Technological University of the Philippines

COLLEGE OF ENGINEERING

Department of Mechanical Engineering

A Project study

Alternative Activated Charcoal Maker

( Pyroligneous Acid as a by Product )

In Partial Fulfillment

Of the Requirements for the Degree of

Bachelor of Science in Mechanical Engineering

By:

Amayo John Christian M.

Consultado, Annalisa C.

Dalo, May Ann A.

Manabat, Jinky R.

Lagundi, Lallaine N.

Taganas, Aris Jerry L.

October 2007

ACKNOWLEDGEMENT
 We would like to recognize some of the people who have

benevolently and willingly shared their profound ideas, skills, efforts,

valuable time and overflowing support in improving this study.

To Engr. Nenet Graza, our project study adviser, for her

indefatigable effort, encouraging ideas for the improvement of the

study.

Gratitude is extended to Mr.Tirso Amayo, Ms. Methel Angela

Zafra, Mr. Allan Bacolongan, Engr. Elvine M. Leyba and Engr. Raymond

Chua for the constructive criticisms, suggestions and in making their

presence felt in the duration of the project.

We sincerely appreciate Engr. Carlos Zapanta and Engr. Gonzalo

Salvador, in fostering supports, ideas for the betterment of our study.

Finally, we would like to offer this labor of love to our beloved

parents, sisters and brothers who served as inspiration. Most of all to

the Almighty God who bestowed us talents to make this study come

into existence.
 Approval Sheet

In partial fulfillment of the requirements for the degree of

Bachelor Of Science In Mechanical Engineering, this project study

entitled “Alternative Activated Charcoal Maker ( Pyroligneous Acid

as a by Product )” has been prepared and submitted for approval.

Approved by the committe on oral examination:

1. Engr. Romulo Vicente D. Basaen ______________________
2. Engr. Benedicto Fortaleza ______________________
3. Engr. Florencio G. Balanay Jr. ______________________

Engr. Nenet Graza

Project Adviser

Dr. Ronaldo A. Juanatas

Technical Adviser

Accepted and approved in partial fulfillment of the requirements for

the degree of BACHELOR OF SCIENCE IN MECHANICAL
ENGINEERING.

Engr. Mario Regino M. Norbe

Head, ME Department

Engr. Jesus C. Manalastas

Dean, Collage of Engineering
 Table of Contents

Title Page
Dedication
Approval Sheet
Dedication
Acknowledgements
Abstract
List of Tables
List of Figures

Chapter 1 The Problem and its Background

1. Introduction

2. Background of the Study

3. Objectives
4. Scope asnd Delimitations
5. Significance of the Study

Chapter 2 Theoretical Framework

1. Local Literature
2. Foriegn Literature
3. Local Studies
4. Foreign Studies
5. Relevante to the Present Study
6. Conceptual Framework
7. Assumptions
8. Definition of Terms
Chapter 3 Methodology and Procedure
1. Project/ Research Design Method
2. Project Development Model and Procedure
3. Operation and Testing Procedure
4. Evaluation Procedure
5. Evaluation Criteria
6. Instruments and Techniques Used

Chapter 4 Results and Discussions

1. Project Technical Description
2. Project Structure/ Orgajnization
3. Project Limitations and Capabilities
4. Project Evaluation

Chapter 5 Summary of Findings, Conclusions &

Recommendations
1. Summary of Findings
2. Conclusions
3. Recommendations

References
Appendices
Researcher’s Profile
 Abstract

Activated carbon adsorption is an effective means for reducing

organic chemicals, chlorine, lead, and unpleasant tastes and odors in

effluent or colored substances from gas or liquid streams. Typically for

activated materials, surface areas range from 500-1400 m2/gm.

Adsorption can be classically defined as absorption on the surface of

the material due to capillary condensation inside the multitude of

pores/active sites available. Because organic chemicals are often

responsible for taste, odor, and color problems, activated carbon

filtration can generally be used to improve such impurities.

Pyroligneous acid is a liquid generated from the gas and

combustion of fresh wood burning in airless condition. As the gas was

cooled, it condenses into liquid. It is made from burning fresh wood in a

charcoal kiln.

It is a process of oxidation and activation of fresh woods in a fully

insulated chamber. Scrap woods are used as a fuel for combustion

wherein it produces steam for the reduction chamber to produce

charcoal and pyroligneous acid in a certain time.

Presently, the production of activated carbon is expensive and

complicated. The study was conducted in order to fabricate and

characterize an alternative activated carbon maker that is simple,

compact and easy to use.

The prototype with a maximum of feed capacity of 0.117 m 3 and

maximum operating temperature of 600˚ was successfully completed

and characterized.
 Chapter 1

THE PROBLEM AND ITS BACKGROUND

Introduction

The Philippines is one of the countries endowed with rich natural

resources. Its tropical forests have been acclaimed as one of the most

valuable in the world. Its wood industry is a big dollar earner. These

wood materials are deemed as potential sources of quality activated

carbon and a pyroligneous acid, a by-product of charcoal making.

Pyroligneous acid is a liquid generated from the gas and

combustion of fresh wood burning in airless condition. As the gas was

cooled, it condenses into liquid. It is made from burning fresh wood in a

charcoal kiln.

Activated charcoal is a highly absorbent gritty black material

commonly found in air and water filters. Activated charcoal is created

by carbonizing organic matter in a kiln under anaerobic conditions and

activating the material with oxidizing gases like steam or air at high

temperatures. As such, it is very much in demand in both local and

foreign markets with increasing industrial activities and with stringent

environmental regulations and concerns in place.

Background of the Study

Activated charcoal is extremely porous with a large surface area,

and typically produced from organic precursors such as bamboo,

coconut shells, ipil-ipil wood and madre de cacao wood.

The shell charcoal used as the raw material required for the

manufacture of activated carbon. The shell charcoal is manufactured

by burning shells of fully matured nuts in limited supply of air sufficient

only for carbonization, but not for complete destruction.

This study is in consonance with our desire to expand the

applications of activated carbon prepared from wood and wood wastes

like coconut shells for such purposes as water purification, vapor and

gas adsorption.

Due to extensive evaluation, the researchers came up with the

idea of modifying the existing activated carbon maker. It will ease the

production of activated carbon in a lesser time and in a much easier

way.

The project will produce not only an activated charcoal but will

also produce an extract (pyroligneous acid) from condensed steam

during the carbonization process done on wood materials. That is used

as a raw material for fertilizers.

Objectives

The main objective of the study was to fabricate and characterize

an alternative activated charcoal maker that in simple, compact and

easy to use. Its aim is to achieve the following sub-objectives:

1. To design an activated charcoal maker that can accommodate

0.117 cubic meter of biomass feed to produce pyrolignoeus

acid and activated carbon up to a temperature of 600˚.

2. To fabricate a prototype in accordance with the design

3. To characterize the prototype in terms of carbon yield per unit

mass of feed material and activation period.

Scope and Delimitations

The project included the prototyping and characterization of an

activated carbon maker that can operate up to 600˚ C accommodate

0.117 cubic meter of biomass feed.

The testing and characterization of the prototype were limited to

carbon and pyroligneous acid yield per unit mass of feed for a number

of temperature values between 300˚C and 600˚C and activation period

of between 2 hours and 3 hours. The biomass feed is limited to

coconut shell.
Significance of the Study

The alternative activated carbon maker designed for simpler and

easier use in order to encourage the production of activated carbon

and pyroligneous acid.

Activated carbon is used in large quantities in the refining of

vegetable oils (as decolorizer and deodorizer), sugar, molasses, fruit

juices, glycerine and syrup. It is used for the removal of tastes and

odors from water supplies, vegetable and animal fats and oils,

alcoholic beverages, in wastewater treatment, air purification and

treatment of drinking water.

It is used in the pharmaceutical industry for its absorbent action

on alkaloids, enzymes and poisons of various types. Also for recovery

volatile solvent vapours associated with the manufacture of coated

fabric and the paint and lacquer industries. Owing to the fact that

active carbon is the best general purpose absorbent for toxic gases, it

is used for the removal and abatement of industrial stenches.

Pyroligneous acid serves as a raw material of fertilizer that

improves soil quality, eliminates pests and controls plant growth.

Activated carbon is one of the agent most commonly used in

accidental poisoning. It can absorbs large amounts of poison quickly .In

addition, it is non-toxic, may be stored for a long time, and can be

conveniently administered at home. It works by binding to irritating or

toxic substance in the stomach and intestines. This prevents the toxic

or drug or chemical from spreading throughout

the body. For severe poisoning, several doses of activated

charcoal maybe needed.

Activated carbon may be used to induce vomiting in adults who

have attempted suicide by taking an overdose antidepressants,

barbiturates or benzodiazepine tranquilizers.

 Chapter 2

THEORETICAL FRAMEWORK

This chapter presents the review of related literature. The

proponents gathered information, from books and from the Internet,

which are relevant for the development of the project. The concepts

and ideas taken from these are the basis for the model of the study. It

also includes some operational definition of terms.

Review of Related Literature and Studies

For Pyroligneous Acid

One chemical industry that was ubiquitous in earlier times

(1920’s) was the wood distillation industry. The principle product, after

processing, was a charcoal with low yields of chemical products. The

wood used for the distillation was air dried for 6 to 18 months.

Artificial drying methods were later developed to shorten the drying

time and better control the moisture content.

During distillation, wood is placed inside an oven and heating

started above 270C, it begins a process of decomposition called

carbonization. If air is absent, the final product is charcoal (since there

is no oxygen present to react with the wood).

 If wood is heated while away from air, moisture is first driven off,

and until this is complete, the wood temperature remains at 100-

110C. When wood is dry its temperature rises to about 270C, it

spontaneously decomposes, heat is emitted. This is the well-known

reaction that takes place during charcoal burning.

The first distillate (condensation from the gasses) is almost

entirely water and it is not until about an hour and half that the liquor

slowly darkens and contains increasing amounts of acid. The crude

condensate ingredient produced from the distillation of wood is called

Pyroligneous Acid.

For Activated Carbon

Characteristics of importance in choosing carbon types include

pore structure, particle size, total surface area and void space between

particle (Clark, 1989). After selection of source, preparations for use

are made. These preparation often include dehydration, carbonization

and activation. Dehydration and carbonization involve slow heating of

the source in anaerobic conditions. Chemicals such as zinc chloride or

calcium chloride can be used to enhance these processes. The stage

of activation requires exposure to additional chemicals or other

oxidizing agents such as mixture of gases. Depending upon the

specifics of the processes and source of carbon, the newly activated

carbon can be classified according to density, hardness, and other

characteristics (AWWA, 1971).

 Activated charcoal (charcoal activated with CO2, water vapor, or

chemical compounds) made from coconut shell has advantages

compared to other materials.

Process of Producing Pyroligneous Acid, Charcoal and Activated

Local Literature
Distillation of Distillation of
woods at PYROLIGNEOUS woods at
90-100○ C ACID 250-300○ C

Chemical
Activation with
Zinc Chloride CHARCOAL
Of charcoal in
18 hours

Thermal
Activation
at
100-120○ C

Activated
Charcoal
 Activated carbon, also called activated charcoal, is the most

widely used absorbent for industrial applications and environmental

cleanup such as in wastewater treatment, air purification, and

treatment of drinking water.

The Department of Science and Technology (DOST) has

development sophisticated equipment that will minimize the cost and

time of producing activated carbon used for water and air purification.

Russell Pili, senior science research specialist of the DOST’

Philippines Council for Industry and Energy Research and Development

(PCIERD), claimed that the new activated carbon reactor has a capacity

of 15 kilograms per hour compared to the current 12 kg per hour.

According to Pili (said) the development of the new activated

carbon reactor was the third project conducted by the Industrial

Technology Development Institute (ITDI), also an attached agency of

the DOST, on activated carbon processing.

The ITDI developed the first two activated carbon reactors with a

capacity of one and 12 kg per hour, respectively.

Activated carbon, commonly made from coconut shell, is ideal for

gas or liquid phase application where purification is required.

Vapor phase application includes indoor air quality, gas

respirators, industrial processes, and pollution control.

On the other hand, liquid phase application includes those on

gold recovery and water purification. Pili claimed that it only takes
eight hours to produce activated carbon using the new equipment.

The process requires one day when using the old equipment. There

are many private companies, mostly from the charcoal manufacturing

business, that are interested in the new equipment.

The technology would also boost the income of those engaged in

the charcoal business since one kilogram of activated carbon is double

the price of one kilogram of charcoal. A small medium enterprise(s)

could make use of the technology, which will be ready for

commercialization by next year.

The price of the equipment has yet to determined, although its

present affordable.

Aside from coconut shell, other raw materials that can be used to

make activated carbon are wood, coal, and agricultural materials.

The equipment has minimum energy requirements, since heat

required to maintain the temperature for activated carbon production

is generated within the reactor. It is not emitting sulfur oxide since heat

is obtained from biomass combustion, assuring no increase in

greenhouse gases.

Energy in the form of “low-calorific” gas is formed during the

process, which can be used for other application such as drying

coconut meat and other agro-industrial operations.

 “The low production cost result in a cheaper product. This gives

the product a competitive edge in local and foreign market,” PCIERD

said.

PCIERD said the Philippines, being a foremost coconut-producing

country, has a comparative advantage in the production of coco

activated carbon.

“Demand for activated carbon worldwide grows with the increase

in industrial activities and the stringent environmental regulations and

concerns in protecting the environment. Coconut shell activated

carbon is very much in demand in foreign markets,” it said.

Foreign Literature

Hippocrates and Pliny the Elder described adsorption on porous

carbons as early as 1550 B.C. in an ancient Egyptian papyrus and later,

mainly for medicinal purposes. In the 18th century, carbons made from

blood, wood and animals were used for the purification of liquids. All of

these materials, which can be considered as precursors of activated

carbons, were only available as powders. The typical technology of

application was the so-called batch contact treatment, where a

measured quantity of carbon and the liquid to be treated were mixed

and, after a certain contact time, separated by filtration or

sedimentation.
 At the beginning of the 19th century the decolourization power of

bone char was detected and used in the sugar industry in England.

Bone char was available as a granular material which allowed the use

of percolation technology, where the liquid to be treated was

continuously passed through a column. Bone char, however, consists

mainly of calcium phosphate and a small percentage of carbon; this

material therefore was only used for sugar purification.

At the beginning of this century the first processes were

developed to produce activated carbons with defined properties on an

industrial scale. However, the steam activation (V. Ostreijko, 1900 and

1901) and chemical activation (Bayer, 1915) processes could only

produce powder activated carbon.

During the First World War, steam activation of coconut char was

developed in the United States for use in gas masks. This activated

carbon type contains mainly fine adsorption pore structures suited for

gas phase applications.

CALGON CARBON Corporation (USA), the parent company of

CHEMVIRON CARBON succeeded after World War II, in developing coal

based granular activated carbons with a substantial content of

transport pore structure and good mechanical hardness. This

combination allowed the use of activated carbon in continuous

decolourization processes resulting superior performance. In addition

CALGON CARBON and CHEMVIRON CARBON pioneered work on the

optimization of granular carbon reactivation.

Today many users are switching from the traditional use of

powdered activated carbon as a disposable chemical to continuous

adsorption processes using granular activated carbon combined with

reactivation. By this change they are following the modern tendency

towards recycling and waste minimization, thereby reducing the use of

the world's resources.

Local Studies

The Department of Science and Technology (DOST) through its

Philippine Council for Industry and Energy Research and Development

(PCIERD) and Industrial Technology Development Institute (ITDI) are

currently looking for technology adopters of the newly developed

reactor for the production of activated carbon. The new activated

carbon reactor combines the two stages of carbonization and

activation in a continuous process and has a bigger capacity. In an

investors forum conducted early in June, PCIERD said that the

technology can be transferred through Licensing Agreements.

Foreign Studies

In China, there is a long history at charcoal processing ways, in

which, have a kiln- making way and another inter- kiln way. As a
evident, for example, at Mawangdui West Han dynasty tomb,

Changsha, Hunan, there is a charcoal layer by side, since early 2000

years ago, China could make a good quality wood charcoal. About 1300

years ago, Chinese ¡®kiln- making way¡¯ was introduced into Japan. At

the long historical practices, Chinese people had made a lot of style

kiln (or kettle) for charcoal processing. For an example, Mupiaoyao (like

a wooden spoon) kiln, Zhutouyao (like a pig head) kiln, Liyuyao (like a

carp fish) kiln, Sichuanyao (famous in Sichuan province) kiln, Hunanyao

(famous in Hunan province) kiln, etc.

Definition of Terms

Activated Carbon – also called activated charcoal or activated

coal, refers to any amorphous form of carbon processed to increase its

absorption capacity. It is an absorbent derived from carbonaceous

materials such as coal, woodchips, sawdust, and coconut shells. It’s

absorptive properties result from thermal or chemical treatment to

produce internal pores, which increases the surface area of the carbon

material available for absorption.

Adsorption - accumulation of substance on surface: the process by

which a layer of atoms or molecules of a substance, usually a gas, is

formed on the surface of a solid or liquid.

Carbonization - treatment to turn something into carbon: the burning,

fossilization, or chemical treatment of something that turns it into

carbon.

Also called carbonation.

Calcium Chloride - is an ionic compound of calcium and chlorine. It is

highly soluble in water and it is deliquescent. It is a salt that is solid at

room temperature, and it behaves as a typical ionic halide.

Kiln - industrial oven: a specialized oven or furnace used for industrial

processes such as firing clay for pottery or bricks and for drying

materials such as hops or timber.

Oxidation - The combination of a substance with oxygen. A reaction in

which the atoms in an element lose electrons and the valence of the

element is correspondingly increased.

Pyroligneous Acid - acid from destructive distillation of wood: a red-

dish-brown liquid, produced by the destructive distillation of wood, that

was once a commercial source of acetic acid, which is its primary con-

stituent. Among its impurities may be acetone, methanol, wood oils,

and tars.

Also called wood vinegar.

Thermocouple - temperature-measuring device: a device for

measuring temperature in which two wires of different metals are

joined. The potential difference between the wires is a measure of the

temperature of something they touch.

Zinc Chloride - is the name of chemical compound with the

formula ZnCl2 and its hydrates. Zinc chlorides, of which at nine

crystalline forms are known, are colorless or white and highly soluble in

water. ZnCl2 itself is hygroscopic and even deliquescent. Samples

should therefore be protected from sources of moisture, including the

water vapor present in ambient air.

 Chapter 3

METHODOLOGY

This chapter discusses the research design, the stages of project

development, the evaluation procedure, criteria for evaluation,

research instruments and techniques used.

Research Design

The descriptive design was employed in the conduct of the

research. The descriptive design of research is believed to be more

applicable in providing essential knowledge about the nature of the

situation as it exists at the time of the study and to establish facts that

may be useful to the entire development of the project.

The study also employed the prototyping technique in the

development of the project. Prototyping is a method of proving

concepts. It provides a fast track and inexpensive way of testing

theories, ideas and materials used, functions and reliability.

Research and Development Procedure

The following figure illustrates the flow of the different phases of

the research and development process. The phases include preliminary

investigation, design, fabrication, testing and evaluation, and final

modification of the project prototype.

Preliminary
Investigation

Design

Fabrication

Testing &
Evaluation

Final
Modification

Figure 2: Research and Development Process

Preliminary Investigation Phase

There are many types of activated charcoal and pyroligneous

acid available in the market. Investigation and surveys were conducted

to determine what improvements can be done on these existing

designs of wheelchairs.

Latest developments on activated charcoal maker and

pyroligneous acid as a by product of charcoal making designs were

also gathered through internet.

Design

With the information gathered, initial ideas were transformed into

preliminary sketches and given initial dimensions. After a series of

modifications on the design, a final sketch of the project was drawn.

Canvassing of fabrication materials followed. Canvassing for the most

reasonable and affordable price was done to come up with the most

practical budget for the materials needed in the project.

Fabrication

A prototype was made for preliminary testing. The fabrication

started on every minor part of the prototype.

Cutting

Material Size (cm) Quantity

38 4

102 3

30.5 4
Angle Bar
112 2

5 4

Sheet Metal 48x49 3

(gage 18)
29 42
Round Bar
(stainless) 3.8 16

124 1
Stainless Pipe
47 1
Bending

Bend the 194x112 cm sheet metal to a 49x48 x112 cm

rectangular box.

Welding

-Assemble the base support of the prototype using the angle

bars and attach the four castor wheel at the bottom of each foot

of the base.

-Join together the edges of the sheet metal that form as the body

of the prototype using gas welding (oxyacetylene).

-Put a steel divider, with an inlet opening for about 35.3x5.08

cm, at the upper part of the sheet metal.

-Assemble the parts of the chimney using gas welding.

-Build the case that will hold the bricks for the cover of the

reduction chamber.

-Attached the bolt and nut to the body of the prototype to serve

as lock to the cover, and the G.I. nipple at the back of the

prototype.
 -Fixed the parts of the chimney used for collecting pyroligneous

by arc welding.

-Mount the bricks inside the prototype with the use of refractory

clay.

Testing and Evaluation

Testing ensured that the prototype is free from errors made

during the fabrication. Any defects found were carefully modified. Tests

for the attachment included determination of the maximum load the

prototype can carry and its mobility.

OPERATION AND TESTING PROCEDURE

• Enclose a 2 kg of coconut shell inside the reduction chamber. The

reduction chamber must be sealed. The air entering the chamber

must come up from the oxidation chamber.

• Arrange a certain amount of coconut shell inside the oxidation

chamber. These woods will serves as the firewood. Put a fire

brand onto the arranged woods to start the fire.

• Continually load certain amount woods inside the oxidation

chamber. In this manner, it will continually raise the temperature

inside the reduction chamber.

 • Observe the temperature inside the reduction chamber. When

the temperature ranged at 80 °C, start collecting the

pyroligneous acid from the condensed steam at the opening of

the chimney.

• Continually raise the temperature until it reached 300 °C inside

the reduction chamber in order to produce charcoal.

• When the temperature reached 300 °C, let the reduction

chamber cools down itself then remove the cooled charcoal

inside.

• Soak the charcoal produced in a zinc chloride solution for 12-18

hours. Heat it again in a temperature range of 100-120 °C for

about 3 hours. Remove it and let it cooled.

Evaluation Procedure

After the fabrication and testing procedures have conducted, the

following basis was observed in the test:

• Is the air inside the oxidation chamber enough to support the

combustion process?

• Does the smoke being released from the oxidation chamber

minimal?

• How long is the operation?

• Does the metal used thawed when the temperature reaches

600°C?
 • How much fuel was consumed?

Chapter 4
RESULTS ANS DISCUSSION

This chapter includes presents the technical description of the

developed project, material specifications, and the results of the

testing and evaluation conducted.

1. Technical Design/ Description of the Project

The MACPAM (Modified Activated Charcoal and Pyroligneous Acid

Maker) is a prototype that produces activated charcoal that can be use

in industrial field and medical applications and pyroligneous acid (a by

product in charcoal making), is a raw material in fertilizer making and

used as a commercial source for acetic acid. It will greatly benefit the

agricultural industry.

It is a process of oxidation and activation of fresh woods in a fully

insulated chamber. Scrap woods are used as a fuel for combustion

wherein it produces steam for the reduction chamber to produce

charcoal and pyroligneous acid in a certain time.

Actual Picture of the Activated Charcoal Maker

 Figure 1

Sectioned Part
 Figure 2

2. Specification

Table 1 summarizes the material specification by parts used in

the fabrication of the prototype.

 Table 1
Materials, Specification and Cost

Quant Unit Description Unit Total

ity Specifica- Price (peso)
tion (peso)
3 3Pc Angle Bar 3/16”x1 300 900
½’x20’
2 Pc Stainless Steel 1 900 900
Pipe ¾’x1.2”x20’
4 Pc Castor Wheel 1½” 30 120
3 Pc Hacksaw Blade 70 225
1 kg Welding rod 60 60
1 Pc Bolt and Nut 5/8”x2” 40 40
2 Pc G.I Sheet (gage 4’x8’ 950 1900
18)
2 Pc Tire Wire 30 60
80 Pc Insulating 9x4½x2½ 50 4000
Bricks
50 kg Fire Clay SK-36 820 820
1 Pc G.I Elbow, 45° 1½” 50 50
1 Pc G.I Tee 3” 235 235
2 Pc G.I Nipple 3”x6” 210 220
1 Pc End Plug 1½” 35 35
Total 9,565

Table 2
MISCELLANEOUS EXPENCES
 MACHINE RENT DAY/S RATE, Php PRICE
Welding Machine 3 200 600
Oxyacetylene 2 200 400
TOTAL 1000

3. Project Performance

After the fabrication of the prototype, the testing of the project

was conducted. Table 2 shows the results of the tests on the

performance of the project in terms of the amount of products produce

in a given temperature at a certain time. Three trials were performed

to describes the average amount of the products attained by grams of

fuel used , fixed temperature and time allotted.

Table 1
PYROLIGNEOUS ACID

TRIAL TYPE OF PRODUCT FUEL TEMP. TIME

WOOD PRODUCED kg °C min.
USED Ml
Kg
1 Coconut 42 4 90-100 45

shell
2 Fresh 60 4 90-100 45

Bamboo

Table 2 presents the test results of pyroligneous acid based on

the type of wood used. It was shown that fresh bamboo produces a

greater value of the said acid than that of the coconut shell.
 Table 2
CHARCOAL

TRIAL PRODUCTS FUEL TEMPERATURE TIME

PRODUCED kg °C hour
Grams
1 850 8 250-300 2

2 910 9 250-300 2½

3 650 11.5 250-300 3

AVERAGE 736.67 9.5 250-300 2½

As evaluated the average amount of product produced was

736.67 grams per 9.5 kg of fuel used in 2½ hour at a temperature

range of 250-300 °C. Therefore, the amount of products produced var-

ies in time and fuel consumption. The lower the time the higher the

amount of product produced.

Activated Charcoal

Based on the process of activation, charcoal produced will now

soak into a zinc chloride solution for 12-18 hours then heat it to a tem-

perature range of 100-120 °C in 3 hours.

PROJECT LIMITATIONS AND CAPABILITIES

Limitations
• The prototype is not for mass production operation.
• It takes a long period of operation when it comes to activation
process.
• Massive
• Manually operated.

Capabilities
• Can produce an activated carbon from woods as a raw material.
• It can also produce pyroligneous acid (a raw material for
fertilizer).
• Possible to transfer from one place to another.
• No need to in earth.
 Chapter 5
CONCLUSIONS AND RECOMMENDATIONS

This chapter presents the conclusions and recommendations

based from the findings of the study. The presentation is parallel with

the sequence of the objectives stated in Chapter 1.

Conclusions

After some tests and modifications done on the prototype, the

following conclusions were drawn:

1. The design of an Alternative Activated Carbon Maker (AACM) in

relation with the existing Activated Carbon Maker uses charcoal
as raw material for activation and LPG as a source of oxidation.
While the AACM uses fresh wood as a raw material which pro-
duces pyroligneous acid in charcoal making at a certain temper-
ature and coconut shell as fuel. To produce activated carbon it
undergoes chemical and thermal activation.

2. Based on the tables from several testing done, it was proven

that the AACM can produced charcoal in a desired temperature
as well as pyroligneous acid in a process of charcoal making by
distillation of wood in accordance with the design.
3. Characterization:
a. Pyroligneous acid as a Product
Pyroligneous acid is a reddish brown liquid that is
composed mostly of acetic acid, but also contains
methanol (wood alcohol), acetone, wood oils, and tars in
varying amount. Pyroligneous is known as wood vinegar.
It is obtained by the distillation of wood
in the process of charcoal making, by which it meant the
burning of wood in an airless condition, a chamber of
firebricks and iron is substituted for the mound of earth,
and a chimney that serves as a collecting device for
pyroligneous acid.

b. Charcoal as a Product
Charcoal is obtained by heating wood or another
organic substance in an enclosed space without air in a
given temperature, and based on our research the
temperature ranges from 300-600 ○C theoretically. But in
the process we have conducted charcoal can be obtained in
a temperature ranges from 200-300 ○C.

c. Activated Charcoal as a Product

Activated Charcoal is obtained by chemical and
thermal activation. Chemical activation can be achieved by
soaking the charcoal in a zinc or calcium chloride solution
for 12-18 hours. Thermal activation is done in the process
 of heating the charcoal with a temperature of 110○ C but in
our process the temperature ranges from 100-120○ C.

Recommendations

Based from the conclusions drawn from the findings of the study,

the following are suggested:

1. A need to install an adjustable firewood rack for a more

convenient fire initiation.

2. A need to use a longer stack for a better ventilation of smoke.

APPENDICES
COMBUSTION PRINCIPLES

Wood combustion process are quite complex due to the nature of

the fuel and it’s non-uniformity. Wood consists of cellulose, hemi-

cellulose and lignin. It also contains water, small amounts of sulphur

and some inorganic compounds that remain as ash after combustion is

complete. For dry wood (zero moisture) a combustion equation is:

C4.17H6.5O2.71+4.44O2 4.17CO2 +H2O

Stoichiometric combustion equation for dry wood

CONDUCTION OF PLANE WALL

K A (ta – tb)
Q = -------------------
X

W
79.5 ----------- (0.35) (0.32) m2 (888 – 250) ○C
m ○K
= ---------------------------------------------------------------------------
0.5 x 10 -3

Q = 11.362 x 106 W
SOAKING SOLUTION (zinc chloride solution)

Weight of Zinc Chloride

-------------------------- = Total weight of solution
0.25

Weight of water = (Total weight of solution) – Weight of Zinc Chloride

Volume water = Weight of water

FEED CAPACITY OF OXIDATION CHAMBER

Feed capacity=Lo x Wo x Ho

Lo - Length of Oxidation
Wo - Width of Oxidation
Ho - Height of Oxidation

Feed Capacity= 0.66 m x 0.353 m x 0.363 m

Feed Capacity = 0.085 m3