Design and Development of a Batch-Type Drum Kiln with Heat Insulation and Heat
Distribution Pipes
Chapter 1
Introduction
This chapter provides an overview about the study’s background, problem statement,
its objectives and significance, conceptual and theoretical framework, and its limitations. It
starts by addressing problems encountered in the biochar production specifically, the products
quality and its yield due to its in accurate design and implementation.
Background of the Study
Biochar production has gained significant attention due to its potential to improve soil
health, enhance carbon sequestration, and offer a sustainable solution for biomass waste
management. Despite its environmental and agricultural benefits, the production process faces
several challenges that hinder its widespread adoption and efficiency. One of the primary issues
is the inefficiency of traditional kilns, which often result in incomplete carbonization,
inconsistent biochar quality, and high energy consumption. Many small-scale producers rely
on primitive methods which may not be inefficient. Additionally, feedstock variability affects
the yield and quality of biochar, as different biomass materials require specific conditions for
optimal conversion. Overcoming these challenges, especially ensuring consistent and efficient
heating, is essential for producing high-quality biochar, reducing operational costs, and making
the process more accessible and sustainable for broader applications in agriculture and
environmental management.
One of the traditional ways of making charcoal in the Philippines is through pit and
mound charring (Rondina, 2018). This method involves burning wood or other organic
materials in a pit or a mound covered with soil or clay to limit airflow and oxygen supply.
However, this often leads to incomplete combustion, making the process inefficient and
resulting in low charcoal yields of only 8 to 15% (Energypedia, 2002). In contrast, modern
biochar production techniques, such as indirect heating, provide better control over the process,
leading to higher-quality charcoal and improved efficiency (Carrascosa, 2016). Among these,
drum kilns have gained popularity because they use readily available oil drums, are affordable,
and require minimal technical expertise to operate. These methods produce a low amount of
charcoal and take a long time to complete. Additionally, they are not very efficient, making the
process less effective overall. The researchers became interested in exploring a drum kiln
design that features a central pipe to evenly distribute heat throughout the kiln, aiming to
enhance the efficiency of the charcoal production process (Sangsuk et al., 2020). Additionally,
since heat loss is unavoidable in high-temperature operations, they also focused on
incorporating insulation materials into the kiln to minimize energy waste. One of the most
effective ways to achieve this is by using firebricks, which are specifically designed to
withstand extreme temperatures while offering excellent insulation (David et al., 2024).
Moreover, this will a batch-type kiln which offers an efficient and practical approach to
charcoal production by operating in cycles. Once a batch is fully processed, it is removed and
allowed to cool in a separate location, freeing up the kiln for the next batch. This system reduces
downtime, increases productivity, and improves fuel efficiency by retaining heat for the next
cycle. Unlike methods where charcoal cools inside the kiln, which wastes residual heat, this
approach ensures continuous operation and minimizes energy loss. Additionally, it provides
better control over the process, making it a cost-effective and sustainable choice for small-scale
producers and communities. By adopting this design, biochar production can be improved in
terms of quality, efficiency, and overall yield. However, research on this method is still fairly
new and has mostly focused on specific types of agricultural biomass.
This study seeks to explore biochar production further by designing and developing a
similar reactor suited for small-scale use, making use of locally available agricultural materials.
Statement of the Problem
Traditional ways of handling agricultural waste, like pit and mound charring to convert
agricultural waste into charcoal. However, this method is inefficient, slow, and yields minimal
charcoal, all while contributing to the growing problem of agricultural waste accumulation. As
environmental concerns rise, researchers are seeking more effective biochar production
methods that are faster, more efficient, and environmentally sustainable.
Modern biochar technologies, particularly indirect heating systems, have demonstrated
significant advantages in efficiency and output. However, these systems remain costly,
complex, and inaccessible to small-scale farmers and rural communities. As a result, many
continue to rely on outdated and inefficient techniques, missing the opportunity to improve
waste management and energy production. To bridge this gap, there is a need for affordable,
user-friendly, and scalable biochar production solutions tailored to local conditions. By making
advanced biochar technology more accessible, farmers can transform waste into a valuable
resource, minimize environmental impact, and promote sustainable agricultural practices.
Objective of the Study
This study aims to maximize the use of agricultural waste, develop a more efficient biochar
production process, and turn these goals into reality by designing, constructing, and evaluating
a functional reactor.
1. Design and develop a batch type kiln, with heat insulation and heat distribution pipes.
2. To evaluate the combustion efficiency and heat transfer of the kiln.
3. To ensure the kiln design is adaptable for small-scale farmers and rural communities,
making it cost-effective, easy to construct, and maintain.
Significance of the Study
This study provides a more efficient and sustainable way to produce biochar from
agricultural waste. By using a batch-type reactor with heat distribution pipes and insulation, it
seeks to improve charcoal yields and optimize energy use. Beyond enhancing production, this
research could help farmers generate extra income while encouraging better waste management
practices. In the long run, it has the potential to support a greener, more cost-effective approach
to biochar production, benefiting both people and the environment.
Scope and Limitations
The researcher’s scope and limitations, in which a factor in the study are as follows:
1. It will focus solely on the Design and development of a batch-type kiln with heat
insulation and heat distribution pipes.
2. The study will ensure that the kiln is practical for small-scale farmers and rural
communities, making it affordable, easy to build, and maintain using locally available
materials.
3. The study is limited to batch-type kilns and does not explore continuous or large-scale
industrial reactors.
4. It will focus on design and efficiency, but long-term economic viability and widespread
adoption will require further real-world testing and refinement.
Theoretical Framework
This part aims to offer a systematic understanding of the key factors influencing the
reactor’s performance, considering the yield of charred biomass, the conversional efficiency of
the drum, and mass insulation.
1. Mass Insulation
The calculation of the required mass for insulation hinges on the considerations of the
cylindrical hollow’s volume and the density of the insulation material employed. (Totala
et al., 2014).
2. Temperature Difference
The temperature difference in insulation refers to the variation in temperature between
the two sides of the insulation material.
3. Heat Loss
Heat loss in insulation refers to the amount of the thermal energy that escapes or
transfers through a material used for insulation. The unit of the heat loss is in Watts (W)
(Cengel & Ghaljarc, 2020).
Conceptual Framework
Design Process Development
1. Design Considerations 1. Canvassing of Materials
2. Design Parameters 2. Fabrication and Assembly
3. Modeled Design and Simulation 3. Calibration and Commissioning
Study Flow Process
Design Process
The design of the reactor plays a crucial role in biochar production, as it directly affects
efficiency, quality, and sustainability. To create an effective and reliable system, it is essential
to identify the key components needed for an efficient pyrolysis process. The initial step
involves drafting the preliminary design in SolidWorks, which will provide a clear visual
representation of the concept, including labeled dimensions and essential features.
Development
Once the design is finalized and the necessary materials are carefully selected, the
project will move into the development phase. All materials will be locally sourced, ensuring
accessibility and cost-effectiveness. Skilled local craftsmen will handle the assembly, while
researchers closely monitor the fabrication process to ensure the design meets specifications.
Throughout development, the team will also track costs, material usage, and overall efficiency
to optimize the final product.
