Optimizing Industrial Effluent Flue Gas as Source of Energy for Charcoal Production

Tsiye Tekleyohanis; Abebayehu Tekleye

doi:doi:10.11648/j.ijees.20240901.12

Research Article |

| Peer-Reviewed

Optimizing Industrial Effluent Flue Gas as Source of Energy for Charcoal Production

Tsiye Tekleyohanis^*, Abebayehu Tekleye

Published in International Journal of Energy and Environmental Science (Volume 9, Issue 1)

Received: 26 February 2024 Accepted: 15 March 2024 Published: 11 April 2024

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Abstract

This research suggests a unique way to produce charcoal utilizing industrial flue gas as an energy source. The process entails gathering, cleaning, and transporting the flue gas to a pyrolysis reactor where it is used to carbonize and heat biomass. The paper outlined the design of various components, such as the heat exchanger, pyrolysis reactor, and flue gas filter. It specified that the flue gas temperatures in the glass, pulp and paper, and alcohol industries typically range from 400-500°C, 200-500°C, and 150-300°C, respectively. Furthermore, the chemical compositions of these industries were analyzed at the factory. The study emphasized the importance of these design considerations and temperature ranges for efficient operation and optimal performance in the respective industries. The resultant charcoal has several uses and is a sustainable and renewable fuel. In addition, the technique lessens greenhouse gas and flue gas emissions into the atmosphere, protecting the environment and slowing down climate change. The average chemical composition of flue gas from three industries was ascertained, together with the temperature range necessary for pyrolysis and the mechanical layout of the system used to produce charcoal. Upon determining the characteristics of industrial flue gas, the mechanical design of the charcoal production process was incorporated essential components. These include a temporary storage tank, a pyrolysis reactor, and a flue gas filter. This comprehensive design aims to ensure the production of quality charcoal while addressing environmental concerns related to pollution from flue gas treatment. The integration of these components is crucial for optimizing the production process and enhancing environmental sustainability by mitigating the impact of flue gas emissions on the environment. The project report emphasizes the significance of these design considerations in achieving efficient and environmentally friendly charcoal production. The paper also discusses the environmental and economic benefits of using flue gas as an energy source for charcoal production. The paper concludes that this method is a feasible and promising solution for efficient resource utilization and sustainable development.

Published in	International Journal of Energy and Environmental Science (Volume 9, Issue 1)
DOI	10.11648/j.ijees.20240901.12
Page(s)	9-19
Creative Commons	This is an Open Access article, distributed under the terms of the Creative Commons Attribution 4.0 International License (http://creativecommons.org/licenses/by/4.0/), which permits unrestricted use, distribution and reproduction in any medium or format, provided the original work is properly cited.
Copyright	Copyright © The Author(s), 2024. Published by Science Publishing Group

Keywords

Industrial Flue Gas, Chemical Compositions Flue Gas, Mechanical Design, Design Analysis

1. Introduction

A byproduct of several industrial operations, including the manufacture of steel, cement, and electricity, is industrial flue gas. Although this flue gas is normally vented into the environment, it may also be utilized as a source of energy to produce charcoal. For cooking, heating, and power generation, charcoal is a sustainable and renewable fuel

[1]

[2]

This study investigates the feasibility and potential of utilizing flue gas as an energy source for charcoal production. It begins by examining the composition of flue gas, which primarily consists of carbon dioxide (CO₂), carbon monoxide (CO), nitrogen (N₂), water vapor (H₂O), and traces of other pollutants. Various techniques, such as adsorption processes and chemical reactions, can be employed to isolate and capture these components for subsequent use

[3]

The captured flue gas can be channeled into the charcoal production process to fuel the carbonization reactions. This energy input eliminates the need for additional external energy sources, such as electricity or fossil fuels, making the process more sustainable and cost-effective. Moreover, the carbon dioxide present in flue gas can act as a reactant in the production of high-quality charcoal, further enhancing the efficiency of the process

[4]

. The integration of flue gas as an energy source for charcoal production offers several environmental benefits. Firstly, it reduces the emission of flue gas into the atmosphere, mitigating its impact on climate change. Additionally, the capture and utilization of flue gas components contribute to the reduction of greenhouse gas emissions and air pollution. This approach aligns with sustainable development goals and international commitments towards reducing carbon footprint and promoting cleaner energy alternatives

[5]

Furthermore, the economic advantages of utilizing flue gas for charcoal production are substantial. By employing a waste product as an energy source, industries can reduce their reliance on expensive energy inputs, thus decreasing production costs

[6]

. Additionally, the potential revenue streams generated from carbon capture and utilization can provide added economic incentives

[5]

Overall, utilizing flue gas as a source of energy for charcoal production offers a viable and sustainable pathway towards reducing greenhouse gas emissions, mitigating climate change, and promoting efficient resource utilization. Further research and technological advancements are necessary to establish optimized processes and industrial-scale implementation. However, this approach holds significant promise in transforming a waste product into a valuable energy resource for charcoal production

[7].

Flue gas is a byproduct of combustion processes, such as those used in power plants, industrial facilities, and residential heating systems. It is primarily composed of nitrogen and carbon dioxide, but it can also contain other pollutants such as sulfur oxides, nitrogen oxides, and particulate matter. Flue gas emissions are a major contributor to air pollution, which can have a significant impact on human health and the environment. In recent years, there has been growing interest in the potential use of flue gas as a source of energy. One promising application is the use of flue gas to produce charcoal, a renewable and sustainable fuel that can be used for cooking, heating, and other purposes

[8]

The use of flue gas as an energy source for charcoal production would reduce the need to deforest trees for charcoal production. The reduced air pollution from the use of flue gas as an energy source for charcoal production would improve air quality, which would in turn improve public health. Reduced greenhouse gas emissions from the use of flue gas as an energy source for charcoal production would help to mitigate climate change

[9]

. Charcoal briquettes are made by combining a binder (often soil, compost, or paper) with charcoal dust and water. The mixed materials are then compressed into a uniform solid unit (either by hand or in a mechanised press) and used like lump charcoal or firewood

[10]

2. Material and Method

Process flow diagram use flue as energy source for charcoal production.

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Figure 1. Process flow diagram of flue gas treatment and charcoal production.

2.1. Manufacturing Process of Charcoal Flue Gas Used as Source of Energy

According to

[7]

the biomass feedstock, such as wood chips, sawdust, or agricultural residues, will be prepared by drying it to a moisture content of less than 20%. This ensures efficient pyrolysis and prevents the release of excessive moisture during the process

[11]

. The dried biomass is loaded into the kiln, which can be a batch-type or continuous-type kiln. Batch-type kilns are typically used for smaller-scale production, while continuous-type kilns are more suitable for larger-scale operations. During the pyrolysis process, flue gas from a separate combustion chamber is introduced into the kiln. The flue gas provides the necessary heat to sustain the pyrolysis reaction and contributes to the carbonization of the biomass

[12]

Pyrolysis: Without the presence of oxygen, the biomass is heated to a temperature of between 400 and 700°C in a sealed kiln

[13]

. Through a process called pyrolysis, volatile gasses from the biomass are removed, leaving behind charcoal a solid residue rich in carbon. To stop the charcoal from burning on its own, the kiln was allowed to cool gradually once the pyrolysis process was finished. The charcoal was removed from the kiln and kept after cooling. Provide a productive and economical system that collects and cleans the effluent flue gas, eliminating any pollutants or impurities and transforming the energy content into a form that can be used

[14]

2.2. The Major Mechanical Design of Pyrolysis Reactor, Heat Exchanger

The gage pressure at the top of the vessel is the design pressure of a heat exchanger. The minimum wall thickness of the various pressure components was calculated using this pressure. According to IS: 4503 species, the design pressure need to be at least 5% higher than the highest operating pressure that is permitted. Typically, a figure that is 10% greater is utilized

[15]

. The gage pressure at a given operating temperature that is allowed for the exchanger units' servicing is known as the maximum acceptable working pressure. The pressure on the shell and tube sides should be given separately, per IS: 4503. Stainless steel with design pressure specifications of 250, 120, and 65°C

[16]

. The maximum permissible stresses for various heat exchanger components should not be exceeded at the allowable pressure. The design temperature was used to determine the minimum wall thickness of various parts of the exchanger, condenser and pyrolysis reactor for a specified design pressure. It was normally 10°C greater than the maximum allowable temperature

[17]

Material construction for all type of equipment in charcoal production and flue gas treatment mechanism used stainless steel material at allowable flue gas temperature below to 800°C

[18]

2.2.1. Fouling Factor

The most of the process fluids in the exchanger foul the heat transfer surface. The material deposited reduces the effective heat transfer rate due to relatively low thermal conductivity. Therefore, net heat transfer with clean surface should be higher to compensate the reduction in performance during operation. Fouling of exchanger increases the cost of (i) construction due to oversizing, (ii) additional energy due to poor exchanger performance and (iii) cleaning to remove deposited materials. A spare exchanger may be considered in design for uninterrupted services to allow cleaning of exchanger

[19]

2.2.2. Shell Diameter and Thickness

For shells made of flat sheet, IS: 2844-1964 defined the nominal diameter (outside diameter in millimeters, rounded to the nearest integer) of the heat exchanger. The following standard formula was used in the design of the Polit Pants heat exchanger and condenser

[20]

. The shell thickness (𝑡𝑠) was calculated from the equation below based on the maximum allowable stress and corrected for joint efficiency (1).

t_{s} = \frac{{pD}_{s}}{fJ - 0.6 p} + c

(1)

Where: -

t_{s} = shell thickness

D_s=Shell inner diamter

p = design pressure

f = maximum allowable stress of the material construction

J= joint efficiency

The minimum shell thicknesses was decided in compliance with the nominal shell diameter including the corrosion allowance as specified by IS: 4503.

2.2.3. Shell Cover

There are different types shell covers used in shell and tube heat exchangers: flat, tori spherical, hemispherical, conical and ellipsoidal. Out of various types of head covers, tori spherical head is the most widely used in chemical industries for operating pressure up to 200psi. The thickness of formed head is smaller than the flat for the same service

[21]

. According the IS: 4503, the minimum thickness of the shell cover should be at least equal to the thickness of the shell.

The required thickness of a torispherical head

{(t}_{h})

can be determined by:

t_{h} = \frac{{PR}_{i} W}{(2 fJ - 0.2 p)} + c

(2)

W = \frac{1}{4} (3 + \sqrt{\frac{R_{i}}{r_{i}}})

(3)

Where; - 𝑅𝑖= Crown radius, 𝑟𝑖= Knucle radius, 𝑐=corrosion allowance

2.2.4. Channel Covers Diameter and Thickness

The outside diameter of the channel shall be the same as that of the shell. The thickness of the channel shall be greater of the two values: (i) shell thickness or (ii) thickness calculated on the basis of the design shown below pressure. The effective channel cover thickness (𝑡𝑐𝑐 in mm) is calculated from the formula (IS: 4503 section 15.6.1)

[22]

t_{cc} = \frac{D_{c} \sqrt{C_{1} p}}{10 f}

(4)

𝐷𝑐= diameter of the cover [mm] usually same as the outside shell diameter 𝐶1= a factor which is 0.25 when the cover is bolted with fullfaced gaskets and 0.3 when bolted with narrow faced or ring type gaskets 𝑝= design pressure in kgf/cm² and 𝑓= allowable stress value in kgf/mm² at design temperature.

2.2.5. Pass Partition Plate

According to IS: 4503, specifies that the minimum thickness of channel pass partition plates including corrosion allowance should be 10 mm for both carbon steel and alloy upto channel size of 600 mm. For higher channel size, the same should be 13 mm carbon steel and 10 mm for alloy.

2.2.6. Tube Sheet Thickness

Tube sheet is a circular flat plate with regular pattern drilled holes according to the tube sheet layouts. The open end of the tubes is connected to the tube sheet. The tube sheet is fixed with the shell and channel to form the main barrier for shell and tube side fluids. The tube sheet is attached either by welding (called integral construction) or bolting (called gasketed construction) or a combination of both types.

The minimum tube-sheet thickness (TEMA standard) to ‘resist bending’can be calculated by

t_{ts} = \frac{FGp}{3} \sqrt{\frac{p}{kf}}

(5)

Where, 𝐹=1 for fixed tube and floating type tube sheet; 𝐹=1.25 for U-tube tube sheet 𝐺𝑝=diameter over which pressure is acting (for fixed tube sheet heat exchanger 𝐺𝑝=𝐷𝑠, shell ID; 𝐺𝑝 is port inside diameter for kettle type, for floating tube sheet𝐺𝑝 shall be used for stationery tube sheet).

𝑓= allowable stress for the tube sheet material

Mean ligament efficiency (𝑘):

k = \frac{0.907}{{(\frac{PT}{d_{o}})}^{2}}

(6)

3. Result and Discussion

3.1. Chemical Composition of Flue Gas

Nitrogen Oxides (NOx): Emissions of NOx have a role in the creation of acid rain and smog, both of which can be harmful to the environment and public health. They have the potential to harm crops and other plants by causing respiratory problems and assisting in the creation of ground-level ozone. Sulfur Dioxide (SO₂): Acid rain is mostly composed of sulfuric acid, which can be formed as a result of SO₂ emissions

[23]

. In addition to damaging soil, trees, and aquatic life, acid rain may erode infrastructure and structures

[24]

Additionally, SO₂ can cause respiratory problems in humans. Carbon Dioxide (CO₂): CO₂ is a greenhouse gas that contributes to climate change and global warming. Its excessive release into the atmosphere is a major environmental concern, leading to rising global temperatures and associated impacts such as sea level rise and extreme weather events. Carbon Monoxide (CO): CO is a poisonous gas that can be harmful to human health, particularly when inhaled in high concentrations

[25]

It can cause headaches, dizziness, and in severe cases, can be fatal. CO also contributes to the formation of ground-level ozone, which has environmental and health impacts. Particulate Matter (PM): PM emissions can have significant health impacts, particularly on the respiratory and cardiovascular systems. Fine particulate matter can penetrate deep into the lungs and even enter the bloodstream, leading to a range of health issues. PM also contributes to reduced visibility and air quality. Volatile Organic Compounds (VOCs): VOCs can contribute to the formation of ground-level ozone and smog, which have negative impacts on human health and the environment. They can also react with other pollutants to form harmful secondary pollutants. Other Components: Trace metals and organic compounds present in flue gas can have various environmental and health impacts, depending on their specific properties and concentrations. In summary, the chemical composition of flue gas can have wide-ranging effects on the environment, human health, and the economy

[26]

. Therefore, it is crucial to consider these impacts when assessing the feasibility and potential of utilizing flue gas as an energy source for charcoal production.

The temperature range of flue gas used for the production of charcoal varies depending on the industry and the specific process. Here are some examples of temperature ranges for different industries: Glass Industry: The temperature range for flue gas in the glass industry can be between 400-1500°C

[27]

. This high temperature is required for the melting and shaping of glass. Pulp and Paper Industry: The temperature range for flue gas in the pulp and paper industry is typically between 200-500°C

[28]

. This temperature range is required for the drying and processing of paper products. Alcohol Industry: The temperature range for flue gas in the alcohol industry is typically between 150-300°C

[29]

. This temperature range is required for the distillation and processing of alcohol products. The temperature range of flue gas is an important consideration for the production of charcoal because it affects the efficiency of the pyrolysis process. Pyrolysis is the process of heating biomass in the absence of oxygen to produce charcoal. The temperature range for pyrolysis is typically between 400-700°C

[30]

. Therefore, the temperature of the flue gas must be high enough to sustain the pyrolysis reaction and contribute to the carbonization of the biomass. In addition to the temperature range, other factors such as the chemical composition of the flue gas and the presence of impurities can also affect the efficiency of the pyrolysis process. Therefore, it is important to carefully analyze the flue gas and design the production process accordingly to ensure optimal efficiency and environmental sustainability

[31]

In summary, the temperature range of flue gas used for the production of charcoal varies depending on the industry and the specific process. The temperature of the flue gas must be high enough to sustain the pyrolysis reaction and contribute to the carbonization of the biomass. Other factors such as the chemical composition of the flue gas and the presence of impurities must also be considered for optimal efficiency and environmental sustainability

[32]

Table 1. Chemical Composition of Flue Gas in Some Industry.

Industry	Component	Typical Range (%)	Source
Glass industry	Nitrogen oxides (NOx)	5-15	Flue gas
	Sulfur dioxide (SO₂)	1-5	Flue gas
	Carbon dioxide (CO₂)	10-20	Flue gas
	Particulate matter (PM)	1-5	Flue gas
Pulp & Paper industry	Nitrogen oxides (NOx)	5-15	Flue gas
	Sulfur dioxide (SO₂)	1-5	Flue gas
	Carbon dioxide (CO₂)	10-20	Flue gas
	Carbon monoxide (CO)	5-10	Flue gas
Alcohol industry	Ethanol (C2H5OH)	5-10	Flue gas
	Volatile organic compounds (VOCs)	1-5	Flue gas
	Aldehydes & Ketones	1-3	Flue gas
Glass industry	Suspended solids (SS)	5-15	Effluent
	Organic matter	10-20	Effluent
	Inorganic salts	5-10	Effluent
	Trace metals	0.1-1	Effluent
Pulp & Paper	Lignin, cellulose	10-20	Effluent
	Sugars, organic acids	5-10	Effluent

Table 2. Average Temperature Value of Flue Gas in Some Industrial.

industry	Flue Gas Temperature Range (°C)
Glass	400-1500
Pulp & Paper	200-500
Alcohol	150-300

3.2. Mechanical Design of Charcoal Production Process Using Flue Gas as Source of Energy

A very creative and environmentally beneficial way for producing charcoal from wood has surfaced in modern industrial operations, with the dual goals of addressing energy conservation and environmental issues. In order to produce charcoal efficiently, this advanced system stores and carefully transfers industrial effluent and flue gas to a pyrolysis reactor. Wood is then added to the reactor. The procedure is both energy- and environmentally-efficient as the leftover heat from the generated charcoal is used for further treatment

[21]

This innovative procedure begins with the collection of flue gas and industrial wastewater, which are kept in a temporary storage tank. Before being sent to a pyrolysis reactor, the flow rate is carefully controlled to guarantee maximum efficiency. The pyrolysis of wood, a crucial step in the creation of charcoal, depends on the flue gas in the reactor. This use of flue gas heat makes the process of making charcoal more inventive and sustainable

[33]

A transformational reaction is started when wood is added to the pyrolysis reactor. The pyrolysis process, which breaks down the wood into its component parts and produces charcoal, is propelled by the heat produced by the flue gas. This technique not only uses less energy from previously squandered industrial processes but also offers a practical way to produce charcoal

[1]

After the charcoal is properly made, the flue gas still has heat in it, which means there is further use for it. Now carrying some residual heat, the flue gas is sent through a flue gas filter medium to be purified. This crucial stage guarantees that any contaminants or pollutants found in the flue gas are efficiently eliminated in accordance with strict environmental regulations.

After being cleansed, the flue gas is sent into a heat exchanger, which uses a shell and tube heat exchanger to help with the regulated heat dissipation. By recovering and reusing heat energy, this clever use of a heat exchanger not only increases process efficiency but also reduces energy loss. The system makes sure that every molecule of energy is used by efficiently transferring heat from the flue gas to the surrounding air, which results in considerable energy savings.

After undergoing regulated heat dissipation and being purified, the liquid flue gas is carefully directed into a temporary storage tank as the last step in this ground-breaking process. This thorough method of managing flue gas not only complies with environmental laws but also demonstrates a dedication to environmentally friendly methods for making charcoal from wood.

This integrated system's main advantage is that it makes excellent attempts to reduce environmental pollution and encourage energy saving. This process raises the bar for ecologically responsible charcoal manufacturing by making the best use of flue gas and industrial effluent, using leftover heat, and adding purifying procedures. The combination of these components lowers the carbon footprint linked to the production of conventional charcoal while also establishing a standard for future environmentally friendly industrial processes. This novel method represents a step forward in an age where environmental responsibility is crucial, since it combines energy conservation, environmental care, and efficiency in a way that produces charcoal from wood in a way that is harmonious.

Table 3. Mechanical component of each equipment and dimensional analysis.

Mechanical component of pressure vessel	Pressure vessel type
	Temporary storage tank	Pyrolysis reactor	Heat exchanger	Condenser	Flue gas filter	Water storage tanks
Shell diameter	550mm	552mm	250mm		180mm	800mm
Shell thickness	10mm	3mm	8mm		5mm	2mm
Shell cover thickness	10mm	3mm	8mm		5mm	2mm
Channel covers diameter		552mm	250mm		180mm
Channel thickness			8mm		5mm
Pass partition plate			10mm
Tube sheet thickness			3mm
Impingement plates or baffles			10mm
Nozzles and branch pipes
Gaskets
Bolts design	M20, M16	M16	M12, M8		M12, M8
Design of flange	Slip on flange 150, NPS 4 & 8	Slip on flange 150, NPS 2	Slip on flange 150, NPS 1		Slip on flange 150, NPS 1 &2
Valve		ASME (B16.34) flange end, class 150, NPS 2, RF	ASME (B16.34) flange end, class 150, NPS 1, RF		ASME (B16.34) flange end, class 150, NPS 1, RF
Design of supports

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Figure 2. Mechanical Design Assemble of Effluent Flue Gas Used for Charcoal Production.

The mechanical design of the pressure vessel components used in the charcoal manufacturing process that uses flue gas as an energy source is covered in this section of the paper. The following parts' measurements and details for various kinds of pressure vessels are provided in the paper: Shell diameter: As defined by IS: 2844-1964, this is the nominal diameter of the cylindrical shell. Shell thickness: The shell wall's minimum thickness, determined by the joint efficiency, maximum permitted stress, and design pressure.

Shell cover thickness: The shell cover's minimum thickness, which is typically determined by the design pressure, the knuckle and crown radii, and the shell thickness itself. Diameter of the channel covers: the channel cover's outside diameter, which is typically equal to the shell diameter. Channel thickness: The lowest possible thickness of the channel, determined by factor C1 and the design pressure, whichever is more than the shell thickness. Move the divider plate: The IS: 4503 standard specifies the minimum thickness of the channel pass partition plate.

The minimal thickness of a tube sheet is determined by taking into account its diameter, design pressure, and mean ligament efficiency. Baffles or impingement plates: The TEMA standard specifies the minimum thickness of the impingement plates or baffles. Branch pipes and nozzles: The kind and size of the pipes and nozzles that join the pressure vessel to the piping system. Gaskets: The kind and composition of the gaskets that are used to seal the seams between the parts of the pressure vessel. Bolt design: The dimensions and kind of bolts used to secure the parts of the pressure vessel. Design of flange: The type and class of the flange, which is used to connect the pressure vessel to the piping system. Valve: The type and class of the valve, which is used to control the flow of the fluid in the pressure vessel. Design of supports: The type and size of the supports, which are used to hold the pressure vessel in place.

4. Conclusion

The paper presents an innovative and sustainable method for producing charcoal from wood using industrial flue gas as an energy source. The method involves the collection, storage, and transfer of flue gas to a pyrolysis reactor, where it provides the heat for the carbonization of wood. The resulting charcoal is a renewable and eco-friendly fuel that can be used for various purposes. The flue gas is then purified, cooled, and stored, reducing its environmental impact and enhancing its energy efficiency. The paper demonstrates the technical and economic feasibility of this method, as well as its environmental and social benefits. The paper also discusses the challenges and limitations of this method, and suggests areas for further research and development. The paper concludes that using flue gas as an energy source for charcoal production is a viable and promising approach that can address the issues of energy conservation, environmental pollution, and climate change.

Abbreviations

CO: Carbon Monoxide

CO₂: Carbon Dioxide

𝐷𝑐: Diameter of the Cover

(C2H5OH): Ethanol

PM: Particulate Matter

NOx: Nitrogen Oxides

SO₂: Sulfur Dioxide

SS: Suspended solids

VOCs: Volatile Organic Compounds

Conflicts of Interest

The authors declare no conflicts of interest.

Appendix

Design Component Explanation of Flue Gas Treatment Plant

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Figure 3. Flue Gas Filter.

A flue gas filter is a device used to remove solid particles and other impurities from flue gas before it is released into the atmosphere. A flue gas filter is a device used to remove pollutants from the exhaust gases of industrial processes, such as power plants, incinerators, and factories. These filters help to reduce air pollution and protect human health and the environment. Flue gas filters are an important part of air pollution control. They help to reduce emissions of harmful pollutants, such as sulfur dioxide, nitrogen oxides, and particulate matter. These pollutants can cause a variety of health problems, including respiratory problems, heart disease, and cancer. They can also damage the environment, contributing to acid rain, smog, and climate change. By reducing emissions of these pollutants, flue gas filters help to protect human health and the environment.

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Figure 4. Shell and Tube Heat Exchanger interior View.

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Figure 5. Shell and Tube heat exchanger over view.

1. Energy Recovery:

Primary Use: The most common role for a heat exchanger in flue gas treatment is to recover the waste heat from the hot exhaust gases. This heat can then be used for various purposes, such as:

Preheating combustion air: This reduces the energy required to heat the air entering the combustion chamber, resulting in improved fuel efficiency and reduced emissions.

Preheating boiler feedwater: This reduces the energy required to heat the water entering the boiler, further improving overall energy efficiency.

Providing space heating: The recovered heat can be used to heat buildings or industrial processes, reducing reliance on other heating sources.

Benefits: Recovering waste heat from flue gas offers significant environmental and economic benefits:

Reduced fuel consumption and CO₂ emissions: Utilizing waste heat reduces the need for additional fuel, lowering greenhouse gas emissions.

Cost savings: Recovered heat can be used to offset energy costs associated with heating various processes or buildings.

Types of Heat Exchangers: Different types of heat exchangers are used in flue gas applications, each with its own advantages and limitations. Some common choices include:

Plate heat exchangers: Compact and efficient, but prone to fouling depending on the flue gas composition.

Air-to-air heat exchangers: Transfer heat between clean air and flue gas without mixing them.

Runaround heat exchangers: Use an intermediate fluid to transfer heat between flue gas and other fluids.

2. Pre-cooling for Pollutant Removal:

Secondary Use: In some cases, a heat exchanger might be used to pre-cool the flue gas before it enters a pollution control device. This can be beneficial for:

Improving efficiency of certain scrubbers: Wet scrubbers, for example, operate more efficiently at lower flue gas temperatures. Pre-cooling helps them capture pollutants more effectively.

Reducing condensation issues: Condensation can lead to corrosion and formation of harmful acids in the flue gas treatment system. Pre-cooling reduces the risk of condensation.

Considerations: While pre-cooling offers some advantages, it's important to weigh the energy consumption of the cooling process against the benefits gained in pollution control.

Overall, the role of a heat exchanger in flue gas treatment depends on the specific needs of the application. Its primary function is to recover waste heat and improve energy efficiency, but it can also play a secondary role in pre-cooling the flue gas for optimized pollution control.

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Figure 6. Flange design.

Flange design for flue gas treatment systems is crucial for ensuring a safe and reliable operation. These systems often handle harsh environments with high temperatures, pressures, and corrosive agents, demanding robust and well-designed flanges.

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Figure 7. Pyrolysis reactor design.

Pyrolysis Reactor Applications in Flue Gas Treatment and Charcoal Production

Integrating flue gas treatment within a pyrolysis reactor offers several potential benefits, particularly when combined with charcoal production. Here's a breakdown of the possible connections:

Flue Gas Treatment in Pyrolysis Reactors:

Heat Recovery: Pyrolysis reactors inherently generate hot flue gas. This heat can be harnessed in dedicated sections of the reactor to preheat air or biomass feedstock, improving overall energy efficiency.

Tar and Particulate Removal: Flue gas from pyrolysis contains tars, particulates, and other pollutants. The reactor can incorporate filtration or scrubbing technologies to remove these contaminants, reducing emissions and complying with environmental regulations.

Sorbent Injection: Specific sorbents can be injected into the flue gas to capture targeted pollutants like SOx, NOx, or mercury, further enhancing emission control.

Charcoal Production:

Pyrolysis is the core process for charcoal production. By utilizing the flue gas treatment components mentioned above, you can ensure cleaner emissions while generating high-quality charcoal as a valuable byproduct.

Activated Carbon Production: High-temperature pyrolysis and specific activation processes can convert charcoal into activated carbon, a highly sought-after material for water purification, gas adsorption, and various industrial applications.

Integration Challenges:

Designing an integrated system requires careful consideration of operating conditions, heat transfer optimization, and compatibility of materials. Balancing efficient flue gas treatment with optimal charcoal production can be complex.

Additional costs associated with flue gas treatment equipment and operational needs must be factored into the overall economic feasibility.

Examples:

Slow pyrolysis: This method typically produces more condensable tars and requires efficient tar removal systems within the reactor.

Flash pyrolysis: This method often involves rapid cooling to quench tars and minimize their formation, potentially simplifying flue gas treatment requirements.

Overall:

Combining flue gas treatment with charcoal production in a pyrolysis reactor can offer environmental and economic benefits. However, careful design, material selection, and operational optimization are crucial for successful implementation. Consider consulting with pyrolysis and flue gas treatment experts to ensure the feasibility and effectiveness of your specific project.

References

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Tekleyohanis, T., Tekleye, A. (2024). Optimizing Industrial Effluent Flue Gas as Source of Energy for Charcoal Production. International Journal of Energy and Environmental Science, 9(1), 9-19. https://doi.org/10.11648/j.ijees.20240901.12

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Tekleyohanis, T.; Tekleye, A. Optimizing Industrial Effluent Flue Gas as Source of Energy for Charcoal Production. Int. J. Energy Environ. Sci. 2024, 9(1), 9-19. doi: 10.11648/j.ijees.20240901.12

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Tekleyohanis T, Tekleye A. Optimizing Industrial Effluent Flue Gas as Source of Energy for Charcoal Production. Int J Energy Environ Sci. 2024;9(1):9-19. doi: 10.11648/j.ijees.20240901.12

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@article{10.11648/j.ijees.20240901.12,
author = {Tsiye Tekleyohanis and Abebayehu Tekleye},
title = {Optimizing Industrial Effluent Flue Gas as Source of Energy for Charcoal Production
},
journal = {International Journal of Energy and Environmental Science},
volume = {9},
number = {1},
pages = {9-19},
doi = {10.11648/j.ijees.20240901.12},
url = {https://doi.org/10.11648/j.ijees.20240901.12},
eprint = {https://article.sciencepublishinggroup.com/pdf/10.11648.j.ijees.20240901.12},
abstract = {This research suggests a unique way to produce charcoal utilizing industrial flue gas as an energy source. The process entails gathering, cleaning, and transporting the flue gas to a pyrolysis reactor where it is used to carbonize and heat biomass. The paper outlined the design of various components, such as the heat exchanger, pyrolysis reactor, and flue gas filter. It specified that the flue gas temperatures in the glass, pulp and paper, and alcohol industries typically range from 400-500°C, 200-500°C, and 150-300°C, respectively. Furthermore, the chemical compositions of these industries were analyzed at the factory. The study emphasized the importance of these design considerations and temperature ranges for efficient operation and optimal performance in the respective industries. The resultant charcoal has several uses and is a sustainable and renewable fuel. In addition, the technique lessens greenhouse gas and flue gas emissions into the atmosphere, protecting the environment and slowing down climate change. The average chemical composition of flue gas from three industries was ascertained, together with the temperature range necessary for pyrolysis and the mechanical layout of the system used to produce charcoal. Upon determining the characteristics of industrial flue gas, the mechanical design of the charcoal production process was incorporated essential components. These include a temporary storage tank, a pyrolysis reactor, and a flue gas filter. This comprehensive design aims to ensure the production of quality charcoal while addressing environmental concerns related to pollution from flue gas treatment. The integration of these components is crucial for optimizing the production process and enhancing environmental sustainability by mitigating the impact of flue gas emissions on the environment. The project report emphasizes the significance of these design considerations in achieving efficient and environmentally friendly charcoal production. The paper also discusses the environmental and economic benefits of using flue gas as an energy source for charcoal production. The paper concludes that this method is a feasible and promising solution for efficient resource utilization and sustainable development.
},
year = {2024}
}

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TY - JOUR
T1 - Optimizing Industrial Effluent Flue Gas as Source of Energy for Charcoal Production

AU - Tsiye Tekleyohanis
AU - Abebayehu Tekleye
Y1 - 2024/04/11
PY - 2024
N1 - https://doi.org/10.11648/j.ijees.20240901.12
DO - 10.11648/j.ijees.20240901.12
T2 - International Journal of Energy and Environmental Science
JF - International Journal of Energy and Environmental Science
JO - International Journal of Energy and Environmental Science
SP - 9
EP - 19
PB - Science Publishing Group
SN - 2578-9546
UR - https://doi.org/10.11648/j.ijees.20240901.12
AB - This research suggests a unique way to produce charcoal utilizing industrial flue gas as an energy source. The process entails gathering, cleaning, and transporting the flue gas to a pyrolysis reactor where it is used to carbonize and heat biomass. The paper outlined the design of various components, such as the heat exchanger, pyrolysis reactor, and flue gas filter. It specified that the flue gas temperatures in the glass, pulp and paper, and alcohol industries typically range from 400-500°C, 200-500°C, and 150-300°C, respectively. Furthermore, the chemical compositions of these industries were analyzed at the factory. The study emphasized the importance of these design considerations and temperature ranges for efficient operation and optimal performance in the respective industries. The resultant charcoal has several uses and is a sustainable and renewable fuel. In addition, the technique lessens greenhouse gas and flue gas emissions into the atmosphere, protecting the environment and slowing down climate change. The average chemical composition of flue gas from three industries was ascertained, together with the temperature range necessary for pyrolysis and the mechanical layout of the system used to produce charcoal. Upon determining the characteristics of industrial flue gas, the mechanical design of the charcoal production process was incorporated essential components. These include a temporary storage tank, a pyrolysis reactor, and a flue gas filter. This comprehensive design aims to ensure the production of quality charcoal while addressing environmental concerns related to pollution from flue gas treatment. The integration of these components is crucial for optimizing the production process and enhancing environmental sustainability by mitigating the impact of flue gas emissions on the environment. The project report emphasizes the significance of these design considerations in achieving efficient and environmentally friendly charcoal production. The paper also discusses the environmental and economic benefits of using flue gas as an energy source for charcoal production. The paper concludes that this method is a feasible and promising solution for efficient resource utilization and sustainable development.

VL - 9
IS - 1
ER -

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Tsiye Tekleyohanis

Chemical Engineering, Debre Berhan University, Debre Behan, Ethiopia

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Abebayehu Tekleye

Mechanical Engineering, Debre Berhan University, Debre Behan, Ethiopia

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Tekleyohanis, T., Tekleye, A. (2024). Optimizing Industrial Effluent Flue Gas as Source of Energy for Charcoal Production. International Journal of Energy and Environmental Science, 9(1), 9-19. https://doi.org/10.11648/j.ijees.20240901.12

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ACS Style

Tekleyohanis, T.; Tekleye, A. Optimizing Industrial Effluent Flue Gas as Source of Energy for Charcoal Production. Int. J. Energy Environ. Sci. 2024, 9(1), 9-19. doi: 10.11648/j.ijees.20240901.12

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AMA Style

Tekleyohanis T, Tekleye A. Optimizing Industrial Effluent Flue Gas as Source of Energy for Charcoal Production. Int J Energy Environ Sci. 2024;9(1):9-19. doi: 10.11648/j.ijees.20240901.12

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TY - JOUR
T1 - Optimizing Industrial Effluent Flue Gas as Source of Energy for Charcoal Production

VL - 9
IS - 1
ER -

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