Bio Fuel Briquettes, Compress Paper Pulp and Sawdust Into Fuel Bricks

Project:

To find a use for the large amount of sawdust produced from wood turning sawing firewood etc, the 2choices had was to dunp / compost it or burn it.

loose sawdust can be burned in a wood burner but can easily kill the fire and cause a lot of smoke.decide to try and compress it back into bricks that would burn better.

I researched the options of either dry compacting and the forces need where just to beyond mycapabilities.

My only other option is to compress a wet mixture and use a binder such as news pulp.

I researched on youtube and instructables to see what the other people where using.

I found all the info needed but found some of the method where a bit fiddly for me as i have a few old

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AKG Wood Pellet Plantwww.akgbioline.comIndustrial Pellet Mill from AKG, low-cost,high-output, top-quality.

mtek briquette-presswww.briquetting-presses.comsolutions for your wood-, paper-, straw-,metal-and plastic-disposal.

wood-plastic machinerywww.87257222.comto produce wpc decking. indoor/outdoordecorating materials

Simple Project Managementwww.smartsheet.comSome tools are too hard. Some are too weak.Smartsheet is just right.

About This Instructable

Posted:Jul 11, 2010

License:Public Domain

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Bio fuel briquettes, compress paper pulp and sawdust into fuelbricks. by Dr Qui (/member/Dr+Qui/)

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1 of 21 06/05/2013 18:53

hand injury's that make fiddly not an option. other option made small briquettes or the process was justto slow for the amount of sawdust i had lying around about 12 fertilizer bags full to be exact.

Ive done nothing new here, just added my 2 cents worth to the mix and try to improve what others havedone before to inspire my own effort. Enjoy. :-)

Thanks for looking and I hope you like my idea

Step 1: The plan.

Even a little bit of wood turning creates a large amount of sawdust..

I decided to build a mould that would be easy to fill and compress but would would produce a larger brickthan that I had seen, and have a press that would be faster to operate.

I was lucky that I had the chance to buy a Sealy No2 bench press a few months back and had yet to fina job for it. I decided that I could modify the pressto use for this job and more usefull for other jobs.

I decided to use only what I had at hand. this would be a no budget build.

Materials used:3/4" plywood (I do like the 3/4" plywood)6" sewer pipe.

Step 2: The mould.

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2 of 21 06/05/2013 18:53

The mould is made from a 6" length of sewer pipe cut square on a friends band saw My own saw hasonly 4" throat. If have access to a few friends large saws when I need to do jobs like this.

The pipe was marked with the use of a set square the lines are the ruler blades width apart and actuallyworked out very evenly spaced, 5 hole where drilled at 1" intervals along each line. I used a 6mm drill bitin the pillar drill to do this, the sewer pipe is quite easy to drill.

I used the wood back plate on my wood lathe and turned 2 disks of 3/4" plywood.

One was the same as the outer diameter of the pipe with a 6mm recess cut on one edge a snug fit for

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3 of 21 06/05/2013 18:53

the inner diameter of the pipe, this would be the base plate.

the other would be 1-2mm smaller than the inner diameter of the pipe, this would be the plunger.

That is the mould taken care of.

Step 3: Update, better bottom plate



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4 of 21 06/05/2013 18:53

I found that the small recess I had used on the first bottom plate was starting to get built up with loosefibers of the pulp and this had lead to the ass falling out of the mould and causing a right mess and somestrong language.

to solve this I made a disk with a deeper recess and a wider lip so the pipe now fits on easier and willnot be able to slip off

The new disk is again made of 3/4" plywood but is recessed about 8-10 mm and is a slightly loose fit forthe pipe.

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5 of 21 06/05/2013 18:53

Step 4: The press

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6 of 21 06/05/2013 18:53

I only had to add a flat steel plate to the press, was going to do that anyway to make it more usefull thanbefore.

A friend said he would profile me some plate steel disks for this and another lathe project. a loadspreading plate on the the press would make the press more usable.

Other than add an old bike crossbar to the arm of the press to give it more leverage and get more waterout with less effort.

The press is rated at about 2 tonne of pressure, the longer arm increased this so much that the solidsteel arm started it bend from me pressing hay to hard, I just rotated the arm 180* and use to muchforce to bend it straight again. I now know the right amount of force to use not to bend the arm again.

Step 5: The mixture and mixer

The mixture is 2 parts sawdust to 1 part paper pulp.

Some people soak shredded newspapers over night and then mix then. some say to soak the sawdustover night, here is mu recipe.

If the heating has been on and I have hot water to spare, I use warm water to soak the paper after onlyabout 5mins you can use the paint mixer and it will be in pulp in a few minutes, if i have cold water aboutan 30 mins will have it softened up and will not take long to be in pulp.

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7 of 21 06/05/2013 18:53

For course sawdust I just add it to the paper pulp and turn the hose into the mix until it looks about right,it should be very a very sloppy slurry so the mixer can do its stuff.

I find that very fine dust is best mixed with the pulp and then left to soaked over night.

I use builder's plaster trugs to do my mixing as they are flexible and large enough to mix a decent sizedbatch.

I am going to try an electric cement mixer to do the mixing which should make the job much faster withless effort.

UPDATE: I have found that for a fine sawdust you may need to add more paper pulp to the mix or thebricks will have a tendency to crumble.

Step 6: The method

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8 of 21 06/05/2013 18:53

First place the mould on the the base plate firmly and fill with the pulp mixture.

level of the mixture and place the plunger on the top and gently press down.

Now carefully place the mould in place on the press without letting the base plate falling out.

And the load spreading plate if it not fixed to the press, i used on load plate at first and the plywoodfinally split in 2.

Press the mould until water stop running out, if you you slack of and press again only foam should pressout, its just about right at this stage.

To remove the brick from the press I turn it upside down and use the rack in the press in theup position to tap the plunger out and this forces out the brick.

Once you get the hang of things you can press a brick about ever 30 - 40 seconds, a full trug makes on

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9 of 21 06/05/2013 18:53

average about 15 bricks.

The press needs to be clamped down to the work surface , I have the press mounted to a work bench,the bench is weighed down with 4 12" concrete blocks. the work bench is not coping well with thepressure and is now just about goosed, i need to build a very solid bench just for the press.

Step 7: And here's some we made earlier.



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10 of 21 06/05/2013 18:53

The pressed bricks are stacked to dry outside for a few days, if it looks like rain I cover the pile with atarpaulin. once they are starting to dry out well I re stack then in a shed with a good air flow where theycan take their time to dry out fully.

Once fully dry I move them into storage.

I have about 400 + made, and have still not used all the sawdust.

My stove is out of action and I have not got a chance to to see how well they burn, they are claimed to

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11 of 21 06/05/2013 18:53

Post Comment

1(/member/lukeyj15/)

Jan 19, 2011. 7:20 PM Reply (C2ZCPCVGJ289ZDT)

65(/member/Dr+Qui/)

May 21, 2011. 9:32 AM Reply (C4YJWO1GNXWXW67)

1(/member/lukeyj15/)

May 23, 2011. 2:20 AM Reply (CYVQ8AIGO14Q98Q)

3(/member/_soapy_/)

Jun 1, 2013. 4:51 AM Reply (C0CWWV8HH2VFQIZ)

have the same btu value as coal but I cant say anything yet.

I did just set a dry one alight outside to see if it burned but threw it into the mixing bucket again when itstarted to get out of control.

I have a rough plan as how to build a box section press that would be suitable if you don't have aworkshop press, if you would like to see my idea just ask and I can sketch it up and post it.

Well that my 2 cents worth on the subject.

Comments and ideas welcome.

Thanks for looking.

1-40 of104

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lukeyj15 (/member/lukeyj15/) says:

I was thinking that instead of making bricks with the sawdust, would it work if I injected the sawdustinto an air stream and burnt it that way. I have tried burning sawdust myself and it tends to form asmoldering pile on the bottom of my fireplace. I think it does that when it has insufficient air to burnwith. Due to the nature of sawdust, it tends to smother itself. But I remember seeing an instructablewhere you can breathe fire by using cornflour or some other fine powder by making a cloud of thestuff and igniting it. Similar thing with canola oil. By itself, a puddle of oil won't ignite, but when it issucked through a wick it burns.

Dr Qui (/member/Dr+Qui/) (author) in reply to lukeyj15

A high pressure air streamcapable of moving sawdust ,sawdust and fire would be the 3key ingredients for a dustexplosion.

lukeyj15 (/member/lukeyj15/) in reply to Dr Qui

Yes, but so would gas coming outof a stove. The key is control. Onlyhaving a small amount of sawdustburning at a time. Same with a car.It has thousands of explosions aminute in the cylinders, but theyare controlled.

_soapy_ (/member/_soapy_/) in reply to lukeyj15

However, the day it went wrong,much like a gas stove, might well beyour last. Is it worth it when there isno gain?

thepelton (/member/thepelton/) in reply to lukeyj15



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12 of 21 06/05/2013 18:53

May 6, 2011. 9:54 AM Reply (C9KUGHEGNBEU5PC)

1(/member/thepelton/)

65(/member/Dr+Qui/)

Jan 23, 2011. 3:08 PM Reply (CK9I1TKGJ7MQGVQ)

(/member/jsy982002/)

Nov 28, 2011. 12:54 AM Reply (CDGK7WZGVEI9RRZ)

65(/member/Dr+Qui/)

Nov 28, 2011. 6:27 PM Reply (CSDIM8NGVHH1WDN)

My brotherdropped aloose handful ofsawdust on a litmatch, and itflared up. If youcouldcontinuouslydrop loosesawdust onto aheat source itwould burnmore efficientlythan piling it up.The stuff at thebottom tends toget smotheredby thesurroundingburnt ash.

Dr Qui (/member/Dr+Qui/) (author) in reply to lukeyj15

When you compress the sawdustinto briquettes they burn muchbetter than loose sawdust, theydon't smother themselves.

I burned a few dozen over theChristmas holidays and they burnvery well, they light quickly andburn like charcoal.

jsy982002 (/member/jsy982002/) says:

Hi,

I saw your post regarding the conversion of sawdust to solid blocks.

I would just like to ask how much is the difference of the compressed saw dust tosolid blocks of wood in term of Density and heat output.

I am planning to use this as firewood in my Boiler, do you think it would be advisable?

Thanks!

-Justin Sy

Dr Qui (/member/Dr+Qui/) (author) in reply to jsy982002

I honestly don't know, I did thismethod because I had an excessof sawdust and waste paper, thewet compressed blocks are theeasiest for me to male as drycompressed blocks or pelletsrequire a serious amount ofhydraulic pressure and thesawdust need to be ground to auniform consistency.

There is a Who its made thatshows how the compressed

Solid wood burns well on its own itend to keep this briquets for usein the open fire in my house as itonly takes a few minutes to get afire going.

I burn scrap wood in the woodstove in my shed but it has noboiler.



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13 of 21 06/05/2013 18:53

(/member/jsy982002/)

Dec 4, 2011. 5:37 PM Reply (CSN7TSVGVSETEOI)

65(/member/Dr+Qui/)

Dec 10, 2011. 12:13 PM Reply (C29N5YUGVZOHXYN)

I would suggest that you contact the boiler manufacturer as some woods like pine cancause a build up of resin in the flue that can build up and block the flue, my first flue madewas 3" (also poorly made) and blocked up with resin, I have i replace with 5" now whichdraws much better and has less chance of getting blocked.

jsy982002 (/member/jsy982002/) in reply to Dr Qui

Hi sir,

Sorry for the extremely delayedresponse.

I have been busy with an upcomingconference and was not able toattend to your reply.

Thanks for the detailed response.There is actually no problemregarding the blockage of the flueas I am already using actualfirewood of the same wood specieto run my boiler.

I am just trying to find some use forthe sawdust (same wood specie)produced in our sawmill.

Just in terms of density, can you stillremember if the wet compressesbriquettes were comparable or evenclose to actual firewood?

Thank you and sorry for the trouble.

-Justin

Dr Qui (/member/Dr+Qui/) (author) in reply to jsy982002

Hi,

I did this as a way to getsawdust to burn withoutdampening the fire out as itusually does if thrown on loose. I never put any thought into thefuel value of the end product,

I'm happy that they burn but thegeneral view is that they have thesame fuel value as coal, but icant vouch for this as i would notknow how you would go about acomparison test.

A friend of mine uses thecommercial compressed bricksand they seem to burn pound forpound at the same rate a scraptimber that i have given him

Depends on how you definecomparable, the answer is thatthey burn well in mu opinion 4-6of them placed in an openfireplace (all i have used themfor) either started with a firelighter or a spray of wd40 orother oil or anything flammable ifim lazy or want heat now, theylight quite quickly and look as ifthey are going to burn out veryquickly.

They actually turn to red hotcoals and sit in the hearth



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14 of 21 06/05/2013 18:53

3(/member/nickmccullough/)

May 9, 2011. 7:37 PM Reply (C42685XGNFSK7TQ)

65(/member/Dr+Qui/)

May 21, 2011. 9:28 AM Reply (CR7ZOTHGNXWXW0V)

3(/member/nickmccullough/)

May 22, 2011. 4:31 PM Reply (CJ9C7Y5GNXX161Q)

glowing red for quite some time, once the fire is light 2-3 are added every 30 mins or so asneeded, i find that about 10-12 will burn for an evening, i have only used them for when wehave visitors and want a bit of fire going just for sake of it.

If you have a commercial sawmill you should look into building a sawdust compressor, acouple of places in my area that ued to give sawdust to any farmers that would come takeit away have now built or installed brick compressors to make a salable product out of theirwaste, they sell well and are a good earner if you have a constant supply.

http://www.youtube.com/watch?v=WZQK1vlhA2Y (http://www.youtube.com/watch?v=WZQK1vlhA2Y)

this seems to be a piton based thing, a hopper with auger that feeds small amounts of dustinto a chamber with a piston that reciprocates and compresses the dust into a tube, thetube seems to need to be about 20feet long or so < i think this is so the back pressure canbuild up to the amount needed to compress the bricks. heavy flywheels are needed to keepthe momentum up on the piston. this method seems to be the simplest method for the diybuilder, if i had a constant supply of sawdust i would build something like this.

I saw an episode of how its made that showed the compressed brick method for thosefancy logs that city folk burn in their trendy wood stoves. The dusts need to be very uniformand to use anything rather than saw dust Ie bark wood shavings and cuttings required aheavy duty shredder to grind the dust uniform.

You can also have a hydraulic machine check youtube for these as i cant seem to find whati found there. the hydraulic method is more complicated and slower.

In summary for small amounts ie 20kg or so of dust every once in a while i would go withthe wet brick method. for a constant supply from a saw mill i would put the effort in andbuild a piston based machine as it would give you a additional income from the waste and intheory should pay for its self in next to no time.

over here a 10kg bag of compressed logs are around 5 and seem to be sold in everygarage or convenience store i walk into,

hope this helps.

Andy.

nickmccullough (/member/nickmccullough/) says:

Have you ever thought about adding grassclippings to the mixture? Ive got a lottasawdust, but really, i think that this could bevery benificial to me, so I wouldnt be able tokeep up the sawdust output with how much iwould burn, so i would have a continuoussupply of more than enough grass clippingsevery week... you think it would work?

Dr Qui (/member/Dr+Qui/) (author) in reply to nickmccullough

Problem is trying to get thegrass clipping 100% dried out asthey tend to start composting ifthere is any moisture left inthem.

nickmccullough (/member/nickmccullough/) in reply to Dr Qui

hmmmm, ok, well i think sometimeill give it a try, with some 1"brickets since those should dry outfaster so they wont have as muchtime to compost

lennyb (/member/lennyb/) says:

good instructable. i wonder could you put them in a charcoal barrel and char them to make cooking



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15 of 21 06/05/2013 18:53

Jul 18, 2010. 3:15 PM Reply (C5GDBKMGBSBHG1K)

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briquets? ive seenbriquets with that shapefor sale at the dollarstore for a buck each. idoubt very much if theyused fine hardwood forthat.

Dr Qui (/member/Dr+Qui/) (author) in reply to lennyb

I have since burned a few of thebricks, as soon as the catch firethey almost instantly turn to ablock of red hot smoldering ashthat slowly burns away.

I recon that they would beperfect for use on a BBQ and ihope to try this out sometime.

djsc (/member/djsc/) in reply to lennyb

I think they will tend to insulatetheir own centres from the heat,nice thin pieces might be good forbiochar, and some uncharredbriquettes could provide at leasthalf the heat source to do thecharcoalling. worth a try.

Dr Qui (/member/Dr+Qui/) (author) in reply to lennyb

Thanks,

From what I have see on youtubeetc they are OK to use on a BBQas is

I have not burned any yet in mystove as its to warm to need tolight it.

I have burned one to see what itwas like and it looked similar tothat of a BBQ coal.

thepelton (/member/thepelton/) says:

I wasn't thinking of burning them, but inoculating them with edible cellulose eating mushrooms, suchas Pleurotis Ostreatus. I wonder how well that would work?

kretzlord (/member/kretzlord/) in reply to thepelton

to get sterile conditions, take thefinal product and stick it in apressure cooker for about 20minutes, should be fine after that.

Dr Qui (/member/Dr+Qui/) (author) in reply to thepelton

I dunno to be honest, i recon therewould be to much bad bacteria inthe sawdust that you may havedifficulty in getting the mushroomsstarted.

A few years ago a friend was



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selling mushroom and truffle kits in his shop, they all used boiled rice as the food sourceand demanded almost sterile conditions.

From what I know re mushroom houses and how they work there is a web like nervesystem that is about 2 - 3" under the surface of mushroom compost, it almost like like aburied spider web that is the thing that acutely gets the mushrooms to grow. To farmmushrooms you have to emulate and maintain perfect growing condition all the time.

Some mushrooms and truffles have a symbiotic relationship with certain genus of trees.Can't remember what show this was on , probably BBC's life on earth with DavidAttenbourough.

Being neither plant nor animal mushrooms are literally mindblowing if you start to investigatehow they work.

capt.tagon (/member/capt.tagon/) in reply to Dr Qui

Truffles live under Oaks and Pinesin the US Pacific Northwest.

thepelton (/member/thepelton/) in reply to capt.tagon

I understand the concept ofsymbiosis. There are species ofmushrooms that only grow nearaspens in Colorado, and blackmorels are always found near aspecies of orchid.

djsc (/member/djsc/) says:

I like the idea of a multipurpose press; I have a bottle jack that I am using to build a cider press,never though of using it to compress paper briquettes.

Dr Qui (/member/Dr+Qui/) (author) in reply to djsc

I have seen some other videos ofguy using bottle jacks and scissorjacks, these work fine but I justfound them to be to slow to allowyou to work at a decentproduction speed for largevolumes of material.

The bottle jack will be prefect foryour cider press because youwant more pressure to get asmuch juice out as possible.

I would like to see you cider pressdesign as I have a small orchardthat produces more than we caneat or give away and i have oftenthought of making juice or cider.

Andy.

thepelton (/member/thepelton/) in reply to Dr Qui

There should be a basic ciderpress on Instructables, or maybeon the web in general.

Angstridden.Hipster (/member/Angstridden.Hipster/) in reply to Dr Qui



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17 of 21 06/05/2013 18:53

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Jan 7, 2011. 3:52 AM Reply (CJJKRH3GIJG16D2)

The thing aboutcider productionis that youideally want toshred the fruit asmuch aspossible beforepressing, that iswhat reallyreleases thejuices.

Check outMattiasWendle'sexperience inthis matterhttp://www.sentex.net/~mwandel/press/apple_grinder.html

His appleGrinder is thebee's knees!

mjlush (/member/mjlush/) says:

I wonder if you can spike the mix with coaldust... I always end up with a bucket of it at the bottom ofthe bunker. Its just puts out the fire and/or falls through the grate if I try and burn it.

thepelton (/member/thepelton/) in reply to mjlush

the chinese have beencompressing coal dust intobrickettes for some time.

origamifox (/member/origamifox/) in reply to mjlush

Yes, you can! This will also help thebriquettes to burn better. Thisprocess has been used to recyclenewspaper and charcoal waste inKenya.

Dr Qui (/member/Dr+Qui/) (author) in reply to mjlush

Thanks,

From what I have see on youtubeetc they are OK to use on a BBQas is

I have not burned any yet in mystove as its to warm to need tolight it.

I have burned one to see what itwas like and it looked similar tothat of a BBQ coal.

quadracer (/member/quadracer/) says:

I make something sort of like this, But just to start fires. I add 1 tablespoon of left over candle waxto aid in the starting. Keep up the good work good sir



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tweakgeek (/member/tweakgeek/) says:

Hi, I have nothing relevant to add tothis fine instructable.

Except my wife woke up startled andgave me a hard time when I read thisfrom step 3:

" this had lead to the ass falling out ofthe mould and causing a right messand some strong language."

Thank you, unknown poet.

melmcc (/member/melmcc/) says:

Hi Dr Qui, in my part of the world old newspaper is made into mulsh and put into a brick makingpress, water squeezed out and the brick put out to dry. With the saw dust even better. Maven: in apart of Natal there is no fuel to burn and the local people collect all the cow patts pack them in thesun to dry and that is the fuel for the fire to see them through the winter. Due to the fact the dunghas dried it has no smell when burning.

drewSaysGoVeg (/member/drewSaysGoVeg/) says:

I have a gasoline log splitter that I'm thinkingof rigging up to make some of these with.Question: When you press your pulp, howlong do you leave it to drip? Minutes orhours? Do you press enough of the liquid outimmediately that you can move to the nextone? To give me a rough idea, how manybricks can you make in a day?

Dr Qui (/member/Dr+Qui/) (author) in reply to drewSaysGoVeg

If you have a gas poweredhydraulic system you may be ableto dry compress sawdust, checkout youtube as there are loads ofideas thee.

Pressing the pulp forms a solidbrick that can be handled with outfall to bits if the mix is right. theyare still quite wet at this stage,depending on the weather and yourclimate it can take between 3 daysto maybe 2 weeks for them to dry, Iair dry mine for a few days untilthey firm up a bit and then movethem to a shed with a good air flowgoing though it until they are bonedry and hard.

I have only ever done 3 trugs at atime that would make on average45 bricks, that is the my limit beforemy bones start to creak and I ambest to stop.

If you had an electric cement mixerto prepare the pulp you could makehundreds in a day, I can fill andpress 3 trugs full in under an hour,about 1 brick every 30-40 secondsif I am set up right.

explosivemaker (/member/explosivemaker/) says:

dang...we need a pic showing how high theycould be stacked TOWER OF FIRE!!!!!!!



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ourmoneypit (/member/ourmoneypit/) says:

Thanks for this instructable. My spouse isa woodworker and we have both turnedwood, also. I find her planer produces themost sawdust, by far, though. I waswondering what I was going to do with allthe wood shavings once I was donelevelling the various dips on our property.This is an excellent idea.

Dr Qui (/member/Dr+Qui/) (author) in reply to ourmoneypit

Cheers,

You should make compressed bricksand burn them to heat your home andthen use the wood ash to level outyour property. you get the most outof your waste that way, wood ash isalso a good fertilizer.

Good luck

Captain John (/member/Captain+John/) says:

Hi . I have two cows, and they poop a lot.Can i use dried cow dung in the samemanner? It might smell, but it would alsoburn and some tree did not have to die.

faileas (/member/faileas/) in reply to Captain John

dried cowdung is a pretty traditionalfuel. It also dosen't smell too bad...go for it!

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Bio fuel briquettes, compress paper pulp and sawdust into fuel by Dr Qui (/member/Dr+Qui/)


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Bio Fuel Briquettes, Compress Paper Pulp and Sawdust Into Fuel Bricks

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