Charcoal without smoke…from the armchair…ARMCHAIR WANNABE
Ok I too would like to make charcoal, and eventually benefit from the heat byproduct thereof.
So I want to build a ‘stationary stove’, that requires tending but hopefully after it is fully warmed up, will process wood/biomass into charcoal without any adverse emissions, that is the goal, for little or no emissions. I’m hoping to process all of the pyrolysis gas from the 30 gal. batch barrel (full of raw wood/biomass to be baked-charcoalized), and utilize that dirty pyrolysis off-gas thereof to be diverted into & flow thru the ignited charbed that resides in the 55 gal. batch barrel, therefore cleaning the gas and increasing the exit temperature thereof.
These pictures shows some of the main pieces, the 55 gal. drum on the left side, it will be nearly filled with charcoal, generally no raw wood is used in this barrel, primarily charcoal. I’m hoping that all offgases within this barrel will be converted to a cleaner higher grade & higher temperature syngas, as the fumes pass thru the ignited charbed in the bottom of the barrel and out thru a nozzle & pipe [brown] in the bottom of the barrel. And since the 55 gal. drum is sealed at the top with a removable lid, the pressure developed will force the syngas thru a pipe [brown colored/yellow flow line] that connects to a used disc brake [located in the center of the unit]. A blower may become necessary to force the syngas thru the nozzle in the bottom of the 55 gal. barrel, I expect to put a ‘condensation inner plate’ on the lid, this hopefully will help condensate moisture & direct it to the gutter & drain in the side of the 55 gal. barrel. Perhaps eventually adding a contained ‘cooling coil’ that circulates water in the lid area, perhaps to condensate moisture faster. This disc brake seems to me to be similar to a propane gas kitchen stove top burner. The disc brake should act like a gas stove burner, the syngas escaping thru the equal spaced ‘cooling ports’ that are already cast into the assembly. The interior void of the disc brake will be covered somewhat when the 30 gal. raw batch barrel is set upon it, the cast iron should make a structurally stable foundation for the 30 gal. barrel to set directly upon. As the syngas arrives into the hub of the disc brake via the sch. 40 [brown colored] pipe [follow the yellow flow lines] [additional structural support is given by embedding the pipe ‘T’ into the foundation brickwork] , the syngas should ignite & sustain just outside of the disc brake perimeter, as it is in this burner area, hot air mixes with the syngas, hopefully at a mixture of about 1 part syngas to 5-7 parts hot air. The hot air inlet ports may be adjustable somewhat to change the 1:5 ratio. A cool air inlet into the same area may be used, as a simple access door [facing front], of which is used to light the burner.(the door is not shown in the pictures because of the ‘cut-away views’ (imagine) a simple door to see how the disc brake flame is burning.
In the pictures you will also see the 30 gal. raw wood/biomass barrel (in the middle of the picture), it has a lid & locking ring, and a single pipe that protrudes out of the bottom of the barrel. This bottom of the barrel pipe connects by sliding inside the stationary [grey colored] pipe below & sealing & lending structural support. The flow of the pyrolysis gas developed within the 30 gal. barrel is forced downward and [follows the red flow direction lines] thru the grey colored pipe [sch. 40]. This pipe goes directly to the 55 gal. batch barrel, and by anchoring the pipe into the brick foundation area, it is used as a structural support of the 55 gal. barrel & 30 gal. barrel but primarily transmits the pyrolysis gas into that barrel. I expect to run the [grey] pipe nearly to the top (on the interior of the 55 gal. barrel) so that it can release it’s pyrolysis gas into the upper part of the barrel.[red flow line] There it will probably be necessary to have an inline-one-way-check-valve, near the top of this grey pipe to somewhat prevent backflow, as if the 55 gal. charcoal batch is pressurize with a blower.
A few words about the brick ‘hot air tunnel’, it is the hollowed out foundation to the whole unit, it allows inlet air to pass thru it, and the air temperature is increased substantially as the 2 pipes (the brown & the grey) are radiating their heat into the air flow. The brickwork tunnel should help stabilize temperatures of the whole unit, while generally keeping it’s operation on the hot side.
The disc brake, resides within a burner area, a 5-10" tall section of a 55 gal. barrel is used around this area, and has been cut-away view, but basically is rigidly mounted to give the structural support of the removable outer 55 gal. flue/chimney assy. [which fits over the 30 gal. batch barrel, pilots onto the 5- 10" lower section of barrel] which contains the flames and emissions to be directed upward between the sides of the 30 gal. barrel & the 55 gal. flue, & finally out the top of the 8" stove pipe chimney. I would probably weld some handle bars onto the 30 gal. barrel, and the 55 gal. flue, the stove pipe might be easily attachable to the 55 gal. flue.
Most of my ideas are fairly impractical, but I’m just about willing to give something like this a try, any constructive criticism or suggestions are welcome.