Fan palm fronds
Breaking to size (25 cm)
Spindle stick
De-barking
Splitting
Assembling impeller
Base stone to hold spindle in while spinning
Fanning flames
Digging clay from creek
Fan palm
Fan palm fiber
Mixing clay and fiber (so it won't crack as it dries)
Forming fan housing
Matching fan to housing diameter (allow for some space inside the housing)
Making air entry (between 1/3 to 1/4 the diameter of the housing is my rule)
Forming spout
Forming sides
Note: Air exit is same diameter as air entry (air in equals air out)
Covering vine rings with clay
Fanning flames
Turn over when dry
Testing blower
Making air pipe (to prevent the blower from touching the fire and getting damaged and to better concentrate the air jet)
Making a small furnace
Making a charcoal retort (only 50 cm in diameter as an experiment)
6 holes made around the base of cylindrical retort
Stacking the retort with wood
Plastering top with clay
Hot coals from the fire
Lighting from the top
Fire burns back down towards the air entries
When you see fire through the holes it's time to seal it up
Finally closing the air exit last (about 2 to 3 hours burn time all up)
Opening the retort the next day
Charcoal on one side, un-burnt wood on the other (for next time)
Next batch
Only need to rebuild the top this time
Notice here that charcoal burns a lot hotter than the wood it's made from
Water with thin film that breaks easily (a sign of iron bacteria)
Collecting congealed iron bacteria
Dried iron bacteria
Pre heating furnace with wood
Charcoal
Bacteria
After 3 hours of work
The next day
Just slag no visible iron this time
Vitrified furnace
Vitrified air pipe
Blower and charcoal