Single-chamber combustion with pyrolysis

Abstract

A multi-walled single-chamber pyrolysis system includes an inner cylinder defining an oxygen-starved pyrolysis zone and an overlying primary combustion zone in fluid communication through an opening for biomass gas flow and combustion. A first annulus encircling the inner cylinder forms a secondary combustion zone, sharing inner walls with both the pyrolysis and primary combustion zones for heat transfer. A second annulus around the first annulus defines a primary combustion air flow zone, with thermally coupled walls and channels isolating primary air from the secondary zone while directing it from lower air inlets to the primary combustion zone. A portal at the top of the inner cylinder enables biomass feed and secondary air ingress, with gravity-fed biomass descending through the primary zone into the pyrolysis zone. Exhaust outlets at the base of the first annulus discharge secondary combustion gases.

Description

SINGLE-CHAMBER COMBUSTION WITH PYROLYSISCLAIM TO PRIORITY

[0001] This application claims the benefit of the following provisional application, which is hereby incorporated by reference in its entirety: USSN 63 / 674,407 filed July 23, 2024. [GFEX-0001-P01]BACKGROUND

[0002] Field:

[0003] This disclosure relates to the field of pyrolysis.

[0004] Description of the Related Art:

[0005] Current pyrolysis systems use two separated chambers to ensure that the biochar does not come in contact with oxygen during the pyrolysis process. The combustible gases are combusted in a separate chamber. The exhaust gas from this combustion chamber then transfers heat to the pyrolysis chamber, where the biomass is located. This heat causes more combustible gases to be released from the biomass. This approach utilizes two chambers connected by complex tubing. Additionally, the pyrolysis chamber needs to be airtight. Current pyrolysis systems produce, in addition to the combustible gases, pyrolysis oils which condense on the cold surfaces of the piping causing them to clog. Therefore, current multi-chamber pyrolysis systems need to be cleaned often (e g., several times yearly) to avoid clogging. The complex design and high maintenance requirement result in very high capital and operational costs.

[0006] There remains a need for producing biochar via pyrolysis at a significant reduction in investment and operating costs.SUMMARY

[0007] Usage of only one biochar generating reaction chamber for both pyrolysis and combustion of combustible gases cuts investment costs drastically. As a biomass bed is sufficiently heated, it begins to emit combustible gases. These gases ascend to an upper section of the chamber, where they ignite and combust above the biomass bed. This combustion generates heat within the chamber, further raising the temperature of thebiomass bed. This increased temperature prompts the biomass to release additional combustible gases and undergo a transformation via pyrolysis into biochar. As benefit of a single chamber solution, combustion of the gases above the biomass ensures that no oxygen gets in contact with the produced biochar since all oxygen in the chamber is reacted in the combustion of the combustible gases.

[0008] In some aspects, the techniques described herein relate to multi-walled single chamber pyrolysis system including: an inner cylinder that defines a primary combustionprimary combustion zone above and having an opening to a pyrolysis zone, the primary combustionprimary combustion zone hosting combustion of biomass gases flowing up from the pyrolysis zone thereby configuring the pyrolysis zone as substantially free of oxygen; a first annulus that defines a secondary combustion zone, the first annulus having an inner wall, a first portion of which is in common with a portion of the pyrolysis zone that facilitates heat transfer therebetween, and having a second portion of the inner wall in common with a portion of the primary combustionprimary combustion zone; a second annulus that defines a primary combustion air flow zone, the second annulus having an inner wall in common with an outer wall of the first annulus that facilitates heat transfer therebetween and having channels that isolate the primary combustion air from the secondary combustion zone while facilitating flow of primary combustion air to the primary combustionprimary combustion zone; one or more primary combustion air inlets disposed near a lower extent of the second annulus in fluid communication with the primary combustion air flow zone through which air from outside of the system flows; a portal disposed at a top of the inner cylinder, the portal facilitating ingestion of secondary combustion air by the secondary combustion zone and ingestion of biomass into the primary combustion zone; the inner cylinder constructed for gravity fed flow of biomass from the portal through the primary combustion zone through the opening into the pyrolysis zone; and one or more exhaust gas outlets disposed near a lower extent of the first annulus in fluid communication with the secondary combustion zone through which combustion exhaust flows.

[0009] In some aspects, the techniques described herein relate to a system, further including a biochar extractor disposed at a lower extent of the pyrolysis zone and operativeto facilitate removal of biochar from the pyrolysis zone by positioning portions of the biochar above one of a plurality of gravity fed biochar exit ports.

[0010] In some aspects, the techniques described herein relate to a system, wherein the biochar extractor includes a rotary arm constructed to facilitate movement of biochar in a radially outward direction.

[0011] In some aspects, the techniques described herein relate to a system, further including a pyrolysis control system constructed to ensure interior portions of the single chamber pyrolysis system operate at negative pressure relative to an ambient environment exterior thereto.

[0012] In some aspects, the techniques described herein relate to a system, wherein the pyrolysis zone includes a biomass bed region of disposed adjacent to and above a biochar bed region, a top portion of the biomass bed accessible through the opening for receiving ingested biomass and for receiving heat generated by combustion of the combustion gases in the primary combustionprimary combustion zone.

[0013] In some aspects, the techniques described herein relate to a system, further including a controllable biomass ingestion spreader disposed within the pyrolysis zone above the biomass bed region, the controllable biomass ingestion spreader operative to disperse biomass passing through the opening onto the biomass in the biomass bed region.

[0014] In some aspects, the techniques described herein relate to a system, further including guide vanes disposed in the secondary combustion zone causing rotationally oriented flow of secondary combustion gases flowing within the first annulus.

[0015] In some aspects, the techniques described herein relate to a system, wherein the guide vanes increases a residence time of secondary combustion gases in the secondary combustion zone.

[0016] In some aspects, the techniques described herein relate to a system, wherein the guide vanes direct particles in the secondary combustion gases to impact an outer wall of the first annulus.

[0017] In some aspects, the techniques described herein relate to a system, further including an air exchange module connected to the portal and having a first interface through which secondary combustion air and new biomass pass, a second interfacedisposed approximately 90 degrees relative to the portal through which additional secondary combustion air flows.

[0018] In some aspects, the techniques described herein relate to a system, wherein during nominal operation of the system the air exchange module facilitates delivery of the secondary combustion air from the first interface with the additional secondary combustion air of the second interface and the new biomass to the portal.

[0019] In some aspects, the techniques described herein relate to a system, wherein the air exchange module is constructed to facilitate removal of hot exhaust gas from the system through the portal in an absence of negative pressure of the system relative to ambient by inducing an updraft within the air exchange module that draws ambient air through the first interface, thereby preventing hot exhaust gas from passing out of the first interface.

[0020] In some aspects, the techniques described herein relate to a system, wherein an interface proximal to the portal between the inner cylinder and the first annulus causes secondary combustion air passing through the portal to be directed away from the primary combustionprimary combustion zone toward the secondary combustion zone.

[0021] In some aspects, the techniques described herein relate to a system, wherein the portion of heat transferred to the pyrolysis zone from the secondary combustion zone facilitates raising a temperature of portions of biomass in the pyrolysis zone to a biomass combustion gas producing temperature.

[0022] In some aspects, the techniques described herein relate to a system, wherein air in the primary combustion air flow zone is heated through inductive heat transfer of heat circulating through the secondary combustion zone to a temperature of between 200°C and approximately 300°C.

[0023] In some aspects, the techniques described herein relate to a single chamber pyrolysis system, including: a pyrolysis zone defining a lower region of the single chamber pyrolysis system, whereat biomass is transformed into biochar substantially in an absence of oxygen; a primary combustion zone defining an upper region of the single chamber pyrolysis system, the primary combustion zone and the pyrolysis zone defining an open region formed therebetween through which ingested biomass passes from the primary combustion zone to the pyrolysis zone and biomass produced combustion gases pass from the pyrolysis zone to the primary combustion zone, the primary combustion zone hostingcombustion of the combustion gases received from the pyrolysis zone in a presence of primary combustion air introduced to the primary combustion zone proximal to and above the open region; a biomass bed region of the pyrolysis zone disposed adjacent to and above a biochar bed region of the pyrolysis zone, a top portion of the biomass bed accessible through the open region for receiving ingested biomass and for receiving heat generated by combustion of the combustion gases in the primary combustion zone; a biomass ingestion port disposed at an upper limit of the primary combustion zone through which fresh biomass is ingested and secondary combustion air flows; a secondary combustion zone external to and adjacent to the pyrolysis zone, an upper extent of the secondary combustion zone in fluid communication with the primary combustion zone whereat heat resulting from the combustion in the primary combustion zone is received into the secondary combustion zone, the secondary combustion zone transferring a portion of the received heat to the pyrolysis zone through a shared thermal transfer membrane; a biochar extractor disposed at a lower extent of the pyrolysis zone and operative to facilitate removal of biochar from the biochar bed by positioning portions of the biochar above one of a plurality of gravity fed biochar exit ports; and a pyrolysis control system constructed to ensure interior portions of the single chamber pyrolysis system operate at negative pressure relative to an ambient environment exterior to the single chamber pyrolysis system.

[0024] In some aspects, the techniques described herein relate to a system, further including a controllable biomass ingestion spreader disposed within the pyrolysis zone above the biomass bed region, the controllable biomass ingestion spreader operative to disperse biomass passing through the open region onto the biomass in the biomass bed region.

[0025] In some aspects, the techniques described herein relate to a system, further including guide vanes disposed in the secondary combustion zone causing increased residence time of secondary combustion gases in the secondary combustion zone through rotationally oriented flow of secondary combustion gases therein.

[0026] In some aspects, the techniques described herein relate to a system, further including an air exchange module connected to the biomass ingestion port and having a first interface through which secondary combustion air and new biomass pass, a secondinterface disposed approximately 90 degrees relative to the biomass ingestion port through which additional secondary combustion air flows.

[0027] In some aspects, the techniques described herein relate to a system, wherein during nominal operation of the system the air exchange module facilitates delivery of the secondary combustion air from the first interface with the additional secondary combustion air of the second interface and the new biomass to the biomass ingestion port.

[0028] In some aspects, the techniques described herein relate to a method including: ingesting biomass through a biomass ingestion portal; facilitating gravity fed flow of the ingested biomass from the biomass ingestion portal through a primary combustion zone into a pyrolysis zone; heating biomass in the pyrolysis zone to a combustion gas producing temperature in the absence of oxygen; combusting the combustion gas in the primary combustion zone thereby configuring an oxygen barrier between the primary combustion zone and the pyrolysis zone; facilitating movement of combustion exhaust due to combustion in the primary combustion zone into a secondary combustion zone by introducing secondary combustion air through the biomass ingestion portal; heating the pyrolysis zone and primary combustion air through thermal transfer of heat in the secondary combustion zone, while isolating the secondary combustion zone from the pyrolysis zone and the primary combustion air.

[0029] These and other systems, methods, objects, features, and advantages of the present disclosure will be apparent to those skilled in the art from the following detailed description of the preferred embodiment and the drawings.

[0030] All documents mentioned herein are hereby incorporated in their entirety by reference. References to items in the singular should be understood to include items in the plural, and vice versa, unless explicitly stated otherwise or clear from the text. Grammatical conjunctions are intended to express any and all disjunctive and conjunctive combinations of conjoined clauses, sentences, words, and the like, unless otherwise stated or clear from the context.BRIEF DESCRIPTION OF THE FIGURES

[0031] The disclosure and the following detailed description of certain embodiments thereof may be understood by reference to the following figures:

[0032] FIG. 1 depicts a classic pyrolysis design as prior art.

[0033] FIG. 2 depicts a basic schematic of the single chamber pyrolysis reactor.

[0034] FIG. 3 depicts a detailed view of sections and air flows of the reactor.

[0035] FIG. 4. depicts secondary combustion air flow trajectories.

[0036] FIG. 5 depicts a perspective view of combustion gas rotation guide vanes.

[0037] FIG. 6 depicts a diagram of combustion air flows through a power out exhaust hood.

[0038] FIG. 7 depicts a diagram of the power out exhaust hood geometry.

[0039] FIG. 8 depicts a biochar extractor.

[0040] FIG. 9 depicts a perspective view of a biomass spreader of the chamber.

[0041] FIG. 10 depicts a block diagram of inputs and outputs of a pressure controller.

[0042] FIG. 11 depicts a block diagram of control flow for an air blower of the chamber.

[0043] FIG. 12 depicts a block diagram with inputs, outputs, and interconnections between elements of an integrated chamber controller.

[0044] FIG. 13 depicts a flow chart of a method of oxygen-free pyrolysis using a single chamber pyrolysis reactor.DETAILED DESCRIPTION

[0045] Pyrolysis, a process to produce biochar involves heating of a bed of biomass under the restriction of oxygen. By preventing oxygen from reaching the biomass, combustion of the complete biomass is avoided, ensuring the preservation of its carbon content. When biomass is heated to temperatures exceeding approximately 300°C, it releases combustible gases rich in hydrogen, leaving behind a carbonaceous residue, thus facilitating the production of biochar. These gases can be combusted and provide heat required for the pyrolysis process.

[0046] Referring to FIG. 1 that depicts a prior art pyrolysis design 100, current systems use two separated chambers to ensure that the biochar does not come in contact with oxygen during the pyrolysis process. The combustible gases are combusted in a separate chamber 104. The exhaust gas from this combustion chamber 104 then transfers heat, such as through induction, to the pyrolysis chamber 102, where the biomass is located. This heat causes more combustible gases to be released from the biomass. This approach employs two chambers which must be connected by complex tubing 106. Additionally, the pyrolysischamber 102 needs to be airtight. Most pyrolysis systems produce, in addition to the combustible gases, pyrolysis oils which condense on the cold surfaces of the piping causing them to clog. Therefore, these systems need to be cleaned several times a year to avoid clogging. The complex design and high maintenance requirement result in very high capital and operational costs.

[0047] Disclosed herein is a novel pyrolysis system that cuts investment and operational costs drastically. Referring to FIG. 2, a single reaction chamber 200 is used for both performing pyrolysis and combusting of combustible gases. Heating of a biomass, such as a bed of biomass 202, may begin with heat from an external energy source. As the biomass in the bed 202 reaches a first gassing temperature, it begins to emit combustible gases 204. These gases 204 ascend to an upper section of the chamber, a combustion zone 206, where they ignite and combust above the biomass bed 202. The resulting combustion generates heat, further raising the temperature of the biomass in the bed. This increased temperature prompts the biomass to release additional combustible gases as it undergoes transformation into biochar 208. The combustion of the gases above the biomass bed 202 ensures that little to no oxygen gets in contact with the portion(s) of the biomass bed 202, including those portions that are close to transformation to biochar 208. The combustion of the combustible gases in the combustion zone 206 harvests oxygen within the chamber 200, causing it to feed the combustion and exit the chamber from above.

[0048] New biomass 210 may fall via the influence of gravity through this upper combustion zone 206 onto a bed that may include already produced biochar and / or partially pyrolyzed biomass. The gravity feed of the new biomass 210 from above eliminates the need of complex air tight feeding systems. This is due to the combustion zone 206 itself acting as an airlock that keeps excessive or substantially all oxygen away from produced biochar 208 and / or partially pyrolyzed biomass while allowing new biomass 210 to fall through. The new biomass 210 may be then heated up by the combustion of the combustible gases 204 released from biomass 202 already in the chamber that is in the process of transformation to biochar. This new biomass 210 starts to release its combustible gases as its temperature rises and it transforms into biochar.

[0049] To extract the biochar 208, an extraction system 212 may be placed typically at or near the bottom of the reactor chamber. Air supply 214 for combustion, as well as newbiomass 210 supply, and the amount of biochar extracted may be controlled by a control system 216. This control system 216, optionally embodied as a one or more software modules, undertakes several control tasks. Firstly, the control system 216 ensures the provision of sufficient although controlled air supply 214 for maintaining stable combustion. Secondly, the control system 216 regulates a level of biochar in a biochar bed 208 located typically below the biomass bed near or at the bottom of the chamber 200, maintaining it at a near consistent level. Thirdly, the control system 216 monitors and adjusts the new biomass 210 feed, such as to sustain effective combustion. The control system 216 is configured to avoid introducing excessive amounts of new biomass, which could potentially introduce excess moisture into the reactor 200, leading to undesirable cooling.

[0050] Referring now to FIG. 3, a block diagram depicts zones for combustion, pyrolysis, and air flow paths. A single chamber pyrolysis system 300 may include a biomass input port 302, secondary combustion air 304, a primary combustion zone 306, secondary combustion zones 308, primary combustion air channels 310, primary combustion air 312, a combusted gas exhaust port 314, a pyrolysis zone 318 in which a bed of biomass and / or biochar may be found, and a biochar output port 320. The pyrolysis system 300 may further include thermal insulation 322 disposed to retain and / or direct heat generated within the system 300.

[0051] In example embodiments, a single chamber reactor 300 may ensure a stable and clean combustion of the pyrolysis gases. This may include distributing combustion heat fairly evenly to the biochar bed in a biomass bed region of the pyrolysis zone 318. Even or near even heat distribution may promote homogeneous pyrolysis of the biomass. Distributing heat to the biochar bed may include passing the combustion flue gases in a secondary combustion zone 308 alongside at least one of a plurality of walls of the reactor, such as along the walls of the pyrolysis zone 318 in which the biomass and biochar reside. This facilitates transfer of the heat, such as through induction, of the flue gas back into the biomass bed.

[0052] The reactor may operate at negative differential pressure relative to ambient to facilitate flow of the flue gases alongside the reactor walls (e.g., through the secondary combustion zone 308) and prevent the outflow of flue gases via the biomass feed opening302, at or near a top of the reactor 300. The biomass may be gravity fed into the reactor 300 via a simple opening at the top 302. Due at least in part to the negative differential pressure inside the reactor 300, additional mechanical equipment (pistons, rotary valves, and the like) may not be needed for biomass ingestion. As well, further equipment may not be needed to prevent outflow of combustion gases through the biomass opening 302 due at least in part to this negative relative pressure scenario.

[0053] Secondary combustion air 304 may be received by the chamber 300 near the biomass opening 302 at or near the top of the chamber 300. This additional air supply may be used to enhance combustion for achieving near complete clean combustion of the pyrolysis gases in the secondary combustion zone 308 of the reactor. The continuous inflow of this secondary air 304 near or through the biomass feed opening 302 contributes to a fluid dynamic function that further inhibits the outflow of combustion gases through this opening. The primary combustion air 312 may be preheated in one or more primary combustion air channels 310 through conduction of heat from adjacent secondary heat distribution plenums 316. This preheating may facilitate near optimal combustion of the pyrolysis gases. It may also facilitate a reduction of heat losses to the surrounding environment, such as through the exhaust gas outlet port 314. The reactor may be thermally insulated 322 to further diminish heat losses to the surrounding environment. Thermal insulation 322 may also contribute to a homogeneous temperature distribution in the biochar bed.

[0054] In example embodiments, a height of the biochar bed, optionally in a biochar bed region of the pyrolysis zone may be determined via a measurement of the reactor weight with and without biomass or biochar. This measurement and output of a biochar bed level sensor that may be located at the top of the reactor may be utilized for controlling the height of the biochar bed. The biochar may be extracted from the reactor 300 via a biochar extractor and port 320 that may be located at the bottom of the reactor 300. A variety of materials may be used for the reactor, including, without limitations, mild or stainless steel. Such material may be used as structural material for the reactor 300. This type of material choice supports the reactor withstanding process temperatures and mechanical loads for single chamber pyrolysis over a desired lifetime of at least ten years.

[0055] An interior of the reactor 300 may include one or more primary combustion zones 306 and one or more secondary combustion zones 308. In example embodiments, the primary combustion zone 306 may be located directly above the pyrolysis zone (biomass / biochar bed) 318. The primary combustion zone 306 may perform at least the following functions: (i) ensure the stable and continuous combustion of the pyrolysis gases that are released from the biomass; (ii) directly heat the biomass / biochar bed from above; and (iii) shield the biomass / biochar bed from excessive oxygen that may prevent complete transformation of the biomass into biochar.

[0056] At least functions (i) continuous stable combustion and (iii) shielding of the biomass / biochar bed from excessive oxygen may be achieved by control of one or more of various parameters of the reactor, the combustion process, and the biomass transformation. One such parameter includes the combustion air supply 312 being made available to the primary combustion zone 306.

[0057] The primary combustion air 312 may be circulated around at least one or more portion(s) of the secondary combustion zone 308 before introduction to the primary combustion zone. Circulation of the primary combustion air 312 increases the inlet air temperature proximal to the primary combustion zone 306 to approximately 200°C -300°C. The mass flow of the primary combustion air 312 within the reactor 300 may be controlled by a mass flow sensor and a variable speed fan. These elements may be controlled by a controller that is described below herein. A target temperature in the primary combustion zone 306 may be in the range of 500-900°C.

[0058] The secondary combustion zone 308 may be located around the primary combustion chamber 306 and at least a portion of the pyrolysis zone 318, such as a portion for the biomass / biochar bed. This secondary combustion zone 308 may perform at least the following functions: (i) ensure complete and clean combustion of the pyrolysis gases; (ii) heating the pyrolysis zone 318 (biomass / biochar bed); and preheating the primary combustion air 312.

[0059] Preferred combustion of the pyrolysis gases (e.g., complete and clean) may be achieved by the introduction of additional secondary combustion air 304, such as through the biomass feed opening 302 at the top of the reactor 300. The heating of the pyrolysis zone 318 may be achieved at least in part by locating at least a portion of the secondarycombustion zone 308 to facilitate flow of the combustion gases through secondary heat distribution plenums 316 around walls of the pyrolysis zone 318.

[0060] In example embodiments, the reactor 300 may comprise a multi-walled single chamber pyrolysis system. The system may include an inner cylinder that defines a primary combustion zone above. The inner cylinder may have an opening to a pyrolysis zone that may be disposed below the primary combustion zone. The primary combustion zone may host combustion of biomass gases flowing up from the pyrolysis zone thereby configuring the pyrolysis zone as substantially free of oxygen. In example embodiments, a first annulus may define a secondary combustion zone. The first annulus may have an inner wall, a first portion of which is in common with a portion of the pyrolysis zone. The common wall portion, which may comprise a thermal transfer membrane, may facilitate heat transfer therebetween. The first annulus may also have a second portion of the inner wall in common with a portion of the primary combustion zone. In example embodiments, a second annulus may define a primary combustion air flow zone. The second annulus may have an inner wall in common with an outer wall of the first annulus that facilitates heat transfer therebetween. The system may have channels that isolate the primary combustion air from the secondary combustion zone while facilitating flow of primary combustion air to the primary combustion zone. The system may further have one or more primary combustion air inlets. These air inlets may be disposed near a lower extent of the second annulus and be in fluid communication with the primary combustion air flow zone through which air, from outside of the system, flows. In example embodiments, a portal may be disposed at or near a top of the inner cylinder. The portal may faciliate ingestion of secondary combustion air by the secondary combustion zone and / or ingestion of biomass into the primary combustion zone. In example embodiments, the inner cylinder may be constructed for gravity fed flow of biomass from the portal, through the primary combustion zone, through the opening, into the pyrolysis zone. The system may have one or more exhaust gas outlets that may be disposed near a lower extent of the first annulus. These gas outlets may be in fluid communication with the secondary combustion zone through which combustion exhaust flows.

[0061] Referring to FIG. 4 a diagram of flow trajectories and rates of the secondary combustion air 304 from the biomass feed opening 302 to the input of the secondarycombustion zone 308 is depicted. The mass flow of the secondary combustion air 304 may be monitored by a pressure sensor that directly or indirectly measures a differential pressure between region(s) inside the reactor and the surrounding environment. This monitored pressure differential may be used to control a variable speed fan disposed in at least a portion of the mass flow of the secondary combustion air 304 Increases in the variable speed fan may increase the mass flow of the secondary combustion air 304. Residual oxygen in the combustion air may be measured via a lambda probe (not depicted) that may be located at or near an exhaust gas output of the secondary combustion zone (e.g., combusted gas exhaust port 314). Based on one or more outputs of the lambda probe, the combustion of the pyrolysis gases may be controlled by a lambda controller. In example embodiments, the lambda controller may be associated with a controller that is described below herein. The temperature in the secondary combustion zone(s) 308 of the reactor may be in the range of 600-1100°C. The temperature of the exhaust gas at the lambda probe may be in the range of 600-900°C. The lambda value may be in the range of 1-2.

[0062] Referring to FIG. 5, a set of guide vanes 502 may be disposed in the secondary combustion zone 308. At least one or more of the set of guide vanes 502 may generate a rotation of the combustion gases around a longitudinal axis of the reactor within the secondary combustion zone 308. In example embodiments, one or more of the primary combustion zone 306 or the pyrolysis zone 318 of the reactor may form a cylindrical shape. The guide vanes 502 in the secondary combustion zone 308 may facilitate rotational movement of the combustion gasses along exterior walls of this cylindrical shape. The guide vanes 502 may facilitate the complete and clean combustion of the pyrolysis gases by increasing a residence time of the combustion gases in the secondary combustion zone due at least in part to this rotational movement of the combustion gasses as they traverse the longitudinal length of the secondary combustion zone 308. A benefit of the guide vanes 502 may include decreasing an amount or quantity of particles (e.g., glowing solid particles) that exit the secondary combustion zone 308, such as through the combusted gas exit port 314.

[0063] Due to the rotational motion of the combustion gases enabled by the guide vanes 502, particles in the gas stream move on the curved trajectory. This motion causes the particles to be subjected to a centrifugal force. This centrifugal force acts substantiallyperpendicular to the general longitudinal direction of motion of the particles. This causes the particles to move radially outwards, increasing the likelihood that they will collide with an outer wall of the secondary combustion zone 308. A proportion (e.g., a large proportion, or more than 50%, 80%, or 90%) of the particles may adhere to the cylinder wall after the collision and will be completely (or nearly completely) burnt due to even further increased residence time in the secondary combustion zone 308.

[0064] Referring to FIG. 6, a powerout air exchange system 600 may be configured with a biomass manifold 602 that may include a biomass feed port 604. The exchange system 600 may also be configured with a rain cover 606 and air exchange opening 608. The rain cover 606 may facilitate communication of air among the reactor 300, the biomass feed port 604 and the air exchange opening 608. In example embodiments, the rain cover 606 may be stacked above a vertical portion of the biomass manifold 602 that is in airflow communication with but distinct from the biomass feed port 604. The powerout air exchange system 600 may facilitate flow of, among other things combustion gasses to improve, among other things biomass ingestion. The powerout air exchange system 600 may be located over the biomass input port 302, which may be located proximal to the top of the reactor 300. In example embodiments, the biomass manifold 602 may enable gravity driven flow of biomass, such as from a conventional conveying system (not shown) to the biomass input port 302. The rain cover 606 may prevent ingress of rainwater into the reactor chamber, such as when the reactor 300 is operated outdoors.

[0065] The powerout air exchange system 600 may operate in a nominal operating mode 610 that assists ingress of secondary combustion air 304 through the biomass input port 302. Nominal operating mode may include or be characterized at least in part by, as described above, a negative pressure differential of the combustion chambers and pyrolysis zone relative to environmental air pressure outside of the reactor. Nominal operation 610 may typically occur when, for example, control systems (later described) are operative (e g., receive sufficient power, such as electricity) so that flows of primary combustion air 312 and secondary combustion gases through the exhaust gas port 314 are sustained.

[0066] During nominal operation 610 the reactor generally operates under negative differential pressure. Due to this negative pressure differential relative to the environmental pressure outside of the reactor, secondary combustion air 304 is drawn through the biomassinput port 302 into the reactor chamber via the biomass feed port 604 and the air exchange opening 608 of the powerout air exchange system 600. Secondary combustion air flow via the air exchange opening 608 is shown by arrow 612. In this embodiment, a portion 612 of secondary combustion air 304 flows into the air exchange opening 608, travels through the rain cover 606, into the biomass manifold 602 and into the reactor 300 through the biomass input port 302. Further in this embodiment, a portion of secondary air flow (shown by arrow 614) flows into the biomass feed port 604, through the biomass manifold 602 and into the reactor 300 through the biomass input port 302. In example embodiments, secondary combustion air 304 of flow 612 may fluidly combine with secondary combustion air flow 304 of flow 614 in the biomass manifold 602. Optionally, flows 612 and 614 may enter the reactor 300 via the biomass input port 302 without substantially combining in the biomass manifold 602. New biomass 210 or the like may be fed (e.g., by gravity, via an external conveyor, or the like) into the biomass feed port 604, through the manifold 602 and into the reactor via the biomass input port 302 during this nominal operation.

[0067] When nominal operation is not present, such as during an electric power outage, the negative pressure differential of nominal operation may be absent and may not be maintained. As a result, due at least in part to buoyancy forces (e.g., induced by density differences between the hot exhaust gas and air surrounding the reactor 300), hot combustion gas from the reactor chamber may rise through the reactor toward and through the biomass input port 302 into the biomass manifold 602. Due at least in part to aspects of the shape of the powerout air exchange system 600, these rising combustion gasses are guided upward into and through the rain cover 606 toward and through the air exchange opening 608. This flow, indicated by arrow 616, may be substantially a reverse of flow 612.

[0068] This flow 616 may be influenced by one or more aspects of the shape of the powerout air exchange system 600. The shape of the powerout air exchange system 600 is designed to, among other things, induce an updraft (e.g., flow 616). This updraft draws external air 618 (which is at a lower temperature than the flow 616) through the biomass feed port 604 into the manifold 602. This drawn air is carried by the updraft into an upper portion of the manifold 602 that is in fluid communication with the rain hood 606, joiningflow 616 to exit through the air exchange port 608. This aspect of the shape of the powerout air exchange system 600 mitigates, or effectively prevents, flows of hot combustion gas 616 from exiting through the biomass feed port 604, thereby protecting a biomass conveyor system or the like that is proximal to the biomass feed port 604 from overheating.

[0069] In example embodiments, the powerout air exchange system 600, may operate passively. Its function may be defined, as exemplified herein, by aspects of its shape, including various geometric relationships. These relationships among dimensions and angles of the system 600 facilitate reliable operation.

[0070] Referring to FIG. 7, geometries of the powerout air exchange system 600, and various dimensions that influence its function are depicted. The following geometric relationships may help to ensure reliable operation. In example embodiments, dimension B 702 preferably is configured to be equal or greater than dimension A 704. Angle Alpha 706 is preferably between 30 degrees and 80 degrees. Angle Beta 708 is preferable between 0 degrees and and 90 degrees. The air exchange port 608 of the rain cover 606 is preferably disposed on the same side as the biomass feed port 604 of the manifold 602.

[0071] Referring to FIG. 8, output of biochar from the reactor 300 may be realized via a biochar extractor 800 disposed substantially at or near the interior bottom of the bioreactor (e.g., at or near the bottom of the biochar bed 208 from FIG. 2. This biochar extractor 800 may ensure near uniform outflow of biochar by positioning portions of the biochar above one of a plurality of gravity fed biochar exit ports. This may be contrasted with formation of outflow cones or the like that would disturb the desired layered structure of biomass (generally above) and biochar (generally below). The biochar extractor 800 consists of a rotor 802 with two or more arms 804 that rotate around a vertical axis 806. The rotation of the rotor 802 facilitates movement of biochar radially outward to one or more exit ports 808 disposed in a bottom surface of the reactor 300. The arms 804 may be constructed with ramps, tapered to be thicker near the vertical axis 806, substantially as depicted, or include other features that may further encourage movement of the biochar radially outward. In embodiments, the rotational speed of the biochar rotor may generally be between 1 and 20 rpm, although lower and higher rotational speeds are contemplated and included herein.

[0072] Referring to FIG. 9, one or more spreaders 902 may be located variously along the height of the reactor. In embodiments, spreaders 902 may be located variously along theheight of the pyrolysis zone 318, generally above the biomass bed 202. Each of these spreaders 902 may rotate at controllable rates to help evenly disperse fresh biomass over the surface of the biomass bed 202 as the fresh biomass exits (e.g., falls out of) the primary combustion zone 306. For exemplary purposes, FIG. 9 depicts a spreader 902 located directly below an interface between the primary combustion zone 206 and the biomass bed 202. In embodiments, this may include being disposed below one or more portals 904 between the primary combustion zone 302 and the primary air flow channels 310. One or more of the spreaders 902 may be constructed with two or more metal rotors 906 that may be directly or indirectly coupled to a rotational axle 908. In embodiments, the rotational axle 908 may be directly or indirectly coupled to the vertical axis 806 of the biochar extractor system 800. In embodiments, one or more of the spreaders 902, individually or in unison, may rotate, optionally through connection to the biochar extractor system 800 at a range of 1-20 rpm, or the like. Lower and higher rpm values are possible and contemplated herein.

[0073] A control architecture for the methods and systems of single chamber pyrolysis described herein may include multiple subcontrollers. Each subcontroller may be responsible for managing one or more portions of the pyrolysis process (e.g., one or more process parameters). One such process parameter to be measured and controlled is depicted in FIG. 10 and includes pressure of one or more of the combustion chambers of the reactor 300. In embodiments, a pressure sensor may be disposed to measure pressure within the combustion chamber. This pressure sensor's output 1002 (e.g., measured reactor pressure) may be fed into a pressure controller 1004. The pressure controller 1004 may be implemented in software, hardware, or a combination thereof (e.g., a processor executing software and the like). The pressure controller 1004 may ensure that the measured reactor pressure remains below ambient pressure, thereby facilitating a desired negative relative pressure within the reactor 300. This control of the reactor pressure may prevent gas or other leakage out of the reactor 300. The controller 1004 may regulate the pressure, such as based on a pressure set point 1006. To regulate the pressure, the controller 1004 may adjust operation of one or more fans associated with the reactor 300, such as an exhaust gas fan, an inlet air fan, and the like. In embodiments, the controller 1004 may provide a signal 1008 to regulate RPM of an exhaust air blower.

[0074] Referring to FIG. 11 , an air supply and emission controller 1102 is depicted. A desired level of combustion performance, such as optimal or near-optimal combustion of pyrolysis gases may be achieved using cascaded air supply controllers. A primary controller (aka air mass controller) 1104 may regulate air mass flow rate of the various flows of the reactor 300. One or more of these flows may be measured by an air mass flow sensor that produces one or more signals indicative of a measured air mass flow 1106. The primary controller 1104 may respond to the measured air mass flow 1106, along with an air mass flow setpoint 1108 by adjusting operation, such as RPM 1120 of one or more air blowers associated with the reactor 300. This air mass controller 1104 may receive the air mass flow setpoint 1108 from a lambda controller 1110. The lambda controller 1110 may communicate with a lambda probe to measure, for example, a residual oxygen content in flue gas (e g., combustion gas at or near the exhaust gas output 314) that may be represented by a measured lambda signal 1112. By adjusting the air mass flow, the lambda controller 1110 may facilitate desired combustion. Desired combustion may describe optimal combustion, which may also include minimal emissions. The lambda controller 1110 may also reference a lambda setpoint 1114. The lambda set point 1114 may be manually set to target generally in the range of 1 and 1.4. The lambda setpoint 11114 may be calculated. Such a calculation may include measuring the carbon monoxide (CO) 1118 content of the exhaust gas, and determining through one or more calculations a lambda setpoint at which the CO content is minimal, or nearly zero. Calculating a lambda setpoint 1114 may be performed by a CO minimizer module 1116. In embodiments, CO may be the slowest of the flue gases to combust. Therefore, by ensuring exhaust gas output 314 achieves near- minimal CO content, other undesirable emissions, such as methane can be projected or expected to be minimal or non-measurable.

[0075] One exemplary process of finding a desired lambda setpoint (e.g., to minimize CO content) may include, without limitation, gradient descent, a Kalman filter, or a neural network that learns one or more relationships between various lambda set points and measured CO.

[0076] In embodiments, a gradient descent method may include initially arbitrarily adjusting a lambda setpoint. Changes in the measured CO value are observed and used to calculate the gradient. Based on the calculated gradient, the lambda setpoint is adjusted andthe CO is re-measured with a goal of adjusting the lambda setpoint to minimize the measured CO value. As the gradient approaches zero, a minimum CO measured value may be achieved. An excessively large step size of the adjusting the lambda setpoint may result in overshooting a minimum CO measured value. This may result in further adjustments of the lambda setpoint to oscillate so that a minimum value may not readily be reached.

[0077] In embodiments, a Kalman fdter approach includes estimating a relationship between lambda and measured Co using a quadratic function. Parameters of the quadratic function are estimated during operation, allowing for estimation of the function’s minimum. A Kalman filter approach may achieve minimum measured CO more quickly than the gradient descent method and may avoid oscillation.

[0078] In embodiments, a neural network approach may include training a neural network to approximate a relationship between lambda and measured CO. Training the neural network may be performed separately from reactor operation. A reinforcement learning algorithm can be employed to learn this relationship, optionally during operation of the reactor. One or more of these processes for finding a desired lambda setpoint that minimizes CO may enable efficient combustion and minimize emissions effectively.

[0079] Referring to FIG. 12, material flow, such as biomass feed rate, and the like may be managed based on various reactor-related parameters, such as a desired combustion chamber temperature, a biomass quantity inside the reactor, a reactor's water content, and the like. In embodiments, at low moisture levels (e.g., low reactor water content), temperature may rise quickly with increased biomass supply, causing pyrolysis gases to be rapidly released. However, as moisture levels rise, this relationship between temperature rise with increased biomass supply becomes more complex. Therefore ensuring that unevaporated water does not accumulate may prevent extinguishing combustion.

[0080] A reactor state estimator 1202 may estimate amounts of biomass, biochar, and moisture content. The state estimator may rely on, for example, the reactor chamber’s weight 1204. This weight may be measured by load cells. Based on a derivative of the weight measurement 1204 the estimator 1202 may determine a plurality of material flow control variables, including without limitation an amount of water evaporated, an amount of pyrolysis gases combusted, a residual amount of biochar left inside the reactor, and the like that may be input to a material flow controller 1208. Additionally the estimator 1202can calculate an amount of time remaining for the biomass to gas out, which can be used for further projections of a target amount of biomass to be fed into the reactor. Temperature of the reactor 1206 may be measured with a temperature sensor. In embodiments such a temperature sensor may include a high temperature radar sensor. As an example, the temperature sensor may be installed near or at the top of the interior of the reactor. This sensed temperature may facilitate measuring a fill level of the reactor. It may be beneficial that the reactor maintains a near constant fill level that includes fresh biomass in order to avoid the reaction being extinguished. Based at least in part on a determined fill level and an amount of biomass and / or biochar in the reactor, the biochar extraction system (e.g., from FIG. 8) may be activated to transport the biochar out of the reactor. In embodiments the fill level can also be estimated using the weight measurement 1204.

[0081] In embodiments, material flow controller 1208 may receive, as input, one or more estimates from state estimator 1202. These estimates may include one or more of an estimated amount of water, an estimated amount of dry biomass, an estimated amount of biochar, an estimated amount of water content, an estimated fill level, an estimated amount of pyrolysis gasses, and the like. The material flow controller may also receive as inputs one or more of a temperature set point 1210, a maximum amount of water value 1212, a fill grade setpoint 1214. The material controller 1208 may produce control signals for biomass feeder RPM 1216, biochar extractor RPM 1218, and the like.

[0082] Integrated Control: While various controllers, such as pressure controller 1004, lambda controller 1110, air mass flow controller 1104, material flow controller 1208, or the like can operate independently with fixed setpoints, process efficiency can be significantly enhanced by using a model or Al-based control approach. Such a control approach may determine optimal setpoints for one or more of the controllers, ensuring they work together efficiently and effectively.

[0083] An Al-based control approach may ensure stable operation of this single chamber pyrolysis system. In embodiments, the various measurements described herein may be used by one or more of the controllers to compare an estimated or forecasted state or states of the reactor 300 with an actual state (e.g., as indicated by the various measurements). This will enable refining of a model of operation. A camera may be used to provide images of the produced biochar. These images may be analyzed to determine, among other things,an assessment of biochar quality generated during operation. In an example, biochar quality information may be fed back to one or more of the control systems, to adapt at least a timing of introduction of new biomass into the reactor.

[0084] Referring to FIG. 13, a flowchart of an example method for converting biomass to biochar in a pyrolysis zone of a single chamber pyrolysis reactor in the absence of oxygen is depicted. At step 1310, biomass is ingested through a biomass ingestion portal. At step 1320, biomass flows due at least in part to gravity from the biomass ingestion portal through a primary combustion zone into a pyrolysis zone. At step 1330, the biomass in the pyrolysis zone is heated to a combustion gas producing temperature. At step 1340, the produced combustion gas is combusted in the primary combustion zone thereby configuring an oxygen barrier between the primary combustion zone and the pyrolysis zone. At step 1350, movement of combustion exhaust due to combustion in the primary combustion zone into a secondary combustion zone is facilitated by introducing secondary combustion air through the biomass ingestion portal. At step 1360, the pyrolysis zone and primary combustion air are heated through thermal transfer of heat in the secondary combustion zone, while isolating the secondary combustion zone from the pyrolysis zone and the primary combustion air. At step 1370, biomass is transformed into biochar in the pyrolysis zone in the absence of oxygen.

[0085] The single chamber pyrolysis reactor control and operational methods and systems described herein may be deployed in part or in whole through a machine that executes computer software, program codes, and / or instructions on a processor. The processor may be part of a server, client, network infrastructure, mobile computing platform, stationary computing platform, or other computing platform. A processor may be any kind of computational or processing device capable of executing program instructions, codes, binary instructions and the like. The processor may be or include a signal processor, digital processor, embedded processor, microprocessor or any variant such as a co-processor (math co-processor, graphic co-processor, communication co-processor and the like) and the like that may directly or indirectly facilitate execution of program code or program instructions stored thereon. In addition, the processor may enable execution of multiple programs, threads, and codes. The threads may be executed simultaneously to enhance the performance of the processor and to facilitate simultaneous operations of the application.By way of implementation, methods, program codes, program instructions and the like described herein may be implemented in one or more thread. The thread may spawn other threads that may have assigned priorities associated with them; the processor may execute these threads based on priority or any other order based on instructions provided in the program code. The processor may include memory that stores methods, codes, instructions and programs as described herein and elsewhere. The processor may access a storage medium through an interface that may store methods, codes, and instructions as described herein and elsewhere. The storage medium associated with the processor for storing methods, programs, codes, program instructions or other type of instructions capable of being executed by the computing or processing device may include but may not be limited to one or more of a CD-ROM, DVD, memory, hard disk, flash drive, RAM, ROM, cache and the like.

[0086] A processor may include one or more cores that may enhance speed and performance of a multiprocessor. In embodiments, the process may be a dual core processor, quad core processors, other chip-level multiprocessor and the like that combine two or more independent cores (called a die).

[0087] The methods and systems described herein may be deployed in part or in whole through a machine that executes computer software on a server, client, firewall, gateway, hub, router, or other such computer and / or networking hardware. The software program may be associated with a server that may include a file server, print server, domain server, internet server, intranet server and other variants such as secondary server, host server, distributed server and the like. The server may include one or more of memories, processors, computer readable transitory and / or non-transitory media, storage media, ports (physical and virtual), communication devices, and interfaces capable of accessing other servers, clients, machines, and devices through a wired or a wireless medium, and the like. The methods, programs or codes as described herein and elsewhere may be executed by the server. In addition, other devices required for execution of methods as described in this application may be considered as a part of the infrastructure associated with the server.

[0088] The server may provide an interface to other devices including, without limitation, clients, other servers, printers, database servers, print servers, file servers, communication servers, distributed servers and the like. Additionally, this coupling and / or connection mayfacilitate remote execution of program across the network. The networking of some or all of these devices may facilitate parallel processing of a program or method at one or more location without deviating from the scope of the disclosure. In addition, all the devices attached to the server through an interface may include at least one storage medium capable of storing methods, programs, code and / or instructions. A central repository may provide program instructions to be executed on different devices. In this implementation, the remote repository may act as a storage medium for program code, instructions, and programs.

[0089] The software program may be associated with a client that may include a file client, print client, domain client, internet client, intranet client and other variants such as secondary client, host client, distributed client and the like. The client may include one or more of memories, processors, computer readable transitory and / or non-transitory media, storage media, ports (physical and virtual), communication devices, and interfaces capable of accessing other clients, servers, machines, and devices through a wired or a wireless medium, and the like. The methods, programs or codes as described herein and elsewhere may be executed by the client. In addition, other devices required for execution of methods as described in this application may be considered as a part of the infrastructure associated with the client.

[0090] The client may provide an interface to other devices including, without limitation, servers, other clients, printers, database servers, print servers, file servers, communication servers, distributed servers and the like. Additionally, this coupling and / or connection may facilitate remote execution of program across the network. The networking of some or all of these devices may facilitate parallel processing of a program or method at one or more location without deviating from the scope of the disclosure. In addition, all the devices attached to the client through an interface may include at least one storage medium capable of storing methods, programs, applications, code and / or instructions. A central repository may provide program instructions to be executed on different devices. In this implementation, the remote repository may act as a storage medium for program code, instructions, and programs.

[0091] The methods and systems described herein may be deployed in part or in whole through network infrastructures. The network infrastructure may include elements such ascomputing devices, servers, routers, hubs, firewalls, clients, personal computers, communication devices, routing devices and other active and passive devices, modules and / or components as known in the art. The computing and / or non-computing device(s) associated with the network infrastructure may include, apart from other components, a storage medium such as flash memory, buffer, stack, RAM, ROM and the like. The processes, methods, program codes, instructions described herein and elsewhere may be executed by one or more of the network infrastructural elements.

[0092] The methods, program codes, and instructions described herein and elsewhere may be implemented on a cellular network having multiple cells. The cellular network may either be frequency division multiple access (FDMA) network or code division multiple access (CDMA) network. The cellular network may include mobile devices, cell sites, base stations, repeaters, antennas, towers, and the like.

[0093] The methods, programs codes, and instructions described herein and elsewhere may be implemented on or through mobile devices. The mobile devices may include navigation devices, cell phones, mobile phones, mobile personal digital assistants, laptops, palmtops, netbooks, pagers, electronic books readers, music players and the like. These devices may include, apart from other components, a storage medium such as a flash memory, buffer, RAM, ROM and one or more computing devices. The computing devices associated with mobile devices may be enabled to execute program codes, methods, and instructions stored thereon. Alternatively, the mobile devices may be configured to execute instructions in collaboration with other devices. The mobile devices may communicate with base stations interfaced with servers and configured to execute program codes. The mobile devices may communicate on a peer to peer network, mesh network, or other communications network. The program code may be stored on the storage medium associated with the server and executed by a computing device embedded within the server. The base station may include a computing device and a storage medium. The storage device may store program codes and instructions executed by the computing devices associated with the base station.

[0094] The computer software, program codes, and / or instructions may be stored and / or accessed on machine readable transitory and / or non-transitory media that may include: computer components, devices, and recording media that retain digital data used for computing for some interval of time; semiconductor storage known as random accessmemory (RAM); mass storage typically for more permanent storage, such as optical discs, forms of magnetic storage like hard disks, tapes, drums, cards and other types; processor registers, cache memory, volatile memory, non-volatile memory; optical storage such as CD, DVD; removable media such as flash memory (e.g. USB sticks or keys), floppy disks, magnetic tape, paper tape, punch cards, standalone RAM disks, Zip drives, removable mass storage, off-line, and the like; other computer memory such as dynamic memory, static memory, read / write storage, mutable storage, read only, random access, sequential access, location addressable, file addressable, content addressable, network attached storage, storage area network, bar codes, magnetic ink, and the like.

[0095] The methods and systems described herein may transform physical and / or or intangible items from one state to another. The methods and systems described herein may also transform data representing physical and / or intangible items from one state to another.

[0096] The elements described and depicted herein, including in flow charts and block diagrams throughout the figures, imply logical boundaries between the elements. However, according to software or hardware engineering practices, the depicted elements and the functions thereof may be implemented on machines through computer executable transitory and / or non-transitory media having a processor capable of executing program instructions stored thereon as a monolithic software structure, as standalone software modules, or as modules that employ external routines, code, services, and so forth, or any combination of these, and all such implementations may be within the scope of the present disclosure. Examples of such machines may include, but may not be limited to, personal digital assistants, laptops, personal computers, mobile phones, other handheld computing devices, medical equipment, wired or wireless communication devices, transducers, chips, calculators, satellites, tablet PCs, electronic books, gadgets, electronic devices, devices having artificial intelligence, computing devices, networking equipment, servers, routers and the like. Furthermore, the elements depicted in the flow chart and block diagrams or any other logical component may be implemented on a machine capable of executing program instructions. Thus, while the foregoing drawings and descriptions set forth functional aspects of the disclosed systems, no particular arrangement of software for implementing these functional aspects should be inferred from these descriptions unless explicitly stated or otherwise clear from the context. Similarly, it will be appreciated thatthe various steps identified and described above may be varied, and that the order of steps may be adapted to particular applications of the techniques disclosed herein. All such variations and modifications are intended to fall within the scope of this disclosure. As such, the depiction and / or description of an order for various steps should not be understood to require a particular order of execution for those steps, unless required by a particular application, or explicitly stated or otherwise clear from the context.

[0097] The methods and / or processes described above, and steps thereof, may be realized in hardware, software or any combination of hardware and software suitable for a particular application. The hardware may include a dedicated computing device or specific computing device or particular aspect or component of a specific computing device. The processes may be realized in one or more microprocessors, microcontrollers, embedded microcontrollers, programmable digital signal processors or other programmable device, along with internal and / or external memory. The processes may also, or instead, be embodied in an application specific integrated circuit, a programmable gate array, programmable array logic, or any other device or combination of devices that may be configured to process electronic signals. It will further be appreciated that one or more of the processes may be realized as a computer executable code capable of being executed on a machine readable medium.

[0098] The computer executable code may be created using a structured programming language such as C, an object oriented programming language such as C++, or any other high-level or low-level programming language (including assembly languages, hardware description languages, and database programming languages and technologies) that may be stored, compiled or interpreted to run on one of the above devices, as well as heterogeneous combinations of processors, processor architectures, or combinations of different hardware and software, or any other machine capable of executing program instructions.

[0099] Thus, in one aspect, each method described above and combinations thereof may be embodied in computer executable code that, when executing on one or more computing devices, performs the steps thereof. In another aspect, the methods may be embodied in systems that perform the steps thereof, and may be distributed across devices in a number of ways, or all of the functionality may be integrated into a dedicated, standalone device orother hardware. In another aspect, the means for performing the steps associated with the processes described above may include any of the hardware and / or software described above. All such permutations and combinations are intended to fall within the scope of the present disclosure.

[0100] While the disclosure has been disclosed in connection with the preferred embodiments shown and described in detail, various modifications and improvements thereon will become readily apparent to those skilled in the art. Accordingly, the spirit and scope of the present disclosure is not to be limited by the foregoing examples, but is to be understood in the broadest sense allowable by law.

Claims

SINGLE-CHAMBER COMBUSTION WITH PYROLYSISCLAIMSWhat is claimed is:

1. Multi-walled single chamber pyrolysis system comprising: an inner cylinder that defines a primary combustion zone above and having an opening to a pyrolysis zone, the primary combustion zone hosting combustion of biomass gases flowing up from the pyrolysis zone thereby configuring the pyrolysis zone as substantially free of oxygen; a first annulus that defines a secondary combustion zone, the first annulus having an inner wall, a first portion of which is in common with a portion of the pyrolysis zone that facilitates heat transfer therebetween, and having a second portion of the inner wall in common with a portion of the primary combustion zone; a second annulus that defines a primary combustion air flow zone, the second annulus having an inner wall in common with an outer wall of the first annulus that facilitates heat transfer therebetween and having channels that isolate the primary combustion air from the secondary combustion zone while facilitating flow of primary combustion air to the primary combustion zone; one or more primary combustion air inlets disposed near a lower extent of the second annulus in fluid communication with the primary combustion air flow zone through which air from outside of the system flows; a portal disposed at a top of the inner cylinder, the portal facilitating ingestion of secondary combustion air by the secondary combustion zone and ingestion of biomass into the primary combustion zone; the inner cylinder constructed for gravity fed flow of biomass from the portal through the primary combustion zone through the opening into the pyrolysis zone; and one or more exhaust gas outlets disposed near a lower extent of the first annulus in fluid communication with the secondary combustion zone through which combustion exhaust flows.

2. The system of claim 1, further comprising a biochar extractor disposed at a lower extent of the pyrolysis zone and operative to facilitate removal of biochar from the pyrolysis zone by positioning portions of the biochar above one of a plurality of gravity fed biochar exit ports.

3. The system of claim 2, wherein the biochar extractor includes a rotary arm constructed to facilitate movement of biochar in a radially outward direction.

4. The system of claim 1, further comprising a pyrolysis control system constructed to ensure interior portions of the single chamber pyrolysis system operate at negative pressure relative to an ambient environment exterior thereto.

5. The system of claim 1, wherein the pyrolysis zone includes a biomass bed region of disposed adjacent to and above a biochar bed region, a top portion of the biomass bed accessible through the opening for receiving ingested biomass and for receiving heat generated by combustion of the combustion gases in the primary combustion zone.

6. The system of claim 5, further comprising a controllable biomass ingestion spreader disposed within the pyrolysis zone above the biomass bed region, the controllable biomass ingestion spreader operative to disperse biomass passing through the opening onto the biomass in the biomass bed region.

7. The system of claim 1, further comprising guide vanes disposed in the secondary combustion zone causing rotationally oriented flow of secondary combustion gases flowing within the first annulus.

8. The system of claim 7, wherein the guide vanes increases a residence time of secondary combustion gases in the secondary combustion zone.

9. The system of claim 7, wherein the guide vanes direct particles in the secondary combustion gases to impact an outer wall of the first annulus.

10. The system of claim 1, further comprising an air exchange module connected to the portal and having a first interface through which secondary combustion air and new biomass pass, a second interface disposed approximately 90 degrees relative to the portal through which additional secondary combustion air flows.

11. The system of claim 10, wherein during nominal operation of the system the air exchange module facilitates delivery of the secondary combustion air from the first interface with the additional secondary combustion air of the second interface and the new biomass to the portal.

12. The system of claim 10, wherein the air exchange module is constructed to facilitate removal of hot exhaust gas from the system through the portal in an absence of negative pressure of the system relative to ambient by inducing an updraft within the air exchange module that draws ambient air through the first interface, thereby preventing hot exhaust gas from passing out of the first interface.

13. The system of claim 1, wherein an interface proximal to the portal between the inner cylinder and the first annulus causes secondary combustion air passing through the portal to be directed away from the primary combustion zone toward the secondary combustion zone.

14. The system of claim 1, wherein the portion of heat transferred to the pyrolysis zone from the secondary combustion zone facilitates raising a temperature of portions of biomass in the pyrolysis zone to a biomass combustion gas producing temperature.

15. The system of claim 1, wherein air in the primary combustion air flow zone is heated through inductive heat transfer of heat circulating through the secondary combustion zone to a temperature of between 200°C and approximately 300°C.

16. A single chamber pyrolysis system, comprising:a pyrolysis zone defining a lower region of the single chamber pyrolysis system, whereat biomass is transformed into biochar substantially in an absence of oxygen; a primary combustion zone defining an upper region of the single chamber pyrolysis system, the primary combustion zone and the pyrolysis zone defining an open region formed therebetween through which ingested biomass passes from the primary combustion zone to the pyrolysis zone and biomass produced combustion gases pass from the pyrolysis zone to the primary combustion zone, the primary combustion zone hosting combustion of the combustion gases received from the pyrolysis zone in a presence of primary combustion air introduced to the primary combustion zone proximal to and above the open region; a biomass bed region of the pyrolysis zone disposed adjacent to and above a biochar bed region of the pyrolysis zone, a top portion of the biomass bed accessible through the open region for receiving ingested biomass and for receiving heat generated by combustion of the combustion gases in the primary combustion zone; a biomass ingestion port disposed at an upper limit of the primary combustion zone through which fresh biomass is ingested and secondary combustion air flows; a secondary combustion zone external to and adjacent to the pyrolysis zone, an upper extent of the secondary combustion zone in fluid communication with the primary combustion zone whereat heat resulting from the combustion in the primary combustion zone is received into the secondary combustion zone, the secondary combustion zone transferring a portion of the received heat to the pyrolysis zone through a shared thermal transfer membrane; a biochar extractor disposed at a lower extent of the pyrolysis zone and operative to facilitate removal of biochar from the biochar bed by positioning portions of the biochar above one of a plurality of gravity fed biochar exit ports; and a pyrolysis control system constructed to ensure interior portions of the single chamber pyrolysis system operate at negative pressure relative to an ambient environment exterior to the single chamber pyrolysis system.

17. The system of claim 16, further comprising a controllable biomass ingestion spreader disposed within the pyrolysis zone above the biomass bed region, the controllablebiomass ingestion spreader operative to disperse biomass passing through the open region onto the biomass in the biomass bed region.

18. The system of claim 16, further comprising guide vanes disposed in the secondary combustion zone causing increased residence time of secondary combustion gases in the secondary combustion zone through rotationally oriented flow of secondary combustion gases therein.

19. The system of claim 16, further comprising an air exchange module connected to the biomass ingestion port and having a first interface through which secondary combustion air and new biomass pass, a second interface disposed approximately 90 degrees relative to the biomass ingestion port through which additional secondary combustion air flows.

20. The system of claim 19, wherein during nominal operation of the system the air exchange module facilitates delivery of the secondary combustion air from the first interface with the additional secondary combustion air of the second interface and the new biomass to the biomass ingestion port.

Images