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How to Make some Charcoal

by juggler on March 13, 2007 Table of Contents How to Make some Charcoal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intro: How to Make some Charcoal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Step 1: Make the container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Step 2: Provide holes for gasses to escape and Burn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Step 3: Collect wood and take your stuff to the burn site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Step 4: Load it up and cover it to keep the heat in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Step 5: More on trying to keep the heat in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Step 6: Load the drum with wood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Step 7: Start a fire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Step 8: Burn for a good long time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Step 9: Examine this video . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Step 10: Watch out for too much smoke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Step 11: Enjoy Charcoal!! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Step 12: Updated Design of the Kooker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2 4 4 4 5 5 6 6 7 7 8 8 8

Step 13: Video of new kooker burning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Related Instructables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

http://www.instructables.com/id/How-to-Make-some-Charcoal/

Intro: How to Make some Charcoal

I have been involved in a local school (Portland Waldorf School) which has a blacksmithing program. There have been complaints about the smell of the coal burning and so I found out that charcoal can be used as the fuel instead of coal/coke. So I am building this charcoal maker so that the children can see how to blacksmith without coal. There are health benefits too! Coal produces sulfer when burned which can combine with water in your lungs creating sulfuric acid (acid rain) as well as the water in your sweat. If this helps someone have a better experience blacksmithing, I will be happy. Here I describe how I made a charcoal retort. This is also known as the "indirect" method of making charcoal. Basically you take a metal container and cook it until all of the volatile gasses leave the wood.

http://www.instructables.com/id/How-to-Make-some-Charcoal/

http://www.instructables.com/id/How-to-Make-some-Charcoal/

Step 1: Make the container

I decided to go ahead full bore for my first charcoal attempt. Many online sources indicate that they started out with small metal containers, but I figured a 55 gallon drum would be the best bet. So I found a recycled drum merchant on craigslist, paid $25 for a drum and proceeded to cut into it. I took some 3 inch round steel tubing and made the retort tube. This is a tube which takes gasses from the wood as it is heated, and redirects them to where they can be burned to add to the heat for charcoaling the wood. You can see from the image that I made the bends using miter cuts. If you don't have the tool to make these cuts, you can use Black Pipe and fittings. That would increase the cash outlay, and since I had this stuff waiting for a use, I used it.

Step 2: Provide holes for gasses to escape and Burn

Next, you need to provide holes in the pipe under the drum. The point is to create a large burner-like thing. I drilled 1/4 inch holes every 3 inches in both sides of the tube. Later I thought that might not be enough so I used my die grinder to cut 3 slits in the top of the pipe so that the gasses would be directed more directly at the drum.

Step 3: Collect wood and take your stuff to the burn site
At first, I figured on using all pallet wood. So I loaded everything in my van to take it to the burn site. Below you can see that I have everything loaded up and ready to go

http://www.instructables.com/id/How-to-Make-some-Charcoal/

Step 4: Load it up and cover it to keep the heat in

On my way to the burn, I realized that I did not have any way to keep the heat in the drum. So I stopped off at Lowes and bought 3 pieces of cement board at $9 each. You can see that I put a tray below the assembly in an attempt to have a low impact on the site. I did not want to burn the grass where I was doing this, and we had a copper fire place on hand. I think this detracted from the overall effeciency, however, so I would not do this again.

Step 5: More on trying to keep the heat in

Here you see the cement board leaned against the assembly. I have some left over KaoWool (kiln refractory blanket) from a forge project so I draped that on top to keep the heat in the drum as much as possible. I draped chains over it to keep it on the drum

http://www.instructables.com/id/How-to-Make-some-Charcoal/

Step 6: Load the drum with wood

Here we put some wood in the drum. this is Fir heartwood which my friend uses to heat his home. They are mill ends from a plywood mill. We filled the drum that much.

Step 7: Start a fire

Pile wood up under the drum and set it ablaze. An old indian showed me how to start a fire without flint, steel, paper or tinder. He called it a weed burner and it's fuel is propane. It works real well.

http://www.instructables.com/id/How-to-Make-some-Charcoal/

Step 8: Burn for a good long time

we lit the fire at 10:30AM and did not see gasses come out of the tube below until about 3PM.... We wound up burning about 5 pallets, plus 2 moving boxes full of scraps from the school's woodshop. Probably about 150 lbs or so. There is about 120Lbs of wood inside the drum. not as efficient as I had hoped...

Step 9: Examine this video

it's a good step to watch video

http://www.instructables.com/id/How-to-Make-some-Charcoal/

Step 10: Watch out for too much smoke

this really does not smoke much. See the picture.

Step 11: Enjoy Charcoal!!

I really can't believe this worked! Enjoy some awesome home made charcoal!! for more information enjoy these google results: Making Charcoal

Step 12: Updated Design of the Kooker

I decided that even though we were successful, that the process could use a major improvement. The first burn lasted about 6 hours and consumed what seemed like a lot of wood. I figured if I insulated the space around the Barrel that the heat would concentrate more on the container and the result would be faster conversion time and less wood burned. I was right. Here are pictures of my updated burner. The walls are one inch thick refractory cement. I used about 6.5 bags of refractory which weigh 55 lbs each. (So now the kiln / retort weighs at least 350 pounds!!) You can see in the photos the steel structure and the refractory walls. I welded 1/4 inch round bar between the members as rebar and also tied chickenwire to those bars for supporting the refractory cement. The front is bolted on so that it can be removed when the barrel wears out and needs to be replaced. The floor is just the ground, and I laid down a piece of hardy-backer cement board to protect the concrete there. I added a hinged plate of steel there as a "fire box" door. It is about 1/4 inch thick and when closed there is about 4 inches open below it. When burning it gets red hot as do the steel members of the structure!! I also added a hole in the top as a place where the smoke can emit. I plan to add an insulated chimney to it there in the hopes that the fumes coming out can have a secondary burn to perhaps make less smoke. The chimney will need to be very well insulated for this to occur, so I plan to make it a double-wall arrangement probably 10-12 inches diameter outside with a 6-8 inch diameter inside pipe, and fill the gap between with kaowool or perlite. The next step will be a short video of this one burning.

http://www.instructables.com/id/How-to-Make-some-Charcoal/

http://www.instructables.com/id/How-to-Make-some-Charcoal/

Step 13: Video of new kooker burning

So This is a definite improvement - once I lit the fire below, after 10 minutes, gas was burning from the tube. After 2.5 hours gas had stopped coming out and I let the fire below die completely. In the morning I discovered that 100% of the contents had converted to charcoal!!

The pile of wood in the picture below is what I took from to burn in the firebox. It is mostly still there! So I don't know for sure, but I think I burned less wood in the firebox than was in the barrel, which is a huge improvement! The next burn will have more science. We will weigh the wood placed in the barrel, and note the type of wood. We will also weigh the wood burned in the firebox and then weigh the charcoal produced and time the process again. This process should give us a much better idea of the efficiency of the improved process. Thanks for watching!

http://www.instructables.com/id/How-to-Make-some-Charcoal/

Related Instructables

Making Your Own Charcoal Powder by nebraska

how to make Improvised Gas charcoal pencils Mask by by GlueyMcGee TimAnderson

How to make charcoal carbon and flammable gas? by dava_2

Quick and cheap aluminum melting furnace setup by robbtoberfest

Making a Simple and Easy Charcoal/ Coal Forge by acer73

Comments
50 comments Add Comment view all 62 comments

butcherboy says:

Dec 20, 2008. 1:53 AM REPLY If you were to forego the chimney and the gas retort/burner and instead routed the gas into a basic distillation apparatus you should get primarily methanol, which, I think, could probably yield a more efficient return of energy to the system (in regards to a supplemental heat source).

romedeiros1970 says:

Aug 6, 2009. 9:40 PM REPLY I do not think that is correct, butcherboy. With all due respect, I believe the primary outputs are carbon monoxide and hydrogen gas, both of which are highly flamable. They can be collected and used as fuel, or can be redirected as fuel for the carbonization as done here. I guess it depends on the goal of the process.

butcherboy says:

Aug 8, 2009. 11:36 AM REPLY Good point, though IMHO, if not redirecting the gases for system efficiency, distilling the methanol might be easier to accomplished than gas storage for the purpose of getting a second fuel product, at least as far as a backyard charcoal set-up is concerned that is. A simple reflux still vs. pressurized tanks is the scenario I'm envisioning.

romedeiros1970 says:

Aug 9, 2009. 10:27 AM REPLY Sorry, but I think I was unclear. One of my points is that I do not think that methanol is produced in pyrolysis. I think some methane is produced, but I could be wrong. The reason I want to be sure about that is methanol can be used to make biodiesel, and I would not want any of our biodiesel making members to think methanol can be produced by pyrolysis. Again, I could be wrong, but I have not found any references to methanol production in the literature. I do like your points about either using a reflux or a pressurized tank. I wonder if armature pyrolyzers can produce more gas than is needed. That would be great!

butcherboy says:

Aug 9, 2009. 6:36 PM REPLY Actually methane is the main volatile released during pyrolysis. Most of the CO released occurs during gasification, which actually occurs after combustion (which occurs after pyrolysis given an oxidizing agent). Methanol is also known as wood alcohol because it used to primarily be produced in a still similar to the charcoal set up. The key was sequestering the wood from as much O2 as possible and thus minimizing combustion and allowing the volatiles to be distilled. Another useful product of the process is of course charcoal, which is essentially the remaining carbon matrix of the wood (less O2, less CO, more C...carbon that is!)

http://www.instructables.com/id/How-to-Make-some-Charcoal/

Darrell Knight says:

So is there a way to make moonshine (for fuel purposes) at the same time we are making the charcoal?

Jan 17, 2011. 8:15 PM REPLY

romedeiros1970 says:
Theoretically, perhaps, but not in an economically feasible way to my knowledge.

Jan 18, 2011. 10:18 AM REPLY

Darrell Knight says:

Jan 18, 2011. 12:53 PM REPLY LMWAO, I understand, but while we're making charcoal, wouldn't it be more feasible to bottle the spirits of the ummmmm, vehicle, or not? Just wondering, I am not able to make charcoal as of yet. Something in the lease at the apartments that say no making of charcoal on the grounds or something, lol. I was just wondering, thanks and have a great day.

Darrell Knight says:

I didn't that the indians in the old days had propane.

Jan 18, 2011. 10:23 AM REPLY

blazingpencilsdotcom says:

Feb 24, 2009. 9:35 AM REPLY The charcoal can be an awesome additive for compost & gardening, see terra preta on Wikipedia. You would need to soak the charcoal in urine, or compost tea or something (grey water?) and then work it into your soil, supposedly it will start a natural carbon capture / sequestration cycle that lasts hundreds of years.. Also might look into having the gases escape the cooking container downward so they get burned in the fire & contribute to the fire energy - good news -instead of offgassing into the atmosphere - bad news. I wanna try using an old 275 gal oil tank (like a pig smoker) as the outer fire box, and have (2 or 3) 55 gal drums inside it with feed stock. I would like to use wood chips from tree trimming for the feed stock, as it is in plentiful free supply. i would like to rotate the drums out of the fire box as soon as cooked and insert newly filled ones to keep the process more constant. any comments appreciated.

comander01 says:

Oct 6, 2009. 12:03 PM REPLY I'm not sure if this would work, but try making a rotating stand with about 3 55 gal drums. As the wood burns, it releases gasses, making the resulting charcoal light than wood. The heavier weight of the wood on top would rotate it down into the burner.

Superstormj says:

Nov 30, 2010. 5:18 PM REPLY That's a good idea, all that would require is the weighing of the wood put in each barrel to be the same, and then just stand back and let it do it's thing.

cody316 says:

Oct 7, 2010. 11:26 AM REPLY this is kinda new to me so tell me if this is stupid... could i just put some of my scrap 2x4s in my 55 gallon drum and throw it on my fire pit and BLAMO i got charcoal?? Aug 31, 2010. 7:51 PM REPLY Cool idea. I'm filing this one for my TEOTWAWKI knowledge. . . It's a good way to get charcoal to work and forge any metal. And it would be a good way to make a product for bartering in a survival economy. Aug 12, 2010. 5:18 PM REPLY $25 for a steel drum. Are you mad, dear Sir? I saw a lot of thick walled 55 gallon drums in a factory today. I asked a worker what they did with the old drums and he said they gave them away.

discowhale says:

Esmagamus says:

boogieman697 says:
wow 25$ for a drum i paid 5$ for a water tank at the dump which is almost twice as big and made of thicker steel

Jun 2, 2010. 5:33 PM REPLY

RedneckAsian says:
how nessecary is it to keep the heat in

Dec 15, 2009. 1:28 PM REPLY

abadfart says:
you also use charcoal in black powder

Jun 29, 2008. 2:02 PM REPLY

Radar252 says:
i did not know that is it a dye to make it black?

Aug 22, 2008. 7:33 PM REPLY

Kaelessin says:

Aug 26, 2008. 8:05 AM REPLY yes and no lol. . . it is what makes black powder black but it has other more important purposes in black powder. It's really porous even at the microscopic level having had all kinds of stuff burned out of it. This allows the sulfur and the saltpeter to be bound together into these holes which really helps the burn. Being flammable itself, the charcoal also acts as a fuel though the sulfur is fuel too.

http://www.instructables.com/id/How-to-Make-some-Charcoal/

romedeiros1970 says:
Charcoal is also the main ingredient in mascara!

Aug 6, 2009. 9:41 PM REPLY

OldOwlIronworks says:
Excellent Instructable, this has always been an aspiration of mine, to make charcoal.

Jul 25, 2009. 9:03 AM REPLY

wenui says:
I suggest you look at these pages are in Spanish. Can be translated using GOOGLE TRANSLATER. http://www.taringa.net/posts/recetas-y-cocina/2195482/Horno-mixto-o-de-alto-rendimiento.html

Jul 11, 2009. 8:45 AM REPLY

http://www.agmer.org.ar/secretarias/educacion/ambiental/soluciones/pdf/como 20construirse%% 20UN% 20horno% 20mixto.pdf

Muzhik says:

Jul 2, 2009. 11:19 AM REPLY If you want to make activated charcoal for filtering water, etc., take the charcoal from this process, soak ("treat") it in sulfuric acid for a few minutes, then put it back in the kooker for another few hours. (You can get the sulfuric acid from old car batteries.) After this, crush the resulting charcoal into granules. NOTE: you don't need ACTIVATED charcoal to filter water, air, etc., but it is more efficient and effective.

ijt25 says:
Out of interest, how efficient was the new burner in comparison with the uninsulated one?

May 27, 2009. 6:25 AM REPLY

maxa says:
that is so cool i am going to make one how do you know if it is done

May 18, 2008. 3:14 PM REPLY

Rishnai says:

May 26, 2008. 10:27 PM REPLY It would seem that when gasses have stopped coming out of the tube, that means it's all gone from the charcoal, therefore it's done. I assume that if you open it and find anything that's not totally charcoal, it's not done.

lucek says:

Aug 1, 2008. 10:23 AM REPLY you don't want to open it up till its completely cool (not saying you dumb but there are people who would and I'd prefer they didn't go to the emergency room with 3rd degree burns from a flair up.)

Rishnai says:

Aug 1, 2008. 5:40 PM REPLY Excellent point. I should have mentioned that. I've lost eyebrows just from opening the grill. Wouldn't want to find out firsthand what happens when you open a hot charcoal cooker.

gillibiabtiag says:

Jan 20, 2009. 8:04 PM REPLY The other danger with opening it before it is totally cold is that the only thing keeping the charcoal from turning to ash is the fact that there is no oxygen in the tank. If you open it while still warm, the charcoal can start turning to ash VERY QUICKLY. This is a lame way of losing a load of charcoal. One interesting thing that you can do with these is to put gnarled wood into it (old pine roots are awesome). When they turn to charcoal, all the twisty bits of the grain show up really nicely, and when properly coated, makes an awesome living room ornament (especially above the fireplace :D).

lennyb says:

Mar 14, 2007. 6:56 AM REPLY i did something like this a few years ago for a gunpowder experiment . i needed willow charcoal so i cut some small sticks of willow into 2 inch chunks then put them in a 70mm steel film can 3inches high by 3 inchs across i put a single nail hole in the top for a vent and chucked it in the fireplace. in the morning i had nice charcoal. the gunpowder experiment didnt work though cauise i couldnt get any saltpeter .:(

static says:

Jan 13, 2009. 9:51 PM REPLY Read volume 5 of the foxfire series. I recall it detailed how those not near saltpeter deposits processed urine to obtain the Potassium nitrate needed to manufacture black powder.

lucek says:
stump remover is between 50% and 90% sodium nitrate, or in some brands potassium nitrate.

Aug 1, 2008. 10:33 AM REPLY

Derin says:

Nov 10, 2008. 9:26 AM REPLY You do not have to use a miter saw to make those mitered ends.Any saw that can cut metal and some skill and common sense can do the job when combined. :)

http://www.instructables.com/id/How-to-Make-some-Charcoal/

Morpheus says:

Sep 5, 2008. 6:52 PM REPLY Great Instructable! I use a small version of this to make char-cloth using a 1/2 pint paint can with a lid that has a nail hole in the top of the can. I wire on the lid. I use 100% cotton cloth (ratty old t-shirts work great)cut into 2x2 inch squares and stacked in piles of 50(about 150 to 200 squares per can). Put it in the fire (bbq, fireplace etc.) The hole will vent gas that ignites and gives you a great gauge for when the reduction is complete; the flame from the hole goes out when it's done. Put the nail back in the hole with pliers, and let it cool completely. Take off lid: E voila! Char-cloth stacked and ready to make fire with your flint and steel. Peel off a piece and go for it. I have also done this putting the can on the kitchen stove, and lighting the vented gas with a match. Again, the flame goes out when the reduction is complete. Put the nail in the vent hole, cool, and use. Just don't let yer wife catch you doing it. She didn't like me using her spotless oven top for my "stupid man-stuff"!

crcarter says:
Have you had a chance to collect yield information on the updated design?

Aug 30, 2008. 4:41 AM REPLY

Radar252 says:
cool dude i like charcoal my cousin has a charcoal grill

Aug 22, 2008. 7:31 PM REPLY

lucek says:

Aug 1, 2008. 11:31 AM REPLY just thinking I have an old coal furnace converted to natural gas. when I upgrade it, it may well be suited to this application. just hook the water pipe to the gas line and unseal the door's Jul 13, 2008. 1:22 PM REPLY to overclock ANY carbon fire,add some cow poop(eww) disgusting but IT WORKS!!!we did it for a winter and now we are burning 100 less tons of coal/wood!just make sure the thing is DRY and it burns hotter while using less fuel

Derin says:

maxa says:
thanks

May 27, 2008. 6:31 AM REPLY

Poppa Chubby says:

Apr 17, 2008. 11:28 PM REPLY I like this idea, I've also seen it done in a hole in the ground. A large fie is built, then a barrel with holes in the end is put on the fire with the holes down. I'd bet you could make fair dollar selling alder charcoal for cooking, I pay plenty for mesquite lump charcoal. Nice job. BTW, your backyard looks like mine :)

NJB says:

Apr 23, 2008. 1:07 PM REPLY Interestingly enough, the traditional (read original/ancient) method of charcoal burning was to dig a medium sized hole in the ground, saving the turf from the top, light a fire in the hole and get it burning fairly strongly, then add wood all around it and cover the whole lot with turf (grass side down) to the point of practically smothering it, the heat would then turn the wood into charcoal with not enough air being supplied to burn it. I tried it with my Dad when I was younger with mixed results.

technodude92 says:

Apr 18, 2008. 8:33 PM REPLY wouldn't this bee more efficient if the wood to be charcoal-ed was cut and not in solid chunks? also, when burning is the outside cement of the charcoalifier(?) hot to the touch?

casey321b says:
do u think if I widdled a stick into a cylinder and put it in a fire it would come out round? or would it break?

Apr 17, 2008. 8:06 PM REPLY

funwithfire325 says:
you could make a mini one...... ..

Jul 31, 2007. 12:19 PM REPLY

juggler says:
You can just throw a can with holes in the lid in a fire to make artist's stick charcoal. It's fun! so, yeah. mini.

Dec 20, 2007. 4:10 PM REPLY

masterochicken says:
Wood chip box in a bbq

Dec 20, 2007. 3:21 PM REPLY

voultsides says:

Jul 27, 2007. 10:50 AM REPLY i use used cooking oil (i get it for free from the taverns) and wood chips to start the gassing procedure. it's smokeless when fairly ventilated with high temperature burn (aprox 450 C) also have the double barrel retort config great Video

http://www.instructables.com/id/How-to-Make-some-Charcoal/

bowmaster says:
use a fan to make the fire hotter

May 27, 2007. 5:37 PM REPLY

juggler says:

Apr 16, 2007. 1:18 PM REPLY I'm working on updating this project. I agree with all who said that I should get the fire to go on top of the drum. I will also try one of the concepts from the "rocket stove" movement. I will add a way to make the incoming combustion air get a slight pre-heat

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