The raw materials for charcoal briquette production are widely available across the Middle East in the form of date palm biomass, crop wastes and woody biomass. With a population of date palm trees of 84 million or 70% of the world’s population, the potential biomass waste from date palm trees is estimated at 730,000 tons / year (approximately 200,000 tons from Saudi Arabia and 300,000 tons from Egypt). Date palm trees produce huge amount of agricultural wastes in the form of dry leaves, stems, pits, seeds etc. A typical date tree can generate as much as 20 kilograms of dry leaves per annum while date pits account for almost 10 percent of date fruits.

The fronds and trunks of date palm trees are potential raw materials for charcoal because of the potential to produce high calorific value and low ash content charcoal. Leaf waste will produce a low calorific value due to high ash content. In addition, woody biomass waste such as cotton stalks that are widely available in Egypt can also be a raw material for making charcoal. The contribution of the agricultural sector in Egypt is quite high at 13.4%.

Charcoal is compacted into briquettes for ease in handling, packaging, transportation and use. Briquettes can be made in different shapes such as oval, hexagonal, cube, cylinder or octagonal. An adhesive (called binder) is needed for the manufacture of the briquette. Two common binders are saw dust and corn starch.

Continuous pyrolysis is the best technology for charcoal production. Continuous pyrolysis has the ability to handle large biomass volumes, the process is fast and smoke production is negligible. When using conventional pyrolysis technology  (or batch carbonization), the process is lengthy, processing capacity is small and there are concerns related to harmful smoke emissions.

Apart from charcoal, continuous pyrolysis also gives bio oil, wood vinegar and syngas. Syngas can be converted into electricity by using a gas engine or converted into a wide variety of biofuels through different processes. Bio oil can be used as boiler fuel and marine fuel. Wood vinegar can be used as biopesticide and liquid organic fertilizer. Low water content in date palm waste fronds and trunks make it very suitable for thermochemical conversion technologies, especially pyrolysis and gasification.

Charcoal can also be used for the production of activated charcoal/carbon. Activated carbon is used by a lot of industries for purification processes. In addition, a number of industries that are using petcoke as fuel can switch to charcoal due to its better combustion properties and eco-friendly nature.

For more information on how to set up charcoal production plant based on date palm biomass or other crop residues in the Middle East, please email salman@bioenergyconsult.com or eko.sb.setyawan@gmail.com

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