International Journal of Scientific Research and Engineering Development

This study presents the design, construction, and testing of a 5kg smokeless fuel manufacturing reactor by forced convection that converts locally available sub-bituminous coal and lignite into cleaner solid fuel (coke) via lowtemperature carbonisation. The device was designed using locally sourced materials and incorporates a lagged steel reactor, a coal crucible, a combustion chamber, and a forced-air supply to achieve controlled heating in the range of 300–600 °C. Proximate and ultimate analyses were conducted on coal samples before and after carbonisation to evaluate changes in moisture content, volatile matter, ash content, fixed carbon, and elemental composition. Experimental tests were performed on different coal particle sizes (10 mm, 15 mm, and 20 mm) to assess temperature profiles, heating rates, and carbonisation efficiency. Results showed a significant reduction in volatile matter and sulphur content, increased fixed carbon, and improved calorific value, confirming the production of smokeless and cleaner fuel. The developed reactor offers a cost-effective and environmentally friendly solution for domestic and small-scale industrial energy needs, with strong potential for reducing indoor air pollution and dependence on firewood in rural communities.

Engr Christopher Zakariya, Dr Mary D Samuel, Engr Michael Alaku, "Design, Construction and Testing Of A 5Kg Smokeless Fuel Manufacturing Reactor by Forced Convection" International Journal of Scientific Research and Engineering Development, V9(4): Page(224-239) May-June 2026. ISSN: 2581-7175. www.ijsred.com. Published by Scientific and Academic Research Publishing.