Continuous biochar kiln system

Abstract

The continuous biochar kiln makes biochar from biomass. The continuous biochar kiln is continuously operated by using an updraft fire through a vertical rotating fire tube. The rotary fire tube is attached to a blade that acts as a conveyor or mixer. The blade conveys the biomass from the inlet to the outlet of the cylinder shape and air-tight kiln. As the biomass is conveyed it receives the heat transfer from the vertical rotating fire tube wherein the biomass transforms into biochar at the outlet valve through the process of pyrolysis. The pyrolysis combustible gas may be generated during the process and that gas becomes the thermal energy to continue fueling the kiln.

Description

[0001] Continuous Biochar Kiln System

[0002] FIELD OF THE INVENTION

[0003] The present invention relates generally to kilns. More specifically, the present invention is a continuous biochar kiln.

[0004] BACKGROUND OF THE INVENTION

[0005] The field of kilns is technologically important to several industries, business organizations, and / or individuals. In particular, the use of kilns is prevalent for producing biochar.

[0006] A Biochar kiln is a device to produce biochar from biomass in a pyrolysis reactor whereby the kiln has limited oxygen. The device heats up the biomass and lets the volatile matter evaporate into pyrolysis gas when the biomass reaches a certain temperature and beyond. Pyrolysis gas is combustible and harmful to the environment, so it needs to be burnt outside the kiln chamber with combustion air in the atmosphere. Since pyrolysis gas is started ignition, it creates heat from its combustion that will make a spontaneous combustion. The volatile mass that transforms into pyrolysis gas will be the thermal energy for the kiln without using any fuel from other external sources except the starting up heat. During this pyrolysis process in the kiln, the biomass will transform into rich carbon material, also known as “biochar”. Biochar is the end product from the kiln and may be utilized as soil improvement material or mixed with concrete to improve their property or fuel of a significantly higher heating value as compared to the original biomass.

[0007] Utilizing biochar is regarded as greenhouse gas mitigation since the biomass absorbs carbon dioxide from the atmosphere during its planting and growing, so carbon credit may be gained. Existing techniques for biochar production using a biochar kiln are deficient with regard to several aspects. For instance, current continuous kiln technologies use more energy, are more complex and massive, and also not friendly mobile or portable. Therefore, there is a need for improved biochar kiln that may overcome one or more of the above-mentioned problems and / or limitations.

[0008] BRIEF DESCRIPTION OF THE DRAWINGS

[0009] FIG. 1 is a top front left perspective view of the present invention.

[0010] FIG. 2 is a bottom rear right perspective view of the present invention.

[0011] FIG. 3 is a top front left exploded perspective view of the present invention.

[0012] FIG. 4 is a front view of the present invention.

[0013] FIG. 5 is a rear view of the present invention.

[0014] FIG. 6 is a right-side view of the present invention.

[0015] FIG. 7 is a left-side view of the present invention.

[0016] FIG. 8 is a top view of the present invention.

[0017] FIG. 9 is a bottom view of the present invention.

[0018] FIG. 10 is a block diagram view of the present invention.

[0019] DETAILED DESCRIPTION OF THE INVENTION

[0020] All illustrations of the drawings are for the purpose of describing selected versions of the present invention and are not intended to limit the scope of the present invention.

[0021] As a preliminary matter, it will readily be understood by one having ordinary skill in the relevant art that the present disclosure has broad utility and application. As should be understood, any embodiment may incorporate only one or a plurality of the above-disclosed aspects of the disclosure and may further incorporate only one or a plurality of the above-disclosed features. Furthermore, any embodiment discussed and identified as being “preferred” is considered to be part of a best mode contemplated for carrying out the embodiments of the present disclosure. Other embodiments also may be discussed for additional illustrative purposes in providing a full and enabling disclosure. Moreover, many embodiments, such as adaptations, variations, modifications, and equivalent arrangements, will be implicitly disclosed by the embodiments described herein and fall within the scope of the present disclosure.

[0022] Accordingly, while embodiments are described herein in detail in relation to one or more embodiments, it is to be understood that this disclosure is illustrative and exemplary of the present disclosure, and are made merely for the purposes of providing a full and enabling disclosure. The detailed disclosure herein of one or more embodiments is not intended, nor is to be construed, to limit the scope of patent protection afforded in any claim of a patent issuing here from, which scope is to be defined by the claims and the equivalents thereof. It is not intended that the scope of patent protection be defined by reading into any claim a limitation found herein that does not explicitly appear in the claim itself.

[0023] Thus, for example, any sequence(s) and / or temporal order of steps of various processes or methods that are described herein are illustrative and not restrictive. Accordingly, it should be understood that, although steps of various processes or methods may be shown and described as being in a sequence or temporal order, the steps of any such processes or methods are not limited to being carried out in any particular sequence or order, absent an indication otherwise. Indeed, the steps in such processes or methods generally may be carried out in various different sequences and orders while still falling within the scope of the present invention. Accordingly, it is intended that the scope of patent protection is to be defined by the issued claim(s) rather than the description set forth herein.

[0024] Additionally, it is important to note that each term used herein refers to that which an ordinary artisan would understand such term to mean based on the contextual use of such term herein. To the extent that the meaning of a term used herein — as understood by the ordinary artisan based on the contextual use of such term — differs in any way from any particular dictionary definition of such term, it is intended that the meaning of the term as understood by the ordinary artisan should prevail.

[0025] Furthermore, it is important to note that, as used herein, “a” and “an” each generally denotes “at least one,” but does not exclude a plurality unless the contextual use dictates otherwise. When used herein to join a list of items, “or” denotes “at least one of the items,” but does not exclude a plurality of items of the list. Finally, when used herein to join a list of items, “and” denotes “all of the items of the list.” The following detailed description refers to the accompanying drawings. Wherever possible, the same reference numbers are used in the drawings and the following description to refer to the same or similar elements. While many embodiments of the disclosure may be described, modifications, adaptations, and other implementations are possible. For example, substitutions, additions, or modifications may be made to the elements illustrated in the drawings, and the methods described herein may be modified by substituting, reordering, or adding stages to the disclosed methods. Accordingly, the following detailed description does not limit the disclosure. Instead, the proper scope of the disclosure is defined by the appended claims. The present disclosure contains headers. It should be understood that these headers are used as references and are not to be construed as limiting upon the subjected matter disclosed under the header.

[0026] The present disclosure includes many aspects and features. Moreover, while many aspects and features relate to, and are described in the context of a continuous biochar kiln, embodiments of the present disclosure are not limited to use only in this context.

[0027] According to some embodiments, disclosed herein is a continuous biochar kiln configured for making biochar from biomass. Further, the continuous biochar kiln may be continuously operated by using an updraft fire through a vertical rotating fire tube 112 whereby the vertical rotating fire tube is attached to at least one blade 111, wherein the at least one blade 111 is a screw blade or mixing blade that may act a as screw conveyor. The screw conveys the biomass from an inlet 13 to the outlet 14 of the cylinder shape and air-tight kiln whereby the biomass receives the heat transfer from the vertical rotating fire tube 112. The vertical rotating fire tube 112 transfers heat from an outer surface of the vertical rotating fire tube 112 to the biomass inside the kiln body 1. The biomass from the inlet 13 transforms into biochar at the outlet 14 through the process of pyrolysis. Pyrolysis combustible gas may be generated during the process and that gas becomes the thermal energy to continue fueling the kiln. In case there is excess pyrolysis gas, the pyrolysis gas may be released into the atmosphere through a gas flare to protect the environment. This continuous updraft biochar kiln with a vertical screw with rotating firetube and flare allows it to work with higher productivity, less total energy consumption, and less pollution while small enough to be portable and easy to operate.

[0028] In reference to FIG. 1-10, the continuous biochar kiln system comprises a kiln body 1, a starting fuel 2 and a gas tube 3. The kiln body 1 may be a portable natural draft biochar kiln wherein in the kiln body 1 is an air-tight cylindrical shape. The kiln body 1 is configured to receive biomass. The starting fuel 2 is utilized to begin the heat transfer process until pyrolysis gas is generated and becomes the heat source for the continuous biochar kiln system. The kiln body 1 comprises a conveyor system 11, a motor housing 12, an inlet 13, an outlet 14 and a thermocouple 15. The conveyor system 11 is configured to convey biomass within the kiln body 1 upwards or downwards from the inlet 13 to the outlet 14. The conveyor system 11 may also be utilized as a mixing system. The inlet valve 131 is an opening wherein the user may introduce biomass into the kiln body 1. The gas tube 3 comprises an excess gas burner 31, a junction 32, a bottom end 33, a top end 34, and an exit end 35. The excess gas burner 31 is configured to burn off excess pyrolysis gas that is produced. The bottom end 33 further comprising a gas burner 31. The gas tube 3 is coupled along the length of the kiln body 1. As a result, the gas tube 3 may transfer pyrolysis gas from the top of the kiln body 1 to the bottom of the kiln body 1. The kiln body 1 is positioned above the starting fuel 2. Consequently, the kiln body 1 is heated by the starting fuel 2. The motor housing 12 mechanically couples to the conveyor system 11. Accordingly, the motor 121 conveyor system 11 may be automatically rotated by the motor housing 12. The inlet 13 extends outwards from the kiln body 1. Thus, the inlet 13 does not interfere with the conveyor system 11, enabling a user to introduce biomass into the kiln body 1 easily. The outlet 14 extends outwards from the kiln body 1. The outlet 14 is positioned above the inlet 13 or below the inlet 13. So, the conveyor system 11 moves the biomass introduced into the kiln body 1 upwards towards the outlet valve 14, wherein the biomass may exit the kiln body 1 once it has become biochar due to the high temperature within the kiln body 1. Further, the conveyor system 11 further comprises at least one blade 111, and a vertical rotating fire tube 112 as seen in FIG. 3. The at least one blade 111 is configured to move or mix the biomass introduced into the kiln body 1. The at least one blade 111 connecting radially along the vertical rotating fire tube 112. As a result, the at least one blade 111 rotates with the vertical rotating fire tube 112, pushing and moving the biomass within the kiln body 1. The vertical rotating fire tube 112 is configured to conduct hot flue gas and flame upwards from an ignition fire started by the starting fuel 2 below the kiln body 1. Additionally, the vertical rotating fire tube 112 is configured to transfer heat to the biomass within the kiln body 1. As a result, the biomass being conveyed upwards from the inlet 13 to the outlet 14 becomes biochar by the time it reaches the outlet 14 due to the heat transfer. During the process, pyrolysis gas is generated and becomes the self-sufficient heat source for the present invention. At this point, the initial fire or external heat source, started with the starting fuel 2, is extinguished as it is no longer needed for the present invention to operate. The continuous biochar kiln system may be portable and consume as little energy as possible. The vertical rotating fire tube 112 further comprises a tube gear 113.

[0029] Furthermore, the tube gear 113 mechanically couples to the motor housing 12 as shown in FIG. 1. Consequently, the motor housing 12 may rotate the tube gear 113 and thus the vertical rotating fire tube 112. The vertical rotating fire tube 112 rotates along a vertical axis 114. The vertical axis 114 is the central axis travelling vertically through the vertical rotating fire tube 112. Preferably the vertical rotating fire tube 112 is positioned vertically. Accordingly, the at least one blade 111 moves the biomass upwards within the kiln body 1 within this embodiment. The present invention may be configured for making biochar from biomass that can be continuously operated by using an updraft fire through the vertical rotating fire tube 112 whereby at least one blade 111 is connected that may act a as screw conveyor and heat distributor. The at least one blade 111 coveys the biomass from the inlet 13 to the outlet 14 of the cylinder shape and air-tight kiln body 1 whereby the biomass receives the heat transfer from the vertical rotating fire tube 112. The biomass from the inlet 13 transforms into biochar at the outlet 14 through the process of pyrolysis. Pyrolysis combustible gas may be generated during the process and that gas becomes the thermal energy to continue fueling the system. In an alternative embodiment the vertical rotating fire tube 112 is positioned at an angle. In another alternative embodiment the vertical rotating fire tube 112 is positioned horizontally. Thus, the kiln body 1 moves the biomass longitudinally within the kiln body 1 within this embodiment.

[0030] In reference to FIG. 1, the motor housing 12 further comprises a motor 121 and a chain 124. The motor 121 is configured to automatically rotate the chain 124. The chain 124 mechanically couples the motor 121 to the conveyor system 11. So, the chain 124 enables rotational movement from the motor 121 to be translated to rotational movement of the vertical rotating fire tube 112 within the conveyor system 11. The motor 121 further comprises a motor gear 122 and a controller 123. The motor gear 122 is integrated within a rotating axle of the motor 121. The motor gear 122 mechanically couples to the chain 124. The controller 123 is configured to control the speed and power output of the motor 121. In reference to FIG. 1, the inlet 13 further comprises an inlet valve 131 valve. The inlet valve 131 valve is configured to prevent air from entering the kiln body 1 and prevents gas from leaking out. The outlet 14 further comprises an outlet valve 141 valve. The outlet valve 141 valve is configured to prevent air from entering the sealed kiln body 1 as the biochar exits. The thermocouple 15 integrates within the kiln body 1. As a result, the thermocouple 15 is positioned along the top of the kiln body 1 and detects the temperature of the exiting biochar. The thermocouple 15 is positioned above the outlet 14. Consequently, the thermocouple 15 indicates to the user if the vertical rotating fire tube 112 needs to rotate slower or faster to achieve the optimal biochar output.

[0031] Furthermore, the top end 34 connects to a top side 16 of the kiln body 1 as seen in FIG. 1. Accordingly, the pyrolysis gas produced by the heated biomass exits the kiln body 1 through the top side 16 of the kiln body 1 wherein it enters the gas tube 3 and may be recycled to heat the kiln body 1 again. The junction 32 couples the bottom end 33, the top end 34 and the exit end 35 together. As a result, the pyrolysis gas may flow towards the bottom end 33 or the exit end 35. The excess gas burner 31 connects to the exit end 35. Thus, excess pyrolysis gas is burned off via the excess gas burner 31 to prevent unmanageable pressure loads. Further, when there is excess pyrolysis gas, the pyrolysis gas may be released into the atmosphere through a gas flare to protect the environment. This continuous updraft biochar kiln with at least one blade 111 with the vertical rotating fire tube 112 and the excess gas burner 31 allows it to work with higher productivity, less total energy consumption, and less pollution while small enough to be portable and easy to operate.

[0032] To operate the present invention a user may generate initial heat with the starting fuel 2 underneath the kiln body 1. The heat of an initial fire may rise through the vertical rotating fire tube 112 and be the thermal energy that starts the heating within kiln body 1. In the process of producing biochar, pyrolysis gas may be generated and create pressure inside the kiln body 1. The pressurized pyrolysis gas may be delivered by a gas tube 3 that is connected from a top end 34 of the kiln body 1 to a bottom end 33 of the kiln body 1 and feeds to the exit end 35. An air intake at the bottom of the vertical rotating fire tube 112 may mix with the feeding pyrolysis gas and ignite by the heat at the vertical rotating fire tube 112. This spontaneous combustion of pyrolysis gas may replace the heat from starting fuel 2. At the steady state when pyrolysis gas continuously generates and combusts, the starting fuel 2 is no longer needed as long as biomass is continuously fed into the inlet 13 by the user. In a case of over-feeding of biomass by a higher rotating speed of vertical rotating fire tube 112 or the at least one blade 111 or motor 121, the produced biochar may have less quality. This quality of biochar is detected by the thermocouple 15. If the temperature is too low then the biochar quality will drop. In order to increase the biochar temperature, the rotating speed may be decreased by reducing the speed of the motor 121 with the controller 123. In a case of overheating, also detected by the thermocouple 15, the rotating speed may be increased by increasing the speed of the motor 121 with the controller 123. To prevent the kiln body 1 from overheating in the continuous-combustion process, excess pyrolysis gas from the combustion chamber may need to be destroyed. Simply releasing this excess pyrolysis gas into the atmosphere is polluting, so the released pyrolysis gas may be burnt using the excess gas burner 31 connected to the gas tube 3 along the exit end 35.

[0033] Although the invention has been explained in relation to its preferred embodiment, it is to be understood that many other possible modifications and variations can be made without departing from the spirit and scope of the invention as hereinafter claimed.

Claims

What is claimed is:

1. A continuous biochar kiln system comprising: a kiln body, a starting fuel and a gas tube; the kiln body comprising a conveyor system, a motor housing, an inlet, an outlet and a thermocouple; the gas tube comprising an excess gas burner, a junction, a bottom end, a top end, and an exit end; the being coupled along the length of the kiln body; the kiln body being positioned above the starting fuel; the motor housing mechanically coupling to the conveyor system; the inlet extending outwards from the kiln body; the outlet extending outwards from the kiln body; the outlet being positioned above or under the inlet; and the conveyor system comprising a vertical rotating fire tube.

2. The continuous biochar kiln system as claimed in claim 1 comprising: the conveyor system further comprising at least one blade; the bottom end further comprising a gas burner; the at least one blade connecting radially along the vertical rotating fire tube; and the vertical rotating fire tube further comprising a tube gear.

3. The continuous biochar kiln system as claimed in claim 2 comprising: the tube gear mechanically coupling to the motor housing; and the vertical rotating fire tube rotating along a vertical axis.

4. The continuous biochar kiln system as claimed in claim 2 wherein the vertical rotating fire tube being positioned vertically.

5. The continuous biochar kiln system as claimed in claim 2 wherein the vertical rotating fire tube being positioned at an angle.

6. The continuous biochar kiln system as claimed in claim 2 wherein the vertical rotating fire tube being positioned horizontally.

7. The continuous biochar kiln system as claimed in claim 1 comprising: the motor housing further comprising a motor and a chain; and the chain mechanically coupling the motor to the conveyor system.

8. The continuous biochar kiln system as claimed in claim 7 comprising: the motor further comprising a motor gear and a controller; and the motor gear mechanically coupling to the chain.

9. The continuous biochar kiln system as claimed in claim 1 comprising: the inlet further comprising an inlet valve; the outlet further comprising an outlet valve; the thermocouple integrating within the kiln body; and the thermocouple being positioned above the outlet.

10. The continuous biochar kiln system as claimed in claim 2 comprising: the top end connecting to a top side of the kiln body; the junction coupling the bottom end, the top end and the exit end together; and the excess gas burner connecting to the exit end.

11. A continuous biochar kiln system comprising: a kiln body, a starting fuel and a gas tube; the kiln body comprising a conveyor system, a motor housing, an inlet, an outlet and a thermocouple; the gas tube comprising an excess gas burner, a junction, a bottom end, a top end, and an exit end; the gas tube being coupled along the length of the kiln body; the kiln body being positioned above the starting fuel; the motor housing mechanically coupling to the conveyor system;the inlet extending outwards from the kiln body; the outlet extending outwards from the kiln body; the outlet being positioned above or under the inlet the conveyor system further comprising at least one blade, and a vertical rotating fire tube; the bottom end further comprising a gas burner; the at least one blade connecting radially along the vertical rotating fire tube; the vertical rotating fire tube further comprising a tube gear; the tube gear mechanically coupling to the motor housing; and the vertical rotating fire tube being positioned vertically.

12. The continuous biochar kiln system as claimed in claim 11 wherein the vertical rotating fire tube rotating along a vertical axis.

13. The continuous biochar kiln system as claimed in claim 11 wherein the vertical rotating fire tube being positioned at an angle.

14. The continuous biochar kiln system as claimed in claim 11 wherein the vertical rotating fire tube being positioned horizontally.

15. The continuous biochar kiln system as claimed in claim 11 comprising: the motor housing further comprising a motor and a chain; the chain mechanically coupling the motor to the conveyor system; the motor further comprising a motor gear and a controller; and the motor gear mechanically coupling to the chain.

16. The continuous biochar kiln system as claimed in claim 11 comprising: the inlet further comprising an inlet valve; the outlet further comprising an outlet valve; the thermocouple integrating within the kiln body; the thermocouple being positioned above the outlet;the top end connecting to a top side of the kiln body; the junction coupling the bottom end, the top end and the exit end together; and the excess gas burner connecting to the exit end.

17. A continuous biochar kiln system comprising: a kiln body, a starting fuel and a gas tube; the kiln body comprising a conveyor system, a motor housing, an inlet, an outlet and a thermocouple; the gas tube comprising an excess gas burner, a junction, a bottom end, a top end, and an exit end; the gas tube being coupled along the length of the kiln body; the kiln body being positioned above the starting fuel; the motor housing mechanically coupling to the conveyor system; the inlet extending outwards from the kiln body; the outlet extending outwards from the kiln body; the outlet being positioned above or under the inlet the conveyor system further comprising at least one blade, and a vertical rotating fire tube; the bottom end further comprising a gas burner; the at least one blade connecting radially along the vertical rotating fire tube; the vertical rotating fire tube further comprising a tube gear; the tube gear mechanically coupling to the motor housing; the vertical rotating fire tube being positioned vertically; the vertical rotating fire tube rotating along a vertical axis; the motor housing further comprising a motor and a chain; the chain mechanically coupling the motor to the conveyor system; the motor further comprising a motor gear and a controller; and the motor gear mechanically coupling to the chain.

18. The continuous biochar kiln system as claimed in claim 17 wherein the vertical rotating fire tube being positioned at an angle.

19. The continuous biochar kiln system as claimed in claim 17 wherein the vertical rotating fire tube being positioned horizontally.

20. The continuous biochar kiln system as claimed in claim 17 comprising: the inlet further comprising an inlet valve; the outlet further comprising an outlet valve; the thermocouple integrating within the kiln body; the thermocouple being positioned above the outlet; the top end connecting to a top side of the kiln body; the junction coupling the bottom end, the top end and the exit end together; and the excess gas burner connecting to the exit end.

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