Modular Char and Biochar Combustion System
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Solution Overview
Problem
Current combustion and pyrolysis systems for vegetative materials and biomass face challenges such as high transportation costs, inefficient combustion due to inadequate air supply, lack of automated ignition, and cumbersome ash and char removal, leading to incomplete carbon release into the atmosphere.
Innovation Solution
A combustion/pyrolysis system with a dual air supply mechanism, including a preheated second source of combustion air and a perforated grate for periodic discharge of char and biochar, along with a char collection bin for cooling and quenching, to enhance combustion efficiency and prevent complete carbon release.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional fireboxes or fire pits are used for burning vegetative material, then combustion can be achieved, but transportation costs are high and relocation is cumbersome requiring cranes or specialized trailers
Solution Approach 1:
The combustion system is divided into separate modular components: a combustion chamber assembly and a char collection bin assembly. These modules can be independently handled and reconfigured, eliminating the need for heavy cranes or specialized trailers during relocation. The segmented design allows each component to be moved and assembled at the new location using standard equipment.
Solution Approach 2:
The system incorporates movable and reconfigurable elements including removable grates, adjustable air supply mechanisms, and detachable connections between modules. This dynamic design enables easy assembly and disassembly during relocation, transforming a static heavy structure into a flexible modular system that can be quickly repositioned.
2Productivity
If conventional fireboxes are used, then burning can occur, but adequate combustion air supply to the lower portion of the combustion chamber is insufficient leading to inefficient combustion
Solution Approach 1:
The air supply system is segmented into multiple independent sources: a primary air supply for the upper combustion zone and a secondary air supply specifically targeted at the lower combustion chamber. This segmented approach ensures adequate oxygen delivery to all combustion zones, preventing incomplete combustion and improving overall efficiency.
Solution Approach 2:
A perforated grate serves as an intermediary structure that facilitates air distribution. The grate allows secondary combustion air to pass through to the fuel bed below while supporting the burning material above, enabling efficient combustion in the lower chamber region that would otherwise be starved of oxygen.
3Quantity of substance
If material is completely burnt in conventional systems, then energy release is maximized, but carbon is released into the atmosphere and char/biochar production is lost
Solution Approach 1:
The system extracts char and biochar from the combustion process by providing a dedicated collection bin positioned to receive falling char particles. This extraction prevents complete combustion of the carbon-containing material, allowing the char to be collected and removed from the system before it would otherwise be completely burned and released as CO2.
Solution Approach 2:
Instead of allowing complete combustion, the system discards unburnt char particles into a collection bin where they are recovered and preserved. This recovered char can be used as a valuable product (biochar for soil amendment, fuel, or carbon sequestration) rather than being lost to atmospheric release, transforming a waste product into a recoverable resource.
4Ease of operation
If conventional systems are used, then combustion occurs, but automated removal of char, ash, and debris is lacking making removal dirty and time-consuming
Solution Approach 1:
The system performs self-service regarding char and ash removal through gravity-assisted discharge. The combustion chamber is positioned above the collection bin with a removable grate, allowing char and debris to automatically fall into the bin during operation. This eliminates the need for manual scraping or cleaning, as the system self-manages the separation and collection of combustion residues.
Solution Approach 2:
The system adds a vertical dimension to the combustion process by positioning the collection bin beneath the combustion chamber. This dimensional arrangement allows char and ash to naturally fall downward into the bin during combustion, enabling passive, automated removal without requiring lateral access or manual intervention for cleaning.
5Ease of operation
If automated ignition systems are added to conventional burners, then ignition convenience is improved, but system complexity and cost increase
Solution Approach 1:
The system achieves self-service ignition through the natural combustion process. Fuel is fed onto the combustion chamber where it self-ignites through contact with already-burning material or external ignition sources. The design eliminates complex automated ignition systems by relying on the inherent properties of the combustion process and simple mechanical fuel feeding mechanisms.
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 system enables efficient combustion and pyrolysis of various materials into char and biochar, reducing transportation costs and maintaining carbon content for subsequent use, while allowing for continuous operation without supplemental fuels and easy relocation.
Implementation Method 1
a first blower (58) which generates a first source of combustion air to assist with forming an air curtain
Implementation Method 2
a second blower (62) which generates a second source of combustion air to assist with combustion/pyrolysis of the feed material
Implementation Method 3
combustion/pyrolysis system for generating at least one of char and biochar
Implementation Method 4
designed to quench accumulated char and biochar
Data Source
AI summary
A combustion/pyrolization system for generating at least one of char and biochar comprising an upper base frame supporting a combustion/pyrolization housing, and the combustion/pyrolization housing having both an open top end and an open bottom end. A char collection bin defining a collection chamber therein and a perforated grate normally covering the open top end of the char collection bin. The perforated grate being sized so as to permit desired sized char and/or biochar to pass therethrough into the collection chamber. The open bottom end of the combustion/pyrolization housing of the upper base frame is movable into an engaged position where the combustion/pyrolization housing partially receives and surrounds the perforated grate and defines a combustion/pyrolization chamber for receiving and consuming feed material. The upper base frame is movable out of engagement with the perforated grate to facilitate movement of the perforated grate and removal of the generated char and/or biochar.