CarbonZero Biochar Reactor
We have designed a larger capacity horizontal bed kiln that will a) produce biochar from nearly any feedstock b) condense wood vinegar from the raw syngas stream, c) crack and filter the raw syngas remaining after the condensation step to produce a clean mixture of hydrogen and carbon monoxide, known as syngas, and d) optionally burn the syngas to generate electricity. Syngas can also be used as a replacement for natural gas or propane for heating purposes.
The horizontal bed kiln has excellent heat distribution characteristics; the feedstock is spread out in a thin layer and passes through the kiln on a conveyor, heated from both sides by hot, oxygen free gas. Mechanically, it is very reliable, since there are no bearings in the hot zones of the device, a minimum of simple moving parts, and the evolving tars have plenty of open, uniformly heated space to escape from the feedstock bed. For its capacity, it is also relatively inexpensive to manufacture, and its modular design allows for a variety of capacities and capabilities.
We would develop the plant to your specifications in stages, which would include planning and modification of the manufacturing drawings, manufacture, testing, any modifications you would require that testing indicates, possible retesting if needed, and final installation and commissioning if testing is carried out in another location.
The challenge we are attempting to address with this system is to maximize the potential for profitability, in particular by monetizing the gas stream in the most economical way possible. In this regard, we have developed a very inexpensive catalyst to crack the syngas for this device. Under favorable conditions, the revenue from the combined products of biochar, wood vinegar and electricity could recoup the capital investment cost for this unit in as little as 6 months of operation.
This biochar kiln is manufactured in a modular fashion, in 3 main sections, and its throughput capacity can be easily increased by adding units to the mid-section to make it longer. Its functional capacity can be enhanced by adding sections to fractionate the condensate yield, producing essential oils or chemicals like terpenes for instance. A section can also be added to the end to convert the char to activated char. The feedstock stream required for the lowest capacity unit would be about 16 tonnes of wood chip (@ 20% moisture content) per day. The unit is intended to run 24/7. Once started, this kiln is self-sufficient in terms of energy. Startup is accomplished with either natural or bottled gas. See the attached file "HorizontalBedReactor.pdf", which describes the horizontal bed reactor and its possible end-products in detail.
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