production process | pt. ruby privatindo
We are serious about the quality of our coconut shell charcoal briquettes and utilize the strictest quality control measures at all stages of production, from shell selection to final packaging of the briquettes. We can produce up to 300 tons per month of high quality briquettes.
We work with dozens of suppliers and farmers who transport high quality coconut shell directly to our production centers around Indonesia. We only use coconut shells from fully mature and fresh coconuts to ensure improved yields and quality during charcoal production. The coconut shells are then manually inspected and cleaned before carbonization. We always make sure to store our coconut shells under dry conditions.
We believe the charcoal used in briquettes is the most important factor determining quality of the final product. We produce our own raw charcoal from carefully selected coconut shells. Our production process results in charcoal with a high fixed carbon content and low volatile matter and ash content. Volatile matter which results in more smoke and odors during briquette lighting are driven out during ourcarbonization process. We do not use water to cool down the charcoal and let it naturally cool over several hours. Thus we ensure using only high quality charcoal in the production of our briquettes.
After carbonization, the coconut shell charcoal is crushed and then thoroughly sieved to remove excess ash. Thus we are able to maintain ash content in the briquettes below 2.5%. After this the charcoal is powdered to a fine consistency. This powder is then mixed in an industrial mixer with approximately 4% of a natural, eco-friendly binder such as tapioca starch, until the charcoal powder is all uniformly coated. The binder allows the charcoal powderto stay intact during pressing and briquette production.
We do not mix any other substances or chemicals such as wood charcoal, nitrates, sawdust, borax, lime etc. These additives are commonly added by some briquette manufacturers as filler to reduce production cost or to achieve some desired characteristic such as faster lighting times (which usually results in shorter total burn time). Our briquettes are 100% natural and do not release any harmful smoke or odors during burning. Shisha smokers and grillerscan rest assured!
The mixture of coconut shell charcoal powder and binder is fed into a briquette pressing machine and then manually sliced to produce individual briquettes in the desired shape. Popular briquette shapes for shisha/hookah are 25mm or 26 mm cubes and 20x50mm or 20x35mm hexagonal. For barbecue, briquettes are usually made in hexagonal shapes with hollow centers. We pay strict attention to ensure individual briquettes are uniformly and neatly shaped with straight and smooth edges and faces.
After briquetting, the individual briquettes are dried until the moisture level is below 5%. The lower moisture level allows for quicker lighting and full combustion of the briquettes. We use industrial ovens, drying at up to 80 degrees Celsius to ensure the briquettes are fully dried before packaging. Strict monitoring of the drying process ensures no cracks form inside the briquettes. After drying, the briquettes are cooled down to room temperature before packaging.
We pack our coconut shell charcoal briquettes according to customer requirements. 1 kg of briquettes may be clear plastic wrapped and several 1 kg packages inserted in master carton boxes (of 20kg, 30kg etc. weight) before being stuffed in shipping containers. We can also print individual color carton boxes with inner plastic liningto fit 1kg, 3kg or any desired weight of briquettes. These printed color boxes are then placed in master carton boxes which are stuffed in the shipping containers.
industrial coal coke briquette making process, briquetting machine, binder, etc
The industrial coke is made of pulverized coal as raw material, processed by coals blending (or single coal) and then briquetting to briquette, after that through the coking process gets the coke and coke-type coal products.
For the coal material adopting the hot briquetting technology, pre-heat treatment is carried out before briquetting. That is, low-temperature carbonization treatment, so that the coal material can be briquette in the softening temperature range.
If the raw coal is a two-component, then the main raw coal must be cohesive, it is firstly carbonized at a low temperature, and in its softened state, the secondary constituent coal must be uniformly blended into the hot coal before briquetting by the hot roller briquette machine. It actually acts as a binder.
A typical example of a cold briquetting process without a binder is the lignite cold briquette making process. When lignite is used as raw coal, the characteristics of lignite are soft and plastic, and high-strength briquette is prepared by external force extrusion. This type of coal can be made into lignite coke by coking.
When coal with poor plasticities such as lean coal or anthracite is used as the main raw material, a small amount of cohesive coal may be blended or not, and briquettes may be prepared with or without binder, and then coke is formed by the high-temperature coking.
The bituminous coal is converted into anthracite coal to produce coke having properties similar to conventional high temperature coke. This conversion is accomplished by one or more stages of the process and includes heat treatment or thermal oxidation of the raw coal.
The production process is: coal drying and dehydration, degassing at 800 degrees Celsius, recovering the removed gas, and cooling by condensation to recover gas and oil, wherein the recovered bitumen is returned as a briquette making binder.
The degassed coal is semi-coke, it is broken into 3-4mm particle size, and briquetted with binder, then oxidized at 200-300 degrees Celsius to obtain hardened briquette. Finally, the briquette is coked at a temperature higher than 1000 degrees Celsius and we get a satisfactory coke product.
The production process uses non-cohesive coal as raw material. In most cases, the cohesive coal, coke breeze or petroleum coke mixture is added to the non-cohesive coal, and about 10% of tar or asphalt binder is added. The raw coal after cold briquetting process is carbonized in a horizontal chamber coke oven inclined at the bottom plate, and the heating method is external heat type, the coking time is as long as 10 hours, and the carbonization kiln flame temperature is about 1300 degrees Celsius.
The carbonization of briquette is carried out under high temperature to produce combustible gases, hydrocarbons and other liquids, tars and cokes through the interaction of many chemical and physical properties of the briquettes themselves during carbonization.
After the briquette is heated, the thermal decomposition begins, and the volatile matter escapes. When the temperature of the briquette reaches 300 degrees Celsius, the thermal decomposition products increase, mainly CO and CO2.
When the temperature in the carbonization kiln reaches 650 degrees Celsius or above, the briquette undergoes secondary thermal decomposition, and the primary degassed product is converted to the secondary degassed product.
When the temperature in the kiln is about 600 degrees Celsius, the amount of tar is the largest, so-called low temperature dry distillation tar. When the temperature in the kiln is higher than 650 degrees Celsius, the tar is decomposed and converted into high temperature tar.
The temperature of low-temperature carbonization is about 350-450 degrees Celsius lower than the temperature of high-temperature carbonization. Some scholars believe that the low-temperature carbonization temperature should be lower than 800 degrees Celsius. At a certain low carbonization temperature, the briquettes break under chemical and physical action into simple components, which are converted into tar, gas products, water and residual solids semicoke.
After briquetting, the briquette may be drying or semi-coking before the pre-sintering process, causing it to coke and heat at different temperatures greater than 1000 degrees Celsius to form a coke product.
The shape and specification of the coke can be determined as needed, and commonly used shapes are ball shape, brick shape, strip shape, etc., and the quality of the coal briquette coke is determined by the shape and size.
The volatiles of the coke products obtained by high-temperature carbonization is about 2%. The coke is lustrous, the semi-coke volatile content is up to 10%, dull, with small strength, low carbon content. It can be used as a smokeless fuel or a synthetic gas raw material.
The decisive factors affecting coal carbonization are the heating rate in the kiln, the duration of heating and the carbonization temperature in the kiln, and the composition and properties of the briquettes from the raw coal have an effect on the control conditions and final products of the carbonization process.
The briquette produced from different coal types expands and shrinks during the carbonization process (heating process). The excessively fast heating rate causes the coal briquette to break or collapse.
The study found that there is a heating process in the critical temperature interval, the heating rate must be reduced in this temperature range to reduce the stress in the briquette structure, prevent the breakage of the briquette, and increase the final strength of the briquette.
If tar pitch or petroleum pitch is used as the binder of the briquette, the briquette may be deformed during the heating process, or the briquette may be bonded together due to the exudation of the binder from the surface of the briquette.
When the temperature in the carbonization kiln is below 650 C, the reaction occurring in the kiln is a decomposition reaction. When the temperature in the kiln is higher than this temperature, it is a condensation reaction.
Some scholars have different views on the temperature boundary, but it is certain that the coal blending type and proportion of briquette determine the temperature boundary line of decomposition reaction and condensation reaction, and control the temperature change in the kiln to produce high quality coke products.
The coal briquette coking process can be used with almost any coal types: lean coal, weakly cohesive coal, unbonded coal, semi-anthracite, and anthracite. It can produce high quality coke that meets the quality standards required by metallurgical coke and foundry coke.
And this is a high-quality, low-pollution production method. The pollutants emitted in production are only 20% of the pollutants emitted by the traditional coking process, and the pollutants discharged are easy to control and recycle.
how to make charcoal briquettes: components and process - nusagro
How to make charcoal briquettes Charcoal briquettes are a type of fuel that is made from charcoal powder. In comparison to traditional fuels, charcoal briquettes not only produce continuous heat but also produce no smoke or odor during combustion.
As a result, it has become the most popular fuel in many countries, including Kenya, the Middle East, and Uganda, India, etc. and has been widely used in domestic and industrial applications in recent years.
The charcoal briquettes process has become one of the hottest processing industries due to the increase in its economic benefits. So, what are the ingredients of charcoal briquettes, and how to make charcoal briquettes?
There are two parts in making charcoal briquette: the charcoal that provides heat and the minor ingredients. Charcoal is the result of incomplete combustion of wood or wood raw materials, or pyrolysis in the absence of oxygen.
Charcoal accounts for more than 70% of all charcoal briquettes. People can make charcoal from a variety of woods, including beech, birch, hard maple, pecan, and oak, as the combustion material that provides heat.
The kiln is primarily responsible for the charcoals processing. The charcoal produced and extinguished in the kiln is commonly referred to as black wood charcoal. It has the advantage of being easy to ignite, but because it burns quickly and produces a lot of smoke, it is prone to exploding.
Because the charcoal briquette cannot make complete contact with oxygen during the combustion process, it will require the accelerator to speed up the combustion. The best accelerator is nitrate, which not only provides oxygen to accelerate combustion but also generates heat during combustion.
Arabic gum or acacia gum is another popular briquette binder. However, when it comes to cost, waste paper pulp is the best option. The final material produced will differ depending on the composition ratios used. The following are a few recipes for making charcoal briquettes:
Crush the carbonized wood with a hammer crusher or a roller crusher. Although different types of wood, such as bark, dry wood chips, wet wood, and so on, should be crushed to different sizes, they can generally be crushed into charcoal pieces of 5mm or less to make high-quality charcoal briquettes.
Briquetting is an important step in the charcoal manufacturing process. After entering the ball press, the raw materials will be subjected to three types of forces: the main driving force of the briquette machine, the friction force, and the centripetal force of the wall.
The charcoal briquettes can maintain their shape when they fall from the bottom of the machine due to moisture, adhesives, temperature (approximately 105 F or 40 C), and pressure of the briquetting machines rollers.
After manufacturing, immediately bag the charcoal briquettes or store them in silos. Following the preceding steps, charcoal briquettes will be produced at a rate of 2200-20,000 pounds (1-9 metric tons) per hour.
According to the information provided above, processing charcoal briquettes is not difficult. However, we must pay close attention to many details, such as component ratio and moisture, as these will all have a direct impact on the final quality.
Users must comprehend and confirm each step and detail of the charcoal briquettes processing process before proceeding. Then, select a reputable supplier for the purchase of the processing equipment, such as a crusher, dryer, briquette machine, and so on. One of the briquette supplier is Nusagro.
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