Bamboo as sustainable biomass Energy: A suitable alternative for firewood and

Charcoal Production in Africa

TRANSFER OF TECHNOLOGY MODEL (TOTEM)

Based on the Experiences and lessons learnt from INBAR and WENZHO Project Trainer of
Trainer Workshop on Bamboo Charcoal and Briquette Production at Daboase-Ghana
(11th -31st October, 2010)

Prepared By

Michael Kwaku-National Project Co-ordinator

Technical Assistance
WENZHAO Bamboo Charcoal Company-China

DISCLAIMER
The contents of this publication are the sole responsibility of INBAR NPMU-Ghana and can
in no way be taken to reflect the views of the European Union, Common Fund for Commodity
and International Network for Bamboo and Rattan
 Table of Contents
1.0 Introduction........................................................................................................................1
1.1 Bamboo Charcoal .........................................................................................................1
1.2 About the Manual..........................................................................................................1

2.0 Brick Kiln Construction....2

2.1 Structure information on the brick kiln........................................................................................2
2.1.1 Materials for kiln construction..................................................................................................2
2.1.2 Kiln Construction......................................................................................................................3

2.2 Sub-structure (Foundation)...............................................................................................4

2.2.1 Foundation Layout..................................................................................................................4
2.2.2 Materials requirement...........................................................................................................4

2.3 Laying of bricks to dome level..........................................................................................5

2.3.1 Kiln dome construction............................................................................................................6

2.4 Final stage kiln of construction.........................................................................................6

3.0. Construction of a Shelter..................................................................................................7

4.0 Bamboo charcoal production background information.................................................7

4.1. Training Technology applied...........................................................................................8

4.2 Raw material preparation.................................................................................................9

4.2.1 Carbonization process of brick kiln.........................................................................................9
4.2.2. Feeding kiln, Lighting and temperature control.........................................................9

4.3 Bamboo Refining and drying..........................................................................................11

4.4 Pre-carbonization.............................................................................................................11
4.4.1 Carbonization .......................................................................................................................11
4.4.2 High temperature refining.........................................................................................11

4.5 Cooling...............................................................................................................................12

5.0 Finishing process of bamboo charcoal...........................................................................12

5.1 Sorting...............................................................................................................................13
5.1.1 Quality control......................................................................................................................13
5.1.2 Packing..................................................................................................................................14

6.0 Bamboo briquette.............................................................................................................14

6.1 Bamboo charcoal properties...........................................................................................15

7.0 Conclusion.........................................................................................................................15

8.0 Recommendations............................................................................................................16

9.0 Reference...........................................................................................................................17
1. Introduction
In Ghana biomass is the most dominant source (about 65% of the total energy consumption)
of energy and is used significantly in the domestic sector for cooking and many other heat
applications
Woodfuels, in the form of forest wood, charcoal and wood processing residues are the most
dominant biomass forms of energy in use in Ghana although crop residue and other non-
woody materials also find some usage. Most rural dwellers heavily depend on fuel wood for
all their domestic and other commercial activities that require heat
The over-dependence of majority of the population on charcoal and fuelwood as energy
sources has contributed to the threat of deforestation and desertification in many parts of the
country. Wood fuel (firewood and charcoal) supply and demand for cooking coupled with
inefficient traditional cooking stoves (coal pot, tripod etc) is arguably one of the most
threatening energy/environmental issues in Ghana today
Ghana has one of the highest deforestation rates in Africa (3% per annum), with current
levels of wood-fuel consumption far exceeding forest growth/yield. In the last 50 years alone,
Ghana has lost over 70% of its vegetation cover and this still continues at an unrelenting
pace.
1.1 Bamboo Charcoal

Bamboo charcoal has been tested and proven to be a viable biomass use in China and an
alternative energy for use both domestic and commercial application in Ghana. The
production of bamboo charcoal will promote the sustainable development of economy and
ecology in Ghana. Bamboo charcoal industry is undertaken in small scale with less
investment, specially attracting wood charcoal producers and to further enhance their income
thereby improving the local economy.

Due to the economic and environmental importance of using bamboo for charcoal
production, a twenty day training workshop was held for sixteen selected participants drawn
from the two project sites Daboase and Tanda under the European Union-EU and
International Network for Bamboo and Rattan-INBA funding Bamboo as sustainable
biomass energy: A suitable alternative for firewood and charcoal production in Africa
project.

The overall objective of the training workshop was to provide basic knowledge in bamboo
charcoal production and briquette making for use as a source of energy for the middle and
low income households in Ghana. Thereby providing a more a more sustainable,
environmentally friendly and economical option to firewood and wood charcoal.

1.2 About the Manual

The aim of this manual is based on bamboo charcoal brick kiln construction, charcoal
production and briquette making during the training workshop. It is also to disseminate
technologies for bamboo charcoal production, to promote information exchange between
China and INBAR member countries (Ghana) concerning its production and utilization, to
increase the economic income of local charcoal producers, and small- and medium scale
investors in the bamboo area of Ghana.

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Technical support was provided based on the Transfer Of Technology Model (TOTEM) from
WENZHAO bamboo charcoal company in China. The manual may be useful for both
technical and non-technical persons who are familiar with wood or bamboo charcoal
production. Although the manual is basically relied upon the brick kiln constructed during the
charcoal production and briquette making training workshop. It can however be adjusted or
modify according to the local situation or use (commercial or family).

2.0 Brick Kiln Construction

The brick kiln can be constructed with the guidance of a technical design or personal past
experience. In the case of this manual, there was no structural design and the Chinese Masters
from WENZHO bamboo charcoal company had to use their personal gain experience in the
construction of the kilns.

2.1 Structure information on the brick kiln

Bamboo charcoal kilns are generally built in wide and open areas of solid soil with
convenient traffic, sufficient electricity and water supply. In the case of constructed double
brick kiln at Daboase-Ghana as shown in Picture 1. The dimension measures: 3.8 meters in
length, 2.8 meters in width and 2.5 to 2.7 meters in height with wall 24 cm thick. The
building process is as follows: First of all, 15 to 20 cm thick stones are levelly paved on the
ground (Picture. 2), followed by a layer of loess 20 cm thick (Picture.3). Then bricks are laid
on the loess. After building the kiln with bricks a layer of loess 20 cm thick are laid on the
top, which serves to keep out the moisture and preserves the heat. The flue of 100 100 cm
is situated at the back.

2.1.1 Materials for kiln construction

Table 1.showing the material requirements for the 10 tonne brick kiln capacity

No Material/description Quantity/units

1 Burnt brick 8000

2 Soil 7.5 cubic meter capacity truck (5trips)

3 5inch cement blocks 700

4 Cement 50kg 10

5 Clay soil 5.0 cubic meter capacity (1-trip)

6 Fine sand 5.0 cubic meter capacity (1-trip)

7 Water 5000 gallon

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8 Firewood 2 tonnes

9 Asbestos Roofing sheet 35 sheets

10 Nail 2 packets

11 Wood lumber 4x4 15pieces

12 Stones 40kilograms

2.1.2 Kiln Construction

Picture1. Laying of foundation bricks Picture.2 Laying of brick layers

Picture4. depicts an explicit illustration of a kiln gate, which is 1.5 meters high, with 50 cm
wide at the bottom and 40 cm wide on the top. There are five intakes on the kiln gate. Intakes
A and B serve not only to add firewood, but also to observe flame and burning situation
(Picture 5). Intakes C, D and E, mainly used to control the increase rate of interior
temperature by adjusting their opening (Fig 6). This type of kiln has a capacity of four to six
tons of bamboo and consumes two tons of firewood in a cycle.

Picture 3: (Kiln gate illustration) Picture 4: (Kiln wall illustration)

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Picture 5: (creating air intake space of kiln) Picture 6: (Loading of firewood through the
kiln gate)

2.2 Sub-structure (Foundation)

Foundation or the base layout of the kiln is an important structure stage. It should be strong
enough to bear and hold the whole upper layers and the dome load. The foundation work
includes layout, clearing, filling and levelling.

2.2.1 Foundation Layout

This is done to layout the digging area of foundation and should be done according to
plan of the kiln.

2.2.2 Materials required

Long rope (preferably nylon)

150mm or 6 long nails or iron or wooden pegs (the number required depending
upon the size of the kiln)

Measuring tape (30m or 50m)

3-4-5 right angled wooden structure

Use your judgement for the alignment of the kiln. It can be done using reference from road
or neighbouring constructed kiln (so that the kiln will be aligned properly).

Decide the first corner (corner A in figure 3) of the building and fix nail or peg

Use 3-4-5 method (i.e. 3 sides of the triangle measure 3, 4 and 5 feet or meter) to fix

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 the other corners of the kiln. You can use tape or wooden structure for the purpose. This
would ensure the right angle of the corner of the kiln. (Picture 6 & 7)

Picture 6: Showing proper alignment of the kiln Picture 7: Showing rope for proper alignment

2.3 Laying of bricks to dome level

Laying of brick should be carefully done to ensure it takes an equal shape from the
foundation level to the dome stage. At the dome stage, stones are to be use to support the
brick laying from caving in. Soil should be filled simultaneously as the brick is being laid to
give support to the brick layer to reach every height kiln.

Picture 7: Truck and type of soil for filling Picture 8: Filling of the kiln with soil

The soil should be pressed or pound to ensure there are no lose soil and prevent oxygen or
smoke leakage (Pictures 9 & 10 showing how the soil should be pressed.

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 Pictures 9 and 10 showing compacting/pressing of the soil

2.3.1 Kiln dome construction

The construction stage of the dome begins at the lentel stage of the circular kiln walls. To
start the dome construction, soil would have to be filled to the lentel level to ensure there is
enough support to the builder to lay the dome brinks using either an edge shape brick or cut
to shape bricks.

Pictures 11 and 12 shows the dome construction stage and the application of stone to aid its
strength.

Picture 11: Kiln dome construction technique Picture12: Application of stones to aid the
strength of the dome

2.4 Final stage kiln of construction

The final stage of the kiln construction is done when the dome is closed and covered with
soil.

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 Picture 13 and 14 depicts the closure of the dome and soil cover of the kiln

3.0. Construction of a Shelter

To prevent rain water from entering the kiln to reduce heating level during carbonisation
process, a shelter is erected to cover the entire kiln. Another usefulness of the shelter is that
charcoal recovery both quantity and quality are improved.

Pictures 15 and 16 showing the final view of the twin kiln constructed.

Picture 15: Front view of the kiln Picture 16: Back view of the kiln

4.0 Bamboo charcoal production background information

Bamboo charcoal is made of bamboo by pyrolysis process. According to the types of raw
material, bamboo charcoal can be classified as raw bamboo charcoal and bamboo briquette
charcoal. Raw bamboo charcoal is made of bamboo body such as culms, branch, and
root.bamboo briquette charcoal is made of bamboo residue such as bamboo dust and saw
powder and etc. by compressing the residue into certain shape sticks and carbonizing the
sticks. There are two kinds of equipment for carbonization, one is brick kiln, and the other is
mechanical. Bamboo production process is divided into three stages: raw material
preparation, carbonization, finishing process (Fig. 4.1). (Source: Bamboo Engineering
Research Center, Nanjing Forestry University, May 2004)

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Raw bamboo (bamboo Brick kiln
culm, branch, root, etc.
Finishing Bamboo
process charcoal

Bamboo briquette Mechanical

kiln

1 Raw material preparation 2. Carbonization 3. Finishing process

Fig.4.1 Three- period process of making bamboo

charcoal
For making raw charcoal, the bamboo at the age of four years or more should be selected.
The culms should be chopped into segments according to the size of kiln before drying. The
moisture content of raw bamboo should be 15%20% by air drying before loading into kiln.
Or the material is directly loaded into kiln for smoking drying before carbonization. Sawed
bamboo culm can be made into bamboo tube charcoal, slice charcoal. Bamboo culm also can
be split into slice before loading into kiln.

4.1. Training Technology applied

For the purpose of INBAR/EC bamboo charcoal training and briquette manual, the raw
material used for charcoal making was the bamboo culm and brick kiln technology was
applied in the carbonisation. Figure 4.2 shows the tool and process for the carbonisation.

Raw bamboo culm Brick kiln Finishing Bamboo

process charcoal

1 Raw material preparation 2. Carbonization 3. Finishing process

Fig.4.2 One process of making bamboo charcoal

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4.2 Raw material preparation
4.2.1 Raw material preparation for raw bamboo charcoal
The raw bamboo charcoal is made of bamboo culms, which was sliced between 4 and 6 feet
picture 4.2. by a handsaw.

Picture 4.2 cutting of bamboo culm

4.2.2 Carbonization process of brick kiln

4.2.2.1 Feeding kiln

All the raw material is fed into a kiln according to its size. A space of a half meter between
the kiln gate and raw material is left for burning firewood. Bamboo culms and bamboo
briquettes in good quality will is set into the most inner of kiln, and those in bad quality is set
near the gate of kiln. Bamboo culms are then put with the smaller end downward. The Picture
4.3 depicts the process of loading with bamboo culms.

Picture 4.3 Loading of bamboo culm

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4.2.2.2. Feeding kiln, Lighting and temperature control

The firewood lying behind the kiln gate is Ignited and then the top two intakes are closed
when the firewood is burned, leaving two intakes at the bottom of the gate to keep the hot
flow circulating in the kiln. It is necessary to add firewood whenever the firewood below is
burned out and clear up the ash to avoid blocking the fire. Bamboo materials in brick kiln are
heated in picture. 4.4. The igniting and sealing after igniting was illustrated in picture.4.5.

Picture 4.4 Igniting of firewood Picture 4.5 Sealing of air in-let gates

It is a process raising the temperature inside the kiln by dismounting the feeding intake on the
gate everyday and feeding firewood to keep burning. The temperature inside the kiln must
escalate gradually in the process. The bamboo in the kiln will crack if the temperature
escalates quickly. The temperature of drying period is 120~220. The temperature in the
kiln is controlled under the self-igniting point of bamboo in seven to eight days after igniting.
Firewood feeding is decreased or stopped if the temperature is enough. The temperature in
the kiln can be regulated by blocking the intakes and flue rim with bricks. Picture 4.6 is a
curve of heating, which delineates the change of the temperature in the process of heating.
Picture 4.7 depict removal of ashes to add new firewood.

Picture 4.6 controlling heat with the Picture 4.7 removal of ashes and firewood and
placement if bricks addition

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4.3 Bamboo Refining and drying

The refining of the bamboo is regulated by the temperature or heating according to each day
and it is expected that it will progressively increase until pre-carbonisation is complete.
Diagram 4.3.1 depicts the normal refine temperature by each day. (Source: Bamboo
Engineering Research Center, Nanjing Forest University, May 2004).
Diagram: 4.3.1.

4.4 Pre-carbonization

At the pre-carbonisation stage, close attention is paid to the change of temperature in the kiln,
keeping it under the auto ignition of the bamboo culm at between 150~280. As a rule, the
temperature in kiln is to be adjusted with bricks blocking floss and air inlet. In this stage a
large quantity of heat is needed to maintain the raising of temperature for thermolysis.

4.4.1 Carbonization

The temperature in the stage of carbonization is 280~450, which exceeds the auto ignition
point of bamboo, the thermolysis process is rapid, releasing a large amount of heat; this is a
stage of exothermic reaction.

4.4.2 High temperature refining

High temperature refining is completed at the temperature above 450. This is a stage of high
temperature thermolysis. The volatile matter is discharged in this process by the raised
temperature; consequently, the fixed carbon content in charcoal is increased.

After the end of carbonization the intakes gate is open. In this process, the intakes of kiln gate
shouldnt be opened wholly in a short time, and they are to be opened gradually within
twenty-four hours or so to make the bamboo charcoal contracted absolutely.

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 Picture 4.6 the curve of temperature time during refining stage

At the end of refining stage, all the intakes should be opened again for one or two hours to
raise the temperature of the charcoal in the kiln to 1000 or more. Fig. 15 depicted the
curves of temperature during the refining stage. The beginning and ending of refining process
will be controlled according to the temperature on the curve

4.5 Cooling

After the refining is finished, seal the kiln (Picture. 17) and start the natural cooling of
charcoal in the kiln. When the temperature in the kiln is below 60, unload the charcoal. The
kiln gate should be partly opened at first to make sure that the bamboo charcoal in the kiln no
longer ignites. Then the kiln gate can be opened thoroughly. The temperature in the kiln
should not be too high during unloading; otherwise bamboo charcoal will be broken easily.
Pictures 4.7 and Picture 4.8 show sealed gate and cooling bamboo charcoal.

Picture 4.7 Picture 4.8

5.0 Finishing process of bamboo charcoal

Finishing process of the bamboo charcoal includes sorting, finishing processing, checking
and packing shown by Fig.5.3

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 Finishing processing
Sorting Checking Packing
(sawing, grinding )

Fig. 5.3 finishing processing flowing chart

5.1 Sorting

The bamboo charcoal was sorted after unloading from the kiln. Bamboo charcoal for fuel is
packed into mini bags whilst crashed bamboo charcoal was grinded into bamboo particle
charcoal and powder for honey comb briquette making.

Picture 5. Sorting of bamboo charcoal

5.1.1 Quality control

The appearance of the bamboo charcoal and its chemical and physical properties is checked
to ensure that the quality bamboo charcoal were selected for packaging

Samples of quality bamboo charcoal from the test production during the training

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5.1.2 Packing

The bamboo charcoal products grouped and packed into plastic mini bags

Removing of bamboo charcoal from Kiln Loading charcoal into mini-bag

6.0 Bamboo briquette

Bamboo briquette test production was undertaken during the training and this manual
explains the process.

i. Particles of the bamboo was collected and crushed in a metal bin.

ii. Limited quantity of clay soil was added for a manual mixing

iii. Water was added to mix the clay and charcoal powder

iv. Handy tool is used to develop honey comb briquette

Bamboo charcoal in a bin Manual grinding of charcoal Honey comb briquette making

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Sample of honey comb briquette Bamboo charcoal use demonstration

6.0 Bamboo charcoal properties

In order to study the effects of carbonization temperature on the properties of bamboo

charcoal, and to improve the production technology, the yield rate and ash generated, this
manual is developed with the principle guidelines of carbonization temperature analyzed by
similar carbonisation process. The results are shown in table 2.

Table : Properties of bamboo charcoal made in different temperature

Temperature of Carbonization
Item of Properties 300 400 500 600 700 800 900 1000

Yield rate% 40.70 35.6 29.68 28.96 27.52 27.43 26.39 26.69

Ash% 2.93 3.48 3.54 3.92 4.07 4.58 4.69 4.57

Yield rate means the percentage of final bamboo charcoal made from raw bamboo.

As we can see from the table, the conclusions are drawn as follows:

The yield rate is converse to the temperature of carbonization, that is, the higher
carbonization temperature, the lower yield rate.

Ash and fixed carbon and density of bamboo charcoal are positively correlated to the
temperature of carbonization.

7.0 Conclusion

Though, the yield of the charcoal produced during the bamboo charcoal training was about 40
percent reasons attributed to the fresh use of the newly constructed kiln, it is expected that

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two additional test carbonisation would fully warm and improve the kiln yield to about 90
percent.

8.0 Recommendations

Based on the training lessons, in Brick kiln as well as the bamboo carbonisation, the
following recommendation are made for consideration in future when undertaking a similar
project.

The production and supply of burnt brick material should be closer to the kiln
construction site to reduce supply cost which turns to affect the kiln construction cost.

Kiln construction and carbonisation of bamboo charcoal should take place during the
dry season

The proximity and availability of soil should be closer to the kiln site to reduce
transportation and labour cost

Bamboo culm should be harvested not less than seven day before carbonisation, this is
to improved yield

There should be maximum control on the use of firewood to aid carbonisation as this
could increase temperature beyond the control level affecting yield and quality.

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 Reference

1. Guan Mingie, (May 2004). Manual for Bamboo Charcoal Production and Utilisation

2. Zhejiang Xinchnag Fuster Bomboo. Mechanism and Science of Bamboo charcoal

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