Technology for the production of charcoal from wood waste. How to start a charcoal business? Equipment for the production of

Manufacturing business charcoal. Technology and equipment for the production of charcoal.

Charcoal production is a fast-payback business using wood waste. To organize a small production, significant capital investments are not needed. The coal business is profitable primarily with the availability of raw materials - wood waste. The wholesale cost of one ton of charcoal is $500 - $900.

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Charcoal is an environmentally friendly fuel, when burned, it does not emit harmful substances, has a high heat dissipation and practically does not smoke.

There are several types of charcoal that can be obtained from certain woods:

• Black - from soft rocks poplar, linden, alder, aspen, willow.
• Red - from coniferous species pine, spruce.
• White - from hardwood birch, oak, hornbeam, elm.

The highest quality and most expensive coal can be obtained from hardwoods.

To organize the production of charcoal, you will need the following equipment.

Pyrolysis smokeless oven.

More recently, kilns were used to produce charcoal. open type, which had a low percentage of coal yield and also harmed the environment by releasing gases into the atmosphere. At the moment, furnaces are used in production closed type(pyrolysis) which make it possible to obtain almost twice as much coal as in open-type furnaces and do not pollute the environment.

When choosing a furnace, you must first focus on performance, maintainability and price.

Also, for sawing wood, you will need chainsaws and a cleaver ax to chop large logs.

Separator for separating coal into fractions.

Scales and bag sewing machine for packing.

Technology for the production of charcoal.

For the production of charcoal, pyrolysis technology is used - burning wood in a container without oxygen at a temperature of up to 500 ° C. During pyrolysis, the gases that are released during combustion remain in the chamber and thereby support the combustion process, the vapor gases are removed through the nozzle in the condenser, the liquid is separated from the gas.

The process takes place in a retort (closed vessel) in which the wood decomposes without air access under the influence of heat.

The wood is loaded into the retort, the furnace is melted and the retort is heated, the temperature is controlled using a pyrometer.

First, the retort is heated to a temperature of 150 °C, moisture is released from the wood, and the wood is dried.

Now coal needs to be separated from resins and non-condensable gases, for this the temperature in the installation is raised to 500 ° C, the process is called calcination.

The process is stopped and the oven is cooled down.

When the coal cools down, it is taken out of the furnace, sifted on a separator and packed.

Business in the production of charcoal.

Production should be located in suburban areas, the best option There will be a site on the outskirts of the village. It should be remembered that sanitary zone production with pyrolysis ovens should be at least 100 meters, this minimum distance to residential buildings.

Furnaces do not require a room, they are placed in an open area, but a covered dry room is required for storing coal.

As for profit, it directly depends on the cost of purchasing wood and its type. By themselves, wood waste is quite cheap, but transportation, loading, delivery can significantly increase the cost of raw materials. Therefore, it is more profitable to organize the production of charcoal directly near sawmills.

If you use soft wood, then the output of 1 ton of coal is obtained from 11 m³ of wood. When using hard rocks 7 m³ per 1 ton of coal. The wholesale price of charcoal, depending on the type of wood used in the production, can be $500 - $900 per ton.

Charcoal is inherently a unique material. It has been known since ancient times, but it was only in the last century that it was truly appreciated. Charcoal has many benefits. It does not pollute the environment, it does not contain any harmful components - it is an environmentally friendly product. How to get products from wood by exposing them to high temperatures was known in ancient times. Several varieties of charcoal are known. It all depends on the manufacturing technology and the raw materials from which it is made. The need for this type of fuel is constantly growing, so many entrepreneurs are turning their attention to this type of business.

Charcoal and its benefits

The production of charcoal in modern world given great attention. Installations for production are constantly modernized and improved, which makes it possible to achieve even better quality. final product. If the technology for the production of charcoal is developed in accordance with all the rules, then it can be considered environmentally friendly and energy efficient.

The birthplace of the production of charcoal on an industrial scale in our country is the Urals. On the African continent many peoples still use this coal for cooking. It is prepared according to a special method.

Today, two types of coal burning are used: pit and heap. They are used in the event that the need for coal is one-time. None of these methods require additional costs. It is necessary to have firewood, water and turf on hand. The best raw materials for charcoal burning are hardwoods. They produce the highest quality product.

Recently, aspen and coniferous waste have been increasingly used. In this case, in order to obtain high-quality coal, it is necessary to adhere to a special production technology.

The yield of the final product will depend on what kind of wood you are using. In scale industrial production coal output is often much less than originally planned. The most common reason is the ingress of oxygen into the furnace and, as a result, the complete burnout of the source material.

There are three types of charcoal:

1. black - it is made from soft woods (it can be: aspen, willow, linden, alder and poplar);
2. white - it is obtained from hardwoods, which are oak, birch, hornbeam, acacia, ash, and so on;
3. red - for its production are used only conifers. Charcoal is obtained by soft charcoal, temperature regime while it should be low.

The benefits of this product are very great. Its use can even be called universal. This alternative view fuel is environmentally friendly and safe to use.

Areas of application for charcoal

It is worth noting that the massive use of charcoal has led to the fact that the emission of harmful greenhouse gases into the atmosphere has significantly decreased. Thus, humanity has a chance to maintain a precarious ecological balance on the planet.

Technology and equipment for the production of charcoal

Despite the fact that the technology for the production of charcoal is simple, it requires certain knowledge and skills. Otherwise, the yield percentage will be small, and the quality of the product will not be up to par.

Any of the known technologies for producing charcoal consists of four stages:

1. Drying. As you know, wet wood will smolder badly.
2. Pyrolysis. This stage is considered the most important in the entire production process.
3. Calcination. At this stage, resins and excess gases are separated from coal.
4. Cooling down.

Until recently, coal production has been damaging to the environment. irreparable harm. The gases released into the atmosphere polluted it. Scientists have developed new technologies that have solved this problem.

The equipment for the production of our product is a special charcoal kiln, in which there is no free access of oxygen.

Modern charcoal kilns are designed so that the gases generated during oxidation are fed into the furnace, where they are burned out and used to maintain the required temperature, which is required to burn the source material. If the wood is not very wet, then these gases are enough to complete the process, which in turn allows you to significantly save energy.

If we are talking about the possibility of using only one container, then in this case there can be no question of the continuity of the process: first, wood is loaded into the oven and melted. The next step is drying the wood. They are allowed to burn out, and the stove is extinguished. Waiting for the coal to cool down. The product is removed and the process is repeated.

The use of removable containers into which firewood is loaded allows solving the problem in the following way: in one of the containers, the firewood is dried, in the other, it is oxidized, in the third, it burns out. The container in which the process is completed is removed and allowed to cool, and another one with new material is installed in its place.

On the this moment There are many different devices for heat treatment wood. Now the most attention is paid to those technical solutions, which can be used at timber industry enterprises and allow processing waste from this production.

Such installations are usually easy to use and manage.

Video: charcoal production technology

The sequence of actions in the production of charcoal

The procedure is as follows: the prepared wood is placed in a special loading chamber. Sensors are installed on it, from which a signal is received about the combustion of the material and the drying of coal.

The next step is to unload the coal for cooling. This is the process for a single chamber charcoal kiln.

Finished products are crushed and packaged in paper bags and bags. For industrial use, coal is crushed into large pieces, and for domestic use, into small pieces.

A month can be from 7-9 to 25-30 cycles. Everything will depend on the volume of loaded raw materials. Performance does not depend on the length of the cycle.

Raw materials - there should be no problems with it. Sawdust, waste paper and furniture industry can be used as starting material. But in this case, the quality of coal may not be at the highest level.

The optimal solution to the issue of the supply of raw materials would be to conclude an agreement with a company that specializes in the harvesting and processing of timber. Branches, stumps, branches and so on will be used - this is one of the most economical options. More expensive - buying chopped firewood.

In order to get 1 ton of charcoal, you will need at least 7 cubic meters of wood. This ratio is applicable for single-chamber furnaces. In three-chamber output will be much larger.

Sales of products

Unfortunately, in our country the consumption of these products is not at the proper level.

The ideal marketing option is an overseas partnership. In European countries, this product has been appreciated for a long time, it is in great demand there. But, if it is not possible to organize a business in this way, then you can find buyers in our country.

For example, you can organize the sale of charcoal in bulk: you can offer your products to energy companies and individuals who use individual heating. Coal is used not only in closed furnaces. It is used for cooking barbecue and barbecue. Owners of blacksmith shops and smelters can become buyers of your products. Pharmaceutical companies may also be interested in your offer.

Do not discount large stores where goods for summer holidays, gas stations, restaurants and barbecue houses are displayed. It is possible that the demand will be seasonal. In summer, your products can sell out much faster.

If you are planning to grow your business, try to come up with some kind of logo to put on the bags and register trademark. This is necessary in order for the product to be recognizable.

To avoid unwanted excesses, marketing routes must be thought out in advance (described in detail each of them in the business plan for the production of charcoal).

Profitability of charcoal production

The profitability of production will largely depend on what strategy of behavior you choose in the market. This business is profitable and quite promising. The switch to biofuels is encouraging many to use charcoal.

The demand for these products is steadily growing. Perhaps not as fast as we would like, but if you want to take another free niche in this area economic activity- hurry up. In the near future, the market may become oversaturated with offers, and the struggle for survival will become even more serious.

It doesn't take much to get started in this area. So, you do not need the construction of large technological premises. Purchase a large number equipment will also be redundant.

Are you into photography? Then our article is for you. Opening your photo studio from scratch:

To set the minimum required amount equipment to produce 30 tons of charcoal per month, you will need about 500 thousand rubles. What is included in these costs?

Equipment:

• oven - from 20 to 100,000 rubles;
• scales - from 3 to 5,000 rubles;
• electric generator - from 25 thousand rubles;
• chainsaws - from 7 thousand rubles;
• hydraulic splitters;
• packing machine.

Raw material: at the rate of 30 tons/month:

• chopped firewood - from 1300 to 1700 rubles. /m3;
• packing bags finished products- 10 12 rubles / piece.

Staff salary in the amount of 5 people - 80-100 thousand rubles. per month.

Monthly income will be about 70 thousand rubles. The cost of 1 kg. charcoal - 18–22 rubles / kg.

The undoubted advantage of technology, equipment, charcoal production is a small initial investment, as well as the absence of problems that you may encounter when starting your own business. The downside is quite a lot of competition. If there are problems with sales, the payback of the project can be at least 2 years. But if you manage to set up an implementation on highest level, then investments can pay off in 3-4 months.

Summary

If we listen to the opinion of experts, we can draw the following conclusions: Russian market charcoal is not fully saturated. Therefore, everyone who wants to try their hand at this field has a good chance of becoming successful businessman. It would take a lot to open a case like this. easier themes who is in any way connected with the forestry and woodworking industry. This will help to significantly reduce the level of initial investment.

In conclusion, I would like to note that charcoal is considered an elite fuel, the fuel of convenience and comfort. IN modern society there are more and more people who want to use this type of biologically clean fuel. Do not miss your chance, draw the appropriate correct conclusions.

Charcoal is still used in many areas of our lives, often being an indispensable product. First of all, you need to draw up a business plan that will help you start an excellent, profitable production.

Today, you can quickly establish the production of various types of charcoal:

• black from softwoods (alder, linden, poplar, aspen);
• white from hardwoods (hornbeam, birch, oak, elm);
• red, obtained by soft charcoal.

Manufacturing technology

The charcoal business is the use of a special technology that allows the production of coal from raw wood, which is used today in many industries. In this case, the pyrolysis process is used, that is, the raw material is burned in a furnace without oxygen access. For such production, special charcoal kilns are used, consisting of a chamber for making coal and drying.

The process is as follows: the raw material is fed into the loading chamber, after which its burning begins.

After the sensors show that the coal has burned out and is completely dry, they begin to unload it to cool.

For the manufacture of charcoal, various raw materials can be used: knots, hemp, most of the waste from logging, furniture factories, other woodworking enterprises. The plan may also take into account the fact that ordinary firewood can also be used for production, although such raw materials are more expensive, and the quality of coal is higher. Approximate consumption of raw materials for the manufacture of one ton of products: birch firewood - 7-8 cubic meters, softwood firewood - 11-12 cubic meters.

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Approximate expenses for the organization of production

When drawing up a coal production plan, we take into account the following financial costs:

Purchase of equipment for the production of charcoal:

• a special charcoal kiln, the cost of which ranges from 17 to 100 thousand rubles;
• hydraulic equipment for chopping firewood and raw materials, an ordinary cleaver. Cost - from 55 rubles. a piece;
• electronic scales costing from 5 thousand rubles;
• chainsaws cost about 5 thousand rubles;
• electric generator cost about 12 thousand rubles;

Purchase of raw materials (plan - 30 tons of products per month):

• chopped firewood. The cost is from 1200 rubles. up to 1700 per cu. m. You can save money by using the waste of a logging company, the cost here is much less, but the quality of the coal is lower;
• bags for packaging production. The cost is from 7-10 rubles per piece.

1. Salary for production workers: based on five people - 75-100 thousand rubles. per month.
2. Documents required to register a business. The cost is from about 10 thousand rubles.
3. The plan should then include the following costs:

• rent of a workshop room for production and a warehouse - from 20 thousand rubles;
• advertising, transport and other expenses.

In total, the minimum plan for the production of charcoal and its implementation requires an initial investment of 500 thousand rubles. The cost of a kilogram of coal is 17-20 rubles. The average income per month that such a business can provide for entry level, is approximately 70 thousand rubles.

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Business payback

Any business development plan must necessarily take into account the payback. In the production of charcoal, in order to have a great initial start, you can start with a capacity of about 30-40 tons per month. To do this, you can buy the most various ovens, it depends on what kind of initial capital you have. Some charcoal kilns are more expensive, there are models that are low in price, but the main thing is to correctly calculate their power and consumption of raw materials. It is recommended that you first plan for more economical production, gradually increasing capacity and identifying new markets.

The total cost of starting a business of your own, such as a charcoal business, including the purchase of equipment, registration necessary documentation, renting a room or plot, hiring employees, can range from about 700 thousand rubles. up to one million, depending on the equipment and performance. Such a plan must necessarily include the costs that will be needed for the installation of equipment, the storage of finished products, and the transportation of coal. Usually requires a plot of 150 to 200 square meters. meters.

Maintenance personnel for one shift can be from two people, usually special training for working with furnaces and separators is not required. It is possible to place production even within the city, since the continuous process of making charcoal practically does not harm environment, that is, the emission of harmful substances is minimal.

The profit received per month depends on how well the planned business is organized. If you preliminarily organize not only the production of charcoal, but also its packaging and sorting, this will make it possible to sell products more profitably and expand the customer base.

With properly established production and the output of finished products in the form of charcoal from forty tons per month, the payback period for investments will be only up to 9 months, that is, the business will begin to make a profit within a year.

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Raw materials for processing

When drawing up a business plan for the production of coal, you need to take care of the procurement of raw materials. Depending on which technology will be chosen for this, the raw materials may be waste from the logging industry, birch wood and other raw materials pressed into large briquettes. Any wood can be purchased for charcoal kilns, but it must be remembered that it is more expensive than other types of raw materials, and the charcoal that is obtained from this is not of very high quality.

When organizing such a business, one must remember that the waste from the logging industry is more profitable as a raw material for charcoal. The length of briquettes made of such material is ideal for ovens, that is, they do not need to be further processed, usually the parameters are 0.4-0.55 meters. It is also well suited that the percentage of end area rot here is only up to 15, while the split line is up to 18 cm. For production, it is ideal to use raw materials from windbreak, growing forest, burnt wood, deadwood.

The business plan must also contain data on the volume of raw materials purchased, its quality. The indicators depend not only on the required production volumes, but also on what type of equipment will be used, what plan for the sale of products was drawn up.

Charcoal– a unique product, with its highest efficiency he is absolutely safe view fuel in terms of environmental impact.

It is widely used not only for industrial purposes, but also in household activities.

In addition to heating houses, it is successfully used as energy source for cooking.

When using it no carcinogens are released, poisoning food, which cannot be said about ordinary firewood and coal.

Construction companies also do not ignore its use as an excellent thermal insulation material. IN agriculture it is used as a biologically valuable feed component for poultry and livestock, as well as in the form of fertilizers for the soil.

Charcoal is of three types:

• red, produced using the soft firing method, mainly from conifers;
• white, made by firing hardwoods (oak, birch, hornbeam, etc.);
• black, obtained by firing soft rocks (poplar, aspen, alder, etc.).

By quality, it is divided into three grades (according to GOST):

Production technology

The basis of production pyrolysis process.

Pyrolysis is the burning of wood in the absence of oxygen.

Pyrolysis requires retort charcoal kilns. They may be:

• stationary;
• mobile.

Retort Furnaces- these are chambers where the firing and drying of the raw materials is carried out.

The main principle of operation of the stove is that the gases and vapors that are released during the combustion of wood flow directly into the furnace.

There they are burned, thereby not harming the environment and providing the combustion process with additional heat.

Coal production is proceeding in the following order:

1. The wood is placed in the chamber of the retort furnace.
2. As soon as the signal from the sensors about the burning and drying of charcoal is received, it is unloaded and left to cool.
3. After that, the product is crushed into pieces and packaged in bags and bags (paper or plastic). Coal for domestic purposes is crushed more finely, for industrial purposes, crushing is coarser.

Raw material

As for raw materials, absolutely any are suitable for coal production:

• knotted pieces of wood;
• sawdust;
• fragments of a wooden canvas;
• branches;
• waste furniture production;
• paper industry, etc.

Suppliers may be:

• woodworking industries;
• furniture factories;
• sawmills;
• organizations that cut down trees.

Can install business contacts with employees of nearby forestry enterprises producing timber harvesting.

Peat can also be used in this production.

Even your neighbors in the dacha can become your suppliers, because many of them cut trees every year.

The consumption of raw materials for one ton of charcoal approximately looks like this: about 8 m3 - birch wood, about 12 m3 - soft varieties.

Equipment

The production of charcoal requires the purchase of the following equipment:

• charcoal kiln. Price from 100 thousand rubles;
• scales. Cost - approximately 5 thousand rubles;
• electricity generator. The costs are approximately 20 thousand rubles;
• chainsaw. Cost - from 5 thousand rubles;
• hydraulic device used for chopping wood. Average prices in the region of 55 thousand rubles.

Personnel

As for the workers, they need no more than 2-3 people, no professionalism is required from them. Workers are needed to:

• load the production line;
• unload raw materials;
• ship finished products.

In addition to workers, you will need to hire:

• watchman;
• sales and purchasing manager (if you do not plan to engage in sales yourself);
• perhaps an accountant.

Permits

Any commercial activity requires the creation of an LLC or IP.

In the case of the production of charcoal, it is better to give preference to the form of IP, since in this case tax rates are much more beneficial.

In addition, you do not have to spend time on processing complex documents.

Unlike many other types commercial activities, no special permissions or licenses not required.

Registration ends with the usual entry of data into a common state database.

Total costs and payback

Speaking of total costs for a business, in addition to the cost of equipment, the following should be taken into account:

• rent (if you do not have your own premises, you will have to pay about 200 thousand rubles a year);
• salary to employees (about 200 thousand rubles annually);
• advertising, marketing, transport (about 50 thousand rubles).

Thus, the cost of starting a business will be about 635 thousand rubles. (or less if you use your own site).

With the cost of charcoal from 18 to 25 rubles. for 1 kg, monthly income from sales of the product will be from 80 to 100 thousand rubles. This will allow you to recoup your investment for a period of six months, and if you do not need to pay for the rental of premises, then even less. Cafes and restaurants alone burn every month, on average, about 4-5 tons of charcoal.

With proper commercial sales, the circle of buyers will grow, which, accordingly, will entail increase in turnover and profit.

The premises for the workshop may be located outside the city. An excellent solution to the problem of the premises can be the use of summer cottages. The main thing is that raw material suppliers are as close as possible.

Sales of charcoal

With regard to the marketing of charcoal in the domestic market, this type of commerce can become profitable and highly profitable.

The main consumers of charcoal are catering facilities (restaurants, cafes), which use about 5 million tons of this product in one season.

Other enterprises and objects of vital activity should be added to this, such as:

• kindergartens;
• schools;
• higher educational establishments and etc.

Private consumers also purchase coal when traveling to:

• fishing;
• dacha;
• hunting.

Production shops that make varnishes and paints are constantly in need of coal.

With an abundance of marketing opportunities, this business does not require costly and high-tech forms of production.

conclusions

Speaking about a business based on the production of charcoal from wood waste, a number of points should be noted that favor the choice of this particular type of commercial activity. Throughout the world, in recent decades, there have been trends in the preservation and maintenance of the ecological balance of nature.

This is about:

• preservation of green areas and untouched human activity ecosystems;
• maintaining a clean environment by creating industries that do not produce harmful emissions.

The activism of environmental organizations has led the governments of many Western countries setting an example for the whole world, have significant state subsidies business based on the processing of wood (and other) waste.

Russia does not remain aloof from new trends in the field of resource and environmental conservation. Developed by the Russian state small and medium business support programs in this area should be regarded as a favorable factor for opening a wood waste processing enterprise.

You may also be interested in: an article about, a small one about the prospects for recycling in Russia, or material about the transformation plastic bottles for recycling

Note that modern technologies do not stand still. If just a few years ago it took about 5 tons of wood to create 1 ton of charcoal, now, using new technical means, waste wood raw material is required by 1.5 tons less.

The most important positive points in assessing the prospects this business perform for free or almost free raw material, low cost of equipment, no need to search for highly qualified personnel, wide opportunities for marketing products.

The process of charcoal production is clearly presented in the video:

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