CHAPTER 1

Background Information on the Design and Fabrication of a Mobile Charcoal-Making Furnace

Charcoal remains a critical source of energy, especially in developing regions where electricity
and alternative fuels are either expensive or inaccessible. Traditional charcoal production
methods, such as earth kilns and pit kilns, are inefficient, environmentally damaging, and labor-
intensive. These methods release significant amounts of greenhouse gases and often result in
incomplete carbonization, leading to low-quality charcoal.
A mobile charcoal-making furnace presents a modern, efficient, and environmentally friendly
alternative. Its mobility allows for on-site production, reducing transportation costs and
promoting sustainable waste-to-energy conversion. Additionally, an improved design ensures
higher efficiency, better heat utilization, and reduced emissions. This research aims to develop a
functional, portable system that enhances the sustainability of charcoal production while
addressing the limitations of conventional methods most especially in the production of compact
highly mobile charcoal making furnace.
The use of charcoal dates back to ancient civilizations, where it played a crucial role in
metallurgy, cooking, and heating. Early charcoal production was done using basic pit kilns,
which were gradually replaced by more sophisticated techniques such as brick kilns and retort
systems. Over time, technological advancements led to improved pyrolysis systems, enabling
better control over the carbonization process. However, many developing regions still rely on
rudimentary methods, leading to inefficiencies and environmental degradation. The demand for
cleaner and more efficient charcoal production methods has driven innovation in mobile and
mechanized furnace designs.
The core principle behind charcoal-making is pyrolysis—a thermochemical decomposition of
biomass in the absence of oxygen. Pyrolysis occurs in three main stages:
1. Drying Phase (100–200°C): Moisture content in the biomass evaporates.
2. Carbonization Phase (200–500°C): Volatile gases, including methane and carbon
monoxide, are released, leaving behind solid carbon (charcoal).
3. Cooling Phase: The charcoal stabilizes and hardens, preventing further oxidation.
The efficiency of a charcoal-making furnace depends on key thermodynamic and fluid
mechanics principles, including heat transfer, combustion efficiency, and gas flow control.
Mobile designs must optimize these factors while ensuring portability, durability, and ease of
use.
Modern innovations in charcoal-making furnaces focus on improving energy efficiency,
reducing emissions, and increasing mobility. Current designs incorporate:
 Metallic and refractory materials to enhance heat retention and durability.
 Forced-air circulation systems for better temperature control.
 Integrated gas recovery units to utilize byproducts such as syngas and bio-oil.
 Compact and lightweight structures for ease of transportation and deployment in
 remote areas.
By designing and fabricating a mobile charcoal-making furnace, this research aims to address
challenges faced by limited studies on highly mobile charcoal making furnaces.
Problem Statement
Charcoal remains a vital source of energy for cooking, heating, and industrial applications,
particularly in developing regions where alternative fuels such as electricity, natural gas, and
kerosene are either expensive or unavailable. However, the traditional methods of charcoal
production, such as earth kilns and pit kilns, are highly inefficient, environmentally harmful, and
labor-intensive. These conventional methods often result in:
1. Low Carbonization Efficiency: Traditional charcoal-making processes lead to incomplete
combustion, producing low-quality charcoal with high ash content and poor energy
output.
2. High Environmental Impact: The use of inefficient kilns results in significant greenhouse
gas emissions, including methane and carbon dioxide, which contribute to climate
change. Additionally, unsustainable wood harvesting for charcoal production leads to
deforestation and ecosystem degradation.
3. Health and Safety Concerns: Open burning and uncontrolled pyrolysis release harmful
smoke and particulate matter, posing severe respiratory and health risks to workers and
nearby communities.
4. Lack of Mobility and Flexibility: Conventional charcoal-making kilns are stationary and
require biomass to be transported over long distances, increasing costs and leading to
wastage of raw materials.
5. Economic Inefficiencies: Small-scale charcoal producers struggle with low productivity
and high operational costs due to inefficient traditional methods, limiting their
profitability and economic sustainability.
To address these challenges, there is a critical need for an improved charcoal-making system that
is mobile, efficient, and environmentally friendly. A mobile charcoal-making furnace provides a
promising solution by allowing charcoal production to occur directly at the source of biomass,
reducing transportation costs and ensuring higher efficiency.

Aim
To design and manufacture a portable mobile charcoal making furnace.
Objectives
- To design
- To fabricate
- To test.
Justification for the Design and Fabrication of a Mobile Charcoal-Making Furnace
1. Improved Efficiency and Productivity
Traditional methods waste a significant portion of biomass due to inefficient combustion.A
mobile furnace allows for better control over pyrolysis conditions, leading to higher charcoal
yield and quality.
 2. Environmental Sustainability
Reduces deforestation by optimizing carbonization efficiency, requiring less wood for the same
charcoal output.
3. Mobility and Accessibility
Can be transported to biomass-rich areas, eliminating the need to move raw materials over long
distances.Enables decentralized charcoal production, benefiting rural communities and small-
scale producers.
A closed, controlled system minimizes fire hazards compared to open-pit kilns.
4. Economic Benefits
Enhances profitability for small and medium-scale producers by reducing production costs and
increasing output.Reduces transportation expenses by processing biomass on-site.
Can create employment opportunities in rural areas by promoting sustainable charcoal
production.
5. Adaptability to Various Biomass Sources
Can process different types of agricultural and forestry waste (e.g., coconut shells, sawdust, corn
cobs), reducing reliance on traditional wood sources.
Supports circular economy initiatives by converting waste into a valuable energy source.
6. Technological Advancement and Innovation
Encourages research into alternative charcoal production technologies, leading to future
improvements.
By addressing the inefficiencies of traditional charcoal-making methods, this research
contributes to a better economic development.

Scope and Limitations of the Design and Fabrication of a Mobile Charcoal-Making Furnace
Scope
1. Design and Development
The study focuses on the design, material selection, and fabrication of a compact and portable
charcoal-making furnace.
The furnace will be designed to operate using controlled pyrolysis, optimizing heat efficiency
and reducing emissions.
2. Biomass Feedstock
The system will be tested using various biomass sources such as wood waste, agricultural
residues (e.g., coconut shells, corncobs, and sawdust), and other organic materials.
The furnace will be designed to handle small to medium-scale charcoal production.

3. Operational Mechanism
The design will focus on mobility, ensuring ease of transportation and deployment in rural and
urban settings.
The system will be evaluated based on carbonization efficiency and charcoal yield

4. Fabrication and Testing

The project includes the construction of a prototype using locally available materials to ensure
affordability and sustainability.
The fabricated furnace will be tested under controlled conditions to assess performance,
durability, and safety.

5. Environmental and Economic Considerations

The study will analyze the efficiency of charcoal production, comparing it to traditional methods.
The economic feasibility of the system, including potential cost savings and market viability,
will be considered.

Limitations
1. Scale of Production
The furnace will be designed for small to medium-scale charcoal production and may not be
suitable for large-scale industrial use.
Production rates will be limited to the capacity of the fabricated prototype.
2. Material Constraints
The choice of materials will be influenced by cost and availability, which may affect heat
retention and long-term durability.
High-end, industrial-grade materials may not be used due to budget limitations.
3. Emission Control
The project may not include advanced emission treatment systems such as carbon capture.
4. Testing Environment
The prototype will be tested under controlled laboratory or field conditions, but real-world
performance may vary based on external factors such as humidity, feedstock variability, and user
handling.
5. Automation and Monitoring
The system will primarily operate on manual controls. Advanced automation features (e.g.,
digital temperature control, real-time monitoring) will not be a core focus due to cost and
complexity constraints.
6. Energy Source Dependency
The furnace will rely on biomass-based combustion for heat generation, and alternative energy
sources (e.g., solar or electric heating) will not be integrated in this phase of the project.
7. Regulatory and Market Constraints
The project does not include detailed regulatory approvals or certifications, though general safety
and environmental considerations will be addressed.
Market testing and commercialization strategies will be outside the immediate scope of this
research.
By defining these scope and limitations, the project ensures a realistic and achievable approach
to developing a functional and efficient mobile charcoal-making furnace.
Chapter 2: Literature Review
This chapter provides a comprehensive review of existing research on charcoal production,
mobile furnace designs, and theoretical principles related to pyrolysis and combustion. It
analyzes previous studies to establish the foundation for this project and identifies gaps that the
proposed mobile charcoal-making furnace aims to address.
2.1 Review of Previous Research Work
Several studies have explored charcoal production technologies, efficiency improvements, and
environmental impacts. Below are key findings from relevant research:
2.1.1 Traditional Charcoal Production Methods
Earth Kilns and Pit Kilns: Earth and pit kilns are traditional, methods for producing charcoal
through pyrolysis.
Earth kilns are above ground structures made of earth and sometimes stones
Biomass is loaded into the kiln, and a fire is lit. The kiln is sealed, allowing the biomass to
undergo pyrolysis, producing charcoal.
For pit kilns they are dug into the ground and used for charcoal production. They are also known
as "pit furnaces" or "earth pit kilns."
Both earth and pit kilns are traditional methods that have been used for centuries. They offer a
low-cost, solution for charcoal production, particularly in rural or developing areas. However,
they can be less efficient and produce more emissions than modern, industrial-scale charcoal
production methods.
Studies have shown that traditional kilns have low carbonization efficiencies (10–30%) and
contribute significantly to deforestation and greenhouse gas emissions[1].

Brick Kilns and Retort Systems:

Brick kilns are pyrolysis structures made from bricks and mortar, designed for charcoal
production through pyrolysis. They are often used for small to medium-scale production.
Similar to earth kilns, biomass is loaded into the kiln, and a fire is lit. The kiln is sealed, allowing
the biomass to undergo pyrolysis, producing charcoal.
On the other hand, retort systems are designed for efficient charcoal production through
pyrolysis. They are often used for industrial-scale production.
Here, the biomass is loaded into the retort, and heat is applied, often through external heating or
recirculating hot gases.
While both brick kilns and retort systems are more efficient (yielding up to 40% charcoal), these
systems are stationary and require high capital investment [2].

2.1.2 Advancements in Charcoal-Making Furnaces

Metallic and Portable Kilns
Metallic and portable kilns are a significant advancement in charcoal making technology. These
kilns offer several benefits over traditional earth or brick kilns such as ;
- Portability: Metallic kilns can be easily transported to different locations, making them ideal
for small-scale or seasonal charcoal production.
- Efficiency: Metallic kilns can be designed for efficient heat transfer and retention, reducing
energy losses and improving charcoal yield.
- Durability: Metallic kilns are more durable than traditional earth or brick kilns, withstanding
harsh weather conditions and repeated use.
- Ease of Use: Metallic kilns often feature simple loading and unloading mechanisms, making
the charcoal production process more efficient and labor-friendly.
Research by [3] highlights that metal-based charcoal furnaces improve heat retention and reduce
production time compared to traditional methods.

Mobile Charcoal Production Units:

Mobile charcoal production units are units designed to produce charcoal on-site, reducing
transportation costs and increasing efficiency. These units are often equipped with advanced
technology to optimize charcoal production.
-Some of the key Features are:
- Portability: They can be transported to different locations, allowing for on-site charcoal
production.
- Efficient Design: These units are designed to minimize energy losses and optimize charcoal
yield.
- Advanced Technology: Some of the units feature advanced technologies like gasification,
pyrolysis, or carbonization to improve efficiency and reduce emissions.
Mobile charcoal production units offer a flexible and efficient solution for charcoal production,
particularly in areas with abundant biomass resources.
These emphasize the benefits of mobile systems in reducing transportation costs and enabling
on-site biomass processing[4].

2.1.3 Environmental and Economic Considerations

A study by [5] found that improved kiln designs can reduce carbon emissions by 50% while
maintaining high yield efficiency.
Also, economic analysis by [6] indicated that mobile charcoal-making furnaces can lower
operational costs by 30% compared to fixed-location kilns.

2.1.4 Gaps Identified in Existing Research

-Limited studies on compact, highly mobile charcoal-making furnaces for small and medium-
scale applications.
-A need for Integrated emission control mechanisms in portable furnaces.
-Lack of optimization in heat distribution to maximize carbonization efficiency.

2.2 Theoretical Framework

This study is based on the principles of pyrolysis, heat transfer, and combustion engineering.
2.2.1 Pyrolysis Theory
Pyrolysis is the thermal decomposition of organic materials in the absence of oxygen. It involves
three key phases:
1. Drying Phase (100–200°C) – Removes moisture from biomass.
2. Carbonization Phase (200–500°C) – Releases volatile gases, leaving behind solid carbon
(charcoal).
3. Cooling Phase – Stabilizes the charcoal, preventing combustion losses.

2.2.2 Thermodynamics of Charcoal Production

First Law of Thermodynamics: Energy conservation principles dictate that heat supplied must be
optimized for maximum carbonization.
Heat Transfer Mechanisms: Radiation, conduction, and convection play vital roles in
determining furnace efficiency.
2.2.3 Combustion and Emission Control
Complete vs. Incomplete Combustion: Controlling oxygen supply is critical in ensuring that
carbonization occurs efficiently while minimizing smoke and pollutant release.
Emission Reduction Technologies: Studies suggest that incorporating gas recovery units can
enhance environmental performance[7].

2.3 Summary of Literature Review

This review highlights the efficiency limitations of traditional charcoal production methods and
emphasizes the advantages of mobile furnaces. It also establishes the theoretical foundation for
optimizing pyrolysis conditions, heat transfer, and combustion processes. The next chapter will
focus on the methodology used in the design and fabrication of the mobile charcoal-making
furnace.
Chapter 3: Materials, Design, and Methodology

3.1 Introduction

This chapter outlines the materials, design, and methodology used in the
design and fabrication of a mobile charcoal making furnace. The goal of this
project is to develop a portable and highly mobile charcoal production
system.

3.2 Materials

The materials to be used in this project include:

- Mild Steel: It will be used for the construction of the furnace body, drum,
and other structural components due to its high strength and durability.

- Refractory Insulation: Will be used to line the furnace to minimize heat loss
and ensure efficient carbonization of biomass.

- Biomass Feedstock: Various types of biomass waste, such as wood chips,

coconut shells, and agricultural residues, will be utilized as feedstock for
charcoal production.

- Pyrolysis Chamber: This is a specially designed chamber where the biomass

will be subjected to high temperatures in the absence of oxygen to produce
charcoal.

- Condenser: Is designated to be used for the cooling nd condensing of the

volatile gases produced during the carbonization process, allowing for the
collection of bio-oil and other by-products.

- Chimney: Will be Used to vent out gases and ensure safe operation of the
furnace.
3.3 Study Area

The study area for this project is Iddo community with abundant biomass
waste, such as agricultural residues and wood waste. This area is
characterized by a high demand for charcoal, primarily used for cooking and
heating purposes. The mobile charcoal making furnace will be designed to be
transported to different locations within Iddo community , allowing for on-site
charcoal production from locally available biomass waste.

3.4 Sample Size

For this project, a sample size of 10 kg of biomass feedstock will be used for
each batch of charcoal production. The biomass feedstock will be carefully
selected and prepared to ensure uniformity and consistency in the charcoal
production process.

3.5 Sample Collection

Data collection involves monitoring the following parameters:

- Charcoal Yield: The amount of charcoal produced from each batch of

biomass feedstock will be measured and recorded.

- Bio-oil Yield: The amount of bio-oil collected from the condenser will be
measured and recorded.

- Gas Emissions: The composition and quantity of gases emitted during the
carbonization process will be monitored and recorded.

- Furnace Temperature: The temperature of the furnace will be monitored and

controlled to ensure optimal conditions for charcoal production.
3.6 Sample Preparation

The biomass feedstock will be prepared by drying and chipping or shredding

the material to a uniform size. The feedstock will then be loaded into the
pyrolysis chamber, where it will be subjected to high temperatures in the
absence of oxygen to produce charcoal.

REFERENCES

1. FAO, 2017

2. Mahamadou et al, (2020)

3. Smith et al, (2019)

4. Adeyemi and Olufemi,(2021)

5. Jones et al, (2022)

6. Okafor and Adebayo(2020)

7. Gao et al, (2023)