Process and system for mobile pyrolysis of biomass for biochar production

Abstract

A system and method of biomass pyrolysis for biochar production. A mobile pyrolysis and oxidizer apparatus is moved through a field of biomass. The mobile apparatus includes a first reactor and a second reactor. The first reactor is coupled to the second reactor via a syngas channel. The first reactor is heated to a first temperature, at least in part, using a syngas via the syngas channel. The second reactor is heated to a second temperature, at least in part, using the syngas via the syngas channel. In some modes of operation, wherein the second temperature is a temperature that is a higher temperature than the first temperature. Collected biomass is conveyed as feedstock through the first reactor and then through the second reactor. The feedstock is torrefied via first rector, and a portion of the feedstock is pyrolyzed via the second rector.

What is claimed is: 
     
         1 . A method of biomass pyrolysis for biochar production comprising the operations of:
 maneuvering a mobile pyrolysis and oxidizer apparatus through a field of biomass, the mobile apparatus comprising:   a first reactor, comprising:
 a first reactor chamber; 
 a first plurality of air injectors; and 
 a first reactor burner; 
   a second reactor, comprising:
 a second reactor chamber; 
 a second plurality of air injectors; and 
 a second reactor burner, wherein the first reactor is coupled to the second reactor via a syngas channel; and 
   a quencher comprising:
 a water supply container; and 
 a quencher chamber; 
 heating the first reactor to a first temperature, at least in part, using a syngas via the syngas channel; 
 heating the second reactor to a second temperature, at least in part, using the syngas via the syngas channel, wherein the second temperature is a temperature that is a higher temperature than the first temperature; 
 collecting the biomass as a feedstock and feeding the feedstock into the apparatus; 
 conveying the feedstock through the first reactor chamber; 
 conveying the feedstock through the second reactor chamber; and 
 conveying the feedstock through the quencher chamber, wherein the feedstock material is cooled to a lower temperature than the second temperature. 
   
     
     
         2 . The method of  claim 1 , wherein the first temperature ranges from between 200-400° C., and the second temperature ranges between 500-800° C. 
     
     
         3 . The method of  claim 1 , further comprising:
 wherein the mobile apparatus further comprises a syngas blower;   extracting from the first reactor, via a suction generated by the syngas blower, syngas that was produced in the first reactor; and   inputting the extracted syngas from the first reactor to the second reactor chamber, thereby mixing resident syngas in the second reactor chamber with the extract syngas from the first reactor.   
     
     
         4 . The method of  claim 1 , further comprising:
 gravity feeding the feedstock from the first reactor to the second reactor.   
     
     
         5 . The method of  claim 1 , wherein a portion of the feedstock is torrefied via the heat applied to the feedstock while being conveyed through the first rector chamber, and a portion of the feedstock is pyrolyzed while being conveyed through the second rector chamber. 
     
     
         6 . The method of  claim 1 , further comprising:
 wherein the mobile apparatus further comprises a thermal oxidizer;   extracting from the first reactor and/or the second reactor syngas that has biomass particles;   combusting via the thermal oxidizer the biomass particles in the extracted syngas thereby producing char of the biomass particles;   quenching the char with water; and   disposing to a ground surface the quenched char.   
     
     
         7 . The method of  claim 1 , further comprising the operations of:
 monitoring via one or more temperature sensors, a temperature associated with the first reactor chamber;   providing air or oxygen into the first reactor chamber via the first plurality of air injectors, and increasing the temperature associated with the first reactor chamber;   monitoring via one or more other temperature sensors, a temperature associated with the second reactor chamber; and   providing air or oxygen into the second reactor chamber via the second plurality of air injectors, and increasing the temperature associated with the second reactor chamber.   
     
     
         8 . The method of  claim 1 , further comprising the operations of:
 controlling the first reactor and the second rector in a plurality of stages, where the first temperature and the second temperature are changed according the predetermined parameters for a respective stage.   
     
     
         9 . The method of  claim 8 , wherein a first stage is a preheat stage wherein the first burner and the second burner are activated using an external fuel source; wherein the preheat stage is maintained until the first temperature reaches a first predetermined threshold temperature and the second temperature reaches a predetermined second threshold temperature. 
     
     
         10 . The method of  claim 9 , wherein in another stage, wherein in another stage, the mobile apparatus heats the first reactor chamber and the second reactor chamber via utilizing as a fuel source syngas that was generated by the mobile apparatus. 
     
     
         11 . A system for mobile pyrolysis of biomass for biochar production comprising:
 a mobile pyrolysis and oxidizer apparatus comprising:   a first reactor, comprising:
 a first reactor chamber; 
 a first air injector; and 
 a first reactor burner; and 
   a second reactor, comprising:
 a second reactor chamber; 
 a second air injector; and 
 a second reactor burner; and 
   a quencher comprising:
 a water supply container; and 
 a quencher chamber; 
   wherein the first reactor is coupled to the second reactor via a syngas channel;   wherein the first reactor heats to a first temperature, at least in part, using a syngas via the syngas channel;   wherein the second reactor heats to a second temperature, at least in part, using the syngas via the syngas channel, wherein the second temperature is a temperature that is a higher temperature than the first temperature;   wherein collected biomass is feedstock that is transferred through the first reactor chamber; and   wherein the feedstock is transferred through the second reactor chamber;   wherein feedstock transferred through the quencher chamber is cooled to a lower temperature than the second temperature.   
     
     
         12 . The system of  claim 11 , wherein the first temperature ranges from between 200-400° C., and the second temperature ranges between 500-800° C. 
     
     
         13 . The system of  claim 11 , further comprising:
 a syngas blower, wherein the syngas blower is configured to generate a suction that causes syngas produced in the first reactor to be extracted from the first reactor; and   wherein extracted syngas from the first reactor is input into the second reactor chamber, thereby mixing resident syngas in the second reactor chamber with the extracted syngas from the first reactor.   
     
     
         14 . The system of  claim 11 , the feedstock is output from the first reactor into the second reactor. 
     
     
         15 . The system of  claim 11 , wherein a portion of the feedstock is torrefied via the heat applied to the feedstock while being conveyed through the first rector chamber, and a portion of the feedstock is pyrolyzed while being conveyed through the second rector chamber. 
     
     
         16 . The system of  claim 11 , further wherein the mobile apparatus further comprises a thermal oxidizer that combusts biomass particles in extracted syngas. 
     
     
         17 . The system of  claim 11 , further comprising:
 one or more temperature sensors that monitor a temperature associated with the first reactor chamber, wherein the first plurality of air injectors provide air or oxygen into the first reactor chamber to increase the temperature associated with the first reactor chamber; and   one or more other temperature sensors that monitor a temperature associated with the second reactor chamber, wherein the second plurality of air injectors provide air or oxygen into the second reactor chamber to increase the temperature associated with the second reactor chamber.   
     
     
         18 . The system of  claim 11 , wherein the first reactor and second reactor are operable in a plurality of stages, where the first temperature and the second temperature are changed according to predetermined parameters for a respective stage. 
     
     
         19 . The system of  claim 18 , wherein a first stage is a preheat stage wherein the first burner and the second burner are activated using an external fuel source; wherein the preheat stage is maintained until the first temperature reaches a first predetermined threshold temperature and the second temperature reaches a predetermined second threshold temperature. 
     
     
         20 . The system of  claim 11 , wherein in another stage, wherein in another stage, the mobile apparatus heats the first reactor chamber and the second reactor chamber via utilizing as a fuel source syngas that was generated by the mobile apparatus.