) designed to operate at a nominal voltage of 24 volts. But, from what I read, it can operate from 12 to 36 volts.
I don’t know the exact RPM, but I am estimating that the rotor speed is around 180 RPM at 24V.
Here it is with the hopper.
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Charcoal Grinder - First Test
I decided to test the grinder at 12V first, so that it would be going a little slower.
The first test went OK, but was a little disappointing.
In particular, the grinder choked several times with the first few handfuls of charcoal I put in it.
A little investigation revealed that I had randomly selected the last 5 gallon bucket from the first batch of charcoal I had made. This would have been the very last of the charcoal out of the retort, which would have been located in the top of the retort during the burn. As I commented previously, I found the most torified wood in this region, and from that burn. And, sure enough, it was choking on the occasional “solid” piece that was not fully charred (even though it might look charred on the outside).
I switched to a bucket from my second batch of charcoal. It digested a few handfuls of this fine at 12V. I decided to kick it up to 24V. It was noticeably faster. I processed a 5 gallon bucket of charcoal in just a few minutes.
After screening, this is what the “fuel” charcoal looked like.
I don’t know if you can see it in this picture, but I think that there are some fines in the dust tray that are big enough to use for fuel as well. I think I need to tighten up my small screen a little bit.
Anyway, I am very happy with the results. It looks like the grinder will produce fuel quality charcoal a lot faster than I can make it. It should work fine for what I have in mind.
The grinding and screening process does make quite a bit of dust. I think it would be better to do that outside.
I can also see the need for some sort of simple screen shaker; or an arrangement like Don’s.
Anyway, a big thanks to Gary for sharing his design, and Don for inspiring me to try this method.
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Pete - Sorry. Just reviewing the thread, and saw your question.
No. I never tested the Jaw Crusher idea.
And, in the end, I decided to go with a rotary crusher like Gary’s and Don’s.
I still think it is possible that the jaw crusher idea would work, and might make less dust, but I just don’t know.
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The Main Event
Anyway, now that I have a way to make charcoal, and turn it into usable fuel, it is time to turn my attention to the main event - making the gasifier.
I have looked over the design.
It looks “simple” enough.
But I am wondering about a few things before I start.
I was thinking about using the flex exhaust pipe because the hose that Gary uses sounds like it might get over-heated when the charcoal gets low. I kind of need an idiot proof design. So, I am wondering what is the best choice for hose from the gasifier outlet to the filter?
I am thinking of using a 5 gallon plastic “ace bucket” for the filter. Is this a reasonable thing to use? Or should I be looking for a metal bucket? I plan to put foam in it with a wool blanket. Should I make the filter 5 gallons, with a 15 gallon gasifier, or is that overkill?
What is the best choice for some kind of blower? I definitely want a blower, so I can flare this thing before I connect it to my engine, and I would rather avoid using any gasoline at all, if possible.
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Hey Kyle congrats on all the progress. I like the gamma lids mounted onto the 5 gallon bucket as a filter body with a water filter as the filter. Standard bilge blower like Wayne uses works for start up.
Best regards David Baillie
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Hi Kyle, You are moving right along! Glad you did not pursue the jaw crusher. I tried it and it allowed large, narrow slivers of charcoal to fall through while the other charcoal just got hung up. I am still using the grinder that is very similar to what you have. Suggestion; If you have enough power, try adding two lugs welded opposite each other (180 degrees apart) on the pipe. This will double the number of lugs to crunch the charcoal.
Watch out for torrified wood in a charcoal gasifier. That stuff will still make tar.
As to your gasifier, let me suggest you use the sump pump hose from the gas outlet to the filter. It is cheap and easy to replace. When it gets to 120F, it starts to soften and soon collapses. So what? You learned how long your gasifier can run before the temp is too much which also means your fuel level is too low. You can use the flexible steel hose, but you will have to order it (most likely since it is 1.25") and you will have to make sure it has air tight connections.
The 5 gallon plastic bucket is an excellent idea. As David suggested, use the Gamma lids. I just ordered a dozen of them. Also use a bilge blower as he suggested. They really work well if you get the ones with enclosed motors. I like the five oceans make. Actually, I need to get some ordered. Once you get everything together, I’ll bet you will be amazed at how easy it can be to run a small engine on charcoal. Welcome to the dark side! 
Gary in PA
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I found that old car radiator hose over the outlet pipe of the gasifier and onto the pipe running to the filter and then more car radiator hose with the correct bend on it connected to the pipe fitting on the drum filter works pretty good , and a lot cheaper than flexi hose here ,as they want $45 a meter for it ,
and will even stand up to the heat of the gas when the charcoal runs low , I also put a cyclone in line as well and that just helps take out very fine dust and cools the gas down even more , the pipe I am using at the moment is 2 inch stainless and helps with cooling as well .
Dave
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Hi guys, good day. Watch this I found in UK, I thought mine was big! No way …THIS is big…
Wow. That thing looks like the Kingsford factory.
David - What kind of water filter do you use and how do you mount it in your bucket?
Hey Kyle I pierced a hole in the gamma lid and use a male and female plumbing abs fixture that screws together then a screw fitting inside then a screw on spa filter that fits the bucket. Air intake is more threaded fittings through the bucket bottom those ones are pipe flanges for support. Everything is sealed with poly butyl caulking; Silicone does not stick to the buckets…
David Baillie
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Ordered some Gamma lids and a blower last night.
Straightened up the shop.
Here’s the whole stack (screens and grinder).
Good way to store everything, but the crusher doesn’t vibrate enough to work everything through the screens since I went with the rotary crusher.
Going to have to re-think that, and add some sort of vibrator for the screens.
I saw Andy’s wood wheel barrow, and that inspired me to (possibly) arrange the whole contraption kind of like a wheel barrow, so I can easily move it in and out of the shop.
From now on, I want to do the crushing outside, to keep the dust down.
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Hi david
your filter (5 gallon bucket) it contains a filter material? (Wood chips, hay, …)
The plastic bucket withstands the heat of the gas?
At what frequency clean your filter?
Thierry
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I have been imagining the use of a mesh drum similar to a grain cleaner to sort charcoal by size. The tumbling action would keep it all moving.
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A rotating screen in the shape of a long cylinder (drum) works real well as does a screen tilted to 45 degrees. Yes, a vibrating screen can also work but the first two are easier to build in my opinion.
Gary in PA
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Andy - Yes. I love the idea of a rotating screen (“Trommel”).
I just figured it would be quite a bit of trouble to build.
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I like the simplicity of a 45 screen.
It looks like it works for Don.
Maybe I will do that.
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I think it depends on a couple of things like how dry the air is. I think Ray Menke keeps his charcoal in some kind of fabric bags, maybe even with an open top but he is in that dry Texas air where you have to lick your lips before you can talk. Up here near Lake Michigan the air usually has quite a bit of moisture in it and I believe in keeping engine charcoal dry so I use closed containers as much as possible.
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