Easy Way to Light Unburned/Leftover Charcoal?

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qrk5001

Newbie
Original poster
Jul 31, 2017
10
12
St. Augustine, FL
Cleaning up after a few smokes, I realized I was ending up with a decent amount of charcoal that went unburned during the smoke. Most of them come from underneath the bottom grate in my firebox. This last time around, I decided to save most of the bigger pieces (anywhere from marble to golf ball size) so I can use them during future smokes. Is it common to end up with a lot of unburned charcoal? Or will I end up with less as I become more experienced?

In the meantime, what's the best way to light these? They're mostly too small for my chimney, they'll mostly just fall out through the bottom unless I add some kind of mesh.
 
I usually shut down all my vents after I'm done cooking. I then save the un-burnt charcoal in a separate container. The next time I fire up the grill or smoker I reuse the old coal by dumping it on top of the new coal. Haven't experienced any issues. Saves a little money.

Chris
 
Unburned charcoal is still good fuel.  I reuse used charcoal in both my Kettle and my WSM.

Kettle for grilling:  I load the chimney with some new charcoal, then leave enough room in the chimney to put the used charcoal on top of that.  Fire it up and use it.  I've cut WAY back on how much charcoal I load in the Kettle to grill.  Once upon a time, I would put just about a full bag of charcoal in the Kettle, then spread hot charcoal over the top of that.  On subsequent uses I'd pick the biggest pieces out and fire them up on the chimney.  Now I only use as much as I need to grill for that session.  There's always some left over, so I put new in the chimney and add the used on top of that. 

Kettle for smoking: The used charcoal is my first layer in my baskets, then I add wood and cold charcoal on top of that.  On top of the cold charcoal I'll add only as much new hot briquette as I need to reach and maintain my chamber temp.  

WSM: I keep track of which smokes by date of the last time I emptied my ash bowl.  I can easily go 20-24 hours of smoking before I need to empty the bowl.  I start each smoke by knocking the ash off the used charcoal, then add some wood on top of the used charcoal.  I'll cover the used charcoal with new briquettes, then add more wood.  I add hot charcoal to the middle of the pile, then once the smoke has stabilized, 30-60 minutes, I'll add the meat.

Based on the three ways I use used charcoal, you can figure out which works best for your smoker.   
 
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