Systems and methods for multi-chamber biomass reactor

Abstract

A system and method for a multi-chamber biomass reactor comprising: a reaction chamber comprising a main chamber for biomass treatment; an outlet chamber adjacent to and connected to the reaction chamber; a biomass inlet, the biomass inlet comprising a zone for inputting biomass into the biomass reactor; a conveyor system including components that actuate biomass and other components from the biomass inlet through the reaction chamber and through the outlet chamber and through the biomass reactor; and a gas exchange system, the gas exchange system controlling a gas flow inside the biomass reactor, the gas exchange system comprising: at least one air vent; and an exhaust device. The system is used to process biomass whereby the system converts input biomass into energy-rich products, such as coal, charcoal, biofuels, fertilizers, briquettes, electrical power. The system and method may further include a tilt variable module including an actuation component capable of changing the tilt and / or height of the biomass reactor and / or biomass reactor component.

Description

Cross Reference to Related Applications

[0001] This application is a divisional application of the application with the application date of May 27, 2021, the application number of CN202180038575.0, and the invention name of “System and method for multi-chamber biomass reactor”, which claims the benefit of U.S. provisional application number 63 / 030,861 filed on May 27, 2020, and U.S. provisional application number 63 / 076,571 filed on September 10, 2020, the entire contents of the parent application and the aforementioned priority applications are hereby incorporated by reference into this application. TECHNICAL FIELD

[0002] The present invention relates generally to the field of biomass processing, and more specifically to new and useful systems and methods for multi-chamber biomass reactors. BACKGROUND

[0003] Moving bed biomass thermochemical reactors often have issues with directing gas flow. When operating at positive pressure, volatile off-gases and exhaust from the thermochemical reaction can exit the reactor from more than one passageway, which can not be desirable. Typically, it is desirable to direct the majority of the volatile off-gases and exhaust to flow in one pass that is directed to an outlet, so that the gases can be properly treated / oxidized / vented in order to extract heat from it and at the same time meet any pollution standards. As an example, in a moving bed reactor that contains one or more post-reaction solids outlets, it is sometimes undesirable to have the volatile off-gases and exhaust travel in the same direction as the solid material. When operating at negative pressure (natural convection), it can be desirable but challenging to have incoming air enter through a dedicated air injection port and not through any other passageway, such as a solids outlet.

[0004] Another undesirable condition that can be observed in a biomass moving bed reactor (e.g., similar to the biomass moving bed reactor described in WO 2018 / 213474 Al, which is incorporated herein by reference in its entirety) is that hot air rising in the main reaction chamber at the moving bed bottom can create a negative pressure (chimney effect) that draws air from the char outlet into the reactor through the length of the char cooling outlet. This air flow, which is counter-current to the output of torrefied / carbonized biomass that should be cooled, can create an oxidizing environment that continues to oxidize / burn the torrefied / carbonized biomass and prevents proper cooling. The result is loss of carbon from the torrefied biomass and reduced output quality and solids energy yield.

[0005] In some cases involving dense biomass (e.g., pine shavings and rice hulls), the biomass within the reactor bed provides enough fluidic resistance ("plugging") to prevent air from freely passing through the reactor and to prevent the formation of a chimney effect (or vice versa). In such cases, while air is present within the char cooling section, the air cannot easily penetrate the dense biomass bed into the moving bed region. Thus, there is no forced flow (chimney effect). In contrast, in the case of loose biomass (e.g., coconut shells), there is enough void space in the moving bed and in the char cooling section so that air can freely enter the moving bed, resulting in a strong chimney effect. In fact, in some cases, the air flow from the char outlet is so strong relative to the forced air inlet that the forced air inlet is useless in terms of setting the air to biomass ratio in the metering reaction zone. In such cases, control over the reaction zone is lost and the air to biomass ratio is set only by the strength of the chimney effect created by the moving bed.

[0006] To address these problems that exist, there is a need for a biological reactor system and method that can control air flow, control exhaust and off-gas, efficiently utilize exhaust and off-gas, and can handle both loose and dense biomass without creating a chimney effect. The present invention provides such a new and useful system and method. BRIEF DESCRIPTION OF DRAWINGS

[0007] Figure 1 is a schematic diagram of an example system.

[0008] Figure 2 is an alternative schematic diagram of an example system.

[0009] Figure 3 is a schematic diagram of an example system including a variable slope module.

[0010] Figure 4 is an alternative schematic diagram of an example system including a variable slope module.

[0011] Figure 5 is a schematic illustration of biomass being processed by the system.

[0012] Figure 6 is a schematic diagram of an example conveyor system.

[0013] Figure 7 is a schematic diagram of an example variable pitch en masse.

[0014] Figure 8 is a sub-portion of an example variable pitch en masse.

[0015] Figure 9 is a sub-portion of one end section of an example variable pitch en masse.

[0016] Figure 10 is a sub-portion of another end section of an example pitch variable pusher.

[0017] Figure 11 is a schematic of an example variable shaft pusher.

[0018] Figure 12 is a schematic of an example pusher blade with holes.

[0019] Figure 13 is a schematic of an example pusher with perforated blades.

[0020] Figure 14 is a schematic example relative to a neutral pressure plane of a system.

[0021] Figure 15 is a schematic example of system component actuation.

[0022] Figure 16 is a schematic example of flue elongation.

[0023] Figure 17 is an example of system actuation relative to a neutral pressure plane.

[0024] Figure 18 is an example of system actuation relative to a neutral pressure plane.

[0025] Figure 19 is a schematic of an example system.

[0026] Figure 20 is a schematic of an example system.

[0027] Figure 21 is an example system architecture that can be used in a system and / or method. DETAILED DESCRIPTION

[0028] The following description of embodiments of the present application is not intended to limit the application to these embodiments, but rather to enable a person skilled in the art to make and use the application. 1. SUMMARY

[0029] As Figure 1As shown, the system and method for a multi-chamber biomass reactor can include: a reaction chamber including a main chamber for biomass processing; an outlet chamber adjacent to and connected to the reaction chamber, primarily for biomass end product cooling; a biomass inlet including a region for inputting biomass into the biomass reactor; a conveyor system including components that actuate biomass through the biomass reactor from the biomass inlet through the reaction chamber and through the outlet chamber; a gas exchange system that controls gas flow within the biomass reactor, the gas exchange system including: an air vent and an exhaust; and a variable module that lowers and raises the inclination of the chamber components. The system and method function as a biomass reactor that utilizes a conveyor system to vary biomass density and a gas exchange system to control air / gas flow through the reactor. This can be particularly useful in a portable biomass reactor that can need to be used in various environments and conditions, and can benefit from a dynamic calibration configuration based on such use of the portable biomass reactor.

[0030] The system and method can be particularly applicable to the field of portable bioreactors (i.e., biomass reactors). That is, the system and method provide a portable biomass reactor that is capable of thermal decomposition reactions such as: pyrolysis (e.g., torrefaction and carbonization) and similar thermal reactions for processing biomass. The portable bioreactor can be used in various environments and conditions, and can use a system and method for a dynamic calibration configuration based on such use of the portable biomass reactor.

[0031] Additionally, the system and method can be applied to the field of carbon fiber production. In addition to processing plastic, polyacrylonitrile (PAN) polyacrylamide, and / or other carbon fiber precursors to produce carbon fiber, the system and method can also enable processing of biological materials for making carbon fiber and carbon fiber products.

[0032] The system and method can provide a number of potential benefits. The system and method are not limited to always providing such benefits, and are presented merely as illustrative representations as to how the system and method can be used. These benefits are not exhaustive, and other benefits can additionally or alternatively exist.

[0033] The system and method potentially provide the benefit of a portable biomass reactor that can efficiently process biomass into energy-dense end products for use.

[0034] The system and method can enable control of air / gas flow within the bioreactor. Control of internal air / gas flow potentially provides the benefit of more efficient processing of biomass.

[0035] Another potential benefit of controlling the internal gas flow is that the system and method can enable the implementation of processing steps that would otherwise be impossible.

[0036] Furthermore, controlling the internal gas flow can provide the benefits of better environmental management of bioreactors. By controlling the internal gas flow, contaminants can be retained and "cleaned" before being discharged from the bioreactor. Additionally, the internal gas flow can allow contaminants to be stored instead of being discharged.

[0037] Controlling the internal gas flow can further provide potential cooling benefits. That is, the system and method can enable the biomass to be cooled in the reaction chamber and / or other areas of the biomass reactor.

[0038] The system and method may additionally include a variable-pitch conveyor for densifying the internal biomass. Changing the internal biomass density offers the potential benefit of achieving the desired size of the final biomass product.

[0039] In addition, biomass densification offers the potential benefit of improved control over gas exchange within the system.

[0040] This system and method can also provide the benefit of advanced carbon fiber production tools. By utilizing the ability to carry out carbonization reactions using a biomass reactor, this system and method offer the potential benefits of efficient and portable carbon fiber production.

[0041] In addition, this system and method can provide portable carbonization tools. Since current carbon fiber production reactors are primarily stationary, this system and method potentially offer the benefit of portable devices for carbon fiber production. 2. SYSTEM

[0042] like Figures 1 to 4 As shown, the system for a multi-chamber biomass reactor includes: a reaction chamber 110, which includes a main chamber for biomass processing; an outlet chamber 120, which is adjacent to and connected to the reaction chamber; a biomass inlet 130, which includes a region for feeding biomass into the biomass reactor; a conveyor system 140, which includes components that actuate biomass and other components from the biomass inlet through the reaction chamber and through the outlet chamber and through the biomass reactor; and a gas exchange system 150, which controls the gas flow within the biomass reactor, the gas exchange system including: at least one air vent 152; and an exhaust device 154.

[0043] The system is used to process biomass, whereby the system converts inputted biomass into energy-rich products, such as coal, charcoal, biofuel, fertilizer, briquettes, electricity, heat production, and other suitable outputs. The system can have multiple variations, where the system can have additional or fewer components, such as a second Figure 2 (as shown in the second example schematic of the system). In some variations, as shown in Figure 3 and Figure 4 , the system can further include a variable inclination module 160, which includes actuated components that can change the inclination and / or height of the reaction chamber, outlet chamber, and biomass inlet, for example, the variable inclination module can raise the positioning of the outlet chamber, such that the outlet chamber is in an inclined state.

[0044] The system is used as a biomass reactor that can hold and process biomass. The biomass reactor can include an open or closed system. That is, the biomass reactor can include a storage space that seals stored biomass within or is open to the external environment. In some variations, the biomass reactor can have open and closed modes of operation, where the entire system and / or chambers can change between a closed system and an open system.

[0045] Depending on the implementation, the system can have additional or alternative components. The additional components can enable different or improved operations. For example, the additional components can enable the processing of different biomass (e.g., processing liquid-based biomass), enable the production of different outputs / end products (e.g., carbon fiber production), and improve general functionality (e.g., insulation layers can improve biomass reactor functionality in extreme weather conditions). Examples of additional components can include: a control unit, a power system (e.g., to power system components and / or initiate reactions), a sensor system (e.g., to better monitor system functionality), a communication system (e.g., for user monitoring and improved operability), a combustion chamber (e.g., to enable the production of high-temperature end products), a cooling system (e.g., air blast cooling, water mist cooling), and / or other suitable components.

[0046] As shown in the example schematic of Figures 1 to 4 , the system can include multiple implementation variations, where components can be differently changed and positioned depending on the implementation. In particular, depending on the implementation, the system can include different positions and sizes for: the biomass inlet 130, the air vent 152, and the exhaust 154.

[0047] The system can additionally be used as a "portable" biomass reactor, where the system can be transported as needed and used on-site. In this way, the system can be implemented in one area with one set of parameters and positioned for processing of one type of biomass processing, then changed and / or moved for processing of another type of biomass processing. The portable bioreactor is used to enable storage and processing of biological material in locations where larger bioreactors cannot typically access. In some variations, the portable bioreactor includes a volume of between approximately 30 to 250 m 3 In some variations, the portable bioreactor is small in size and includes a volume of between approximately 10 to 30 m3. In some variations, the portable bioreactor is miniaturized and includes a volume of between approximately 1 to 10 m 3 In some variations, the portable bioreactor is miniaturized and includes a volume of between approximately 1 to 10 m 3 Preferably, the portable bioreactor can receive multiple types of biomass (e.g., food waste, wild tree branches, agricultural residue). The portable bioreactor 110 can preferably change internal conditions to process the biomass. Internal changes can include thermal conversion (e.g., torrefaction) and biochemical conversion (e.g., fermentation). These processes can be implemented by changing temperature, pressure, and increasing and decreasing gas flow (e.g., oxygen) through the portable bioreactor. In a preferred variation, the portable bioreactor can primarily produce solid products biofuels (e.g., fertilizer, bio-coal) by breaking down the biomass. In one preferred variation, the portable bioreactor 110 functions under low-oxygen conditions.

[0048] In one embodiment, the biomass reactor can include biomass reactor components similar to those described in WO2018 / 213474 Al, filed May 16, 2018, the entirety of which is incorporated herein by this reference. The system can additionally be applied to alternative or additional forms of conversion systems. In another exemplary application, the system and method are used for biomass reactors that include small-scale, process-intensive pyrolysis reactors, where these biomass reactors produce liquid products (e.g., bio-oil, diesel, and other fractionated chemical compounds) and syngas from biomass. In some embodiments, the system can be configured for larger form factor biomass reactors or non-movable biomass reactors.

[0049] As a way of processing biomass into a desired usable, energy-rich end product, the system can have multiple processing mode functionality. The processing mode functionality of the system can be specific to the implemented biomass reactor, the biomass to be processed, and / or the desired end product. For example, one implemented system can be specific to receiving only one type of biomass material (e.g., wood) and converting it into one end product (e.g., wood is partially oxidized / gasified to produce syngas). A second implemented system can receive multiple types of biomass material (e.g., trash, including paper, wood, food waste) and process them into one end product (e.g., trash is partially oxidized / gasified to produce syngas). A third system can receive multiple types of biomass material (e.g., trash) and convert it into multiple types of end products (e.g., separate the trash and produce biogas, bio-coal, ethanol, and biodiesel from these components using combustion, torrefaction, bio-esterification, and fermentation). A fourth biomass reactor 110 can receive a single type of biomass material (e.g., wood) and convert it into multiple end products (e.g., bio-coal and heat).

[0050] In addition to having multiple operational modes for biomass processing, the system can also have operational modes in which the direction of air / gas flow through the system is controlled relative to the direction of biomass movement within the system. Using system components, the system can enable the direction of air / gas flow to be with the motion of the biomass processing, against the motion of the biomass processing, or independent of the motion of the biomass processing. That is, the system can have co-current flow, counter-current flow, cross-flow operational modes in which the air and gas flow is directed in the direction of the biomass processing, against the direction of the biomass processing, and relatively orthogonal to the direction of the biomass processing. Additionally or alternatively, the system can make the current operational mode in other directions depending on or independent of the direction of the biomass processing. Figure 5 An example schematic is shown in FIG. 1 in which biomass enters the system from the flue, is processed, and is driven out as torrefied output. In this example, the air / gas is controlled to be partially counter-current flow in which exhaust is present in the primary region where biomass is added.

[0051] The type of biomass used with the system varies depending on many factors, such as depending on the area where the biomass is collected and the biomass reactor implementation. Although technically, biomass can include any plant material (e.g., branches, leaves) or animal material (e.g., carcasses, food waste), biomass here can be used to refer to any organic material that can be converted into a desired end product, preferably a fuel or energy end product (e.g., biofuel or heat). This can include carbon-containing materials that are not derived from plants or animals, particularly any other hydrocarbons (e.g., synthetically produced organic materials, activated carbon, fly ash, and charcoal dust). In many variations, the biomass can be air permeable or semi-air permeable. That is, the biomass can generally allow air to travel through, but once compressed, the biomass can block the passage of air. In some applications of the system, the biomass can break down into larger material outputs that are not baled or compressed. These larger biomass materials (like coconut shells) can present unique challenges in controlling air travel, which can be addressed by the system. In some variations, the biomass can include unusable materials (e.g., as part of garbage collection). In these variations, the unusable materials can be removed from the system. Alternatively, in some variations, the unusable materials can be stored and "processed" with the usable biomass. This can be the case for implementations where the unusable materials have little impact on the end product.

[0052] The biomass reactor end product is preferably a processed compound from the biomass. More preferably, the end product is an energy-rich compound that is in a form that can be utilized at the time (e.g., fuel) or in a form that requires further processing (e.g., petroleum). Alternatively, the biomass end product can be any generally desired compound. As used herein, to simplify the discussion, the biomass end product will be referred to as "charcoal." The use of the term "charcoal" for the biomass end product is in no way limiting as to what the biomass end product can be. Examples of possible end products include: fertilizer, biofuel, activated carbon (e.g., bio-coal, briquettes), electricity, carbon fiber, and heat production (e.g., from burning biomass). The end product can additionally be in the form of a material intended for carbon sequestration. In some variations, the end product can be a compound that is only partially processed, such as petroleum or coke. In these variations, the end product can be treated as a final end product, or transported / transferred to another processing facility or reactor for further processing.

[0053] As defined herein, the neutral pressure plane (NPP) describes a plane or other surface where the pressure within the biomass reactor matches the pressure outside the biomass reactor, such that gas exchange at the NPP is relatively negligible in the absence of active pumping (note that diffusion still occurs). In many variations, the NPP depends at least in part on the ambient air pressure (P a ) as a function of height. Thus, in many variations, gas exchange above the NPP can cause a net gas flow out of the biomass reactor, and gas exchange below the NPP can cause a net gas flow into the biomass reactor. As part of the biomass functionality, the system can utilize the NPP to facilitate gas exchange. Thus, through the utilization of the NPP, the system can enable biomass processing to occur under different gas flows relative to the biomass processing; that is, the system can enable co-current, counter-current, and / or cross-current gas flow (e.g., gas flow orthogonal to biomass movement / processing) and / or some combination of flow direction. As shown in Figure 14 As shown in FIG. 14, an example schematic of a system is shown, where the NPP is plotted. In this example, air vents above the NPP can enable exchange of gas out of the bioreactor, and air vents below the NPP can enable exchange of air into the system.

[0054] The system can include a reaction chamber 110. The reaction chamber 110 is used to process input biomass. Generally, the reaction chamber 110 includes one or more chambers that enable thermal decomposition reactions to occur on input biomass. Depending on the implementation, any range of thermal decomposition reaction(s) can be implemented, such as mild forms (e.g., torrefaction) and extreme forms (e.g., carbonization). In some variations, the reaction chamber can enable more complex reactions where pyrolysis is only part of the reaction (e.g., combustion or gasification). In other variations, the reaction chamber can enable other types of biomass processing, such as thermal decomposition.

[0055] As part of the reaction chamber 110 functionality, the reaction chamber can include components that enable changes in thermodynamic properties. For example, the reaction chamber 110 can be enabled to undergo intrinsic changes, such as: increasing / decreasing temperature (e.g., heat pump or combustion reaction), increasing / decreasing pressure (e.g., changing chamber volume or preventing exhaust from exiting); and / or extrinsic changes, such as: adding / removing biomass material (e.g., separating different biomass components), adding / removing other components (e.g., removing reaction waste components), increasing / decreasing flow of gas / liquid components (e.g., increasing oxygen flow for combustion).

[0056] In some variations, the reaction chamber 110 can include multiple chambers, where during biomass processing, the biomass can enter different chambers as a moving material and different processes are initiated in these different chambers. These chambers can implement different stages of biomass processing. For example, filtration, oxidation, reduction, dissolution, etc.

[0057] The reaction chamber 110 can include multiple processing modes, where these processing modes can depend on the input biomass, the desired end product, and potential other factors (e.g., environmental conditions, reaction chamber capabilities, etc.). Thus, the reaction chamber 110 can be enabled to "process" the biomass by changing the internal conditions of the chamber. That is, the processing is used to produce the desired end product by inducing physical and chemical changes within the biomass. Depending on the implementation, the different processing modes can be a property of the bioreactor itself (e.g., reaction chamber 110 properties) or specific steps implemented within the reaction chamber for the type of biomass input or the type of desired end product.

[0058] The system can include an outlet chamber 120. The outlet chamber serves as a secondary processing and / or post-processing of the input biomass. The outlet chamber 120 can be directly connected to the reaction chamber 110, such that the input biomass can directly travel into the outlet chamber. The outlet chamber 120 can additionally include an outlet, such that the processed biomass can exit the bioreactor. Alternatively, depending on the implementation, the outlet chamber can be connected to another bioreactor chamber 110.

[0059] In some variations, the outlet chamber 120 can serve as a carbon cooling region. That is, the carbon can be actively and / or passively cooled in this region. In these variations, the outlet chamber S120 can include an open or semi-open region (e.g., air vent), such that the outlet chamber can be cooled by the external ambient temperature. Additionally or alternatively, the outlet chamber 120 can incorporate other cooling methods (e.g., liquid cooling, spraying water mist or steam).

[0060] In some variations, the outlet chamber 120 can be used to implement an extension or second stage of processing of the biomass. As shown in FIG. 1C, in these variations, the outlet chamber can also be connected to a flue or other exhaust, such that heated gases and / or compounds can flow along the biomass to help process the biomass. Figure 2

[0061] The system can include a biomass inlet 130. The biomass inlet serves as an entry point for the biomass. The biomass inlet 130 can be directly connected to the reaction chamber 110, or can include a "pipe" leading to the reaction chamber. Depending on the variation, the biomass inlet can be opened and closed. Alternatively, the biomass inlet is always open. In some variations, the system can have multiple biomass inlets 130.

[0062] ​In one variation, as shown in Figure 3 and Figure 4 Biomass inlet 130 also serves as a system flue in that biomass is input into the system through the same passageway as exhaust is released from the system. Biomass inlet 130 also includes a flue function to enable reverse flow gas exchange. Reverse flow gas exchange can enable efficient heating of biomass by exhaust, potentially enabling better activation / ignition of the biomass material.

[0063] In another variation, as shown in Figure 1 and Figure 2 Biomass inlet 130 can be positioned on a side of reaction chamber 110. Side entry biomass inlet 130 can be used to provide easier access and enable more efficient input of biomass into the biomass reactor. Additionally, side entry biomass inlet 130 can enable better co-current flow processing. That is, side entry can enable more efficient incorporation of co-current air / gas flow, where input air and exhaust flow in the same direction as the direction of biomass processing.

[0064] The system can include a conveyor system 140. The conveyor system is used to transport input biomass through the system; to move input biomass from biomass inlet 130, through reaction chamber 110, through outlet chamber 120, and out of the system. Additionally, conveyor system 140 can participate in altering the physical properties of the biomass (e.g., compression, spreading, mixing, altering the residence time of the biomass processing, etc.). The conveyor system can include a drive and actuation components. In variations that include a variable slope module 160, conveyor system 140 can work in conjunction with the variable slope module; where the conveyor system can utilize system slope to improve desired effects. In some variations, conveyor system 140 can include a pelletizer, briquetting machine, and / or variable pitch auger. As shown in Figure 6 One sample conveyor system 140 includes a moving bed for solids transport, a grinding device, a pelletizing / briquetting machine, and an injection port. In this example, the injection port can enable injection of a binder, carbon cooling fluid, or other fluid to make the carbon more malleable for pelletization.

[0065] Depending on the implementation, conveyor system 140 can also allow for forward or backward transport of biomass and biomass end products. Backward movement of biomass can enable extended processing quantities (e.g., for carbonization), and / or enable multi-stage processing. Additionally, backward movement of biomass can improve mechanical transport of biomass by clearing stuck biomass.

[0066] In some variations, the conveyor system 140 includes a moving bed that carries the biomass through the system. Depending on the implementation, the conveyor system can include a single bed, where the conveyor system actuates the biomass uniformly through the system. Alternatively, the moving bed can include multiple beds, such that each section transports the biomass at a different rate (i.e., non-uniform actuation). For example, a first moving bed section in the reaction chamber 110 can slow the transport of the biomass, such that the biomass is sufficiently treated into charcoal. A second bed section at the end of the reaction chamber 110 and the beginning of the exit chamber 120 can move slowly (or not at all), such that treated biomass can be accumulated (e.g., to prevent gas flow into the exit chamber 120. A third bed section within the exit chamber 120 can move at a desired rate, such that the charcoal is sufficiently cooled. In many variations, the ratio of the diameter of each section is controlled. In some variations, this means that the ratio of the size of the exit chamber 120 to the diameter of the moving bed is no more than a particular ratio, where the size of the exit chamber refers to the shortest cross-sectional length (e.g., the height, width, diameter, etc. of a circular exit chamber). In one example, the ratio is no more than 1. In a second example, the ratio is no more than 0.5. In a third example, the ratio is no more than 0.25. In some variations, the size ratio can also depend, at least in part, on the biomass size.

[0067] Additionally or alternatively, for the moving bed, the conveyor system 140 can include other components to achieve non-uniform actuation. For example, the conveyor system can include a pusher (e.g., a uniform pusher, a variable pitch pusher), a rotating drum, etc. That is, the conveyor system 140 can include any mechanism for non-uniformly actuating the biomass along a defined actuation path. In addition to achieving better treatment of the biomass by allowing the biomass to dwell in a desired region for a relatively optimized amount of time, non-uniform actuation can be used to achieve compression of the biomass. Compression of the biomass can enable better control of the gas exchange flow (e.g., by slowing or blocking gas flow). In one example, the conveyor system 140 can be implemented such that the biomass can be compressed near the region where the reaction chamber 110 and the exit chamber 120 connect, thereby limiting, reducing, or blocking air / gas flow between the reaction chamber 110 and the exit chamber 120. Compression of the biomass places the biomass under pressure (including but not limited to compression or extrusion treatment, such as narrowing the passageway (or increasing the pitch of the screw for systems including a variable pitch pusher).

[0068] In some variations, the conveyor system 140 includes a pusher. As shown in FIG. 1 1 1, the pusher can include a variable pitch pusher. Preferably, the pusher includes a drive shaft, as shown in FIG. 1 12, where the drive shaft drives the pusher. As shown in FIG. 1 13, the drive shaft can include a motor, such as a stepper motor, a servo motor, etc. Figures 7 to 10 Figure 5 In some variations, the conveyor system 140 includes a pusher. As shown in FIG. 1 1 1, the pusher can include a variable pitch pusher. Preferably, the pusher includes a drive shaft, as shown in FIG. 1 12, where the drive shaft drives the pusher. As shown in FIG. 1 13, the drive shaft can include a motor, such as a stepper motor, a servo motor, etc. Figures 7 to 10 ​As shown in the middle, the pusher can have a uniform pitch in the main area of each chamber, with variability between chambers. For example, the pitch variable pusher can have a relatively uniform pitch in the majority of the reaction chamber 110 and the majority of the exit chamber 120, with a denser pitch in the area between the two chambers. Alternatively, the pusher pitch decreases gradually in the reaction chamber 110, or along the initial portion of the exit chamber 120 interior (i.e., the char cooling section) past the reaction chamber. As previously mentioned, the variable pitch can enable densification of the biomass, resulting in a "choke" such that air flow between the reaction chamber 110 and the exit chamber 120 can be reduced or limited. Additionally or alternatively, the variable pitch can enable varying the biomass processing residence time. For the same rotational speed, the biomass residence time in the exit chamber 120 can be increased or decreased by adjusting the pitch of the pusher at that location. This can be used to achieve a desired temperature of the char at the exit.

[0069] Decreasing the pitch of the pusher can compress the torrefied biomass (which has previously had its volume reduced in the reaction chamber). By confining the pitch of the pusher to a particular region, the torrefied biomass can be compressed in a target region of the exit chamber 120. This will increase the level of the torrefied biomass and fill the axially projected cross-sectional area of the exit duct. The ratio between the reduced pitch and the original pitch (in the reaction chamber) can be adjusted such that the axially projected cross-sectional area is greater than a desired amount. In one variation, the projected cross-sectional area is greater than 75% of the full area. In other variations, the projected cross-sectional area is greater than 99% of the full area. If the level of the torrefied biomass is known, the ratio of the reduced pitch can be roughly calculated / predicted as the ratio of the full axially projected cross-sectional area to the cross-sectional area in the duct that is actually occupied by the torrefied biomass. This can increase the fluidic resistance for air to freely enter the moving bed and into the exit chamber 120, thus weakening any chimney effect. In some cases, the ratio of the reduced pitch to the original pitch can be further increased such that the torrefied biomass is compressed into smaller chunks. This breaking up of large particulate biomass into smaller particles can further be used to increase the fluidic resistance in the region of the reduced pitch. Coincidentally, this can be used for the dual purpose of reducing the size of the torrefied biomass, which is often a desired post-processing step after torrefaction or any thermochemical treatment. If the torrefied biomass particle size is reduced, the desired average particle output size can be controlled. In one variation, the output size is a particle less than 100 cm. In a second variation, the output particle is less than 10 cm, depending on the implementation, the output particle size can be in any range greater than 1 micron.

[0070] From the reaction chamber 110, the pitch can gradually decrease over a few turns, or suddenly decrease. A sudden decrease can result in a more sudden compression of the torrefied biomass, which will translate into more torque required on the parts of the motor, and into higher mechanical stresses on the pusher; this can lead to mechanical failures. Therefore, in many variants, a gradual decrease of the pitch can more efficiently create an air "choke". Alternatively, a sudden change of the pitch can be included in variants considering the driving torque. In some variants, the region of decreasing pitch can extend over the entire length of the carbon cooling section.

[0071] In other variants, the region of decreasing pitch can only last for a few turns, after which the pitch is again increased in the direction of the carbon outlet. The increase of the pitch can be a sudden increase or a gradual increase over a few turns. For these variants, the region of decreasing pitch can be at least a few pusher turns (>2) in order to create an efficient air "choke".

[0072] In some variants, as shown in Figure 11 , the outer diameter (OD) of the pusher shaft can gradually or suddenly increase in the reaction chamber 110 or over the initial part of the outlet chamber section 120 inside the tube wall of the conveyor system. This can be used to compress the biomass and create an air choke, where the biomass is compressed between the pusher shaft and the tube wall of the conveyor system. Depending on the implementation, the pitch can or can not remain constant at all times. For a pusher with constant pitch, the increased pusher shaft diameter can have the same effect of forcing the torrefied biomass to compress. The ratio between the enlarged pusher shaft OD and the original pusher shaft OD (in the reaction chamber 110) can be adjusted so that the cross-sectional area axially projected is filled to the desired amount. For example, the cross-sectional area can be: 75%, 90%, 95%, or 99% filled, if the level of torrefied biomass is known, the ratio can be roughly calculated / predicted as the square root of the ratio of the full axially projected cross-sectional area to the cross-sectional area actually occupied by torrefied biomass in the pipe before implementing the solution. Increasing the size of the pusher shaft can have the same compression and air "choke" effect as previously described, and can reduce the biomass particle size to a smaller size (achieving a "grinding" effect). The reduction of the torrefied biomass particle size can be controlled. In one variant, the output size is a particle smaller than 100 cm 3 . In a second variant, the output particle is smaller than 10 cm, depending on the implementation, the output particle size can be in any range greater than 1 micron.

[0073] Depending on the implementation, the pusher shaft OD can gradually increase, or suddenly increase, over one or more turns from the reaction chamber 110. A sudden increase in the pusher shaft OD can result in a more sudden compression on the torrefied biomass, which will translate into more torque required on the parts of the motor. This in turn can result in higher mechanical stresses on the pusher, and thus potentially failure if not initially accounted for. However, a sudden increase in the pusher shaft OD can also be implemented to create an air "choke".

[0074] In some cases, the region of increasing pusher shaft OD can continue over the entire length of the exit chamber 120. Alternatively, the increasing pusher shaft OD can only continue for one or more turns, after which the pusher shaft OD is again decreased, either suddenly or gradually, in the direction of the carbon exit. In variations including an increasing pusher shaft diameter, the region of increasing pusher OD can be at least one turn of the pusher, in order to create an effective air "choke".

[0075] Since wear and tear on the pusher can increase in the region of decreasing pitch conveying high-abrasive substances, such as torrefied biomass, it is recommended that the pusher be made of a wear-resistant material or treated with a wear-resistant technique, such as case hardening, in order to avoid the need for constant repair / re-welding of worn parts of the pusher. If the size of the torrefied biomass particles is decreased, the desired average particle output size can be less than 100 cm, less than 10 cm, less than 1 cm, less than 1 mm, less than 100 microns, less than 10 microns, less than 1 micron. This solution is illustrated below.

[0076] The pusher can be constructed of any type of material. Since wear and tear on the pusher can increase in the region of decreasing pitch or increasing OD shaft diameter conveying high-abrasive substances, such as torrefied biomass, the pusher can preferably be made particularly durable. In some variations, the pusher can be made of a wear-resistant material or treated with a wear-resistant technique, such as case hardening. This can provide the benefit of avoiding the need for constant repair / re-welding of worn parts of the pusher.

[0077] In variations in which the system is inclined, or particularly non-uniformly inclined (e.g., Figure 4 ) the conveyor system 140 can include multiple pushers (e.g., one pusher per inclined region). Alternatively, the pusher can have one or more flexible joints, enabling the pusher to bend and rotate along the incline.

[0078] In many variations, the thruster blades are long enough and shaped to form a relatively airtight (or low gas exchange) path for biomass transport. These shape-fitted blades are used to minimize / control gas flow through the system, particularly between reaction chamber 110 and outlet chamber. In some variations, the blades may have perforations or holes in a given area to allow gas flow. For example, as... Figure 12 As shown, the propeller blades of the propeller may have perforations within the reaction chamber 110 to allow gas to permeate into different compartments, thereby heating the unreacted biomass more quickly and improving overall reaction stability. The perforations should be smaller than the biomass particles in the reactor. Depending on the implementation, the perforations may have a diameter of less than 1 cm, 1 mm, or 0.1 mm. In some variations, for example, for coconut shells, the perforations may have a diameter between approximately 0.1 mm and 10 mm. This series of perforations may also be in the form of a mesh with sufficient thickness and strength to allow biomass to move along it. Figure 13 As shown, different examples of perforations in the propeller blades may include notches at the edges of the propeller blades or larger holes on the surface of the propeller blades, the diameter of which is equal to or greater than the typical size of the biomass pellets. In this case, the perforations (notches or holes) not only allow hot gas circulation, but also allow a small amount of biomass (which may be hot and reactive) to remain behind rather than be carried away by the propeller blades.

[0079] The conveyor system 140 may include a grinder. The grinder can be used to grind biomass, breaking it into smaller pieces (not less than 10 micrometers and not more than 100 cm in size). The grinder may include an in-line grinder. Alternatively, the grinder may include a hammer mill.

[0080] In some variations, conveyor system 140 may include a drying bed. The drying bed is used to aid in drying the biomass during transport along the conveyor system. The drying bed may include an inlet of drying equipment embedded in or near an end of reaction chamber 110. The drying equipment may include a belt dryer, a drum dryer, or any type of commercially available drive, now or in the future. Alternatively, the drying equipment may include a heated bed, wherein heat transfer elements (e.g., an outer casing or heating element in another reactor) are used to transfer heat to the heated bed.

[0081] The conveyor system 140 can include one or more injection ports. The injection ports are used to enable the addition of fluids, chemicals, gases, etc. to the biomass. In some variations, the conveyor system 140 includes injection ports within the reaction chamber 110. Alternatively, the injection ports can be located within the exit chamber 120 region of the conveyor system 140. In one example, the injection ports can enable the addition of a binder to the biomass. The binder can help "solidify" or create a denser biomass. Examples of binders include: tapioca, corn, starch, glue, and water.

[0082] In many variations, the conveyor system 140 transports the biomass out of the system. In some of these variations, the conveyor system 140 can also collate the outputted char. In some variations, the conveyor system 140 can deposit the char submerged in water immediately after the exit such that the solids coming out of the biomass reactor fall into the water without any air being able to enter. In one example, the conveyor system 140 deposits the char directly into water (in a container) with the level just at the solid exit to make the solids fall into the water. In another example, water is injected into the conveyor system 140 and thus submerges the char before deposition.

[0083] The system can include a gas exchange system 150. The gas exchange system 150 is used to control the flow of gases and air within the biomass reactor. The gas exchange system 150 can work in conjunction with the conveyor system 140 and the variable slope module 160 to control the flow of gases and air. The gas exchange system 150 can include at least one air vent 152, where the air vent enables gas exchange with the outside of the biomass reactor, and an exhaust 154 for releasing gases from the reactor. In some variations, the gas exchange system can include a duct connecting the air vent, the exhaust, and the system chamber. The duct can further be used to isolate or heat the chamber (e.g., the duct can direct exhaust gases to be discharged around the reaction chamber 120 to heat the reaction chamber).

[0084] The gas exchange system 150 can include at least one air vent 152. The at least one air vent 152 enables passive gas exchange with the exterior of the biomass reactor. The at least one air vent 152 includes a first air vent positioned on the exit chamber 120. The gas exchange system can include multiple air vents 152 positioned on the reaction chamber 110 and / or the exit chamber 120. Depending on the implementation, the air vents 152 can be active (i.e., pump air / gas into or out of the system) or passive (i.e., allow passive air / gas flow into or out of the system). In some variations, the air vents 152 can be "open" to allow active flow or "closed" to allow only passive flow. Additionally, the air vents can be "open" or "closed" where open air vents enable gas exchange and closed air vents are sealed and do not allow gas exchange.

[0085] In some variations, the at least one air vent 152 further includes a second air vent positioned on the reaction chamber 110. Depending on the implementation, the second air vent 152 can be angled in comparison to the slope of the reaction chamber 110. In some variations, the angle of the second air vent 152 can be changed as needed. In this manner, the second air vent can be used to reduce the chimney effect. The second air vent 152 can enable active or passive air flow. In some variations, the secondary air vent 152 can use this positioning to reduce emissions and pollutants. That is, the secondary air vent 152 can be angled to lower the positive air pressure in the reaction chamber 110, thereby helping to control gas exchange. In some variations, the secondary air vent 152 can have an operational mode that automatically changes the angle of the secondary air vent 152 to improve reactor function and / or reduce reactor emissions. For example, in a first secondary vent operational mode, the angle of the secondary air vent 152 is increased or decreased. These changes can occur to: increase the chimney effect, provide more oxygen for mixing to improve combustion, the flue gas is too hot when it comes out, or the biomass reactor is emitting a lot of smoke / diesel soot.

[0086] The air vents 152 can be positioned within the biomass reactor as needed for each implementation. In some variations, the gas exchange system can include air vents 152 at different heights along the surface of the biomass reactor wall. The air vents 152 are at different heights. Passive air vents at different heights can be used as "test ports." In this manner, the air vents can be dedicated test ports or used as test ports when needed. The test ports can be used to detect a neutral pressure plane (NPP) by detecting the direction of air flow through the test port. As Figure 14As shown in FIG. 1 1, the NPP can be determined by monitoring the test port, where passive air flow will be directed outward above the NPP and inward below the NPP.

[0087] In some variations, air vents 152 can be located near the hottest region in the reaction chamber 1 10. These air vents 152 can be used as air curtains and are useful for incorporating a portion of the drying gas. In some variations, air vents 152 used as air curtains can be positioned in pairs, opposite each other on the reaction chamber wall 1 10. Additionally, the air curtain effect can act to increase the positive pressure within the reactor, thereby affecting the location of the NPP.

[0088] In some variations, the gas exchange system can include gas vents. Gas vents include inlets for incorporating specific gases into specific chambers of the biomass reactor (e.g., outlet chamber gas vents, reaction chamber gas vents). The gas vents can include passive or active input of gases into the system as needed according to the implementation.

[0089] In one variation, a gas vent can be located near the biomass outlet. The gas vent can pump in a "drying" gas in a direction opposite the direction of travel of the torrefied biomass. Preferably, the drying gas is an inert gas, such as steam (which can be low temperature) or nitrogen. The drying gas can fill the char cooling section. In some variations, the drying gas can also be drawn out at one or more outlet / air vents before reaching the reaction chamber 1 10. The drying gas can prevent the hot torrefied biomass from reacting, and can further cool the torrefied biomass more efficiently.

[0090] The gas exchange system 150 can include an exhaust 154. The exhaust is used to carry away waste and / or exhaust gases produced by the operation of the biomass reactor. In many variations, the exhaust includes a flue 154 for dissipating gases. The flue can include one or more "chimney" bodies connected to the biomass reactor directly or through a set of pipes. According to the implementation, the flue can be connected to the reaction chamber 1 10 (as shown in FIG. 1 1), or to the outlet chamber (as shown in FIG. 1 1 1). Alternatively, the flue can also not be connected to either chamber, but have pipes connecting the flue to one or both chambers. In some variations, the flue can serve multiple purposes. For example, the flue can also be used as a biomass inlet 130, such that biomass is input into the reactor via the flue. Figure 3 Figure 1

[0091] ​​The flue can have any desired height (i.e., flue length). The flue height (also called flue length, flue height, or flue body height) can vary depending on the bioreactor implementation. The flue length can be used to regulate the bioreactor temperature. In one variant, the flue length is approximately 0.1-1 times the height of the outlet chamber 120. In another variant, the flue length is approximately 2-3 times the height of the outlet chamber 120. In yet another variant, the flue length is approximately 3-4 times the height of the outlet chamber 120. In one variant, the flue length is approximately 4-5 times the height of the outlet chamber 120. In yet another variant, the flue length is approximately 5-6.5 times the height of the outlet chamber 120. Figure 15 As shown, in some variations, the flue includes an extendable element, allowing the flue length to vary. According to embodiments, flue extension can be automatic (e.g., a servo motor can extend or retract the flue) or manual. The flue extension can occur dynamically during bioreactor operation or when the bioreactor is "shut down." In one variation, the range of flue length variation can include a change in the height of the outlet chamber 120. 1 The flue length variation ranges from 4 to 4 times the height of the outlet chamber 120. In one variation, the flue length variation can range from 2 times the height of the outlet chamber 120 to 6.5 times the height of the outlet chamber 120. Depending on the implementation, the range of flue length variability can be different.

[0092] In some variations, the location of the flue can be altered. This alteration can be used to extend the biomass processing time. For example, moving the end of the flue towards the reaction chamber 110 can increase the biomass roasting time and effectively "extend" the length of the reaction chamber 110. Additionally, moving the flue can change the airflow within the bioreactor. In some variations, the flue can be located on the outlet chamber 120, near the side of the outlet chamber directly adjacent to the reaction chamber 110. In another variation, the flue is located on the outlet chamber 120, near the side of the outlet chamber furthest from the reaction chamber 110. In yet another variation, the flue is located on the reaction chamber 110 itself. In some variations, the flue includes actuable components that allow its location to be changed along the biomass conveying direction. Figure 16 As shown, in some embodiments, the flue can be moved and positioned along the outlet chamber 120. In some embodiments, the flue can be moved and positioned along the reaction chamber 110. In some embodiments, the flue can be moved and positioned along the entire bioreactor (i.e., including both reaction chamber 110 and outlet chamber 120). Depending on the embodiment, the movement of the flue can be done manually or mechanically (e.g., by movement of a servo motor). Depending on the embodiment, the movement of the flue can occur dynamically during operation of the flue and / or when the bioreactor is not in use. The flue may additionally or alternatively have mechanically adjustable settings to change its position and other flue conditions.

[0093] In some variations, the flue can have components that increase or decrease air resistance. Increasing air resistance in the flue can be used to reduce the effect of the stack effect. In some variations, the exhaust can include a spoiler. In some embodiments, the spoiler can be engaged or disengaged to decrease air resistance only when needed.

[0094] In some variations, the exhaust outlet can increase air resistance by including a coiled tube / duct. The coiled tube can include meanders and turns to increase air resistance. The coiled tube / duct can additionally enable the tube to be coiled over components to provide insulation or heating. For example, in one embodiment, the exhaust duct can be coiled over the reaction chamber 110 such that the hot exhaust gas heats the reaction chamber. Additionally or alternatively, for the coiled tube / duct, air resistance can be increased by narrowing the duct or outlet. The flue gas outlet can be narrowed to a choke point (e.g., the gas reaches supersonic speed at the narrowest constriction).

[0095] In some variations, the exhaust can also have an "air curtain." The air curtain can include one or more air vents above the hottest level in the reaction chamber 110 (configured to allow only air in). These air "inlets" can introduce additional air flow that is less than, equal to, or greater than the speed of the rising exhaust flow. The additional air can be introduced at an angle (e.g., perpendicular) to the exhaust flow. In some embodiments, these air inlets can be preferably placed above the biomass bed level and inject air into the exhaust flow that is orthogonal to the vertical direction. Depending on the embodiment, these air inlets can include one or more pairs of 180 degrees spaced apart inlets for introducing counter-rotating jets.

[0096] In some variations, the system can include a variable slope module 160. As Figure 3 and Figure 4As shown in FIG. 1, the variable slope module 160 is used to change the height of the bioreactor components, and / or to tilt the bioreactor or bioreactor components. The variable slope module can include support components that are capable of raising and lowering the bioreactor and bioreactor components. In one variation, the variable slope module 160 includes one or more jacks positioned below the bioreactor to change the angle of tilt of the outlet chamber 120. In another variation, the variable slope module 160 includes a hydraulic mechanism (e.g., a hydraulic bed) positioned below and / or to the side of the bioreactor to change the angle of tilt of the outlet chamber 120. In a third variation, the variable slope module 160 includes a pulley system configured to raise or lower the bioreactor to change the angle of tilt of the outlet chamber 120. In many variations, the variable slope module is configured to operate in conjunction with other system components, particularly the conveyor system 140 and the gas exchange system.

[0097] The variable slope module 160 can function in conjunction with the conveyor system to improve biomass densification. As shown in FIG. 1, the variable slope module 160 can be used to increase the slope of the bioreactor, particularly the slope between the outlet chamber 120 and the reaction chamber 110. The increased slope of the bioreactor can then be used in conjunction with the speed of the pusher to set the level of biomass densification. Figure 3 or Figure 4 As shown in FIG. 1, in some variations, the variable slope module can increase the slope of the bioreactor while the biomass is moved along the conveyor system 140 by the pusher. Increasing the slope of the bioreactor, particularly the slope between the outlet chamber 120 and the reaction chamber 110. The sloped slope can then be used in conjunction with the speed of the pusher to set the level of biomass densification.

[0098] The variable slope module 160 can also function in conjunction with the gas exchange system 150 to regulate and / or control the flow of air / gas. As shown in FIG. 1, the variable slope module 160 can be used to increase the slope of the bioreactor, particularly the slope between the outlet chamber 120 and the reaction chamber 110. The increased slope of the bioreactor can then be used in conjunction with the speed of the pusher to set the level of biomass densification. Figure 17 and Figure 18As shown in the middle, using the test port (or temperature profile of the outlet chamber 120), the NPP can be adjusted relative to the bioreactor such that the desired air vent 152 can allow passive air flow to travel in the desired direction. Thus, the slope variable module 160 can have operational modes to set the slope to the desired type of function. For example, in one embodiment, the slope variable module 160 includes a first neutral pressure plane operational mode such that in the first neutral pressure plane operational mode, the actuating components of the slope variable module dynamically change the height of the outlet chamber 120 such that the air vent 152 on the outlet chamber is above the neutral pressure plane. In a second embodiment, the slope variable module 160 includes a second neutral pressure plane operational mode such that in the second neutral pressure plane operational mode, the actuating components of the slope variable module dynamically change the height of the outlet chamber 120 such that the air vent 152 on the outlet chamber is at approximately the same height as the neutral pressure plane. In a third embodiment, the slope variable module 160 includes a third neutral pressure plane operational mode, where the actuating components of the slope variable module dynamically change the height of the outlet chamber 120 such that the air vent 152 on the outlet chamber is below the neutral pressure plane.

[0099] In one variation, the system can additionally include a power system. The power system is used to provide energy for the processing of the biomass. In many variations, the power system provides the initial net energy to start the energetically favorable reaction. Alternatively, the power system can provide energy throughout the processing. Additionally, the power system can provide energy for other aspects of the system and system components (e.g., to provide energy for heat production for combustion, sensor operation, communication, processors, and actuation of system components). The power system can be particularly useful for embodiments in more remote areas where the system components do not have "grid" energy access. The power system can be specific and can include an energy storage (e.g., a battery), a generator, or both. The power system can also include or integrate a power source, such as a solar power source or other type of power source that can be used to supply more energy for storage. In variations that include only a battery power system, the battery preferably has enough energy to start the bioreactor reaction. Once the bioreactor reaction has been started, in some variations, the reactor can use the energy released by the reaction to recharge the battery. Example power systems include: a thermoelectric generator that uses the thermal gradient of the biomass reactor; a heat / steam engine that generates energy from the bioreactor exhaust; a wind turbine; or a wave generator that generates energy from waves. Additionally, the available energy stored in the power system can be monitored and used to select a processing mode.

[0100] In one variation, the system can further include a sensor system. The sensor system functions as a real-time monitor of the biomass environment. The biomass environment can include the interior of the bioreactor and the biomass itself. The sensor system can additionally or alternatively provide sensor data regarding the exterior of the bioreactor, the source location of the biomass, and any other desired sensor data.

[0101] The sensor system can include at least one sensor (i.e., a sensor subcomponent). The sensor component functions to acquire sensor data specific to the sensor. In general, the sensor system monitors the biomass. This monitoring preferably includes the time in which the biomass is being processed. The sensor system can provide information both to the bioreactor to enable proper action by the bioreactor to properly process the biomass and to other system components to enable proper action in the control system components. In some variations, the sensor system can also provide information to an external user as desired. Examples of possible sensors that the sensor can have include: a camera sensor (e.g., a digital still camera), a temperature sensor (e.g., a thermometer), a pressure sensor (e.g., a barometer), a sample extractor (e.g., for chemical analysis), a humidity sensor (e.g., a hygrometer), a composition sensor (e.g., an ultrasonic, a spectrometer), and / or other suitable types of sensors. The type of sensor used preferably depends on the implementation, more preferably on the particular bioreactor 110 and the type of biomass that the bioreactor can process.

[0102] In some variations, the system can include a control unit. The control unit can function to monitor, synchronize, operate, and coordinate the system components. The control unit can include any Turing complete component (e.g., a microprocessor) capable of communicating with and functioning with the system. In many variations, the control unit can enable complex processing of the other system components by dictating the operational mode of the system. The control unit can be directly connected to the other system components, but can alternatively be located at some other location. In some variations, the control unit 140 can be a processor on some network (e.g., on a network cloud). Additionally, the control unit can enable interaction with human components such that a person can implement particular system activities through the control unit.

[0103] In some variations, the control unit can enable external control of the system. This can be done through a user interface (UI). Through the UI, a user can receive data from system components (e.g., sensor system 120 data, general information online data, control unit data) and issue commands to the system and / or system components before and during bioreactor activity. User controls can include adding additional parameters, modifying control unit operations, adding new control unit operations (prioritizing low carbon emission end products), and canceling current operations. Standard control unit operations can include: inputting the type of biomass, setting the end product, setting the air-gas flow direction, setting the biomass / char end product density / size (e.g., how small the biomass should be ground before or after processing).

[0104] Once the system is activated, the control unit can further interact with system components to enable desired processing. Examples of processing that the control unit can monitor and control include: biomass end product processing, biomass densification, and setting air / gas flow. These processes can additionally include sub-processes. Examples of sub-processes can include: setting group air vent open / close, setting group air vent of active / passive air flow, setting active air vent pressure, angling secondary air vent relative to system components, setting flue length, setting flue position, determining neutral pressure plane (NPP), setting system component inclination relative to NPP, setting conveyor system speed, setting system component inclination relative to biomass densification.

[0105] In some variations, the control unit can enable biomass densification. In one example, given a biomass type and desired end product, the control unit can: determine biomass density (e.g., determine biomass density from sensor system by monitoring gas exchange between reaction chamber 110 and outlet chamber 120), set the conveyor system 140 to deliver biomass at a desired rate, and activate the inclination variable module 160 to raise the bioreactor or just the bioreactor chamber (e.g., outlet chamber 120) to an inclined state to optimize biomass compression.

[0106] In some variations, the control unit can enable setting the bioreactor air / gas flow flow (e.g., setting the flow to co-current flow, counter-current flow, or cross-flow compared to the biomass transport direction. In one example, given a desired cross-flow or a desired lack of passive flow, the control unit can first determine the neutral pressure plane (NPP) by activating the test port air vent along the wall of the outlet chamber 120 and / or reactor, and monitoring the direction of air flow through the test port. Then, the control unit can activate the variable inclination module to raise the outlet chamber 120 such that the first air vent 152 is located at approximately the height of the NPP. In a second example, given a desired co-current flow and given a desired biomass density and end product, the control unit can first implement biomass densification, as described above, setting the outlet chamber 120 to be in an inclined state. Then, the control unit can determine the NPP at the current system inclination. Once the NPP has been determined, the control unit can open the passive air vent below the NPP to achieve co-current air flow.

[0107] In some variations, the control unit can set the end product, where the control unit can enact the appropriate operating mode to produce the end product. The control unit can receive information from the sensor system and external components (e.g., a user). Then, the control unit can utilize the received information (e.g., input biomass, biomass quantity, desired end product, etc.) to activate the appropriate operating mode(s) to produce the end product. In one example, given an input biomass (e.g., coconut shells), a desired end product (charcoal), the control unit can activate the reaction chamber 110 to enact the appropriate operating mode (i.e., process) to process the biomass into the end product. Additionally, the control unit can extend or retract the flue and reposition the flue to match the incorporated process. In variations where the optimal biomass density or desired flow is not given, the control unit can additionally determine the optimal biomass density and the optimal air flow direction. These “optimal” values can be previously input values, extracted from an external source, and / or determined by the control unit through machine learning or implemented optimization processes.

[0108] In some variations, the system can be particularly suitable for the production of carbon fiber end products. As part of the carbon fiber end product, the biomass reactor can incorporate a wider input than just biomass. For example, in some variations, in addition to biomass, the biomass reactor can process plastic, PAN, and / or other carbon fiber precursors. As Figure 19 and Figure 20 As shown in FIGS. 1-3, in these variations, the system can further include a combustion chamber, or incorporate a combustion chamber within the reaction chamber 110; and a separator / washer. This alternative variation can be used with the system described above, or configured for use with any suitable type of reactor system.

[0109] A combustion chamber can be used to initiate carbonization reactions with high temperature combustion (e.g., around 1000C). The combustion chamber can include a spark igniter. In some variations, the exhaust gas from the reaction chamber 110 can flow through the combustion chamber and then circulate around the reaction chamber to heat the reaction chamber. The exhaust gas within the combustion chamber can be mixed with an oxygen-containing gas (e.g., air) to combust the mixture, thereby generating heat that can be used to support the thermochemical processes. This reduces the total external energy required to provide heat to the thermochemical steps, and in some cases, can even make these steps self-heat, meaning that they will not require any external energy to sustain themselves, either continuously or in batches.

[0110] Once the exhaust gas is combusted, the hot post-combustion flue gas can exchange heat with the thermochemical reaction chamber 110. In one variation, the hot flue gas can exchange heat (e.g., conductively) with the reaction chamber 110 through a wall, as shown in FIG. 1 1 A. This heat exchange can be combined in many different ways, depending on the needs of the implementation, such as: a thermally conductive shell, a tube, a pipe, an evaporator, a condenser, etc. In a second variation, the flue gas can exchange heat directly with the reaction chamber 110, with the reactants, as shown in FIG. 1 1 B (e.g., the reacting polyacrylonitrile fibers or other reaction intermediates, such as graphitizable matrix). In a third variation, the flue gas can exchange heat by radiation with the reaction chamber 110. Figure 20 Figure 19

[0111] As shown in FIG. 1 1 A, the exhaust gas can be directed into a combustion chamber, where it is mixed with air and combusted. A spark igniter can be inserted into the chamber to ensure stable combustion. One or more gas and temperature sensors (e.g., thermocouples or thermistors) can be inserted into, before, after, or on the inner or outer surface of the combustion chamber to monitor the temperature of the gas mixture and the post-combustion flue gas. The post-combustion flue gas can then pass through a channel that is external, internal, or both external and internal to one or more thermochemical reaction chambers, separated by a wall (e.g., a thin metal wall, such as stainless steel). The wall can then allow heat into the thermochemical reaction chamber(s) to sustain the thermochemical reactions. Figure 20

[0112] Alternatively, as shown in FIG. 1 1 B, the exhaust gas can be mixed with an amount of oxygen-containing air (e.g., in a stoichiometric ratio) and combusted in the same reaction chamber once it is released within the thermochemical reaction chamber(s) 110. This produces hot post-combustion flue gas, which immediately exchanges heat with the reactants (e.g., the reacting polyacrylonitrile fibers) to support the thermochemical process steps (e.g., oxidation / stabilization or subsequent carbonization). In steps that require inert conditions (e.g., carbonization steps), the reaction kinetics of the exhaust gas oxidation can be kept fast enough so that the resulting post-combustion products will still be able to maintain an approximately inert environment. Figure 19 ​​​​

[0113] For radiative heat transfer, the same setup as described in the "through the wall" heat exchange can be implemented, but the wall is heated to a high enough temperature that it radiates into the thermal chemical reaction chamber and transfers heat into the carbon-based substrate that is reacting. 4. SYSTEM ARCHITECTURE

[0114] The systems and methods of embodiments can be at least partially implemented and / or embodied as a machine configured to receive a computer readable medium storing computer readable instructions. These instructions can be executed by a computer executable component integrated with the hardware / firmware / software elements of an application, applet, host, server, network, website, communication service, communication interface, user computer or mobile device, wristband, smart phone, or any suitable combination thereof. Other systems and methods of embodiments can be at least partially implemented and / or embodied as a machine configured to receive a computer readable medium storing computer readable instructions. These instructions can be executed by a computer executable component integrated with the aforementioned types of devices and networks. The computer readable medium can be stored on any suitable computer readable media such as RAM, ROM, flash memory, EEPROM, optical (CD or DVD), hard disk, floppy disk, or any suitable device. The computer executable component can be a processor, but any suitable special purpose hardware device can (alternatively or additionally) execute these instructions.

[0115] In one variation, a system includes one or more computer readable media storing instructions that, when executed by one or more computer processors, cause a computing platform to perform operations including those of the systems or methods described herein, such as: processing biomass; densifying biomass; and setting an air / gas stream.

[0116] Similarly, in other variations, a non-transitory computer readable medium stores instructions that, when executed by one or more computer processors of a computing platform, cause the computing platform to perform operations of the systems or methods described herein, such as: processing biomass; densifying biomass; and setting an air / gas stream.

[0117] Figure 21 is an example computer architecture diagram of an embodiment of a system. In some embodiments, the system is implemented in multiple devices that communicate over a communication channel and / or network. In some embodiments, elements of the system are implemented in multiple separate computing devices. In some embodiments, two or more of the system elements are implemented in the same device. The system and portions of the system can be integrated into a computing device or system that can be used as or within the system.

[0118] The communication channel 1001 interfaces the processors 1002A-1002N, memory (e.g., random access memory (RAM)) 1003, read only memory (ROM) 1004, processor-readable storage medium 1005, display device 1006, user input device 1007, and network device 1008. As shown, the computer infrastructure can be used to connect the reaction chamber 1101, outlet chamber 1102, biomass inlet 1103, conveyor system 1104, gas exchange system 1105, variable slope module 1106, sensor system 1107, control unit 1108, and / or other suitable computing devices.

[0119] The processors 1002A-1002N can take many forms, such as CPUs (central processing units), GPUs (graphics processing units), microprocessors, ML / DL (machine learning / deep learning) processing units (such as tensor processing units), FPGAs (field programmable gate arrays, custom processors, and / or any suitable type of processor.

[0120] The processors 1002A-1002N and main memory 1003 (or some subcombination) can form a processing unit 1010. In some embodiments, the processing unit includes one or more processors communicatively coupled to one or more of a RAM, a ROM, and a machine-readable storage medium; the one or more processors of the processing unit receive instructions stored by the one or more of the RAM, the ROM, and the machine-readable storage medium via a bus; and the one or more processors execute the received instructions. In some embodiments, the processing unit is an ASIC (application-specific integrated circuit). In some embodiments, the processing unit is a SoC (system on a chip). In some embodiments, the processing unit includes one or more of the elements of the system.

[0121] The network device 1008 can provide one or more wired or wireless interfaces for exchanging data and commands between the system and / or other devices (such as devices of external systems). Such wired and wireless interfaces include, for example, a universal serial bus (USB) interface, a Bluetooth interface, a Wi-Fi interface, an Ethernet interface, a near-field communication (NFC) interface, and the like.

[0122] Configured computers and / or machine-readable executable instructions, including software programs (such as operating systems, application programs, and device drivers), can be stored in the memory 1003 from the processor-readable storage medium 1005, the ROM 1004, or any other storage system.

[0123] When executed by one or more computer processors, the respective machine-executable instructions can be accessed by at least one of the processors 1002A-1002N (of processing unit 1010) via communication channel 1001 and then executed by at least one of the processors 1001A-1001N. Data, databases, data records, or other stored forms of data created or used by the software program can also be stored in memory 1003 and such data is accessed by at least one of the processors 1002A-1002N during execution of the machine-executable instructions of the software program.

[0124] The processor-readable storage medium 1005 is one of (or a combination of two or more of) a hard disk drive, a flash drive, a DVD, a CD, an optical disc, a floppy disk, a flash memory, a solid state drive, a ROM, an EEPROM, an electronic circuit, a semiconductor memory device, etc. The processor-readable storage medium 1005 can include an operating system, software programs, device drivers, and / or other suitable subsystems or software.

[0125] As used herein, first, second, third, etc. are used to characterize and distinguish different elements, components, regions, layers, and / or portions. These elements, components, regions, layers, and / or portions should not be limited by these terms. The use of numerical terms can be used to distinguish one element, component, region, layer, and / or portion from another. Unless the context clearly indicates otherwise, the use of such numerical terms does not imply an order or sequence. These numerical designations can be used interchangeably unless the context clearly indicates otherwise.

[0126] As those skilled in the art will appreciate from the foregoing detailed description and from the accompanying drawings and claims, modifications and changes can be suggested by those skilled in the art in the application of the present teachings without departing from the scope of the present application as defined in the appended claims.

Claims

1. A system for a multi-chamber biomass reactor for processing liquid-based biomass, the system comprising: ●Reaction chamber, configured to allow biomass to be thermally decomposed into diesel fuel within the reaction chamber; ● An outlet chamber, which is adjacent to and connected to the reaction chamber; ● Biomass inlet, which includes a region for feeding biomass into the biomass reactor; ● A conveyor system comprising components that actuate the biomass from the biomass inlet through the reaction chamber and through the outlet chamber into the biomass reactor; as well as ●A gas exchange system that controls the gas flow within the biomass reactor, the gas exchange system comprising: ■ At least one air vent, including a first air vent located on the outlet chamber. ■Exhaust system; and ● Combustion chamber, which is connected to and adjacent to the reaction chamber; The combustion chamber includes a spark ignition device, and in the biomass treatment operation mode, flue gas and oxygen are pumped from the reaction chamber into the combustion chamber and ignited.

2. The system as claimed in claim 1, wherein, The ignited flue gas is pumped to the vicinity of the reaction chamber.

3. The system as described in claim 2, wherein, The system further includes a carbon fiber output biomass processing operation mode, in which ignited flue gas is pumped around the reaction chamber to superheat the reaction chamber.

4. A system for a multi-chamber biomass reactor for processing liquid-based biomass, the system comprising: ●Reaction chamber, configured to allow biomass to be pyrolyzed into diesel fuel within the reaction chamber; ● An outlet chamber, which is adjacent to and connected to the reaction chamber; ● Biomass inlet, which includes a region for feeding biomass into the biomass reactor; ● A conveyor system comprising components that actuate the biomass from the biomass inlet through the reaction chamber and through the outlet chamber into the biomass reactor. ■The conveyor system includes a variable-pitch conveyor that both actuates and compresses the biomass; and ●A gas exchange system that controls the gas flow within the biomass reactor, the gas exchange system comprising: ■ At least one air vent, the at least one air vent including a first air vent located on the outlet chamber, and ■Exhaust system; and ● Combustion chamber, which is connected to and adjacent to the reaction chamber; The combustion chamber includes a spark ignition device, and in the biomass treatment operation mode, flue gas and oxygen are pumped from the reaction chamber into the combustion chamber and ignited.

5. The system as described in claim 4, wherein, The ignited flue gas is pumped to the vicinity of the reaction chamber.

6. The system of claim 4, wherein, The system further includes a carbon fiber output biomass processing operation mode, in which ignited flue gas is pumped around the reaction chamber to superheat the reaction chamber.

7. A system for a multi-chamber biomass reactor for processing liquid-based biomass, the system comprising: ●Reaction chamber, configured to allow biomass to be pyrolyzed into diesel fuel within the reaction chamber; ● An outlet chamber, which is adjacent to and connected to the reaction chamber; ● Biomass inlet, which includes a region for feeding biomass into the biomass reactor; ● A conveyor system comprising components that actuate the biomass from the biomass inlet through the reaction chamber and through the outlet chamber into the biomass reactor; as well as ●A gas exchange system that controls the gas flow within the biomass reactor, the gas exchange system comprising: ■ At least one air vent, including a first air vent located on the outlet chamber. ■Exhaust system ● A variable tilt module, including actuating components capable of changing the height of the outlet chamber relative to the current placement of the bioreactor; and ● Combustion chamber, which is connected to and adjacent to the reaction chamber; The combustion chamber includes a spark ignition device, and in the biomass treatment operation mode, flue gas and oxygen are pumped from the reaction chamber into the combustion chamber and ignited.

8. The system of claim 7, wherein, The ignited flue gas is pumped to the vicinity of the reaction chamber.

9. The system of claim 7, wherein, The system further includes a carbon fiber output biomass processing operation mode, in which ignited flue gas is pumped around the reaction chamber to superheat the reaction chamber.

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