Olive Kernel Charcoal Briquette Drying and Mixing Process
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Solution Overview
Problem
The existing method for producing charcoal from olive kernels results in inconsistent moisture levels and lump formation due to incomplete starch dissolution, affecting the heating value and quality of the final product, as well as increasing drying time and production costs.
Innovation Solution
The production process is modified by drying the kernel powder separately before mixing it with starch and hot water in two distinct steps, followed by a closed-circuit air drying of the briquettes to control moisture and prevent lumps, ensuring consistent and efficient drying and improved homogeneity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If water is used for mixing and cooling kernel powder in the production process, then the kernel powder achieves homogenization and temperature control, but moisture is introduced into the final product increasing drying time
Solution Approach 1:
The process is divided into separate stages: mixing with water to form a paste, then drying to remove moisture, and finally forming briquettes. This segmentation allows water to be used effectively for mixing while controlling its presence in the final product through staged processing.
Solution Approach 2:
The kernel powder is mixed with water and starch to form a homogeneous paste before forming briquettes. This preliminary mixing action ensures uniform distribution of ingredients and proper moisture content during formation, while subsequent drying removes excess moisture.
2Ease of manufacture
If starch is mixed with kernel powder and water simultaneously, then the binding agent is incorporated, but lumps form due to incomplete dissolution affecting quality
Solution Approach 1:
Starch is pre-mixed with water to form a gelatinized binding agent before being incorporated with kernel powder. This preliminary preparation ensures complete dissolution and uniform distribution, preventing lump formation in the final product.
Solution Approach 2:
The starch undergoes gelatinization through heating with water, changing its physical state from dry powder to a gelatinized paste. This parameter change enables smooth mixing and eliminates lumping issues while maintaining proper binding properties.
3Device complexity
If ambient air is used for drying the briquettes, then the drying process is simple, but moisture absorption increases production time and affects quality
Solution Approach 1:
The drying process uses the natural evaporation of moisture from the briquettes through exposure to ambient air. The system leverages the self-service mechanism of water evaporation without requiring complex heating or dehumidification equipment, achieving effective drying through simple physical principles.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach results in a higher-quality charcoal with controlled moisture, enhanced heating value, and reduced production time, addressing the issues of inconsistency and cost while maintaining the environmental friendliness and low production costs of the original method.
Implementation Method 1
The drying steps of the product have been doubled, whereas during drying of the briquettes
Implementation Method 2
a closed circuit circulating the already dry air, thereby contributing both in the optimal drying of the product
Implementation Method 3
mixed with pre-gelatinized starch and water
Data Source
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AI summary
The invention relates to a method for producing kernel charcoal of high heating value, which constitutes an alternative and ecological fuel, ideal for domestic or industrial applications. The kernel wood obtained after the separation of the wood part of the olive kernel from the kernel oil, is conveyed with limestone to a kiln. Apart from the lime, kernel powder is obtained, which is conveyed to a dryer, and then is mixed with starch and then with hot water. The produced mixture is conveyed to a press in order to acquire a suitable round shape, whereas the briquettes are dried in dryer of the closed air circuit type in order to remove any residual moisture. Alternatively, the incomplete combustion of the kernel wood may be obviated, instead the kernel wood is directly mixed with starch and water to produce a final product of higher heating value in relation to the simple kernel wood.