Rayt Aps Ni Tute =)

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

ENGINEERING. Engr. Mario Regino M. Norbe Head, ME Department Engr. Jesus C. Manalastas Dean, Collage of Engineering

MECHANICAL

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. coconut shell.

The biomass feed is limited to

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 110C.

until this is complete, the wood temperature remains at 100When 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 woods at 90-100○ C

PYROLIGNEOUS ACID

Chemical Activation with Zinc Chloride Of charcoal in 18 hours

Thermal Activation at 100-120○ C

Activated Charcoal

Distillation of woods at 250-300○ C

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

sedimentation.

certain

contact

time,

separated

by

filtration

or

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 reddish-brown liquid, produced by the destructive distillation of wood, that was once a commercial source of acetic acid, which is its primary constituent. 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

Angle Bar

Sheet Metal (gage 18) Round Bar (stainless)

Size (cm)

Quantity

38

4

102

3

30.5

4

112

2

5

4

48x49

3

29

42

3.8

16

124

1

47

1

Stainless Pipe

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 ity

Unit

Description

3

3Pc

Angle Bar

2

Pc

4 3 1 1 2

Pc Pc kg Pc Pc

2 80

Pc Pc

50 1 1

kg Pc Pc

Stainless Steel Pipe Castor Wheel Hacksaw Blade Welding rod Bolt and Nut G.I Sheet (gage 18) Tire Wire Insulating Bricks Fire Clay SK-36 G.I Elbow, 45° G.I Tee

2 1

Pc Pc

G.I Nipple End Plug

Unit Price (peso) 300

Total (peso)

900

900

5/8”x2” 4’x8’

30 70 60 40 950

120 225 60 40 1900

9x4½x2½

30 50

60 4000

1½” 3”

820 50 235

820 50 235

3”x6” 1½”

210 35

220 35

Specification 3/16”x1 ½’x20’ 1 ¾’x1.2”x20’ 1½”

Total

900

9,565

Table 2 MISCELLANEOUS EXPENCES

MACHINE RENT Welding Machine Oxyacetylene

DAY/S 3 2 TOTAL

RATE, Php 200 200

PRICE 600 400 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

1

TYPE OF WOOD USED Kg Coconut

2

shell Fresh

PRODUCT PRODUCED Ml

FUEL kg

TEMP. °C

TIME min.

42

4

90-100

45

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

FUEL kg

TEMPERATURE °C

TIME hour

1

PRODUCTS PRODUCED Grams 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 varies 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 temperature 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 produces pyroligneous acid in charcoal making at a certain temperature 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, hemicellulose 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 ----------- (0.35) (0.32) m2 (888 – 250) ○C m ○K --------------------------------------------------------------------------0.5 x 10 -3

79.5 =

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