Method & Apparatus for Producing Biochar

Abstract

The present disclosure provides, at least in part, a system for pyrolysis of biomass, the system comprising: (a) a reactor having a retort extending therethrough, said retort comprising a conveyor, an inlet, and an outlet; the reactor further comprising at least one thermosensor, the thermosensor capable of generating a signal when the temperature is above optimal levels; (b) a heating system adapted to heat the reactor; (c) a syn-gas management system; the management system comprising a syn-gas storage tank having an inlet and an outlet, said inlet in fluid communication with the reactor, and said outlet in fluid communication with the heating system and syn-gas outlet such as a flare or storage tank wherein the communication is controlled via a valve configurable between at least a first position where flow is directed to the heating system and a second position where flow is directed to the flare pipe; and (d) a controller in communication with the thermosensor and the valve; wherein the controller switches the valve from the first position to the second position upon receiving a signal from the thermosensor that the temperature in the reactor is above optimal levels.

1 . A system for pyrolysis of biomass, the system comprising:
 a reactor comprising at least one retort extending therethrough, said retorts comprising a conveyor, an inlet, and an outlet; the reactor further comprising at least one thermosensor, the thermosensor capable of generating a signal when the temperature is above a predetermined value;   a heating system adapted to heat the reactor;   a syn-gas management system; the management system comprising a syn-gas storage tank having an inlet and an outlet, said inlet in fluid communication with the reactor, and said outlet in fluid communication with the heating system and a syn-gas outlet wherein the communication is controlled via a valve configurable between a first position where flow is directed to the heating system and a second position where flow is directed to the flare pipe; and   a controller in communication with the thermosensor and the valve;   
       wherein the controller switches the valve from the first position to the second position upon receiving a signal from the thermosensor that the temperature in the reactor is above a predetermined value. 
     
     
         2 . A system for pyrolysis of biomass, the system comprising:
 a reactor having a retort extending therethrough, said retort comprising a conveyor, an inlet, and an outlet; the reactor further comprising at least one thermosensor, the thermosensor capable of generating a signal when the temperature is below a predetermined value;   a heating system adapted to heat the reactor;   a syn-gas management system; the management system comprising a syn-gas storage tank having an inlet and an outlet, said inlet in fluid communication with the reactor, and said outlet in fluid communication with the heating system and a syn-gas outlet wherein the communication is controlled via a valve configurable between at least a first position where flow is directed to the heating system and a second position where flow is directed to the flare pipe; and   a controller in communication with the thermosensor and the valve;   
       wherein the controller switches the valve from the second position to the first position upon receiving a signal from the thermosensor that the temperature in the reactor is below a predetermined value. 
     
     
         3 . The system of  claim 1  or  2  comprising a dryer for drying the biomass prior to entry into the reactor. 
     
     
         4 . The system of  claim 1  or  2  comprising a biochar delivery system for receiving the biochar from the reactor. 
     
     
         5 . The system of  claim 4  wherein the biochar delivery system comprises a cooling zone, a compaction area, with a rotary airlock valve therebetween. 
     
     
         6 . The system of  claim 1  or  2  comprising an additive delivery system for introducing additives to the biochar. 
     
     
         7 . The system of  claim 4 - 6  wherein the additive delivery system is located with the biochar delivery system. 
     
     
         8 . The system of  claim 1  or  2  wherein the controller is a programmable logic controller. 
     
     
         9 . The system of  claim 1  or  2  wherein the controller further controls the speed of the conveyor. 
     
     
         10 . The system of any of  claims 1 - 9  wherein the conveyor is an auger. 
     
     
         11 . A method for converting biomass to biochar, the method comprises the steps of:
 introducing biomass to an interior of a retort in a reactor, the heated reactor;   advancing the biomass through the retort by means of a retort conveyor extending therethrough, the temperature of the retort being elevated to a point where pyrolysis of the biomass occurs;   collecting biochar from the retort; and   applying a additive to the biochar.   
     
     
         12 . The method of  claim 11  wherein the additive is selected from soil nutrients and/or minerals. 
     
     
         13 . The method of  claim 11  wherein the additive is selected from nitrogen, sulphur, magnesium, calcium, phosphorous, potassium, iron, manganese, copper, zinc, boron, chlorine, molybdenum, nickel, cobalt, aluminum, silicon, selenium, sodium, compost tea, humic acids, fulvic acids, plant hormones, pH conditioners, buffers, or combinations thereof. 
     
     
         14 . A modular pyrolysis apparatus, comprising:
 a reactor module comprising at least one retort comprising a conveyor, an inlet, and an outlet; at least one thermosensor; and a heating system adapted to heat the reactor;   a syn-gas management module comprising a syn-gas storage tank, and a valve configurable between at least a first and a second position;   a control module comprising a controller adapted to communicate with the thermosensor and the valve.   
     
     
         15 . The apparatus of  claim 14  wherein a syn-gas management module additionally comprises a condenser and a bio-oil storage tank. 
     
     
         16 . The apparatus of  claim 14  wherein the controller is a programmable logic controller. 
     
     
         17 . The apparatus of  claim 14  wherein the controller further controls the speed of the conveyor.