A charcoal product and uses thereof

Abstract

A method of producing a charcoal product comprises providing a peat substrate, lightly charcoaling the peat substrate in a gasifier furnace, and mixing the lightly charcoaled peat with fully charcoaled wood at a weight ratio of 5:95 to 20:80 lightly charcoaled peat to fully charcoaled wood to provider the charcoal product. The light charcoaling step comprises heating the peat is the gasifier furnace at a maximum temperature of less than 300°C. The use of the charcoal product to roast coffee 10 beans and dry textiles is also described.

Description

[0001] TITLE

[0002] A charcoal product and uses thereof

[0003] Field of the Invention

[0004] The present invention relates to a charcoal product and uses thereof.

[0005] Background to the Invention

[0006] Charcoal is a fuel produced by burning wood is a reduced or zero oxygen environment, in a process called gasification. It is generally provided in briquette form, as small black lumps. It is commonly used to cook foods on a BBQ, where the radiant heat produced from the glowing charcoal provides a gentle and even cook, and vapours produced by juices falling on to the coals adds flavour to the food product.

[0007] Summary of the Invention

[0008] A charcoal product is described comprising a minor amount (e.g. 5-20%) of lightly charcoaled peat and a major amount of fully charcoaled wood (e.g. 80-95%). All % provided herein are w / w unless stated otherwise. The peat is lightly charcoaled in a gasifier at a temperature below 300°C for a time period required to produce a brown (as opposed to a black) charcoaling. The charcoal product of the invention produces a smoke-free high radiant heat that has been found to improve the flavour of foods produced or cooked using the charcoal product. Coffee beans roasted with the charcoal product makes coffee with an improved flavour and crema. In addition, fabrics materials dried using the charcoal product have been found to contain less static charge compared to fabrics dried using conventional heating methods such as hot air and microwave.

[0009] In a first aspect, there is provided a method of producing a charcoal product comprising: providing a peat substrate; lightly charcoaling the peat substrate in a gasifier furnace; and mixing the lightly charcoaled peat with fully charcoaled wood at a weight ratio of 5:95 to 20:80 lightly charcoaled peat to fully charcoaled wood to provider the charcoal product.

[0010] The peat substrate is peat harvested from a bog in a usual way.

[0011] In any embodiment, the light charcoaling step comprises heating the peat is the gasifier furnace at a maximum temperature of less than 300°C.

[0012] In any embodiment, the light charcoaling step comprises heating the peat is the gasifier furnace at 150°C to 250°C.

[0013] In any embodiment, the light charcoaling step comprises heating the peat is the gasifier furnace at 150°C to 200°C, 200°C to 250°C, or 250°C to 300°C.

[0014] In any embodiment, the light charcoaling step comprises heating the peat is the gasifier furnace for 5-10 or 6-8 hours.

[0015] In any embodiment, the light charcoaling step comprises heating the peat in a volume less than 10%, 7.5%, 5% or 2.5% oxygen (v / v). In any embodiment, the lightly charcoaled peat has a dark brown (and not black) colour.

[0016] In any embodiment, the mixing step comprises mixing the lightly charcoaled peat with fully charcoaled wood at a weight ratio of 5:95 to 15:85 lightly charcoaled peat to fully charcoaled wood.

[0017] In any embodiment, the mixing step comprises mixing the lightly charcoaled peat with fully charcoaled wood at a weight ratio of 10:90 to 15:85 lightly charcoaled peat to fully charcoaled wood.

[0018] In any embodiment, the mixing step comprises mixing the lightly charcoaled peat with fully charcoaled wood at a weight ratio of about 11 :89 to about 13:87 lightly charcoaled peat to fully charcoaled wood.

[0019] In any embodiment, the peat substrate has a wood content of greater than 15%. A method of measuring the wood content of peat is described in Virtanen et al. (Virtanen, K., Hanninen, P. & Leino, J. 2003. Turpeen suossa olevien liekopuiden maarasta maakunnittain. Geologian tutkimuslaitos, Kuopion yksikk", Turvetutkimus. Tutkimusseloste 12 / 2003. 28 p.).

[0020] In any embodiment, the peat substrate has a moisture content of about 25% to 35% (v / w).

[0021] In any embodiment, the peat substrate has a through hole, for example an annular briquette. This helps with drying and charcoaling.

[0022] In any embodiment, the peat substrate has a Sulphur content below 0.2% or 0.1 % (v / w).

[0023] In any embodiment, at least 80% of the peat substrate has a decomposition level of H2 to H6 (Von Post Scale). In any embodiment, no more that 20% of the peat substrate has a decomposition level of H1 (Von Post Scale).

[0024] In any embodiment, no more that 10% of the peat substrate has a decomposition level of H7(Von Post Scale).

[0025] In any embodiment, the gasifier is fuelled by a charcoal product of the invention.

[0026] Also described is a peat substrate manufactured according to the method of the disclosure.

[0027] Also described is a charcoal product comprising a minor amount (e.g. 5-20%) of lightly charcoaled peat and a major amount of fully charcoaled wood (e.g. 80-95%).

[0028] In any embodiment, the charcoal product comprises 10-15% of lightly charcoaled peat and 85-90% fully charcoaled wood.

[0029] In any embodiment, the charcoal product comprises 11-13% of lightly charcoaled peat and 87-89% fully charcoaled wood.

[0030] In any embodiment, the charcoal product comprises about 12% of lightly charcoaled peat and about 88% fully charcoaled wood.

[0031] In any embodiment, the lightly charcoaled peat is dark brown.

[0032] Also described is a use of the charcoal product of the invention to roast beans (e.g. coffee beans) or cook food (e.g. meat, fish, poultry, vegetables etc), especially by means of BBQ cooking. The cooking is primarily by means of radiant heat emitted by the burning charcoal product. Also described is a method of roasting coffee beans comprising placing the coffee beans in a drum (or other container), burning the charcoal product of the invention to generate radiant heat, and heating the drum with the generated radiant heat.

[0033] In any embodiment, the heating step is carried out when the charcoal product comprises red coals (or when there are no flames being emitted from the burning charcoal product).

[0034] In any embodiment, the method employs a coffee roasting machine configured to burn a fuel to generate heat to roast the coffee beans. Examples are sold by KRAFFE (Izmir, Turkey) and GIESEN COFFEE ROASTERS (Netherlands). Another example is the DONGYI coffee roaster machine.

[0035] In any embodiment, the coffee beans are roasted to a final coffee bean temperature of 180-185 °C. In any embodiment, the coffee beans are roasted for 40-60 minutes.

[0036] Also described is a roasted coffee bean product obtained by a method of the invention. In any embodiment, the roasted coffee bean product is roasted coffee beans, or a grind thereof.

[0037] Also described is a method of drying textile material comprising placing the textile material in container, burning the charcoal product of the invention to generate heat, and directly heating the container with the generated heat. Using embers of the charcoal product of the invention to heat the container has been found to reduce the static charge of the textiles compared to when the container is heated a different fuel such as, for example, hot air or microwaves.

[0038] In any embodiment, the fabric material is a woven fabric, for example cotton, viscose, rayon, wool & polyester. In any embodiment, the fabric material is dried at 120-160 °C optionally for 1-10 minutes, 3-7 minutes or about 5 minutes.

[0039] In any embodiment, the drying of the textile material is performed in the absence of a commercial static softener.

[0040] In any embodiment, the container is a drum, especially a rotating drum.

[0041] Other aspects and preferred embodiments of the invention are defined and described in the other claims set out below.

[0042] Brief Description of the Figure

[0043] Figure 1 is a block diagram illustrating an embodiment of a method of making a charcoal product according to the invention.

[0044] Detailed Description of the Invention

[0045] All publications, patents, patent applications and other references mentioned herein are hereby incorporated by reference in their entireties for all purposes as if each individual publication, patent or patent application were specifically and individually indicated to be incorporated by reference and the content thereof recited in full.

[0046] Definitions and general

[0047] Where used herein and unless specifically indicated otherwise, the following terms are intended to have the following meanings in addition to any broader (or narrower) meanings the terms might enjoy in the art:

[0048] Unless otherwise required by context, the use herein of the singular is to be read to include the plural and vice versa. The term "a" or "an" used in relation to an entity is to be read to refer to one or more of that entity. As such, the terms "a" (or "an"), "one or more," and "at least one" are used interchangeably herein.

[0049] As used herein, the term "comprise," or variations thereof such as "comprises" or "comprising," are to be read to indicate the inclusion of any recited integer (e.g. a feature, element, characteristic, property, method / process step or limitation) or group of integers (e.g. features, element, characteristics, properties, method / process steps or limitations) but not the exclusion of any other integer or group of integers. Thus, as used herein the term "comprising" is inclusive or open- ended and does not exclude additional, unrecited integers or method / process steps.

[0050] As used herein, the term “peat substrate” or “peat” refers the material obtained from peatlands or “bogs” and is an accumulation of partially decayed vegetation or organic matter. Sphagnum moss, also called peat moss, is one of the most common components in peat, although many other plants can contribute. The biological features of sphagnum mosses act to create a habitat aiding peat formation, a phenomenon termed 'habitat manipulation'.

[0051] As used herein, the term “lightly charcoaling” refers to heating the peat substrate in a gasification furnace I oven until the peat has a dark brown (and not black) colour. Gasification comprises heating the peat in reduced (or zero) levels of oxygen and therefore involves pyrolysis of the peat. The process generally employs heat that is less than 300°C. One embodiment of gasification (or lightly charcoaling) involves heating the peat substrate in a gasification furnace for 6-8 hours at 150 to 250°C.

[0052] As used herein, the term “wood charcoal” refers to the commercially available charcoal product often sold as charcoal briquettes for BBQ’s. Examples include WEBER charcoal briquettes. Exemplification

[0053] The invention will now be described with reference to specific Examples. These are merely exemplary and for illustrative purposes only: they are not intended to be limiting in any way to the scope of the monopoly claimed or to the invention described. These examples constitute the best mode currently contemplated for practicing the invention.

[0054] Referring to the drawing, in a first stage, harvested and dried peat having a moisture level of about 25-35% is size reduced in a milling machine 1 to produce lumps of peat. In a second stage, the lumps of peat are then lightly charcoaled in a gasifier furnace 2 operating at 150 to 250 °C for 6-8 hours until the lumps turn a dark brown. In a third stage, the lightly charcoaled peat is cooled in a cooling container 3. The lightly charcoaled peat is conveyed to a metering machine 4 along with wood charcoal from a silo 5, where they are metered into a continuous mixer 6 at a weight ratio of 12:88 charcoaled peat to wood charcoal to provide the charcoal produce which is then bagged in a bagging machine 7.

[0055] Example 1

[0056] Harvested and dried peat from an Irish blanket bog is milled to provide charcoal sized lumps. The peat has a moisture content of 25-35 % (v / w), a wood content of greater than 15 %, a sulphur content of less than 0.1 %, and more than 80 % of the peat by weight has a decomposition level of from H2 to H6 (Von Post Scale).

[0057] The lumps of peat are added to a gasification furnace and heated to 150-200 °C for 6-8 hours, or until the lumps have turned dark brown.

[0058] The charcoaled peat is then allowed to cool and mixed with wood charcoal (fully charcoaled) at a weight ratio of 12:88 peat charcoal to wood charcoal.

[0059] The mixture is packaged for sale.

[0060] The method of Example 1 is repeated with the exception that the charcoaled peat is mixed with wood charcoal (fully charcoaled) at a weight ratio of 10:90 peat charcoal to wood charcoal.

[0061] The method of Example 1 is repeated with the exception that the charcoaled peat is mixed with wood charcoal (fully charcoaled) at a weight ratio of 15:85 peat charcoal to wood charcoal.

[0062] Example 4

[0063] The method of Example 1 is repeated with the exception that the charcoaled peat is mixed with wood charcoal (fully charcoaled) at a weight ratio of 20:80 peat charcoal to wood charcoal, and that at least 80% of the peat by weight has a decomposition level of H1 (Von Post Scale).

[0064] Example 5

[0065] Coffee beans are roasted in a DONGYI coffee roaster machine using the charcoal product of Example 1 according to the following roasting conditions:

[0066] 40-60 minutes

[0067] 180-185 °C

[0068] Thus, resultant coffee has improved flavour depth, a true coffee taste, improved creaminess and calcium more balanced.

[0069] Example 6

[0070] The textile material (wool fabric) is placed in a drying container. The charcoaled peat product of Example 1 is burned to generate hot embers which are used to heat the container containing the textile material. This is found to reduce the static charge of the textiles compared to when the container is heated a different fuel such as, for example, hot air or microwaves. The textile is dried in this manner at 120-160°C for 5 mins dry time with a static softener. The result wool has a lower static charge than wool dried using conventional hot air drying.

[0071] Equivalents

[0072] The foregoing description details presently preferred embodiments of the present invention. Numerous modifications and variations in practice thereof are expected to occur to those skilled in the art upon consideration of these descriptions. Those modifications and variations are intended to be encompassed within the claims appended hereto.

Claims

CLAIMS:

1. A method of producing a charcoal product comprising: providing a peat substrate; lightly charcoaling the peat substrate in a gasifier furnace; and mixing the lightly charcoaled peat with fully charcoaled wood at a weight ratio of 5:95 to 20:80 lightly charcoaled peat to fully charcoaled wood to provider the charcoal product. in which the light charcoaling step comprises heating the peat is the gasifier furnace at a maximum temperature of less than 300°C.

2. A method according to Claim 1 , in which the light charcoaling step comprises heating the peat is the gasifier furnace at 150°C to 250°C.

3. A method according to Claim 1 or 2, in which the light charcoaling step comprises heating the peat is the gasifier furnace for 6-8 hours.

4. A method according to any preceding Claim, in which the mixing step comprises mixing the lightly charcoaled peat with fully charcoaled wood at a weight ratio of 10:90 to 15:85 lightly charcoaled peat to fully charcoaled wood.

5. A method according to any preceding Claim, in which the mixing step comprises mixing the lightly charcoaled peat with fully charcoaled wood at a weight ratio of about 11 :89 to about 13:87 lightly charcoaled peat to fully charcoaled wood.

6. A method according to any preceding Claim, in which the peat substrate has a wood content of greater than 15%.

7. A method according to any preceding Claim, in which the peat substrate has a Sulphur content below 0.2% (v / w).

8. A method according to any preceding Claim, in which at least 80% of the peat substrate has a decomposition level of H2 to H6 (Von Post Scale).

9. A method according to any preceding Claim, in which no more that 20% of the peat substrate has a decomposition level of H1 (Von Post Scale).

10. A method according to any preceding Claim, in which no more that 10% of the peat substrate has a decomposition level of H7(Von Post Scale).11 . A method of producing a charcoal product comprising: providing a peat substrate; lightly charcoaling the peat substrate in a gasifier furnace; andmixing the lightly charcoaled peat with fully charcoaled wood at a weight ratio of 10:95 to 15:85 lightly charcoaled peat to fully charcoaled wood to provider the charcoal product. in which the light charcoaling step comprises heating the peat is the gasifier furnace at 150°C to 250°C for 6-8 hours.

12. A charcoal product obtained according to the method of any of Claims 1 to 11 .

13. A charcoal product comprising 10-15% of lightly charcoaled peat and 85-90% of wood charcoal (w / w).

14. A charcoal product according to Claim 13, in which the charcoal product comprises 11-13% of lightly charcoaled peat and 87-89% wood charcoal (w / w).

15. A use of the charcoal product of any of Claims 12 to 14 to roast coffee beans.

16. A method of roasting coffee beans comprising placing the coffee beans in a drum, burning the charcoal product of any of Claims 12 to 14 to generate radiant heat, and heating the drum with the generated radiant heat.

17. A method according to Claim 16, in which the method employs a coffee roasting machine configured to burn a fuel to generate heat to roast the coffee beans.

18. A roasted coffee bean product obtained by a method of Claim 16 or 17, in which the roasted coffee bean product is roasted coffee beans, or a grind thereof.

19. A method of drying textile material comprising placing the textile material in container, burning the charcoal product of any of Claims 12 to 14 to generate radiant heat, and directly heating the container with the generated radiant heat.

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