Sustainable conversion of agricultural waste into solid fuel (Charcoal) via gasification and pyrolysis treatment

• The conversion of agricultural waste materials into charcoal helps to promote renewable energy. • Reduce the pollution caused by burning agricultural waste in the fields. • Charcoal produced through PK tends to have larger sizes, higher fixed carbon content, and a cell structure with less damage, making it suitable for premium-grade charcoal or for applications such as filtration or wastewater treatment. • Charcoal from the GK is better for grinding into briquettes as it tends to shrink or break into smaller pieces, and the cost of building a kiln is lower. • The kiln’s design offers an advantage due to its efficient charcoal burning and cooling times. Managing agricultural waste by burning it in the fields is a straightforward method, but leads to significant pollution. One promising alternative is to convert agricultural waste into solid fuel, such as charcoal, to support renewable energy from biomass. The quality of barbecue charcoal depends upon selecting suitable materials and employing heating methods to ensure efficient transformation. This research aims to study the charcoal conversion process from agricultural waste using two types of kilns: 1) direct heating (gasification kiln: GK) and 2) indirect heating (pyrolysis kiln: PK) designed to recirculate syngas from wood as fuel for the pyrolysis process. The study tested three types of agricultural waste materials, including coconut shells (CS), cassava rhizome (CR), and acacia wood (AW), to examine the differences in charcoal produced by the two heating methods. The tests revealed that the maximum temperatures inside the kilns were 792.45 ± 127.18 °C, 907.67 ± 37.3 °C, and 980.07 ± 110.56 °C for the GK, and 921.88 ± 57.84 °C, 801.93 ± 10.16 °C, and 937.82 ± 95.85 °C for the PK. The charcoal from the PK exhibited higher calorific values than the GK, with 7474.68 ± 36.62, 6429.04 ± 72.22, and 7268.33 ± 52.86 calories per gram. The charcoal yield was also higher in the PK, at 31.29 ± 4.39, 34.33 ± 3.39, and 17.58 ± 2.09 percent for coconut shells charcoal (CSC), cassava rhizome charcoal (CRC), and acacia wood charcoal (AWC), respectively. However, the PK required more fuel and longer ignition times. The resulting charcoal from the slow pyrolysis process in the PK is suitable as barbecue fuel due to its size, which is similar to the original material. In contrast, the charcoal from the GK, which tends to shrink or break into smaller pieces, is more suitable for grinding into briquettes. This study provides a guideline for producing high-quality barbecue charcoal, offering commercial benefits including the gasification and pyrolysis processes that improve combustion efficiency and reduce pollution by producing high-quality gas for fuel, unlike traditional kilns that emit a large amount of CO during the conversion of wood to charcoal and enabling the selection of appropriate raw materials for different heating methods to maximise the utility of the products. This approach adds value to agricultural raw materials and helps effectively manage agricultural waste (zero waste) for further utilisation and development.