Horizontal Shaker Biochar Grate for Firebox Retrofit

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing biomass conversion systems to biochar are complex, require multiple actuators for vertical shaker mechanisms, and lack a solution for retrofitting existing fireboxes to produce transportable biochar pieces.

Innovation Solution

A biochar apparatus comprising a firebox, a table with horizontal shaker mechanism, and a conveyor system that allows for cyclic movement of the table to discharge biochar pieces, which can be quenched and cooled in a quenching reservoir pan, and a module for retrofitting existing fireboxes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If a vertical shaker mechanism with multiple actuators is used to move the grate, then biochar can be discharged through openings in the grate, but the device complexity increases and the risk of blockage increases

Engineering Contradiction:

Improvebiochar discharge efficiencyVSAvoidnumber of actuators and control systems

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The grate is divided into multiple sections that can be independently shaken horizontally. Each section has its own shaking mechanism, allowing biochar to be discharged through openings in each section separately, reducing the need for multiple vertical actuators and simplifying the overall control system.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Instead of using a vertical shaker mechanism that moves the entire grate up and down, the invention uses a horizontal shaking mechanism that moves individual grate sections side-to-side. This inversion of the shaking direction reduces complexity and eliminates the need for synchronized control of multiple vertical actuators.

Inventive Principle:

Principle #13The other way round (Inversion)

2Extent of automation

If a vertical shaker mechanism with synchronized extruder and conveyor system is used, then automated biochar production is achieved, but the control system complexity increases

Engineering Contradiction:

Improveautomated biochar productionVSAvoidcontrol system synchronization requirements

Core Design Contradiction:

Extent of automationVSDevice complexity

Solution Approach 1:

The horizontal shaking mechanism automatically discharges biochar through gravity as sections oscillate, eliminating the need for complex synchronized control between extruders and conveyor systems. The system self-regulates biochar flow through the shaking motion and gravitational discharge.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The grate sections undergo periodic horizontal oscillation that naturally controls the timing and rate of biochar discharge. This periodic motion replaces complex automated control systems, as the rhythm of shaking inherently regulates the flow of biochar to the collection area.

Inventive Principle:

Principle #19Periodic action

3Adaptability or versatility

If existing fireboxes are not retrofitted with biochar production capabilities, then simple burning operation is maintained, but biochar cannot be produced for agricultural use

Engineering Contradiction:

Improvefirebox functionalityVSAvoidretrofitting complexity

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The horizontal shaker mechanism and grate system are designed to be universally applicable to existing fireboxes. The same mechanism can operate in both burn modes (complete combustion for heat and incomplete combustion for biochar production), allowing existing fireboxes to gain biochar production capability without requiring fundamentally different equipment.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The firebox operation can dynamically switch between complete combustion mode and incomplete combustion mode for biochar production. The horizontal shaking mechanism adapts to both modes, allowing the firebox to serve multiple functions depending on operational requirements without permanent modification.

Inventive Principle:

Principle #15Dynamics

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The apparatus simplifies the production of biochar by using a horizontal shaker mechanism and conveyor system, reducing complexity and the risk of blockages, while enabling the production of transportable biochar pieces for agricultural and other uses.

Implementation Method 1

cyclically move the table in a horizontal plane relative to the firebox, and the table includes a plurality of openings through which pieces of biochar pass to the conveyor system

Methodology Applied

Scientific EffectGravity: Gravitation

Implementation Method 2

conveyor system under the table having a discharge end... The conveyor system is operable to convey the pieces of biochar

Methodology Applied

Scientific EffectFriction: Friction

Implementation Method 3

a quenching reservoir pan adjacent the discharge end of the conveyor system for containing a quenching liquid

Methodology Applied

Scientific EffectHeat transfer: Heat Exchanger

Data Source

PatentUS12292191B2Biochar apparatus and process

Publication Date: 2025.05.06 AIR BURNERS

AI summary

A biochar apparatus and a related biochar module may have a horizontal table-shaking mechanism and a tapered channel for causing biochar pieces generated in a firebox to fall through openings in the table to a conveyor system below. The table may be configured with replaceable grate panels. A quenching reservoir pan for holding quenching liquid receives a drainage basket at a discharge end of the conveyor system for quenching hot pieces of biochar and allowing easy retrieval of the quenched pieces.