Biochar reactor

Abstract

The 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) to the biochar reactor, a pyrolyzer (108) for pyrolyzing (480) the received biomass to produce the biochar, a cooler (114) for cooling (488) the produced biochar, and a controller (346) for controlling the biochar reactor. The pyrolyzer comprises at least one pyrolyzer section (110) so that each pyrolyzer section (110) is configured to pyrolyze the biomass by using a unique section-typical temperature range. The biochar reactor is configured to mix an additive (AD) with heat gas (HG) that flows forcedly through a pyrolyzer section (110) or with water vapour (VA) that flows forcedly through the cooler to improve a result of a pyrolysis process. The bioreactor is further configured to cause a process temperature (T1, T2) within the section-typical temperature range in said pyrolyzer section by the heat gas flow.

Description

[0001] BIOCHAR REACTOR

[0002] Technical field of the invention

[0003] The application relates generally to a biochar reactor.

[0004] Background of the invention

[0005] Pyrolysis of biomass has been utilized already for thousands of years. In the ancient times wood was pyrolyzed into charcoal by burning wood in a pothole by limiting an air intake, i.e. in a low oxygen atmosphere. The more advanced method is to use closed steel container, wherein the volume of air intake and temperature is easier to regulate. This method works only with big pieces of wood, like the form of firewood. The wood must also be pre-dried, which increases the cost of raw material. Due to the size of the raw material the process takes several hours of time and limits the capacity.

[0006] The more advanced and generally used type of pyrolysis reactor today is a screwtype reactor, where a disintegrated raw material is heated up by heating up either the auger of screw conveyor or pipe, or both. In this type of reactor, the heat transfer takes place by point shaped contact between the wood particle the reactor steel construction. This makes the heat transfer utmost inefficient, since the contact point of the wood particle is carbonized quickly, which makes the surface of the material as good insulation and slows down the process. The physical size of a screw reactor has also certain limitations, which limits the capacity of this construction. Typically, the biggest commercially available reactor suppliers promise capacity maximum about 5.000 tons per year.

[0007] Summary

[0008] One object of the invention is to withdraw the drawbacks of known solutions and to provide a biochar reactor that enables to produce biochar from a lignocellulosic biomass, to produce different type of bio-oils in a single production process, to improve a cost-effectiveness of the production process, to shorten the size of biochar reactor, to improve a pyrolysis process in the biochar reactor, to cause a postcarbonization of the biochar, and to remove carbon dioxide (Carbon Dioxide Removal, CDR) from atmosphere with the biochar reactor. One object of the invention is fulfilled by providing the biochar reactor, production method, computer program, and computer-readable medium according to the independent claims.

[0009] Embodiments of the invention are presented by the biochar reactor, production method, computer program, and computer-readable medium according to the independent claims.

[0010] One biochar reactor for producing biochar comprises a horizontal reactor chamber, a receiver for receiving biomass to the biochar reactor, a pyrolyzer for pyrolyzing the received biomass to produce the biochar, a cooler for cooling the produced biochar, and a controller for controlling the biochar reactor. The pyrolyzer comprises at least one pyrolyzer section so that each pyrolyzer section is configured to pyrolyze the biomass by using a unique section-typical temperature range. The biochar reactor is configured to mix an additive with heat gas that flows forcedly through a pyrolyzer section or with water vapour that flows forcedly through the cooler to improve a result of a pyrolysis process. The bioreactor is further configured to cause a process temperature within the section-typical temperature range in said pyrolyzer section by the heat gas flow.

[0011] One production method for producing biochar is carried out by the biochar reactor according to the previous biochar reactor. The production method comprises at least following steps of pyrolyzing, by the controller and the pyrolyzer, the received biomass in the at least one pyrolyzer section by using the unique section-typical temperature range in each pyrolyzer section to produce the biochar, and cooling, by the controller and the cooler, the produced biochar. The pyrolyzing step comprises the mixing of the additive with the heat gas that flows forcedly through a pyrolyzer section to cause the process temperature within the section-typical temperature range in said pyrolyzer sec-tion by the heat gas flow or the cooling step comprises the mixing of the additive with water vapour that flows forcedly through the cooler to improve a result of a pyrolysis process.

[0012] One computer program comprising instructions, which, when the computer program is executed by a controller (computer), cause the biochar reactor, which is in accordance with the previous biochar reactor, to carry out at least the steps of the previous production method.

[0013] One tangible, non-volatile computer readable medium comprises the computer program, which is in accordance with the previous computer program. Brief description of the figures

[0014] The exemplary embodiments of the invention are explained with reference to the following figures: fig. 1a presents a biochar reactor with a single horizontal conveyor and multiple pyrolyzer sections fig. 1b presents a biochar reactor with a single horizontal conveyor and a single pyrolyzer section fig. 2a presents a biochar reactor with horizontal section conveyors and multiple pyrolyzer sections fig. 2b presents a biochar reactor with horizontal section conveyors and a single pyrolyzer section fig. 3 presents a biochar reactor with inclined section conveyors and multiple pyrolyzer sections fig. 4 presents a flowchart of a production method for producing biochar

[0015] Detailed description of the figures

[0016] Fig. 1a, as well as other reactor figures, presents a horizontal slow-pyrolysis biochar reactor 100 for producing biochar (biocarbon) BC, e.g. biochar chips or coarse biochar powder (dust), from a biomass BM. The biomass BM may be any lignocellulosic biomass, such as a wood-based biomass or an agrobiomass, or any industry and municipal sludge.

[0017] The wood-based biomass BM may comprise e.g. wood chips or coarse wood powder (dust), waste wood chips or coarse waste wood powder (dust), logging residue chips or coarse logging residue powder (dust), or another wood-based biomass. The agrobiomass BM may comprise e.g. corn cobs, straws, peat, palm-oil, coffee bean, side streams from a rice production, or other agrobiomass.

[0018] The reactor 100 comprises a horizontal reactor chamber 102 that has an airtight structure, which makes possible to establish an oxygen free and pressurized or unpressurized interior 103 of chamber 102 to product e.g. biochar chips BC, which is used below as an example of the produced biochar BC. The chamber 102 further encompasses at least part of reactor parts in its interior 103. Such reactor parts are e.g. a drier 106, a pyrolyzer 108, and a cooler 114. The chamber 102 may further encompass other reactor parts in its interior 103. Such reactor parts are e.g. a receiver 104, a retention part 112 if such exists, and an ejector 116. The reactor 100 further comprises dividers 118 that divide the interior 103 in the chamber 102 so that at least the drier 106, the pyrolyzer 108, and the cooler 114 establish sequentially in the chamber 102. The dividers 118 may further divide the interior 103 so that the receiver 104, the drier 106, the pyrolyzer 108, the retention part 112 if such exists, the cooler 114, and the ejector 116 establish sequentially in the chamber 102.

[0019] Each divider 118 comprises a port 120 that allows the biomass BM or the biochar chips BC to exit from one reactor part and to enter to another reactor part. At least one of dividers 118 comprise a guide 122 that guides the biomass BM or the biochar chips BC from one reactor part to another reactor part. The reactor 100 in accordance with fig. 1 comprises the guide 122 in a first and last dividers 118 and the reactor 100 in accordance with fig. 2a and 2b comprises the guide 122, 224 in each divider 118.

[0020] The dividers 118 are installed in the chamber 102 so that one divider 118 is between the drier 106 and the pyrolyzer 108 and another divider 118 is between the pyrolyzer 108 and the cooler 114. The dividers 118 may further be installed so that one divider 118 is between the receiver 104 and the drier 106, another divider 118 is between the drier 106 and the pyrolyzer 108, a third divider 118 is between the pyrolyzer 108 and the retention part 112, a fourth divider 118 is between the retention part 112 and the cooler 114, and a last divider 118 is between the cooler 114 and the ejector 116. If the reactor 100 lacks the retention part 112, then, the fourth divider 118 further lacks and the third divider 118 is between the pyrolyzer 108 and the cooler 114.

[0021] If the pyrolyzer 108 comprises more than one sequential pyrolyzer section 110 and the reactor 100 comprises an intermediate retention part (not presented in the figures) between adjacent pyrolyzer sections 110, as later on has been explained more accurately, additional dividers (not presented in the figures) have been installed so that one additional divider is at a front part of the intermediate retention part after a previous pyrolyzer section 110 and another additional divider at an end of the intermediate retention part before a next pyrolyzer section 110. Each additional divider corresponds with the divider(s) 118 and operates correspondingly as the divider(s) 118.

[0022] The reactor 100 further comprises at least one conveyor 126 that conveys the biomass BM through the drier 106 and the pyrolyzer 108 and the produced biochar chips BC through at least the cooler 114. The conveyor(s) 126 may further convey the produced biochar chips BC through the retention part 112 if such exists.

[0023] The at least one conveyor 126 in accordance with the figure comprises a single horizontal conveyor 126 that conveys the biomass BM and produced biochar chips BC along the whole reactor 100 from the drier 106 through the pyrolyzer sections 110 and the retention part 112 if such exists to the cooler 114.

[0024] A structure of each conveyor 126 is such that the structure allows a heat gas HG to flow through it, e.g. through flow apertures (holes, structures, openings) before the heat gas HG flows through the biomass BM or the biochar chips BC on the conveyor 126. Each conveyor 126 comprises e.g. a perforated plate or wire mesh chain conveyor, which comprise said flow apertures for the heat gas HG.

[0025] The reactor 100 further comprises the receiver 104 that receives the pre-dried biomass BM through an input port (not presented in the figures). The receiver 104 comprises supplier 128 that supplies the biomass BM into the reactor 100. The supplier 128 comprises e.g. a rotary feeder that feeds the incoming biomass BM and a screw distributor (conveyor) that distributes the fed biomass BM across an entire width of receiver 104 as well as a conveyor 126 or other supplier mechanisms that feed and distribute the biomass BM in the receiver 104 correspondingly-

[0026] The receiver 104 further provides the oxygen-free chamber 102. The receiver 104 exposes the incoming biomass BM to an exhaust gas EG from the drier 106 by allowing the exhaust gas EG to flow through the flow of incoming biomass BM such that the exhaust gas EG removes air from among the biomass BM.

[0027] The reactor 100 comprises the drier 106 that final dries the distributed biomass BM. The drier 106 comprises a heat exchanger and a drier blower (fan) that cause a heat gas HG from at least one direction, e.g. from one in accordance with the figures or from two opposite directions so that one of said two directions is in accordance with the figures, to flow through the structure of conveyor 126 and the bed of biomass BM such that an existing moisture removes from the biomass BM.

[0028] The reactor 100 causes (uses) a process temperature TE, which is below 220°C, e.g. 100, 120, 140, 160, 180, or 200°C, into the drier 106.

[0029] The reactor 100 comprises the pyrolyzer 108 that pyrolyzes slowly the dried biomass BM in e.g. a temperature range 200-700°C to produce the biochar chips BC, when the pyrolysis occurs in a temperature above 300-400°C. Alternatively, the pyrolyzer 108 may only torrefy the dried biomass BM in a temperature below 300°C to produce a bio coal (torrefied biomass), when the torrefaction occurs in a temperature below 300°C. The pyrolyzer 108 comprises at least one pyrolyzer section 110, e.g. a single pyrolyzer section 110, or a plurality of sequential pyrolyzer sections 110 in accordance with the figure, whereupon the pyrolyzer 108 pyrolyzes slowly the dried biomass BM sequentially in said temperature range.

[0030] The plurality of sequential pyrolyzer sections 110 enables a slow multiphase pyrolysis and a use of different process temperatures (temperature ranges) T1 , T2 in different pyrolyzer sections 110. The plurality of sequential pyrolyzer sections 110 further enables to produce bio-oils B1 , B2 from different temperature ranges.

[0031] Fig. 1b presents the reactor 100, which corresponds with the reactor 100 in accordance with fig. 1a per contra except its pyrolyzer 108 comprises only the single pyrolyzer section 110 that enables the pyrolysis in a single process temperature (temperature range) T1 in said pyrolyzer section 110. The single pyrolyzer section 110 enables to produce bio-oil B1 from its temperature range. The process temperature is 200-700°C, practically below 300°C in the case of the single pyrolyzer section 110.

[0032] The plurality of pyrolyzer sections 110 comprises at least two pyrolyzer sections 110, e.g. two, three, four, five, or more pyrolyzer sections, and adjacent pyrolyzer sections 110 are divided by a divider 118.

[0033] Irrespective of number of pyrolyzer sections 110, each pyrolyzer section 110 comprises a heat exchanger and a pyrolyzer blower that cause a heat gas HG to flow through the structure of conveyor 126 and the bed of biomass BM, which rests on the conveyor 126, to pyrolyze the biomass BM. The pyrolysis in said pyrolyzer section 110 occurs in the pyrolyzer section-typical temperature T1 , T2, which is different than the rest of the pyrolyzer sections 110 if other pyrolyzer sections 110 exist.

[0034] When the pyrolyzer 108 comprises two pyrolyzer sections 110 in accordance with fig. 1a, the reactor 100 causes the process temperature T1 , which is e.g. between 300-400°C, e.g. 300, 320, 340, 360, 380, or 400°C, into the first pyrolyzer section 110 that follows the drier section 106. Then, the reactor 100 further causes the process temperature T2, which is e.g. between 400-500°C, e.g. 400, 420, 440, 460, 480, or 500°C in the next (second) pyrolyzer section 110. The plurality of pyrolyzer sections 100, which are divided by the dividers 118, enables a sequential lifting of the process temperature T1 , T2 so that a next pyrolyzer section 110 uses a different, higher process temperature T2 than a previous pyrolyzer section 110.

[0035] When the pyrolyzer 108 comprises more pyrolyzer sections 110 than the figures, e.g. three pyrolyzer sections 110, the caused process temperature T1 may be e.g. between 300-330°C, e.g. 300, 315, or 330°C, in the first pyrolyzer section 110, the caused process temperature T2 may be e.g. between 330-450°C, e.g. 300, 330, 360, 390, 420, or 450°C, in the second pyrolyzer section 110, and a caused process temperature in a third pyrolyzer section 110 may be e.g. between 450-500°C, e.g. 450, 475, or 500°C.

[0036] When the pyrolyzer 108 comprises more than one sequential pyrolyzer section 110, e.g. two, three, four, five, or more pyrolyzer sections 110, the caused process temperature T1 may be below 300°C, e.g. 200, 220, 240, 260, or 280°C, in the first pyrolyzer section 110 to occur the torrefaction and to produce a torrefied biomass BM before the torrefied biomass BM enters the next pyrolyzer section(s) 110, wherein the caused process temperature(s) T2 may be e.g. between 300-700°C, e.g. between 330-450°C, e.g. 330, 360, 390, 420, or 450°C, and e.g. between 450-500°C, e.g. 450, 475, or 500°C correspondingly as previously has been explained

[0037] The torrefaction in the first stage causes an advantageous inerting of the pyrolysis process and removes detrimental tars and other substances, which deteriorate a quality of condensed pyrolysis-originated syngases S1 , S2. The torrefaction- cleaned, condensed pyrolysis-originated syngases S1 , S2 are superior source material for renewable liquid fuels and other chemicals, e.g. wood vinegar, and plastic (resin) processing.

[0038] The reactor 100 further comprises a heat generator 130 that generates a flue gases FG, which then are used in the flue gas-operating heat exchangers in the drier 106 and pyrolyzer 108 (pyrolyzer section(s) 110). Alternatively, it is possible to use electricity or other energy source to operate the heat exchangers. The heat exchangers heat the heat gases HG in the drier 106 and pyrolyzer section(s) 110 to expose the bed of biomass BM to the required process temperature TE, T1 , T2 by means of the flowing heat gas HG to dry the biomass BM and to pyrolyze the biomass BM to the biochar chips BC. The reactor 100 further comprises syngas condensers 132 so that each pyrolyzer section 110 has a dedicated syngas condenser 132 that condenses pyrolysis- originated syngases S1 , S2, which have been generated during the pyrolysis process in said pyrolyzer section 110. Each syngas condenser 132 operates so that the condensed part of the pyrolysis-originated syngases S1 , S2 produces the biooil B1 , B2. An uncondensed part of the pyrolysis-originated syngases S1 , S2 produces uncondensed syngases U1 , U2, which are then returned to the heat generator 130 to the generation of flue gases FG.

[0039] Irrespective of number of pyrolyzer sections 110, at least one of the pyrolyzer sections 110, e.g. one, two, three, four, five, or more pyrolyzer sections, or each pyrolyzer sections 110 comprises an additive injector IN that injects at least one additive (reactant) AD, e.g. one, two, three, four, five, or more additives, to the heat gas HG, which flows forcedly through a pyrolyzer section 110 and the of biomass BM, to improve and alter products (a result) of the pyrolysis process, i.e. a so- called additive-assisted pyrolysis process, so that the pyrolysis process produces e.g. at least one of a higher yield, a higher calorific value, pH value, active surface area, and pore volume of the products, i.e. the bio-oil B1 , B2 and the biochar BC. The additive(s) AD comprises e.g. a ceramic additive, e.g. kaolin, different kind of zeolites, arenaceous quartz, and aluminium oxide; or a metal additive, e.g. potassium, sodium, calcium, magnesium, aluminium, copper, nickel, and zinc; an acid additive, e.g. phosphoric acid or nitric acid; or an alkali additive.

[0040] The injector IN is in connection with each pyrolyzer section 110 comprising the injector IN and it comprises at least one injector pump, e.g. one, two, three, four, five, or more pumps, and an additive supplier for each pump, e.g. an additive container or a connection to an external additive container outside said pyrolyzer section 110. The injector IN mixes the additive(s) AD with the heat gas HG during the pyrolysis. The additive(s) AD is mixed effectively and uniformly because of the turbulent heat gas HG flow, which circulates in a space of the pyrolyzer section 110 so that the heat gas HG permeates (flows through) the bed of biomass BM, which rests on the conveyor 126, several times.

[0041] The injector IN may be, alternatively or additively, in connection with the syngas connection between said pyrolyzer section 110 and its syngas condenser 132, whereupon injector IN injects the additive(s) AD to the pyrolysis-originated syngas S1 , S2, which flows out of said pyrolyzer section 110. If said pyrolyzer section 110 comprises the injectors IN in said pyrolyzer section 110 and with its syngas connection, the injected additives AD may be same or different in the injectors IN.

[0042] When the pyrolyzer 108 comprises the plurality of pyrolyzer sections 110 and one pyrolyzer section 110 comprises the injector(s) IN as previously has been explained, another pyrolyzer section(s) 110, which comprises the injector(s) IN, may comprise a same or different injector-additive configuration as said pyrolyzer section 110. If the “another” pyrolyzer section(s) 110 comprises more than one pyrolyzer section 110, the injector configuration may be same or different among these pyrolyzer sections 110.

[0043] The reactor 100 may further comprise a retention part 112, which is divided by the dividers 118 from the last or only pyrolyzer section 110 (pyrolyzer 108) and the cooler 114. The retention part 112 enables a retention of the produced biochar chips BC when the biochar chips BC rest on the conveyor 126 before the cooler 114.

[0044] When the pyrolyzer 108 comprises more than one sequential pyrolyzer section 110, the reactor 100 may further comprise an intermediate retention part between the pyrolyzer sections 110, which is divided by the additional dividers from the pyrolyzer sections 110 as previously has been explained. The additional intermediate retention part operates correspondingly as the retention part 112.

[0045] The reactor 100 further comprises a sprayer 134 that generates a cooling water vapour VA, which then is used in the cooler 114. The sprayer 134 sprays the water vapour VA in the cooler 114 to expose the biochar chips BC to the water vapour VA.

[0046] The reactor 100 comprises the cooler 114 that cools the produced, and possibly retention-exposed, biochar chips BC. The cooler 114 comprises a cooler blower that forces the water vapour WA, which is sprayed by the sprayer 134, to flow through the structure of conveyor 126 and the bed of biochar chips BC such that the biochar chips are cooled.

[0047] The reactor 100 further comprises a vapour condenser 136 that condenses a cooling-originated water vapour VA, which has been generated during the cooling process in the cooler 114. The vapour condenser 136 operates so that a condensed part of the cooling-originated water vapour VA produces water WA, which are then returned to the sprayer 134 to the generation of water vapour VA. The cooling- originated water vapour VA produces hot air HA, which may be used e.g. in a predrying process before the biomass BM enters in the reactor 100.

[0048] The cooler 114 comprises an additive injector IN, which corresponds with the injectors) IN of the pyrolyzer section(s) 110. The additive injector injects at least one additive AD, e.g. the phosphoric acid or nitric acid, to the water vapour VA, which is forced by the cooler blower to flow through the cooler 114 and the bed of the biochar chips BC in the cooler 114 to improve characteristics of the biochar chips BC.

[0049] The reactor 100 further comprise the ejector 116 that ejects the cooled biochar chips BC through an output port (not presented in the figures) from the reactor 100.

[0050] Fig. 2a presents the reactor 100, which corresponds with the reactors 100 in accordance with the other figures per contra except it comprises an alternative embodiment to the at least one conveyor 126.

[0051] The at least one conveyor 126 in the figure comprises a plurality of sequential horizontal section conveyors 238, at least one section conveyor 238 for each of the drier 106, the pyrolyzer sections 110, the retention part 112 if such exists, and the cooler 114, instead of single horizontal conveyor 126. The at least one section conveyor 238 comprises e.g. one in accordance with the figure, two, three, four, five, or more section conveyors.

[0052] The section conveyors 238 are installed in a descending manner in the chamber 102 so that the section conveyor(s) 238 in the first pyrolyzer section 110 is lower than the section conveyor(s) 238 in the drier 106 and the section conveyor(s) 238 in the next pyrolyzer section 110 is lower than the section conveyor(s) 238 in the first pyrolyzer section 110. The section conveyor(s) 238 in the retention part 112, if such exists, is lower than the section conveyor(s) 238 in the last (next) pyrolyzer section 110 and the section conveyor(s) 238 in the cooler 114 is lower than the section conveyor(s) 238 in the existing retention part 112. In any case, the section conveyor(s) 238 in the cooler 114 is lower than the last pyrolyzer section 110.

[0053] Fig. 2b presents the reactor 100, which corresponds with the reactor 100 in accordance with fig. 2a per contra except its pyrolyzer 108 comprises only the single pyrolyzer section 110. The section conveyors 238 are installed in a descending manner in the chamber 102 correspondingly as in the case of the plurality of pyrolyzer sections 110 so that the section conveyor(s) 238 in the only pyrolyzer section 110 is lower than the section conveyor(s) 238 in the drier 106. The section conveyors) 238 in the retention part 112, if such exists, is lower than the section conveyors) 238 in the pyrolyzer section 110 and the section conveyor(s) 238 in the cooler 114 is lower than the section conveyor(s) 238 in the existing retention part 112. In any case, the section conveyor(s) 238 in the cooler 114 is lower than the pyrolyzer section 110.

[0054] A level difference between sequential section conveyor(s) 238 in these descending installations enables a re-arrangement (mixture) of the biomass BM between the drier 106 and the pyrolyzer section(s) 110, and between the pyrolyzer sections 110 in the case of the plurality of pyrolyzer sections 110, when the biomass BM drops from the previous level of section conveyor(s) 238 to the next level of section conveyor(s) 238. The re-arrangement of the biochar chips BC is corresponding between the last or only pyrolyzer section 110 and the retention part 112, if such exists, and between the existing retention part 112 and the cooler 114.

[0055] The dropping-based re-arrangement of biomass BM and biochar chips BC during the conveyance makes the drying, pyrolysis, existing retention, and cooling processes more effective, whereupon it is possible to improve a cost-effectiveness of the biochar BC production method 470.

[0056] Fig. 3 presents the reactor 100, which corresponds with the reactors 100 in accordance with the other figures per contra except it comprises a second alternative embodiment to the at least one conveyor 126.

[0057] The at least one conveyor 126 in the figure comprises a plurality of sequential inclined section conveyors 340, at least one section conveyor 340 for each of the drier 106, the pyrolyzer sections 110, the retention part 112 if such exists, and the cooler 114, instead of single horizontal conveyor 126 and the plurality of horizontal section conveyors 238. The at least one section conveyor 340 comprises e.g. one in accordance with the figure, two, three, four, five, or more section conveyors.

[0058] Each inclined section conveyor 340 is installed (inclined) so that its front end 342 is lower than its rear end 344 and the rear end 344 of the previous section conveyor 340 if such exists. The rear end 344 of said section conveyor 340 is higher than the front end 342 of the next section conveyor 340 if such exists.

[0059] Deviating from fig. 3, the reactor 100, which corresponds with the reactor 100 in accordance with fig. 3 per contra except it may comprise correspondingly as in the previous figures only the single pyrolyzer section 110 and at least one section conveyor 340 in said only pyrolyzer section 110.

[0060] The inclined installations also produce the level difference between the sequential section conveyors 340 to enable the dropping-based re-arrangement of the biomass BM and biochar chips BC correspondingly as the descending installations in accordance with the previous figure.

[0061] The inclined installations also enable to shorten a length of the production line as well as the chamber 102 when the inclined section conveyors 340 are possible to install more serried manner than the horizontal section conveyors 238.

[0062] The reactor 100 further comprises a controller 346 that controls the operations of e.g. reactor parts 104, 106, 108, 110, 112 if such exists, 114, 116, 126, 128, 130, 132, 134, 136, 238, 340, IN so that the reactor 100 operates as previously and below has been explained.

[0063] The controller 346 comprises a processor 348 that carries out operator-initiated instructions, computer program (application, software)-initiated instructions, or both, and processes data to run computer programs. The processor 346 may comprise at least one processor, e.g. one, two, three, four, or more processors.

[0064] The controller 346 further comprises a memory 350 to store and to maintain data. The data may be instructions, computer programs, and data files. The memory 350 comprises at least one memory, e.g. one, two, three, four, or more memories.

[0065] The reactor 100 further comprises the communicator 352 that the controller 346 controls to send commands, requests, and data to at least one of e.g. parts 104, 106, 108, 110, 112 if such exists, 114, 116, 126, 128, 130, 132, 134, 136, 238, 340, IN e.g. the conveyor(s) 126, 238, 340, supplier 128, blowers, sprayer 134, and injector(s) IN in the reactor 100. The controller 346 further controls the communicator 352 to receive commands, requests, and data from at least one of e.g. parts 104, 106, 108, 110, 112 if such exists, 114, 116, 126, 128, 130, 132, 134, 136, 238, 340, IN, e.g. the conveyor(s) 126, 238, 340, supplier 128, blowers, sprayer 134, and injector(s) IN. The communication between the communicator 352 and e.g. the parts 104, 106, 108, 110, 112 if such exists, 114, 116, 126, 128, 130, 132, 134, 136, 238, 340, IN in the reactor 100 is carried out through a wired connection(s), wireless connection(s), or both connections. The reactor 100 further comprises an actuator 354 that the controller 346 controls to cause the movements of at least one of e.g. the parts 126, 128, 238, 340. The actuator 354 comprises e.g. motors, drivers, or other actuator parts.

[0066] The reactor 100 further comprises a power supplier 356 that the controller 346 controls to power the operation of the reactor 100. The power supplier 356 comprises at least one supplier part to power the reactor 100, e.g. a connection to electric plugs, battery, regulator, or other supplier part.

[0067] The reactor 100 further comprises a user interface (III) 358 that the controller 346 controls to receive instructions, requests, or data from an operator of the reactor 100. The III 358 further presents instructions, requests, or data to the operator.

[0068] The memory 350 stores at least a communicator program 360 to operate (control) the communicator 352, an actuator program 362 to operate the actuator 354, a power supplier program 364 to operate the power supplier 356, and an Ul program 366 to operate the Ul 358.

[0069] The memory 350 further stores a computer program 368 that the controller 346 executes (runs) to control the operation of the reactor 100, e.g. the operation of at least one of e.g. the reactor parts 104, 106, 108, 110, 112 if such exists, 114, 116, 126, 128, 130, 132, 134, 136, 238, 340, IN as previously has been explained. The computer program 368 comprises computer readable code instructions.

[0070] The computer program 368 may be stored in a tangible, non-volatile (non- transitory) computer-readable medium, e.g. a Compact disc (CD) or Universal Serial Bus (USB) storage device.

[0071] Other reactors 100 in accordance with the previous figures also comprise the control parts 346, 348, 350, 352, 354, 356, 358, 360, 362, 364, 366, 368 correspondingly.

[0072] Fig. 4 presents a production method 470 to produce the biochar chips BC by the horizontal reactor 100, which has been explained in context of the previous figures.

[0073] At step 472, the receiver 104 receives the pre-dried, incoming biomass BM through the input port into the chamber 102. The received biomass BM contains air among the biomass BM at this stage. At step 474, the receiver 104 feeds and distributes the biomass BM by means of supplier 128 and, while the biomass BM drops towards the drier 106, the receiver 104 allows the drier-originated exhaust gas EG to purge (remove) the air from among the dropping biomass BM to cause the oxygen-free condition in the chamber 102.

[0074] At step 476, the supplied biomass BM, which has been purged and re-arranged during the dropping, arrives in the drier 106 through a divider port 120 and settles as a bed of biomass BM on the conveyor(s) 126, 238, 340. The drier 106 final dries the pre-dried biomass in the process temperature TE by causing the heat gas HG to flow through the bed of biomass BM on the conveyor(s) 126, 238, 340 by means of its heat exchanger and drier blower as well as the flow apertures in the conveyor(s) 126, 238, 340. The exhaust gas EG, which originates from this drying step 476, is conducted to the receiver 104 to the removal of air as previously has been explained.

[0075] At step 478, the conveyor(s) 126, 238, 340 conveys the final dried biomass BM through a next divider port 120 to the pyrolyzer 108 (first or only pyrolyzer section 110). In the case of the plurality of conveyors 238, 340, the biomass BM drops from the conveyor(s) 238, 340 of the drier 106 to the conveyor(s) 238, 340 of the first or only pyrolyzer section 110 causing the further re-arrangement of the bed of biomass BM.

[0076] At step 480, the first pyrolyzer section 110 in the case of the plurality of the pyrolyzer sections 110 carries out a first stage of slow pyrolysis process and pyrolyzes the biomass BM in the process temperature T1 by causing the heat gas HG to flow through the bed of biomass BM the conveyor(s) 126, 238, 340 by means of its heat exchanger and pyrolyzer blower as well as the flow apertures in the conveyors) 126, 238, 340 as previously has been explained. The only pyrolyzer section 110 in the case of the single pyrolyzer section 110 carries out an only stage of slow pyrolysis process correspondingly. When the first or only pyrolyzer section 110 comprises the injector IN, the injector IN injects the additive(s) AD to the heat gas HG to mix the additive(s) AD to the heat gas HG, which circulates in the pyrolyzer section 110 several times through the pyrolyzer section 110, and thus to the biomass BM as previously has been explained.

[0077] At the same stage, the first syngas condenser 132 receives the exhausted, first stage pyrolysis-originated syngases S1 and condenses the syngases S1 so that it results the first or only stage-originated bio-oil B1 and un-condensed syngases U1 , which are conducted to the heat generator 130 to the generation of flue gases FG. When the first or only pyrolyzer section 110 comprises the injector IN in connection with the syngas connection between said pyrolyzer section 110 and its syngas condenser 132, this injector IN injects the additive(s) AD to the pyrolysis-originated syngas S1 , which flows out of said pyrolyzer section 110, as previously has been explained.

[0078] Then, in accordance with step 478, the conveyor(s) 126, 238, 340 conveys the first-stage pyrolyzed biomass BM through a next divider port 120 to the second pyrolyzer section 110 in the case of the plurality of the pyrolyzer sections 110 and, in the case of the plurality of conveyors 238, 340, drops the biomass BM from the conveyor(s) 238, 340 of the first pyrolyzer section 110 to the conveyor(s) 238, 340 of the second pyrolyzer section 110 to cause the further re-arrangement of the bed of biomass BM.

[0079] Then, in accordance with step 480, the second pyrolyzer section 110 carries out a second stage of the slow pyrolysis process and pyrolyzes the biomass BM in the process temperature T2, which is higher than the previously used process temperature T1. The second pyrolyzer section 110 causes the heat gas HG to flow through the bed of biomass BM the conveyor(s) 126, 238, 340 by means of its heat exchanger and pyrolyzer blower as well as the flow apertures in the conveyors) 126, 238, 340 as previously has been explained. When the second pyrolyzer section 110 comprises the injector IN, the injector IN injects the additive(s) AD to the heat gas HG to mix the additive(s) AD to the heat gas HG and thus to the biomass BM as previously has been explained.

[0080] The second syngas condenser 132 receives the exhausted, second stage pyrolysis-originated syngases S2 and condenses the syngases S2 so that it results the second stage-originated bio-oil B2 and un-condensed syngases U2, which also are conducted to the heat generator 130. When the second pyrolyzer section 110 comprises the injector IN in connection with the syngas connection between said pyrolyzer section 110 and its syngas condenser 132, this injector IN injects the additive(s) AD to the pyrolysis-originated syngas S2, which flows out of said pyrolyzer section 110, as previously has been explained.

[0081] The steps 478 and 480 are carried out when a next pyrolyzer section 110 exists and the biochar chips BC has been processed from the biomass BM. When a last pyrolysis stage of the slow pyrolysis process in the case of the plurality of the pyrolyzer sections 110 or the only pyrolysis stage in the case of the single pyrolyzer section 110 of the slow pyrolysis process has been carried out in the last or only pyrolyzer section 110 and when the retention part 112 exists, at step 482, the conveyor(s) 126, 238, 340 conveys the processed biochar chips BC through a next divider port 120 to the retention part 112 and, in the case of the plurality of conveyors 238, 340, drops the biochar chips BC from the conveyor(s) 238, 340 of the last pyrolyzer section 110 to the conveyor(s) 238, 340 of the retention part 112 to cause the further re-arrangement of the bed of biochar chips BC.

[0082] At step 484, the retention part 112 makes the retention of the biochar chips BC possible on the conveyor(s) 126, 238, 340. When the retention part 112 comprises the injector IN, the injector IN injects the additive(s) AD to the biochar chips BC or the interior around the biochar chips BC to mix the additive(s) AD to the biochar chips BC as previously has been explained.

[0083] When the retention has been carried out at step 484 in the case of existent retention part 112 or, alternatively, when the last pyrolysis stage has been carried out at step 480 in the case of non-existent retention part 112, at step 486, the conveyors) 126, 238, 340 conveys the processed biochar chips BC through a next divider port 120 to the cooler 114 and, in the case of the plurality of conveyors 238, 340, drops the biochar chips BC from the conveyor(s) 238, 340 of the retention part 112 or the last pyrolyzer section 110 depending on the existence of retention part 112 to the conveyor(s) 238, 340 of the cooler 114 to cause the further rearrangement of the bed of biochar chips BC.

[0084] At step 488, the cooler 114 cools the biochar chips BC by causing the water vapour VA to flow through the bed of biochar chips BC on the conveyor(s) 126, 238, 340 by means of the sprayer 134 and its cooler blower as well as the flow apertures in the conveyor(s) 126, 238, 340. When the cooler 114 comprises the injector IN, the injector IN injects the additive AD(s) to the turbulent flow of the water vapour VA to mix the additive(s) AD to the water vapour VA, which circulates in the cooler 114 several times through the cooler 114, and thus to the biochar chips BC as previously has been explained.

[0085] At the same stage, the vapour condenser 136 receives the exhausted, cooling- originated water vapour VA and condenses the water vapour VA so that it results the cooling-originated water WA and the hot air HA as previously has been explained. At step 490, the conveyor(s) 126, 238, 340 conveys the cooled biochar chips BC through a next divider port 120 and drops the biochar chips BC from the conveyors) 238, 340 of the cooler 116 to the ejector 116.

[0086] At step 492, the ejector 116 ejects the produced biochar chips BC through the output port from the chamber 102.

[0087] The reactor 100 allows the heat transfer and the injection of the additive(s) AD to take place by the flow of turbulent and circulating heat gas HG, which substantially increases the power of the heat transfer and the mixing of the additives(s) AD, since the whole area of particles of the biomass BM wood particle is utilized. The flow of the turbulent and circulating heat gas HG further causes a so-called postcarbonization of the biomass BM (biochar), which improves a gain and quality of the produced biochar chips BC and the produced pyrolysis-originated syngases S1 , S2. The divided pyrolyzer sections 110 of the reactor 100 further allow to condensate the pyrolysis-originated syngases S1 , S2 separately from the different process temperature ranges T1 , T2. The different fractions of syngases S1 , S2 are used for different purposes that increases their value as raw material in chemical industry, renewable fuel refining, and other chemicals, e.g. wood vinegar.

[0088] The reactor 100 further gives an opportunity to produce the biochar BC and pyrolysis-originated oil (bio-oil) B1 , B2 in large, industrial volumes, up to tenths of thousands of tons per year with one production line. Suitable raw biomass BM materials are e.g. side streams from saw milling, other forestry and wood processing industries, palm oil production (palm oil tree), rubber production (rubber tree), coffee bean production, rice huskies, agrowaste, and sludges. Globally the sustainable availability of these raw materials is several hundred million tons per year that makes possible to produce large quantities e.g. sustainable jet fuels from the pyrolysis-originated condensate.

[0089] The produced biochar BC may be used e.g. to replace fossil coal in steel production, other metal production, or as a carbon storage, when used as soil fertilizer or in other soil improvement, in farming or forestation, or as a pyrogenic carbon capture and storage (PyCCS) carbon dioxide removal (CDR), when used as soil fertilizer.

[0090] The invention and its several advantages have been now explained with reference to the previous exemplary embodiments. The invention is not only restricted to these embodiments, but it comprises all possible embodiments within the scope of the following claims.

Claims

Claims1 . A biochar reactor (100) for producing biochar (BC), comprising a horizontal reactor chamber (102), a receiver (104) for receiving (472) biomass (BM) to the biochar reactor, a pyrolyzer (108) for pyrolyzing (480) the received biomass to produce the biochar, a cooler (114) for cooling (488) the produced biochar, and a controller (346) for controlling the biochar reactor, wherein the pyrolyzer comprises at least one pyrolyzer section (110) so that each pyrolyzer section (110) is configured to pyrolyze the biomass by using a unique section-typical temperature range, characterized in that the biochar reactor is configured to mix an additive (AD) with heat gas (HG) that flows forcedly through a pyrolyzer section (110) or with water vapour (VA) that flows forcedly through the cooler to improve a result of a pyrolysis process, wherein the bioreactor is further configured to cause a process temperature (T1 , T2) within the section-typical temperature range in said pyrolyzer section by the heat gas flow.

2. The biochar reactor according to the previous claim, which further comprises an additive injector (IN) configured to inject the additive to the water vapour that is forced by a cooler blower to flow through the cooler, when the bioreactor is configured to mix the additive with the water vapour.

3. The biochar reactor according to any of the previous claims, which further comprises an additive injector (IN) configured to inject the additive to the heat gas that is forced by a pyrolyzer blower to flow through said pyrolyzer section or to pyrolysis-originated syngases (S1 , S2), which are generated from the heat gas during the pyrolysis process in said pyrolyzer section, that flow out of said pyrolyzer section, when the bioreactor is configured to mix the additive with the heat gas.

4. The biochar reactor according to any of the previous claims, wherein the biochar reactor is further configured to mix the additive or another additive with the heat gas that flows forcedly through another pyrolyzer section (110) to cause the process temperature within the section-typical temperature range in said another pyrolyzer section to improve the result of the pyrolysis process, when the biochar reactor comprises more than one pyrolyzer section (110) and the bioreactor is configured to mix the additive with the heat gas.

5. The biochar reactor according to claim 4, which further comprises an additive injector (IN) configured to inject the additive or the another additive to the heat gas that is forced by another pyrolyzer blower to flow through said another pyrolyzer section or to pyrolysis-originated syngases (S1 , S2), which are generated from the heat gas during the pyrolysis process in said another pyrolyzer section, that flow out of said another pyrolyzer section.

6. The biochar reactor according to the previous claims, wherein the at least one pyrolyzer section comprises sequential divided pyrolyzer sections (110), whereupon each pyrolyzer section (110) is configured to pyrolyze the biomass by using a different section-typical temperature range than rest (110) of the pyrolyzer sections so that a next pyrolyzer section (110) belonging to the pyrolyzer sections is configured to use a higher temperature range than a previous pyrolyzer section (110) belonging to the pyrolyzer sections.

7. The biochar reactor according to any of the previous claims, wherein each pyrolyzer section (110) comprises a dedicated syngas condenser (132) configured to condense (480) pyrolysis-originated syngases (S1 , S2), which are generated during the pyrolysis process in said pyrolyzer section (110), to produce a bio-oil (B1 , B2) from a condensed part of the pyrolysis-originated syngases and to produce uncondensed syngases (U1 , U2) to be used in a heat generator (130) belonging to the biochar reactor from an uncondensed part of the pyrolysis-originated syngases.

8. The biochar reactor according to the previous claims, wherein the additive comprises at least one of a ceramic, metal, acid, and alkali additive to improve characteristics of at least one of the biochar chips and produced bio-oil (B1 , B2).

9. The biochar reactor according to any of the previous claims, which further comprises a drier (106) configured to dry (476) the biomass after the biomass has been received by the receiver, wherein the receiver is configured to expose the received biomass to an exhaust gas flow (EG) from the drier to remove air from among the received biomass to provide the oxygen-free reactor chamber.

10. The biochar reactor according to any of the previous claims, which further comprises at least one conveyor (126, 238, 340) configured to convey (478, 482, 486) the biomass (BM, BC) through the biochar reactor and to allow a sectiontypical heat gas (HG) to flow through a structure of the at least one conveyor.

11. The biochar reactor according to any of the previous claims, which further comprises a retention part (112) configured to enable a retention of the produced biochar before the cooler so that the dividers divide a drier (106) and the pyrolyzer, the pyrolyzer and retention part (108, 112), and the retention part and cooler (112, 114) from each other.

12. The biochar reactor according to any of the previous claims, which further comprises a heat generator (130) configured to generate flue gas (FG) so that each of the drier and the pyrolyzer is configured to expose the biomass to the heat gas flow by means of a flue gas-operating heat exchanger and a pyrolyzer blower, which is configured to cause the heat gas to flow forcedly.

13. A production method (470) for producing biochar (BC) by the biochar reactor (100) according to any of the previous claims, comprising at least following steps of pyrolyzing (480), by the controller (346) and the pyrolyzer (108), the received biomass (BM) in the at least one pyrolyzer section (110) by using the unique section-typical temperature range in each pyrolyzer section (110) to produce the biochar, and cooling (488), by the controller and the cooler (114), the produced biochar, wherein the pyrolyzing step comprises the mixing of the additive (AD) with the heat gas (HG) that flows forcedly through a pyrolyzer section (110) to cause the process temperature (T1 , T2) within the section-typical temperature range in said pyrolyzer section by the heat gas flow or the cooling step comprises the mixing of the additive with water vapour (VA) that flows forcedly through the cooler to improve a result of a pyrolysis process.

14. A computer program (368) comprising instructions, which, when the computer program is executed by the controller (346), cause the biochar reactor (100) according to claim 1 to carry out at least the steps of the production method (470) according to claim 13.

15. A tangible, non-volatile computer readable medium comprising the computer program (368) according to claim 14.

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