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GRET and LDP project participate in the provision of technical assistance to workshops,
including main assignments as follows:
1) Carrying out first production trial.
2) Adjusting techniques- technology of building and burning kilns
3) Reviewing financial and technical aspects of production
4) Making proposals on future investment in charcoal production sector
1. Preparation work
a. Transferring primary production equipments to existing workshops
• It is concluded after discussion with workshop owners and based on the workshops’
needs and demand as well as their strategy, financial situation and land availability.
o Three workshop owners expressed their concern and agreed to the establishment
of kilns (X1, X2 and X4); X3 has no interest in coordination with X5
o X2 is not suitable for charcoal production because the workshop location lies in a
narrow area, failing to provide enough space for building a kiln.
o To make up for this, all workshops allow using X5 as the third trial. Therefore,
charcoal production is carried out in 3 workshops: X1 (Thien Phu - Quan Hoa),
X4 (Dien Chung – Ba Thuoc) và X5 (Xuan Phu – Quan Hoa)
b. Preparing construction materials
o Materials collected on-site (cement, sand, bricks…): Bricks, sand are materials
produced and available in the region. Cement is also available near the
construction site, its price is nearly similar to that is in the plain’s market (only
higher by 7-10%).
o Materials purchased from Thanh Hoa: (glass wool, refractory bricks, glass liquid):
these are special materials used for refractory structure of the kiln. They are not
available in the region (including Thanh Hoa city) and have to be ordered from
companies of refractory materials in Bac Ninh, Thai Nguyen at very high price:
• Refractory brick: Price offered by the Factory is 1,700 VND/Kg, equivalent to
6,000 VND/unit (each brick unit weighs 3.5 Kg on average) excluding
delivery fees.
• Glass wool: 18,000 VND/kg.
- After studying the market, the team bought refractory bricks and glass
wool from Thanh Hoa ceramic company at the price equivalent to 60% of
market price (3,500 VND/brick unit, 1,000 VND/Kg glass wool)
- However, there is not high amount of these materials left. Therefore, on
building the new kiln, material cost should be calculated according to
factory’s price.
c. Collecting raw materials
o After finishing the kiln, it takes at least 1-2 days to dry it before loading material
for burning trial. The first burning time aims to dry the kiln and check its
techniques so it is not necessary to take consideration of material and product
quality.
o From the second one, it is necessary to monitor burning techniques to identify
product quality. Different kinds of material have different period of burning :
• For dry and thin material: burning time is short (ex. X4;1, it’s to say, the first
cycle of kiln build in X4 workshop)
• For thick and fresh material: burning time is prolonged (ex. X4;3)
Then after burning, the whole kiln will be evenly dried, with high temperature and
high quality products.
o Poles with thick wall and small perimeter will take time for fire distribution,
requiring long time of burning and cooling which leads to maximum temperature
inside the kiln and makes products with high quality and suitable for activated
carbon production.
d. Supporting kiln building
After studying reference documents of INBAR on techniques of building kiln and
technology of burning carbon with anaerobic kiln, GRET research team assigned two
officers to carry out following works:
o Studying techniques of loading and burning carbon in anaerobic conditions
according to the traditional method used by some villages and workers of burning
carbon in Tan Thanh, Luan Thanh communes of Thuong Xuan district, Hop Tien,
Hop Ly communes in Trieu Son district, and mountainous areas in Thanh Hoa
province.
o Carrying out burning trial of 3 rudimentary kilns in Kien Tho commune, Ngoc
Lac district - Thanh Hoa for testing burning technology and learning experience.
o Visiting workshops of charcoal production from bamboo luong in provinces of
Hoa Binh (Mai Chau and Ky Son districts), Vinh Phuc, to select building
technology and the kiln shape as well as study more about information of
techniques, market and price of each product.
o Referring to teachers of Hanoi university of technology and some workshops of
ceramic production in Thanh Hoa on techniques and technology of building
refractory kiln, and finally:
- Calculating and designing kiln model - estimating material cost - making
estimates of cost and plan of building kiln for workshops.
8 7 6 5
1
4
* Refractory brick, glass liquid and glass wool are structural material composition
located deep inside aiming at ensuring maximum burning temperature of the kiln and
products with highest quality (activated carbon) due to the following effects:
- Completely preventing the inside heat from releasing
- Absorbing and storing heat inside the kiln to reach maximum
temperature degree.
- Assisting the kiln to have high refractoriness and resistance against
cracks on the wall inside the kiln.
- The rest material is the kiln frame
o During burning, there should be two project staff taking turns to be present at the
workshop, to provide instruction on techniques of anaerobic burning to the
building workers.
o Workshops have searched and mobilized skilled brick-layers on-site to carry out
construction:
Each workshop hires 1 group of workers to carry out construction; these groups
have different capability, leading to delivering kilns with different quality.
On the other hand, due to research activities for learning experience performed
after each kiln building, the one which was built later has better quality and
lower construction fees than the previous one:
Kiln X4:
- After exchanging and reaching agreement with workshops, the research
team and X4 made first construction plan of only a simple kiln. After
finishing the kiln, they had trial burning performed for a period. X1 was
only built after exchanging and drawing experience of X4 first kiln.
Kiln X1:
- X1 was built as a double kiln, with thicker composition to ensure its
tightness and firmness. The cost to build this kiln is equivalent to 80% of
X4 cost (for each kiln).
Kiln X5:
- After firing X1 for two periods, the research team together with
workshops reviewed coal quality, discussed the kiln structure, firing
technology and recognized that more studies need to be done on
technology of building kiln and burning coal in Lam Dong province,
before building a kiln in X5.
- After studying more about techniques of building kiln in Lam Dong and
from advices of the experts visiting the workshop, it is necessary to
change its design (building the kiln in round or ellipse shape) to ensure
higher temperature inside the kiln. However, this shape of kiln can lead to
difficulty in techniques of building the cover, technology that requires
skilled workers with much experience in doming and having enough care
in their work.
2. Carrying out first production periods and checking coal quality
a. Building and performing burning trials in X4 kiln :
1. From 20/1 to1/2 building simple kiln in X4 (Dien Trung commune)
- Size of the kiln:
+ Inside: 2.7 x 1.5 x 1.5 m
+ Outside: 4 x 2.8 x 2.0 m.
- Structure:
+ The first layer: 24 cm fire-resistant brick
+ The second layer: glass wool of 5 cm thickness
+ The third layer: kiln residues (slag) of 15 cm in thickness.
+ The forth layer: normal brick for kiln wall of 21 cm in thickness.
+ Parabolic-shaped dome in 4 layers with domed frame made of iron.
o Expense details of building X4:
No. Details Unit Amount Unit price Total
I Materials 16,150,000.00
1 Refractory brick Brick unit 2000 3,500.00 7,000,000.00
Glass liquid Kg 200 2,500.00 500,000.00
2 Asbestos fiber kg 200 10,000.00 2,000,000.00
3 3-mm iron sheet m2 10 250,000.00 2,500,000.00
4 Normal brick Brick unit 4000 450.00 1,800,000.00
5 Cement Ton 1 750,000.00 750,000.00
6 Sand Trip 1 200,000.00 200,000.00
7 Kiln residues Trip 1 500,000.00
8 Delivery Trip 1 900,000.00 900,000.00
II Total 4,100,000.00
Total 20,250,000.00
Kg of
Kinds of Time of Time of Rate of
loaded Note
material burning cooling products
material
Dry 1,5 tons 48 hours 72 30% Small amount of loaded
bamboo hours material, short time of burning,
knots 30% low quality products (coal
temperature reach about
300oC)
Fresh 1,8 tons 72 hours 98 22% Products are not evenly burnt
bamboo hours with quite low quality (about
knots 400oC≈ To charcoal)
Fresh and 2,5 tons 86-92 98 20% Products are evenly burnt with
small hours hours good quality, temperature
poles inside the kiln is quite high:
(600oC≈ To low quality
activated carbon)
The above table is based on realistic calculation in X4 and from the certificate of quality
control done by Quang Ninh company of quality verification. This table shows that:
- If the material for burning is bamboo knots, bottoms obtained from by-products of
chopstick and slats for flooring production, product quality will not be high because this
material is not equal in terms of freshness and age of culms, leading to not enough
temperature inside the kiln.
- However, this material is available and cheap so it could be used for producing charcoal
instead of wood coal (this could be a potential product replacing wood coal when this
production is being limited due to risk of deforestation and forest-fire from coal fire).
- If fresh and small bamboo poles are used as material for burning, coal can reach high
quality, with the temperature similar to that of activated carbon. This product can become
activated carbon, a product with very high value and demand (for exportation) through
one more step of activation. Despite the availability and not really high value of this
plant, it is necessary to make quick collection and careful selection to ensure both quality
and freshness.
Kiln X4-1
- Time of burning: 45 hours - Time of cooling: 4 days
- Amount of obtained products: 242 kg. (30% of the kiln is not usable, not burnt)
Table of specific expense estimate
• Alternating material:
After gaining experience from the first burning period, there are changes as follows:
- Kilns X4-2: Root + 200kg fresh pole
- Burning material for kiln X4.3 is small poles which are older than 3 years with
thick wall, and completely fresh. Thus, the total amount of material loaded into
the kiln reached 2606 Kg, twice as much as it was in kiln 1.
- Due to fresh and old enough material and a longer time of burning, kiln 3
produces good quality. There is only 5% of those lying the bottom of the kiln
which is not burnt completely.
- Besides, 564kg of products reach high quality (checking quality in Quang Ninh
shows that coal obtained from his kiln reaches the temperature of 600oC). Some
is up to 7800kj/kg (Material coal accepted in Japan and Korea is 6000-6500kj/kg)
b. Building kiln and carrying out trial in the workshop X1: Double kiln - Thien
Phu.
Construction of kiln 1 began after the first period of kiln X4 was finished (in order to
redesign the suitable appearance, wall and gate). Its wall is thicker than that of X4 by
15cm; the gate for loading material is different of the burning gate:
- Size of the kiln:
+ Inside: 2 x (2.5 x 1.5 x 1.5 m)
+ Outside: 4 x 5.4 x 1.8 m
- Structure:
+ The first layer: 24 cm fire-resistant brick
+ The second layer: glass wool of 5 cm thickness
+ The third layer: kiln residues of 15 cm in thickness.
+ The forth layer: normal brick for kiln wall of 21 cm thickness.
+ Parabolic-shaped dome in 4 layers with domed frame made of iron.
• Alternating material:
Thanks to experience gained from the first burning period, there are changes in
the next periods as follows:
Kiln X1- cycle 2: Fresh bamboo ends
o Materials used are completely fresh bamboo ends with thick wall, so there is a
great amount of loaded material; however, it takes time to complete burning (50
hours longer than cycle1).
o Age quality of bamboo poles are not equal, there are still many tender, spongy
poles which make products at low quality.
o Despite longer burning time than kiln 1, too thick wall leads to many non burnt
materials, of which the rate is rather high (25-30%) with the temperature inside
the kiln of only 450oC.
Kiln X1- Cycle 3: Fresh bamboo poles type 3-4 (circumference < 27-30 cm)
o Thanks to experience gained from the 2 previous kilns (cycles), the material of
kiln 3 was completely burnt. Only 10% of poles lying in the kiln bottom is not
completely burnt (due to the too high design of the chimney gate and lack of an
iron support in the kiln bottom).
o Product rate of kiln 3 reaches up to 18% excluding the non burnt part. Quality
obtained is high, with the temperature inside the kiln of 550oC (by deduction).
Kiln X1- cycle 4: Thick bamboo luong ends and knots which are split into laths
o After discussion and experience exchanges, the team decided to have kiln X1 gate
lowered by 10 cm
o Place the iron support in the kiln bottom so that the internal temperature can reach
the material layer lying in the bottom.
o Based on experience of handicraft workers, the team waited until white smoke
was seen around chimney wall to have the kiln covered (combustion stopped).
o All of the above aspects help to gain better quality of product than kiln 3 with
product rate of over 19% (excluding the non burnt part).
o Product rate of kiln X1.5 reaches nearly 20% of loaded material, coal quality
reaches activated carbon at low level (about over 600oC).
o This is the kiln with highest quality compared to other kilns due to the experience
gained from the previous ones.
o After discussion, the team and workshop decided to leave one of two kilns (A) for
burning trial a second time, in order to study activation capacity of the kiln:
To examine the activation capacity in the kiln (second burning cycle), the research
team carried out:
i. Coal gained after burning of kiln X1-5.A was left untouched in the kiln, the gate
was largely open so that the water stream can be absorbed in 3 days before re-
burning.
ii. Carrying out 30 hours of continuous burning so that charcoal can interact with
water stream (H2O) and carbon dioxide (CO2) released from burning period at
high temperature (kiln temperature) then covering for cooling in 3 days.
After unloading, according to visual comments of the team and workers of burning:
Coal gained after re-burning is blacker, more spongy and lighter; however, it is
necessary to have specialists to reexamine the accurate quality.
c. Establishment and burning trial of X5: carried out after first periods of kilns X4 and
X1 and after visits to workshops and traditional kilns in Lam Dong:
• Establishment: Kiln X5: After 2-3 periods of burning carried out in kilns X1 and X4
together with experience gained from visits to kilns of coal burning of Da Lat
company of urban sanitation and advices of some experts, there are changes in
establishment of kiln X5 as follows:
o Kiln was built in round (elliptical) shape – high dome.
o One of the two kilns was built with only one layer of fire-resistant brick and
especially:
After the research visit in Lam Dong, the research team realized that:
Each ton of material can produce 6-8% attar (essential oil) (equivalent to
60-80kg attar), an important income source in the process of coal burning.
And market demand (in Japan, Korea) is very high (« buy all if available»
– said staff of Da Lat company of managing urban facilities)
Amount Unit
Details Unit Total
A B Total price
Loaded material Kg 2600 3100 200
Time of burning + Hour 148 157 157
cooling
Labor for burning Labor 20 20 20 30000
Firewood for burning Kg 750 900 200
Attar (vinegar) Kg 76 100 176
o It is the first time of extracting attar without much experience; on the other hand,
about 20% of loaded material as bamboo ends and knots is dry, these two elements
lead to not high amount of obtained attar; however:
o Attar quality gained can meet exportation standard based on examine instruction of
Da Lat company of managing urban facilities (pH level ranges from 3 to 4).
o This amount of attar was sent as offer to several companies, among which a company
based in Lao Cai (owned by Mr. Dan) agreed to buy at the price of 10.000 VND/kg;
Mr. Dan promised to visit the workshop and apply for purchasing of all the attar
extracted by us.
3. Conclusion:
By April 30th, 2007, all the 3 workshops (X1, X4 and X5) had kilns built and 8 burning trial
have been carried out. After burning, each place had exchange of experience performed
between the research team and workshops owners, therefore:
o Coal quality is always improved kiln after kiln.
o Up to May 30th 2007, all workshops owners had mastered fundamental techniques of
burning and monitoring methods for the highest quality.
o In the last 4 kilns (cycles) in workshops X1 and X4, coal quality reaches at least 600oC
(samples of X4-3 have been sent for examination) equivalent to temperature to obtain
quite low quality activated carbon (>600oC).
o In kiln X1-5, the second period of burning trial was carried out with success and produces
high activated carbon: coal then produced is black, spongy, light (of course, it will be sent
for examination of quality)
o In kiln X5, attar extracting was carried out and produced 176 kg attar (vinegar) with
accepted quality which was sent as offer and accepted by customer at the price of
10.000VND/kg (now pending for order from customers so that mass production (in large
amount) can be carried out)
3.1 Comments on production expense and investment
a. Investment efficiency
o According to INBAR guidance disseminated in Internet together with requirements
on product quality, the research team sees that investment in establishment of kiln and
burning trial in workshops of the project is completely possible and beneficial:
• If bamboo attar (vinegar) is added to final products, we will have more 2,000,000-
3,000,000 VND/5 tons of bamboo. (200-300kg attar) therefore, with the domestic
selling price of 2000 VND/kg bamboo coal, we can gain total revenue on 6 tons
of bamboo (including firewood) of from 4,000,000-5,000,000 VND, in which
total production expense is only 2,000,000 VND (if end knots are used as
material) and 3.500.000 VND (if tender bamboo plants are used as material).
b. Related impacts:
• Additionally, there is much amount of small bamboo luong plants with low
economic value which are often sold for column (pole) at 200-300 VND/kg. This
kind of material is small but firm and has high life-expectancy (over 3 years), so it
is very suitable for production of high quality coal. If this material is taken
advantage for coal burning, it can bring about high economic value (exportation)
to increase income of luong planters.
• All of the materials used in kiln building are produced and sold in large amount
nationwide, and can be easily purchased. Their price is not high (see details at the
table of kiln building expense)
• Especially, after visiting Lam Dong where there are many households producing
activated carbon and charcoal from similar kilns using Japanese technology, the
research team sees that: it is possible to reduce cost of kiln building, if we can
take advantage of land position of the mountainous area to remove some layers
but still ensure kiln and coal quality:
Currently kiln X5 with the volume of 11m3, total building expense is about
25,000,000 VND (double kiln in X5 costs 41,600,000 VND)
If removing fire-resistant layer, each kiln with the volume of 10M3 only costs
10-12,000,000 VND.
If digging a deep hole to build the kiln and only building a refractory layer,
each kiln with the volume of 10M3 only costs 16-17,000,000 VND.
d. Production expense
o After two first period of drying as well as testing for experience, from the third one,
technology of burning has been perfected, burning kiln produces high quality coal,
product rate is 22% (1 ton of fresh bamboo produces 220kg coal + 20-30kg attar).
Coal burning can bring about high economic efficiency:
o Kiln X4- Cycle 3 for ex. (have had quality examined)
o The above table is based on charcoal selling price in domestic market at lowest price
(selling to Truong Phat activated carbon incorporated company - Bac Giang - this
price has excluded delivery cost). The value can greatly increase through exportation.
(0.5 US/kg – FOB Hai Phong)
• The kiln used for coal burning is anaerobic kiln which can resist heat and
burn coal under method of heat distribution. Therefore, it requires that the
following aspects should be ensured:
- Totally close: in order to prevent air circulation as well as heat from releasing
in the process of burning and cooling.
- Heat resistant (refractory): in the process of burning and cooling,
temperature inside the kiln can reach over 1000oC, so kiln structure should
have high capacity of heat-resistance, otherwise phenomenon of crack and
damage can occur.
- Quickly heat absorbent: because temperature and quality of coal will
completely depend on kiln temperature, the inside wall the kiln must have the
capacity of not only absorbing heat but also quickly absorbing heat so that
kiln temperature can reach highest degree in the process of burning and
cooling.
- Resistant against internal pressure: during burning and cooling, because the
kiln is completely close and the inside temperature quickly increases, the air
in the kiln is quickly elastic that creates a very strong push from inside.
Therefore, to ensure that the kiln is not cracked, broken or even exploded, the
kiln wall structure must be really thick and firm (metal support structure
bearing high pressure should be placed in kiln wall and top at the end of
building process).
150~280℃~
120~150℃ 450℃
280~450℃
60℃
Over 450℃
Selecting material for loading: For products with high quality, materials
selected should be fresh poles or fresh end knots of plants aged more than 3
years and not spongy.
Activation: the smoke will change from light white into blue white. At the
end of this process, white powder will dry water around the chimney opening
that leads to the state that white powder is seen around chimney opening as
smoke ash. This is the time for covering (cover the chimney opening first, kiln
gate later)
Coal refining: while the kiln is being covered, coal is still in the process of
heat distribution and heat release => kiln temperature continues to rise, if the
kiln is completely close, at the end of this process, it can reach 1000oC.
Cooling: after 3 days of refining, the kiln can be left gradually cool, or to
make it quickly cool, they use cool water to continuously spill its top.
4. Proposals
Although bamboo luong value chain has been developing and tends to completely alternate
wood coal sector in many countries in the world, especially in Japan, Korea, Taiwan, China
and European developed countries, it’s still a new sector in Vietnam, not only for customers
but also for producers. Therefore, there still exists great challenges in techniques of kiln
building and technology of coal burning for those who want to participate in this sector.
Currently there are 2 workshops producing bamboo coal in small scale (one in Hoa Binh,
another in Vinh Phuc), with different techniques of building burning kiln. There are some
bases and individuals who are studying with the expectance to participate in this new and
potential sector. They are also studying techniques of building and technology of burning
from many different sources.
With experiences gained from trial process, the research team makes some proposals as
follows:
• There are 2 kinds of kiln that can be used for burning bamboo coal
Normal kiln - producing low quality coal - this kind of kiln can be built by local
farmers or inhabitants because the construction techniques aren’t complicated and
it can be used for burning any type of material.
- This is an anaerobic kiln without refractory material: used for burning mixed
materials of which age and quality can not be identified (end knots, by-
products, wastes from chopstick and toothpick production) - these kinds of
material hardly produce products with high quality and high selling price.
- For this kiln, in the process of burning, the temperature inside can not exceed
500-600oC so normal brick mixed with soil can be used to build the wall
inside the kiln, while brick, sand and normal cement can be used to build the
surrounding wall.
- With the above structure, 01 kiln with the volume of 10m3 only costs
12.000.000 VND for construction expenses.
Refractory kiln - producing high quality coal - activated carbon - this kind of
kiln should only be built by enterprises or concentrated workshops due to many
advanced techniques:
- This kind of kiln has the capacity of high heat accumulation and resistance so
refractory brick, glass wool and glass liquid are necessary materials for
construction.
- Each refractory kiln with the volume of 10m3 costs a bit higher than
30.000.000 VND for construction expenses.
• Kiln should be covered only when, or right after, white powder is seen around the
chimney.
Kiln X4- cycle 3: fresh small bamboo poles with thick wall
Loaded material Kg 2606 2
50 651,500.00
Time of burning + cooling Hour 283 0.00
Labor for burning Labor 12 30,0
00 360,000.00
Firewood for burning Kg 750 2
00 150,000.00
Pack Piece 38 1,5
00 56,400.00
Deduction KG 564
60 33,840
Total expense VND 1,161,500
Obtained product VND 2,170,400
Coal kg 564 2,0
00 1,128,000
Attar (4% total material) kg 104 10,0
00 1,042,400
Net profit 1,008,900.00
According to the above detailed tables: if charcoal produced is only for sale in domestic
market, it is necessary to extract attar for economic benefits (it can be much higher through
exportation)