setting up a coke forge

[Mick Annick]

The best forge you can have is one you’ve made yourself to your own specification.

True enough, but assumes you have the tools, knowledge and time - I’m too old and don’t have the skills so bought mine ready made. If I live long enough I might try making one, though a recent diagnosis of osteoarthritis in my hands is making my forging days look numbered

 

[Brad93]

True enough, but assumes you have the tools, knowledge and time - I’m too old and don’t have the skills so bought mine ready made. If I live long enough I might try making one, though a recent diagnosis of osteoarthritis in my hands is making my forging days look numbered

Not great for the joints hammering steel together

 

[minimutly]

you convert the coal to coke by doing that. It's a skill in in itself to get it right. The technique referred to is retorting, basically, put coal into a steel drum and put the lid on loosely, and stick it on a fire, The volatiles evaporate off and you are left with coke. How town gas was made back in the day . there is more to it than that, but I'm no expert on it.

Do a search for this online, the video is of a horrendously poor workplace - workers didn't live long healthy lives. There was one not far from me, but I never went there.

 

[Mick Annick]

I have side openings in mine ,essential with long bars,and as brad stated current coke.....it’s crap now,I’ve resorted to tipping a bucket at a time on the best bit of floor and crushing it back to the size the grain used to be,I still buy from the supplier I’ve used for 20+ years,the drivers who delivered it acknowledged the problem so I assume they’ve had other complaints,I have fire bricks,yet not sure they’re necessary,I’m on my 3rd forge,the current one is an Alldays & Onions,yet it has developed an erratic behaviour lately and curiously burns with a crescent shaped pattern of glowing coke.
Good luck in using yours matchless,hope you find some decent coke.

Could you share a photo of your forge please Nick?

 

[The_Yellow_Ardvark]

Monsieur Vark, do tell us more please. I was told to soak the coal in water, put it around the edge of the forge and gradually draw it in.

@nickk what’s your advice please?

I start with a 5lt paint can. Make a 13mm hole in the lid. Fill the can with as much coal as you can.
Fit the lid and place in a fire with a good ember bed.
You will see a white ish gas escaping from the hole. This will soon burn. It can get jet like.
When it settles down to a candle style flame, remove from the fire and plug the hole.
Let it cool.

This will give you a sample of coke from your coal. It will give you a good indication of how much reduction of the coal to coke there will be.

When you are happy with small scale move up. I did 50 gallon oil drum.
Few changes, the coal gas is ducked to help the conversion of the coal. Plus if you get it right you can tap of the coal tar as well.

Same as small scale, but I used a ball valve and pulled the drum from the fire. Charcoal can be done this way as well.

Then away you go.

I know some one who uses coal in their forge, they told me it was an individual choice what you use.

 

[nickk]

Here you go mick.

 

[tom2207]

Identical set up to one I used a long time ago , in a training centre ,, we had a big steel plate for sitting on top of it on friday afternoons ,,,, bacon and burgers and steak on a pay day.

 

[Mick Annick]

View attachment 237582 View attachment 237583 View attachment 237584 View attachment 237585 View attachment 237586 Here you go mick.

Thanks Nick

 

[The_Yellow_Ardvark]

Further more to my post about coke and charcoal.

Some small scale test burns.
When I started I was adivised to do a small scale test on the coal and wood to see how it would convert.
Now, I don't bother. Just set the retorts up and away I go.



This lot was green hard wood. Gave a better yield of charcoal to the charge, but did not burn as well.
Good for BBQ and melting of alloy with out a blower.




Seasoned hard wood.
This was a good conversion. Lots more dust and crumbs. But they get compressed with wax and sawdust to make another form of fuel to enjoy a beer with.



4 small retorts, gassing off nicely.
When the flame reduced to a large candle flame I removed them and sealed the hole.



The jet.

This is a fun sight.
Also if it topples it will fly.
I know.

 

[Brad93]

Further more to my post about coke and charcoal.

Some small scale test burns.
When I started I was adivised to do a small scale test on the coal and wood to see how it would convert.
No I don't bother. Just set the retorts up and away I go.

View attachment 237609

This lot was green hard wood. Gave a better yield of charcoal to the charge, but did not burn as well.
Good for BBQ and melting of alloy with out a blower.


View attachment 237611

Seasoned hard wood.
This was a good conversion. Lots more dust and crumbs. But they get compressed with wax and sawdust to make another form of fuel to enjoy a beer with.

View attachment 237610

4 small retorts, gassing off nicely.
When the flame reduced to a large candle flame I removed them and sealed the hole.

View attachment 237608

The jet.

This is a fun sight.
Also if it topples it will fly.
I know.

That’s brilliant

 

[bourbon]

They make great breakfasts as well

 

[Mikes]

If you do set it up within a workshop, don't operate it on coke without first ensuring the doors to the workshop are open as coke has an affinity for oxygen and can cause asphyxiation. Best location is under an open sided lean-to.

 

[Mick Annick]

If you do set it up within a workshop, don't operate it on coke without first ensuring the doors to the workshop are open as coke has an affinity for oxygen and can cause asphyxiation. Best location is under an open sided lean-to.

Good point, I have the doors open at both ends of the workshop to try and get some air movement

 

[Matchless]

mine will be outside under an open sided lean-to, just not built that yet so it is just outside!