Biocarbon reactor

Abstract

This application relates to a biochar reactor (100) for producing biochar (BC). The biochar reactor comprises a horizontal reactor chamber (102), a receiver (104) for receiving (472) biomass (BM) into the biochar reactor, a pyrolysis unit (108) for pyrolysis (480) the received biomass to produce biochar, a cooler (114) for cooling (488) the produced biochar, and a controller (346) for controlling the biochar reactor. The pyrolysis unit comprises at least one pyrolysis unit section (110), each pyrolysis unit section (110) configured to pyrolysis biomass by using a specific temperature range for that section. The biochar reactor is configured to flow hot gas (HG) through each pyrolysis unit section (110) to pyrolysis the biomass at a process temperature (T1, T2) within the section-specific temperature range of the pyrolysis unit section (110).

Description

Technical Field

[0001] This application generally relates to a biochar reactor.

Background Art

[0002] The pyrolysis of biomass has been utilized for thousands of years. In the past, wood was pyrolyzed into charcoal by restricting the intake of air, i.e., burning the wood in a depression in a low-oxygen atmosphere. A more advanced method is to use a closed steel container, where it is easier to regulate the intake air volume and temperature. This method only functions with large wood pieces such as in the form of firewood. The wood also has to be pre-dried, which increases the cost of the raw material. Due to the size of the raw material, the process takes several hours and limits the capacity.

[0003] Today, a more advanced and commonly used type of pyrolysis reactor is the screw-type reactor, in which the decomposed raw material is heated by heating a screw conveyor or an auger of a pipe, or both. In this type of reactor, heat transfer is carried out by point-shaped contact between the wood particles and the reactor steel structure. This makes heat transfer extremely inefficient because the contact points of the wood particles are rapidly carbonized, creating a good heat insulation on the surface of the material and slowing down the process. There are also specific limitations to the physical size of the screw-type reactor, which limits the capacity of this structure. Typically, the largest commercial reactor suppliers promise a capacity of approximately 5,000 tons per year at most.

Summary of the Invention

Problems to be Solved by the Invention

[0004] One object of the present invention is to eliminate the shortcomings of known solutions and to provide a biochar reactor that can produce biochar from lignocellulosic biomass, produce different types of bio-oil in a single manufacturing process, improve the cost-effectiveness of the manufacturing process, reduce the size of the biochar reactor, and enable carbon dioxide removal (CDR) from the atmosphere using the biochar reactor.

[0005] One object of the present invention is achieved by providing a biochar reactor, a method of production, a computer program, and a computer-readable medium as described in an independent claim. [Means for solving the problem]

[0006] Embodiments of the present invention are specified by the biochar reactor, manufacturing method, computer program, and computer-readable medium as defined by the independent claims.

[0007] A first embodiment of the present invention includes a biochar reactor for producing biochar. The biochar reactor comprises a horizontal reactor chamber, a receiver for receiving biomass into the biochar reactor, a pyrolysis unit for pyrolyzing the received biomass to produce biochar, a cooler for cooling the produced biochar, and a controller for controlling the biochar reactor. The pyrolysis unit comprises at least one pyrolysis unit section, each pyrolysis unit section configured to pyrolyze biomass by using a specific temperature range for that section. The biochar reactor is configured to flow hot gas through each pyrolysis unit section to pyrolyze the biomass at a process temperature within the section-specific temperature range of the pyrolysis unit section.

[0008] A second embodiment of the present invention includes a method for producing biochar using a biochar reactor according to the embodiment of the biochar reactor described above. The production method includes at least the steps of: pyrolysis of the received biomass in at least one pyrolysis section by using the controller and the pyrolysis unit to use the specific section-specific temperature range within each pyrolysis unit section to produce the biochar; and cooling of the produced biochar by the controller and the cooler. The pyrolysis step includes flowing the hot gas through each pyrolysis unit section to pyrolysis the biomass at the process temperature within the section-specific temperature range of the pyrolysis unit section.

[0009] A third embodiment of the present invention includes a computer program including instructions, which, when executed by a controller (computer), causes the biochar reactor according to the biochar reactor embodiment described above to carry out at least the steps of the manufacturing method embodiment described above.

[0010] A fourth embodiment of the present invention includes a tangible, non-volatile, computer-readable medium containing a computer program according to the computer program embodiment described above.

[0011] Exemplary embodiments of the present invention will be described with reference to the following figures. [Brief explanation of the drawing]

[0012] [Figure 1a] Figure 1a is a diagram of a biochar reactor having a single horizontal conveyor and multiple pyrolysis sections. [Figure 1b] Figure 1b is a diagram of a biochar reactor having a single horizontal conveyor and a single pyrolysis section. [Figure 2a] Figure 2a shows a biochar reactor having a horizontal section conveyor and multiple pyrolysis sections. [Figure 2b]Figure 2b shows a biochar reactor having a horizontal section conveyor and a single pyrolysis section. [Figure 3] Figure 3 shows a biochar reactor having an inclined section conveyor and multiple pyrolysis sections. [Figure 4] Figure 4 is a flowchart of the manufacturing method for producing biochar. [Modes for carrying out the invention]

[0013] Figure 1a and diagrams of other reactors show a horizontal, low-speed pyrolysis biochar reactor 100 for producing biochar (biocarbon) BC, such as biochar chips or crude biochar powder (dust), from biomass BM. Biomass BM may be any lignocellulosic biomass such as woody biomass or agricultural biomass, or any industrial and urban sludge.

[0014] Woody biomass BM may include, for example, wood chips or crude wood powder (dust), waste wood chips or crude waste wood powder (dust), logging residue chips or crude logging residue powder (dust), or other woody biomass. Agricultural biomass BM may include, for example, corn cobs, straw, peat, palm oil, coffee beans, by-products from rice production, or other agricultural biomass.

[0015] The reactor 100 comprises a horizontal reactor chamber 102 having an airtight structure that allows for the establishment of an oxygen-free and pressurized or unpressurized interior 103 of a chamber 102 for the production of, for example, biochar chips BC, which are used below as an example of the biochar produced. The chamber 102 further encapsulates at least some of the reactor components within its interior 103. Such reactor components are, for example, a dryer 106, a pyrolysis unit 108, and a condenser 114. The chamber 102 may further encapsulate other reactor components within its interior 103. Such reactor components are, for example, a receiver 104, a retainer 112 (if present), and an exhaust unit 116.

[0016] The reactor 100 further includes a partition 118 that divides the interior 103 of the chamber 102 so that at least a dryer 106, a pyrolysis unit 108, and a condenser 114 are sequentially established within the chamber 102. The partition 118 can further divide the interior 103 so that a receiving unit 104, a dryer 106, a pyrolysis unit 108, a retainer 112 (if present), a condenser 114, and an exhaust unit 116 are sequentially established within the chamber 102.

[0017] Each partition 118 is provided with a port 120 that allows biomass BM or biochar chips BC to exit one reactor component and enter another. At least one of the partitions 118 is provided with a guide 122 that guides biomass BM or biochar chips BC from one reactor component to another. The reactor 100 in Figure 1 is provided with guides 122 in the first and last partitions 118, while the reactor 100 in Figures 2a and 2b is provided with guides 122, 224 in each partition 118.

[0018] The partitions 118 are installed in the chamber 102 such that one partition 118 is between the dryer 106 and the pyrolysis chamber 108, and another partition 118 is between the pyrolysis chamber 108 and the condenser 114. Further partitions 118 may be installed such that one partition 118 is between the receiver 104 and the dryer 106, another partition 118 is between the dryer 106 and the pyrolysis chamber 108, a third partition 118 is between the pyrolysis chamber 108 and the retainer 112, a fourth partition 118 is between the retainer 112 and the condenser 114, and the last partition 118 is between the condenser 114 and the discharger 116. If the reactor 100 lacks the retainer 112, the fourth partition 118 is also missing, and the third partition 118 is between the pyrolysis chamber 108 and the condenser 114.

[0019] The reactor 100 further includes at least one conveyor 126 that conveys the biomass BM through the dryer 106 and the pyrolyzer 108 and conveys the produced biochar chips BC through at least the cooler 114. The conveyor 126 may further convey the produced biochar chips BC through the retainer 112 (if present).

[0020] At least one conveyor 126 according to the figure includes a single horizontal conveyor 126 that conveys the biomass BM and the produced biochar chips BC along the entire reactor 100, from the dryer 106 through the pyrolyzer section 110 and the retainer 112 (if present) to the cooler 114.

[0021] The structure of each conveyor 126 is such that, by structure, before the hot gas HG flows over the biomass BM or the biochar chips BC on the conveyor 126, the hot gas HG can flow through a structure, such as a flow aperture (hole, structure, opening). Each conveyor 126 includes, for example, a perforated plate or a wire mesh chain conveyor with the said flow aperture for the hot gas HG.

[0022] The reactor 100 further includes a receiver 104 that receives the pre-dried biomass BM through an input port (not shown). The receiver 104 includes a feeder 128 that supplies the biomass BM to the reactor 100. The feeder 128 includes a rotary feeder that supplies the incoming biomass BM and a screw distributor (conveyor) that distributes the supplied biomass BM across the full width of the receiver 104 and the conveyor 126.

[0023] The receiver 104 further provides an oxygen-free chamber 102. The receiver 104 exposes the incoming biomass BM to the exhaust gas EG from the dryer 106 by flowing the exhaust gas EG through the incoming biomass BM flow, and the exhaust gas EG removes air from the biomass BM.

[0024] The reactor 100 includes a dryer 106 for final drying of the distributed biomass BM. The dryer 106 is equipped with a heat exchanger and a fan, and the heat exchanger and fan blow hot gas HG onto the structure of the conveyor 126 and the floor of the biomass BM from at least one direction, for example, one direction as shown in the figure, or two opposite directions, one of which is as shown in the figure, thereby removing existing moisture from the biomass BM.

[0025] The reactor 100 generates (uses) a process temperature TE in the dryer 106 that is less than 220°C, for example, 100°C, 120°C, 140°C, 160°C, 180°C, or 200°C.

[0026] The reactor 100 includes a pyrode unit 108 that, if pyrolysis occurs at temperatures above 300°C to 400°C, for example, in a temperature range of 200°C to 700°C, pyrode the dry biomass BM at a slow rate to produce biochar chips BC. Alternatively, if semi-carbonization occurs at temperatures below 300°C, the pyrode unit 108 may only perform semi-carbonization of the dry biomass BM at temperatures below 300°C to produce biocoal (semi-carbonized biomass). The pyrode unit 108 comprises at least one pyrode unit section 110, for example, a single pyrode unit section 110, or a plurality of consecutive pyrode unit sections 110 as shown in the figure, and the pyrode unit 108 continuously pyrode the dry biomass BM at a slow rate in the aforementioned temperature range.

[0027] Multiple consecutive pyrolysis sections 110 enable slow multiphase pyrolysis and the use of different process temperatures (temperature ranges) T1, T2 in different pyrolysis sections 110. The multiple consecutive pyrolysis sections 110 further enable the production of bio-oils B1, B2 from different temperature ranges.

[0028] Figure 1b shows reactor 100, which corresponds to reactor 100 in Figure 1a, except that its pyrolysis unit 108 comprises only a single pyrolysis unit section 110 that enables pyrolysis at a single process temperature (temperature range) T1 in the pyrolysis unit section 110. The single pyrolysis unit section 110 enables the production of bio-oil B1 from its temperature range. The process temperature is 200°C to 700°C, and in the case of the single pyrolysis unit section 110, it is substantially below 300°C.

[0029] Multiple pyrolysis sections 110 include at least two pyrolysis sections 110, for example, two, three, four, five, or more pyrolysis sections 110, and adjacent pyrolysis sections 110 are separated by partitions 118.

[0030] Regardless of the number of pyrolysis sections 110, each pyrolysis section 110 is equipped with a conveyor 126 structure and a heat exchanger and blower for circulating hot gas HG over the biomass BM on the conveyor 126 to pyrolyze the biomass BM. The pyrolysis in the pyrolysis section 110 occurs at pyrolysis section-specific temperatures T1, T2, which differ from the rest of the pyrolysis section 110 if other pyrolysis sections 110 are present.

[0031] If the pyrolysis unit 108 comprises two pyrolysis unit sections 110 according to Figure 1a, the reactor 100 brings a process temperature T1 in the first pyrolysis unit section 110 following the dryer unit section 106, which is, for example, 300°C to 400°C, e.g., 300°C, 320°C, 340°C, 360°C, 380°C, or 400°C. The reactor 100 then brings a process temperature T2 in the next (second) pyrolysis unit section 110, which is, for example, 400°C to 500°C, e.g., 400°C, 420°C, 440°C, 460°C, 480°C, or 500°C.

[0032] The multiple pyrolysis sections 100, separated by partitions 118, allow for a continuous increase in process temperatures T1, T2, such that the next pyrolysis section 110 uses a higher process temperature T2 than the previous pyrolysis section 110.

[0033] If the pyrolysis unit 108 comprises more pyrolysis unit sections 110 than shown in the figure, for example, three pyrolysis unit sections 110, the resulting process temperature T1 may be, for example, 300°C to 330°C in the first pyrolysis unit section 110, for example, 300°C, 315°C or 330°C, the resulting process temperature T2 may be, for example, 330°C to 450°C in the second pyrolysis unit section 110, for example, 300°C, 330°C, 360°C, 390°C, 420°C or 450°C, and the resulting process temperature in the third pyrolysis unit section 110 may be, for example, 450°C to 500°C, for example, 450°C, 475°C or 500°C.

[0034] The reactor 100 further comprises a heat generator 130 that generates flue gas FG, which is then used in the flue gas-operated heat exchangers of the dryer 106 and pyrolysis unit 108 (pyrolysis unit section 110). Alternatively, the heat exchangers can be operated using electricity or other energy sources. The heat exchangers heat the hot gas HG in the dryer 106 and pyrolysis unit section 110 to dry the biomass BM and pyrolysis the biomass BM into biochar chips BC, exposing the bed of biomass BM to the required process temperatures TE, T1, and T2 by the flowing hot gas HG.

[0035] The reactor 100 further comprises a synthesis gas condenser 132, and each pyrolysis section 110 has a dedicated synthesis gas condenser 132 for condensing the pyrolysis-derived synthesis gases S1 and S2 generated during the pyrolysis process in the pyrolysis section 110. Each synthesis gas condenser 132 operates so that the condensed portions of the pyrolysis-derived synthesis gases S1 and S2 produce bio-oils B1 and B2. The non-condensable portions of the pyrolysis-derived synthesis gases S1 and S2 produce non-condensable synthesis gases U1 and U2, which are then returned to the heat generator 130 for the generation of flue gas FG.

[0036] The reactor 100 may further comprise a retainer 112 separated by a partition 118 from the last or only pyrolysis section 110 (pyrolysis unit 108) and the condenser 114. The retainer allows for the retention of the produced biochar chips BC when the biochar chips BC are on the conveyor 126 in front of the condenser 114.

[0037] The reactor 100 further includes a sprayer 134 that generates cooling steam VA, which is then used in the cooler 114. The sprayer 134 sprays the steam VA into the cooler 114, exposing the biochar chips BC to the steam.

[0038] The reactor 100 includes a cooler 114 for cooling the manufactured and, if applicable, retained biochar chips BC. The cooler 114 includes a conveyor 126 structure and a blower for circulating steam WA over the biochar chips BC floor, along with a sprayer 134, so that the biochar chips are cooled.

[0039] The reactor 100 further comprises a steam condenser 136 that condenses the cooling-derived steam VA generated during the cooling process in the cooler 114. The steam condenser 136 operates so that the condensed portion of the cooling-derived steam VA produces water WA, which is then returned to the sprayer 134 for the generation of steam VA. The cooling-derived steam VA produces high-temperature air HA, which can be used, for example, in a pre-drying process before biomass BM enters the reactor 100.

[0040] The reactor 100 further comprises an exhauster 116 that discharges cooled biochar chips BC from the reactor 100 via an output port (not shown).

[0041] Figure 2a shows reactor 100, which corresponds to reactor 100 in the other figures, except that it includes an alternative embodiment of at least one conveyor 126.

[0042] At least one conveyor 126 in the figure comprises multiple consecutive horizontal section conveyors 238 instead of a single horizontal conveyor 126, with at least one section conveyor 238 for each of the dryer 106, pyrolysis section 110, retainer 112 (if present), and cooler 114. The at least one section conveyor 238 comprises, for example, one, two, three, four, five, or more section conveyors as shown in the figure.

[0043] The section conveyors 238 are positioned to descend within the chamber 102 such that the section conveyor 238 of the first pyrolysis section 110 is lower than the section conveyor 238 of the dryer 106, and the section conveyor 238 of the next pyrolysis section 110 is lower than the section conveyor 238 of the first pyrolysis section 110. The section conveyor 238 of the retainer 112 (if present) is lower than the section conveyor 238 of the last (next) pyrolysis section 110, and the section conveyor 238 of the cooler 114 is lower than the section conveyor 238 of the retainer 112 (if present). In any case, the section conveyor 238 of the cooler 114 is lower than the section conveyor of the last pyrolysis section 110.

[0044] Figure 2b shows reactor 100, which corresponds to reactor 100 in Figure 2a, except that its pyrolysis unit 108 comprises only a single pyrolysis unit section 110. The section conveyors 238 are installed to descend correspondingly into the chamber 102, as in the case of multiple pyrolysis unit sections 110, such that the section conveyor 238 of the single pyrolysis unit section 110 is lower than the section conveyor 238 of the dryer 106. The section conveyor 238 of the retainer 112 (if present) is lower than the section conveyor 238 of the pyrolysis unit section 110, and the section conveyor 238 of the condenser 114 is lower than the section conveyor 238 of the retainer 112 (if present). In either case, the section conveyor 238 of the condenser 114 is lower than the section conveyor of the pyrolysis unit section 110.

[0045] The level difference between the continuous section conveyors 238 in these descending installations allows for the rearrangement (mixing) of biomass BM between the dryer 106 and the pyrolysis section 110, and between the pyrolysis sections 110 in the case of multiple pyrolysis sections 110, as the biomass BM falls from the level in front of the section conveyor 238 to the level behind the section conveyor 238. The rearrangement of biochar chips BC corresponds to the relationship between the last or only pyrolysis section 110 and the retainer 112 (if any), and between any retainer 112 and the cooler 114.

[0046] Rearranging biomass BM and biochar chips BC based on their fall during transport makes the drying, thermal decomposition, retention, and cooling processes more effective, and as a result, it is possible to improve the cost-effectiveness of the biochar BC production method 470.

[0047] Figure 3 shows reactor 100, which corresponds to reactor 100 in the other figures, except that it includes a second alternative embodiment with at least one conveyor 126.

[0048] At least one conveyor 126 in the figure comprises multiple consecutive inclined section conveyors 340 instead of a single horizontal conveyor 126 and multiple horizontal section conveyors 238, with at least one section conveyor 340 for each of the dryer 106, pyrolysis section 110, retainer 112 (if present), and cooler 114. The at least one section conveyor 340 comprises, for example, one, two, three, four, five, or more section conveyors as shown in the figure.

[0049] Each inclined section conveyor 340 is installed (inclined) such that its front end 342 is lower than its rear end 344, and, if present, the rear end 344 of the previous section conveyor 340. The rear end 344 of the section conveyor 340 is higher than the front end 342 of the next section conveyor 340, if present.

[0050] Deviating from Figure 3, the reactor 100 corresponds to the reactor 100 in Figure 3, but may comprise a single pyrolysis section 110 corresponding to the aforementioned figure, and at least one section conveyor 340 within the single pyrolysis section 110.

[0051] The inclined installation creates level differences between the continuous section conveyors 340, allowing for the rearrangement of biomass BM and biochar chips BC based on their fall, corresponding to the lowered installation as shown in the diagram above.

[0052] When the inclined section conveyor 340 can be installed more densely than the horizontal section conveyor 238 due to the inclined installation, it becomes possible to shorten the length of the production line and the chamber 102.

[0053] The reactor 100 further includes a controller 346 that controls the operation of, for example, reactor components 104, 106, 108, 110, 112 (if present), 114, 116, 126, 128, 130, 132, 134, 136, 238, and 340 so that the reactor 100 operates as described above and below.

[0054] The controller 346 includes a processor 348 that executes operator start commands, computer program (software) start commands, or both, and processes data to start a computer program (application, software). The processor 346 may include at least one processor, for example, one, two, three, four, or more processors.

[0055] The controller 346 further comprises memory 350 for storing and maintaining data. The data may be instructions, computer programs, and data files. Memory 350 includes at least one memory, for example, one, two, three, four, or more memories.

[0056] The reactor 100 further comprises a communication unit 352 controlled by a controller 346 to transmit commands, requests, and data to at least one of the following components within the reactor 100, such as conveyors 126, 238, 340, feeders 128, blowers, and sprayers 134. The controller 346 further controls the communication unit 352 to receive commands, requests, and data from, for example, at least one of the components 104, 106, 108, 110, 112 (if present), 114, 116, 126, 128, 130, 132, 134, 136, 238, 340, such as conveyors 126, 238, 340, feeders 128, blowers, and sprayers 134. Communication between the communication unit 352 and, for example, the components 104, 106, 108, 110, 112 (if present), 114, 116, 126, 128, 130, 132, 134, 136, 238, 340 in reactor 100 is carried out via wired, wireless, or both connections.

[0057] The reactor 100 further comprises an actuator 354 controlled by a controller 346 to cause movement of, for example, at least one of the components 126, 128, 238, and 340. The actuator 354 comprises, for example, a motor, a driver, or other actuator components.

[0058] The reactor 100 further comprises a power supply 356 controlled by a controller 346 to supply power to the operation of the reactor 100. The power supply 356 comprises at least one power supply component for supplying power to the reactor 100, for example, a connection to an electrical plug, a battery, a regulator, or other power supply component.

[0059] The reactor 100 further includes a user interface (UI) 358 controlled by a controller 346 to receive commands, requests, or data from the operator of the reactor 100. The UI 358 further presents commands, requests, or data to the operator.

[0060] The memory 350 stores at least a communication program 360 for operating (controlling) the communication unit 352, an actuator program 362 for operating the actuator 354, a power supply program 364 for operating the power supply unit 356, and a UI program 366 for operating the UI 358.

[0061] As described above, memory 350 further stores a computer program 368 that controller 346 executes (starts) to control the operation of reactor 100, for example, the operation of at least one of reactor components 104, 106, 108, 110, 112 (if any), 114, 116, 126, 128, 130, 132, 134, 136, 238, 340. The computer program 368 includes computer-readable code instructions.

[0062] The computer program 368 may be stored on a tangible, non-volatile, computer-readable medium such as a compact disk (CD) or a Universal Serial Bus (USB) storage device.

[0063] Other reactors 100 shown in the aforementioned diagram also include corresponding control components 346, 348, 350, 352, 354, 356, 358, 360, 362, 364, 366, and 368.

[0064] Figure 4 shows a manufacturing method 470 for producing biochar chips BC using a horizontal reactor 100, as described in the context of the previous figure.

[0065] In step 472, the receiver 104 receives the pre-dried biomass BM that enters the chamber 102 through the input port. At this stage, the received biomass BM contains air.

[0066] In step 474, the receiver 104 supplies and distributes biomass BM by the feeder 128, and while the biomass BM falls toward the dryer 106, the receiver 104 allows exhaust gas EG from the dryer to purge (remove) air from the falling biomass BM, thereby creating an oxygen-free environment inside the chamber 102.

[0067] In process 476, the supplied biomass BM, which has been purged and rearranged during its fall, arrives at the dryer 106 through the partition port 120 and settles as the bed of biomass BM on conveyors 126, 238, and 340. The dryer 106 performs final drying of the pre-dried biomass at process temperature TE by flowing hot gas HG onto the bed of biomass BM on conveyors 126, 238, and 340 through its heat exchanger and blower and the flow apertures of conveyors 126, 238, and 340. The exhaust gas EG generated from this drying process 476 is led to the receiver 104 to remove air, as previously described.

[0068] In process 478, conveyors 126, 238, and 340 transport the final dried biomass BM to the pyrolysis unit 108 (first or single pyrolysis unit section 110) via the next partition port 120. In the case of multiple conveyors 238 and 340, the biomass BM falls from the conveyors 238 and 340 of the dryer 106 to the conveyors 238 and 340 of the first or single pyrolysis unit section 110, causing further rearrangement of the biomass BM on the floor.

[0069] In process 480, in the case of multiple pyrolysis sections 110, the first pyrolysis section 110 carries out the first stage of the slow pyrolysis process, pyrolyzing the biomass BM at process temperature T1 by flowing hot gas HG onto the biomass BM bed on conveyors 126, 238, 340 by its heat exchanger and blower, as well as flow apertures in conveyors 126, 238, 340, as described above. In the case of a single pyrolysis section 110, the sole pyrolysis section 110 carries out the sole stage of the slow pyrolysis process accordingly. At the same stage, the first synthesis gas condenser 132 receives the exhausted synthesis gas S1 from the first stage pyrolysis, condenses the synthesis gas S1 to yield bio-oil B1 and non-condensable synthesis gas U1 from the first or sole stage, which is led to the heat generator 130 for the generation of flue gas FG.

[0070] Next, according to step 478, conveyors 126, 238, and 340 transport the biomass BM, which has been pyrolyzed in the first stage, through the next partition port 120 to the second pyrolyzer section 110 in the case of multiple pyrolyzer sections 110, and in the case of multiple conveyors 238 and 340, drop the biomass BM from the conveyors 238 and 340 of the first pyrolyzer section 110 to the conveyors 238 and 340 of the second pyrolyzer section 110, further rearranging the biomass BM on the floor.

[0071] Next, in accordance with process 480, the second pyrolysis section 110 carries out the second stage of the slow pyrolysis process, pyrolyzing the biomass BM at a process temperature T2 higher than the previously used process temperature T1. The second pyrolysis section 110 flows hot gas HG onto the biomass BM bed on conveyors 126, 238, and 340 by its heat exchanger and blower and flow apertures on conveyors 126, 238, and 340, as described above. The second synthesis gas condenser 132 receives the exhausted synthesis gas S2 from the second stage pyrolysis, condenses the synthesis gas S2 to yield bio-oil B2 and non-condensable synthesis gas U2 from the second stage, which are also led to the heat generator 130.

[0072] Steps 478 and 480 are carried out as long as the following pyrolysis section 110 is present and biochar chips BC are being processed from biomass BM.

[0073] If the final pyrolysis stage of the slow pyrolysis process in the case of multiple pyrolysis sections 110, or the only pyrolysis stage in the case of a single pyrolysis section 110 of the slow pyrolysis process, is performed in the last or only pyrolysis section 110 and a retainer 112 is present, in step 482, conveyors 126, 238, 340 transport the processed biochar chips BC to the retainer 112 via the next partition port 120, and in the case of multiple conveyors 238, 340, the biochar chips BC are dropped from the conveyors 238, 340 of the last pyrolysis section 110 to the conveyors 238, 340 of the retainer 112, causing further rearrangement of the biochar chips BC on the floor.

[0074] In step 484, the holder 112 enables the holding of biochar chips BC on conveyors 126, 238, and 340.

[0075] If a retainer 112 is present, when retention is performed in step 484, or alternatively, if a retainer 112 is not present, when the final pyrolysis step is performed in step 480, in step 486, conveyors 126, 238, 340 transport the processed biochar chips BC to the cooler 114 via the next partition port 120, and, in the case of multiple conveyors 238, 340, depending on the presence of the retainer 112, drop the biochar chips BC from the retainer 112 conveyor 238, 340 or the final pyrolysis section 110 to the cooler 114 conveyor 238, 340, causing further rearrangement of the biochar chips BC on the floor.

[0076] In step 488, the cooler 114 cools the biochar chips BC by flowing steam VA onto the bed of biochar chips BC on the conveyors 126, 238, and 340 using the sprayer 134 and its blower, as well as the flow apertures of the conveyors 126, 238, and 340. At the same stage, the steam condenser 136 receives the exhausted cooling-derived steam VA as described above, condenses the steam VA, and produces cooling-derived water WA and hot air HA.

[0077] In process 490, conveyors 126, 238, and 340 transport the cooled biochar chips BC through the next partition port 120, causing the biochar chips BC to fall from the conveyors 238 and 340 of the cooler 116 into the discharger 116.

[0078] In step 492, the discharger 116 discharges the manufactured biochar chips BC from the chamber 102 through the output port.

[0079] Reactor 100 utilizes the entire particle area of ​​the biomass BM wood particles, allowing heat transfer to occur through the turbulent flow of thermal gas HG, substantially increasing the heat transfer output. The divided pyrolysis section 110 of reactor 100 further allows for the condensation of pyrolysis-derived synthesis gases S1 and S2 separately from different process temperature ranges T1 and T2. The different fractions of synthesis gases S1 and S2 are used for various purposes to enhance their value as raw materials in the chemical industry and renewable fuel refining.

[0080] Reactor 100 further provides the opportunity to produce biochar BC and pyrolysis-derived oils (bio-oils) B1 and B2 in a single production line with large industrial production volumes of up to tens of thousands of tons per year. Suitable raw biomass BM materials include, for example, sawing, other forestry and wood processing industries, palm oil production (palm oil trees), rubber production (rubber trees), coffee bean production, rice husks, and by-flows from agricultural waste. Globally, the sustainable availability of these raw materials is hundreds of millions of tons per year, making it possible to produce large quantities, such as sustainable jet fuel, from pyrolysis-derived condensates.

[0081] The manufactured biochar BC can be used to replace coal in steelmaking and other metal manufacturing, or as carbon storage when used as soil fertilizer or other soil improvement in agriculture or afforestation, or as exothermic carbon capture storage (PyCCS) when used as soil fertilizer.

[0082] Herein, the present invention and some of its advantages have been described with reference to the exemplary embodiments described above. It is clear that the present invention is not limited to these embodiments, but also includes all possible embodiments within the scope of the following claims.

Claims

1. A biochar reactor (100) for producing biochar (BC), Horizontal reactor chamber (102), The biochar reactor is provided with a receiver (104) for receiving biomass (BM) (472), In order to produce the biochar, a pyrolysis unit (108) for pyrolyzing (480) the accepted biomass, A cooler (114) for cooling the manufactured biochar (488), A controller (346) for controlling the biochar reactor and Equipped with, The pyrolysis apparatus comprises at least one pyrolysis section (110), and each pyrolysis section (110) is configured to pyrolyze the biomass by using a temperature range specific to that section. The biochar reactor is configured to flow hot gas (HG) through each pyrolysis section (110) and pyrolyze the biomass at process temperatures (T1, T2) within the temperature range specific to each pyrolysis section (110). Biochar reactor (100).

2. The biochar reactor according to claim 1, wherein the at least one pyrolysis section comprises a series of divided pyrolysis sections (110), each pyrolysis section (110) configured to pyrolyze the biomass by using a section-specific temperature range different from the rest of the pyrolysis section (110).

3. The biochar reactor according to claim 2, wherein the next pyrolysis section (110) belonging to the pyrolysis section is configured to use a higher temperature range than the previous pyrolysis section (110) belonging to the pyrolysis section.

4. The biochar reactor according to any one of claims 1 to 3, wherein each pyrolysis section (110) is provided with a dedicated synthesis gas condenser (132) configured to condense (480) the pyrolysis-derived synthesis gas (S1, S2) generated during the pyrolysis process in the pyrolysis section (110).

5. The biocarbon reactor according to claim 4, wherein the condensed portion of the synthesis gas derived from pyrolysis produces bio-oil (B1, B2), and the non-condensed portion of the synthesis gas derived from pyrolysis produces non-condensable synthesis gas (U1, U2) used in a heat generator (130) belonging to the biocarbon reactor.

6. The biochar reactor according to any one of claims 1 to 5, further comprising a dryer (106) configured to dry the biomass (476) after the biomass has been received by the receptor.

7. The biochar reactor according to any one of claims 1 to 6, further comprising at least one conveyor (126, 238, 340) configured to transport the biomass (BM, BC) through the biochar reactor (478, 482, 486).

8. The biochar reactor according to claim 7, wherein each conveyor (126, 238, 340) is configured to allow section-specific hot gas (HG) to flow through the structure of the conveyor (126, 238, 340).

9. The biochar reactor according to claim 7 or 8, wherein the at least one conveyor comprises at least one section conveyor (238, 340) for each of the dryer (106), the pyrolysis unit, and the cooler.

10. The biochar reactor according to claim 9, wherein at least one of the at least one section conveyor (238, 340) is inclined such that its front end (342) is lower than its rear end (344) to create a level difference between the at least one of the at least one section conveyor and a continuous section conveyor (238, 340) for rearranging the biomass (BM, BC).

11. The biochar reactor according to any one of claims 1 to 10, wherein the horizontal reactor chamber is configured to include a dryer (106), a pyrodeulator, and a cooler, and the dryer, the pyrodeulator, and the cooler are sequentially established inside (103) therein by a partition (118), the partitions dividing the dryer and the pyrodeulator (106, 108) from each other, and the pyrodeulator and the cooler (108, 114) from each other.

12. The biochar reactor according to any one of claims 1 to 11, further comprising a retainer (112) configured to allow the manufactured biochar to be held in front of the cooler, wherein the partition divides the dryer (106) from the pyrolysis unit, divides the pyrolysis unit from the retainer (108, 112), and divides the retainer from the cooler (112, 114).

13. The biochar reactor according to any one of claims 1 to 12, further comprising a heat generator (130) configured to generate flue gas (FG) for drying the biomass and thermally decomposing the biomass as biochar, wherein the dryer and the thermal decomposer are configured to expose the biomass to the hot gas flow by means of a heat exchanger and a blower that operate with the flue gas.

14. The biochar reactor according to any one of claims 1 to 13, wherein, in order to provide the oxygen-free chamber, the receiver is configured to expose the received biomass to an exhaust gas flow (EG) to remove air from the received biomass.

15. A method for producing biochar (BC) using a biochar reactor (100) according to any one of claims 1 to 14, (470) The process (480) involves using the controller and the pyrolysis unit (108) to pyrolyze the received biomass (BM) in at least one pyrolysis unit (110) by using the specific temperature range of each pyrolysis unit (110) in order to produce the biochar, The process (488) involves cooling the manufactured biochar using the controller and the cooler (114). A manufacturing method comprising at least a, wherein the pyrolysis step includes flowing the hot gas (HG) into each pyrolysis section (110) to pyrolyze the biomass at the process temperature (T1, T2) within the section-specific temperature range of the pyrolysis section (110).

16. A computer program (368) that, when executed by a computer, includes instructions to cause the computer to perform at least one of the steps of the manufacturing method (470) described in claim 15.

17. A tangible, non-volatile, computer-readable medium comprising the computer program (368) described in claim 16.

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