Low-cost retort kiln called "adam-retort"
or
ICPS (Improved Charcoal Production System)
The ICPS is a modern, innovative and environmentally friendly system to produce charcoal from biomass.
(low-cost retort kiln)
Did You know:
CHARCOAL from RETORT SYSTEMS can often serve as a replacement for fossil fuels,
thereby having a neutral effect on CO² exchanges.
This makes a significant positive contribution to the preservation of our environment!
Advantages:
1) High economy and better efficiency approx. 35% to 40% (Instead of about 18% efficiency compared to the traditional systems; calculated from dry weight).
2) Recycling and clean combustion of the pyrolysis gas during the 2nd phase of operation (retort-system) results in a low-emission of carbon monoxides during the charcoal production! The effective carbonization of the biomass takes only 10 hours.
A retort system reduces the emission of harmful volatiles into the atmosphere to about 70%! (Compared to a traditional earth-mount kiln).
3) Low investment costs (about 300 Euro) and a simple construction with locally available materials.
4) About 3m3 of biomass (corresponding to approx. 600 to 700kg wood, coconut shells, compacted saw-dust briquettes, etc.) can be converted to up to 250kg of charcoal per batch.Per week about 3 batches of biomass can be cabonized which is corresponding to about 0,750 tons of charcoal per week and unit.
5) An effective 30 hour production cycle (batch) and a simple operation of the plant result in an increased income for its operators. The right system to be used at forest projects, sustainable energy-wood plantations and charcoal makers.
6) Only waste wood or residual biomass needs to be burnt (~50kg) in a separate fire box to dry and heat the wood and initiate the carbonization process during the 1st phase.
7) With an extended version the famous "white charcoal" should be possible to be produced? This is an adapted japanese technology to produce high quality and strong charcoal. Also the production of "wood vinegar" is possible during the 1st phase of operation.
perspective drawing of the "adam-retort"
The issue of the introduction of environmentally friendlier procedures for charcoal production in countries such as Africa and South America is one that is badly in need of our attention.
Currently Kenya uses 2 million tons of charcoal for household purposes per year. Zambia’s situation is comparable to Kenya’s, using approximately 1 million tons of charcoal per year. Many other third world countries are showing similar figures as well.
The charcoal is mainly manufactured with an earth-mount-technology, originally used in the Middle Ages. To create 10kg to 15kg charcoal using this method, about 100 kg of wood is needed. Here, the efficiency ratio is only 10%-15%.
There is, however, an alternative method available. Known as ‘retort-technology,’ this is the method used in Europe to manufacture charcoal on an industrial level.
These industrial plants are unfortunately impracticable in the rural areas of the target countries, because the investment and maintenance costs of the process are too high.
After much consideration, as well as experience with the building of a bio-coal plant in Burundi/East Africa, we have succeeded in developing a concept for innovative retort-kilns built with locally available materials. We have confidence that the retort-kiln can be accepted by the population and be widely spread. The retort-kiln was developed according to the principles of ‘intermediate’ or ‘appropriate’ technology
In 2004 in India the development of the model was furthered – now being built in Kenya, we can see how the low-cost retort-kilns are helping aid a more environmentally friendly method of charcoal production.
The plant is called ICPS (Improved Charcoal Production System) or „adam-retort“ and has the following advantages:
* Economical, with an efficiency of approx. 35% to 40% instead of about 18% efficiency compared to the traditional systems (calculated from dry weight of wood).
* Recycling and clean combustion of the pyrolysis gas during the 2nd phase of operation (‘retort-system’) results in a low-emission of carbon monoxides during the charcoal production. The effective carbonisation of the biomass takes only 10 hours.
* Low investment costs (about 300 Euros for materials and work) and a simple construction with locally available materials.
* A volume of approx. 3m3 of biomass (corresponding to approx. 600 to 700kg wood, coconut shells, etc.) can be converted to up to 250kg of charcoal.
* An effective 24-30 hour production cycle (known as a ‘batch’) and a simple operation of the plant result in an increased income for its operators. The right system to be used in rural areas or semi-industrial production like at forest projects, energy-wood plantations and charcoal makers.
* Only waste and residual biomass needs to be burnt (~50kg) in a separate fire box to dry and heat the wood and initiate the carbonisation process during the 1st phase.
* The concept of the ICPS is that the “adam-retort” works in 2 stages – the first and the second phase. In the first phase the wood in the retort chamber is dried by hot flue gases and the carbonisation is initiated. The hot flue gases are produced with cheap waste wood in an external fire chamber. By waste wood we understand branches, crust, charcoal dust and other residual products from agricultural processes, such as coffee husks. About 50 kg of waste wood is burned per batch.
During traditional charcoal production a part of the ‘good’ wood must be burned down in order to carbonise the rest of the wood.
As soon as the water in the wood has evaporated, the smoke is sufficiently hot and the first inflammable wood gases appear, the smoke is now rerouted and burnt in the hot fire chamber, reducing pollution. This additional energy is used to heat up the wood chamber and to further accelerate carbonisation during this second phase
In the traditional carbonisation process, the smoke clouds remain in the air for 4 – 6 days. The smoke created by the “adam-retort” carbonises within approximately 10 hours with some of the smoke being burnt off in a fire box. If the carbonisation begins in the morning, the retort-kiln can be closed by the evening. The charcoal cools overnight by a special cooling method. By the next morning, the charcoal is ready to use.
The plant can be built for approximately 250 euros (300 euros, if a profit is to be included).
About 3m³ volume, or 750 kg wood can be loaded, from which 200-250 kg of charcoal be created.
Our calculations in Kenya mean the initial investment costs can be paid back in about three months, from the sales of the charcoal.
The “adam-retort” can be built in approximately one week by a ‘Retort-Team’ consisting of 2 trained bricklayers and one assistant. The chamber of the retort kiln is build from simple bricks or even unburned earth blocs, also hollow bricks are very suitable.
It makes sense to introduce the “adam-retort” at forest projects or other areas which cultivate wood energy plantations. The farmers are more motivated to plant energy trees because the wood gets a higher economic value because of an about doubled recovery rate for the charcoal! Its also recommended to use the “adam-retort” as well in areas where sustainable trees exist. This is the case in many areas of East- and South Africa where the Lelechwa wood grows. The local farmers call these shrubs ‘weeds,’ partly because after cutting they grow back with renewed vigor. Their hard wood creates an excellent charcoal. The burning of coconut shells to create charcoal is also a possibility.
A 75% reduction of environmental damage has been recorded by an English retort manufacturer. Wood consumption is reduced by over half, while maintaining the amount of charcoal produced. With the retort-technique charcoal of a high quality is obtained – one extra suggestion has been to market it to the medical sector.
We do not advise the introduction of charcoal; it is better to burn wood directly. In many countries, however, charcoal use is socially determined, or traditional, as regards specific meals prepared. In areas where this kind of high charcoal consumption takes place, it is more appropriate to produce it with more efficient, more modern and environmentally friendlier methods, such as the “adam-retort.”
Also information on the ICPS in other languages is available on request: German, French, Spanish and Portuguese.
Partly you can find this information also under: http://www.bioenergylists.org/en/adamretort