Description:FIELD OF INVENTION
[0001] The present invention pertains to systems and processes for producing activated biochar, and more specifically to a biochar production system and method that utilizes a modified gasifier to process bamboo biomass for producing biochar, followed by a steam activation step to enhance its quality. This method also enables the generation of syngas for electricity production and incorporates energy conservation measures to improve overall process efficiency and sustainability.
BACKGROUND OF THE INVENTION
[0002] Biochar production has emerged as a significant technology for carbon sequestration, soil enhancement, and sustainable waste management. Traditional biochar production methods typically employ pyrolysis processes that thermally decompose organic biomass in oxygen-limited environments to produce a carbon-rich solid product. These conventional systems have found applications in agriculture as soil amendments, in environmental remediation for contaminant adsorption, and as a means of carbon storage to mitigate climate change impacts.
[0003] Gasification is a thermochemical process in which biomass undergoes partial oxidation at elevated temperatures within a controlled atmospheric environment. This process converts the organic material into synthesis gas (syngas), comprising carbon monoxide, hydrogen, methane, nitrogen, and carbon dioxide, which can be harnessed for electricity generation and other energy applications. Consequently, gasification serves as an efficient method for integrated biochar and energy production systems.
[0004] Steam activation, by contrast, is a post-treatment process applied to biochar following its initial production. During this procedure, biochar is exposed to steam at high temperatures, facilitating the development of a highly porous structure and increasing the specific surface area. These modifications enhance the adsorption capacity and reactive surface properties of the biochar, rendering it more effective for environmental and industrial applications.
[0005] Conventional biochar production methods, particularly those based on pyrolysis, face several limitations that hinder their broader adoption and operational efficiency. Pyrolysis systems generally require significant external energy inputs and lack integrated mechanisms for recovering and utilizing this energy, resulting in suboptimal overall efficiency. During pyrolysis, there are multiple by-products with no established applications and become a source of liquid emissions. Even the gas emissions are outside the prescribed limits. Furthermore, these systems often produce biochar with variable properties due to process constraints and feedstock variability, which affects performance consistency. Their limited compatibility with local energy infrastructures poses additional challenges, especially in rural or off-grid regions where reliable electricity access is scarce. Moreover, valuable syngas (only by product) generated as a by-product in such processes is frequently underutilized, representing a lost opportunity for enhancing energy recovery and improving the sustainability of the system.
[0006] Patent document EA-034502-B1 describes a method for producing granulated biofuel and synthesis gas with low tar content from biomass waste. The system utilizes low-temperature pyrolysis followed by high-temperature treatment within a biochar bed to convert gaseous intermediates into synthesis gas. However, this approach relies on external heating for the secondary reactor, leading to poor energy efficiency, and the fluidized bed configuration is prone to gas bypass, which further reduces conversion performance.
[0007] Another patent application, EA038366B1, discloses a woody biomass cogeneration plant designed for the continuous production of heat and electricity. The system integrates components for biomass preparation, gasification, and energy generation, along with on-board drying and briquetting capabilities. However, this system is primarily tailored for woody biomass and does not address bamboo as a feedstock. This system focuses only on power generation with minimal biochar production. More importantly, it lacks the incorporation of steam activation processes aimed at enhancing the properties of biochar, thereby limiting its suitability for producing high-quality activated biochar.
[0008] Keeping in view the challenges associated with the state of art, there is a need for an integrated biochar production system that combines modified gasification with steam activation for bamboo biomass processing. Such a system would provide enhanced energy efficiency through syngas utilization for electricity generation while producing high-quality activated biochar with controlled surface characteristics and functional properties.
OBJECTIVE OF THE PRESENT INVENTION
[0009] The primary objective of the present invention is to provide an integrated activated biochar production system in which bamboo biomass is first processed in a modified gasifier to produce biochar, followed by a steam activation step to enhance its quality. The system simultaneously generates syngas for electricity production and incorporates energy-efficient practices to maximize overall process efficiency and sustainability
[0010] Another objective of the present invention is to develop a self-sustaining activated biochar production process that utilizes the syngas generated during gasification for on-site energy generation, thereby eliminating the need for external energy inputs and creating surplus energy, which further enhances overall system efficiency.
[0011] Another objective of the present invention is to provide controlled gasification parameters including temperature, residence time, and air flow regulation to optimize biochar yield and quality characteristics such as surface area, porosity, and functional group composition.
[0012] Another objective of the present invention is to implement steam activation processes that enhance the surface characteristics of gasifier-produced biochar, creating micro- and mesoporous structures with increased adsorption capacity suitable for environmental and agricultural applications.
[0013] Another objective of the present invention is to maximize energy recovery from the activated biochar production process through comprehensive syngas utilization, waste heat recovery, and integrated electricity generation capabilities.
[0014] Another objective of the present invention is to provide a bamboo-specific biochar production system that optimizes the thermochemical conversion parameters for lignocellulosic bamboo feedstock to achieve consistent and reproducible biochar quality.
[0015] Yet another objective of the present invention is to establish an environmentally sustainable biochar production process that incorporates emission control, energy conservation measures, produces surplus energy, and generates value-added activated biochar products for various industrial and agricultural applications.
[0016] Other objectives and advantages of the present invention will become apparent from the following description taken in connection with the accompanying drawings, wherein, by way of illustration and example, the aspects of the present invention are disclosed.
SUMMARY OF THE INVENTION
[0017] The present disclosure provides a biochar production system comprising the following components:
• Biochar processing section: a biomass input means, a gasifier unit for processing bamboo biomass, a sieving system, a steam activation means including rotary activation capabilities, de-stoning equipment, pulverizing means, a vibro-sieving unit, and a blending and packing unit.
• Energy generation section: syngas generation capability, a gas cleaning system with multiple cyclone stages, a waste heat recovery boiler, and electricity generation means, including a gas generator.
[0018] The system is configured to produce activated biochar and syngas, while generating surplus energy through electricity production by utilizing the syngas composition for on-site energy generation. It operates under controlled thermochemical conditions to maintain an oxygen-limited environment at specific temperatures and residence times.
[0019] The present invention also relates to a method for producing activated biochar and surplus energy from bamboo biomass, comprising the steps of processing the bamboo biomass in a gasifier unit, wherein air flow is regulated; separating the products of the gasification process into biochar and syngas streams; sieving the biochar obtained from the gasifier; performing steam activation on the sieved biochar using rotary activation units; conducting de-stoning operations on the activated biochar ; pulverizing the activated biochar ; vibro-sieving the pulverized activated biochar ; cleaning the syngas obtained from the gasifier through multiple cyclone stages; recovering waste heat, including transferring heat for preheating water; converting the cleaned syngas into electricity using gas generators.
[0020] The method is configured to enhance energy efficiency by capturing and utilizing the syngas generated during gasification, thereby eliminating external energy requirements and making the process self-sustaining. The integrated system provides high-quality activated biochar and surplus energy, offering a sustainable and efficient solution particularly suitable for rural and off-grid applications.
BRIEF DESCRIPTION OF FIGURES
[0021] The present invention will be better understood after reading the following detailed description of the presently preferred aspects thereof with reference to the appended drawings, in which the features, other aspects and advantages of certain exemplary embodiments of the invention will be more apparent from the accompanying drawing in which:
[0022] Figure 1 illustrates a flowchart of a biochar production and syngas generation system.
DETAILED DESCRIPTION
[0023] The following description describes various features and functions of the disclosed system. The illustrative aspects described herein are not meant to be limiting. It may be readily understood that certain aspects of the disclosed system can be arranged and combined in a wide variety of different configurations, all of which have not been contemplated herein.
[0024] Accordingly, those of ordinary skill in the art will recognize that various changes and modifications of the embodiments described herein can be made without departing from the scope of invention. In addition, descriptions of well-known functions and constructions are omitted for clarity and conciseness.
[0025] Features that are described and/or illustrated with respect to one embodiment may be used in the same way or in a similar way in one or more other embodiments and/or in combination with or instead of the features of the other embodiments.
[0026] The terms and words used in the following description are not limited to the bibliographical meanings, but, are merely used to enable a clear and consistent understanding of the invention. Accordingly, it should be apparent to those skilled in the art that the following description of exemplary embodiments of the present invention are provided for illustrative purposes only and not for the purpose of limiting the invention.
[0027] It is to be understood that the singular forms “a”, “an” and “the” include plural referents unless the context clearly dictates otherwise.
[0028] It should be emphasized that the term “comprises/comprising” when used in this specification is taken to specify the presence of stated features, steps or components but does not preclude the presence or addition of one or more other features, steps, components or groups thereof. The equations used in the specification are only for computation purpose.
[0029] Accordingly, the present invention relates to the field of activated biochar production and energy generation systems, specifically addressing the conversion of biomass materials into valuable activated biochar products while simultaneously generating renewable energy. The invention encompasses a comprehensive system that first gasifies bamboo and other biomass feedstock materials to produce biochar and syngas, and thereafter subjects the separated biochar to a steam activation process. This integrated approach enables the production of high-quality activated biochar and the generation of renewable energy, thereby improving process efficiency and sustainability.
[0030] The present invention provides a solution for sustainable waste management and renewable energy production by utilizing biomass materials that would otherwise be discarded or underutilized. The system addresses the growing demand for activated carbon products in various industrial applications while providing an environmentally friendly approach to biomass processing. The integrated approach combines biochar production with syngas generation, enabling energy recovery and self-sustaining operation of the production facility.
[0031] The invention encompasses both apparatus and method aspects for processing biomass materials through controlled thermochemical conversion processes. The system incorporates multiple processing stages including biomass preparation, gasification, steam activation, product separation, and energy recovery to maximize the utilization of input materials and minimize waste generation. The integrated design allows for continuous operation and scalable production to meet varying market demands for activated biochar products.
[0032] The present invention provides flexibility in processing different types of biomass feedstock materials and produces biochar products with varying characteristics suitable for diverse end-use applications. The system design incorporates energy recovery mechanisms that enhance the overall economic viability of the activated biochar production process while reducing the environmental impact associated with traditional biomass disposal methods, such as open burning or pyrolysis processes, where energy recovery is limited or unutilized.
[0033] In an embodiment, as shown in Figure 1, the biochar production system (100) comprises multiple interconnected components that work together to process bamboo biomass and generate both biochar products and renewable energy. The system (100) provides an integrated approach for biomass conversion while recovering energy from the process gases.
[0034] (a) A biomass input means (102) feeds bamboo material to the gasifier unit (104), where the biomass input means (102) receives raw bamboo feedstock and prepares the material for processing. The biomass input means (102) includes a storage system for holding raw bamboo materials before processing and incorporates a feeding mechanism that regulates the flow rate of bamboo material into the gasification system. The biomass input means (102) accommodates various forms of bamboo including culms, branches, and processing residues while maintaining consistent feed rates to the gasifier unit (104). The biomass input means (102) connects to a chipper (106) that reduces the bamboo material into smaller, uniform pieces suitable for gasification. The chipper (106) processes the bamboo into chips with dimensions ranging from 10 to 50 millimeters to facilitate uniform heat transfer during gasification. The chipper (106) connects to a dryer (108) that removes moisture content from the chipped bamboo material using hot air supplied from a hot air from exhaust of gas generator (110). The dryer (108) reduces moisture levels from initial values of 40% to 60% down to target levels of 10% to 20% by weight to optimize gasification efficiency and product quality. The system includes de-stoning equipment to remove impurities and foreign materials from the bamboo feedstock before processing. The dryer connects to a chimney with cyclone for ash collection from the drying process.
[0035] (b) A gasifier unit (104) configured for processing bamboo biomass to produce biochar and syngas receives the dried bamboo material from the dryer (108). The gasifier unit (104) operates under controlled thermochemical conditions with air flow regulation including pre-heating air systems to maintain an oxygen-limited environment at a maximum temperature of 600°C to 700°C with a residence time of approximately 30 to 60 minutes to convert the bamboo feedstock into biochar and combustible gases. The gasifier unit (104) is specifically calibrated for bamboo feedstock to optimize thermal conversion parameters for consistent and reproducible biochar quality while simultaneously generating syngas comprising carbon monoxide, hydrogen, methane, nitrogen, and carbon dioxide. The controlled oxidation via air-flow regulation helps minimize oxidation, limit biochar loss, maintain high fixed carbon content, reduce control ash content, and retain syngas generation capability for in-situ energy recovery. The gasifier unit (104) connects to a sieving system (112) that separates the produced powdered biochar (c) The hot air generator (110) powered by syngas with alternate fuel for initial ignition as LPG or diesel supplies hot air to the dryer (108). The hot air generator (110) utilizes syngas produced during the gasification/activation process as the primary fuel source, with LPG or diesel serving as backup fuel for system startup and ignition purposes, as shown in Figure 1. The hot air generator (110) heat air at temperatures ranging from 250°C to 300°C that provides efficient drying capability while preventing thermal degradation of the bamboo material. The hot air generator (110) achieves thermal efficiency exceeding 80% through optimized combustion chamber design and heat transfer surfaces that maximize energy recovery from the fuel gases.
[0036] (d) The sieving system (112) for separating powdered biochar from crystal biochar receives the biochar input from the gasifier unit (104). The sieving system (112) classifies the biochar based on particle size and connects to storage units for temporary holding of the separated biochar fractions. The sieving system (112) directs the crystal biochar to a steam activation means (114) for further processing. The sieving system (112) incorporates mechanical screening technology that efficiently separates the biochar particles based on predetermined mesh sizes. The sieving system (112) utilizes vibrating screens with that enable separation of biochar into fine powder, crystal particles. The sieving system (112) includes automated material handling mechanisms that transport the separated biochar fractions to appropriate storage containers or processing units while minimizing material loss and dust generation. (e) A steam activation means (114) activating the biochar produced in the gasifier unit (104) receives the crystal biochar from the sieving system (112). The steam activation means (114) enhances the surface area and porosity of the biochar through controlled steam treatment at elevated temperatures of 800°C to 900°C for 20 to 30 minutes with a heating rate of 10°C to 20°C per minute. The steam activation means (114) utilizes steam as a physical activating agent to create micro- and mesoporous structures within the biochar, significantly increasing surface area and pore volume while forming oxygen-containing functional groups on the biochar surface. This activation process is critical for enhancing adsorption capacity, catalytic activity, and overall functionality of the biochar for environmental and agricultural applications. The rotary/activation unit operates with diesel supply for initial startup ignition for heating and steam input for the activation process, ensuring uniform treatment of biochar particles through continuous rotation and mixing during the activation process. The activated biochar is produced as activated lumps that proceed to storage before further processing.
[0037] (f) The pulverizing means (116) for pulverizing the granular activated biochar to powder activated charcoal receives the granular activated biochar from storage after the rotary/activation unit (114). The granular activated biochar first undergo de-stoning operations to reduce ash before entering the pulverisor. The pulverisor (116) reduces the activated biochar crystals into fine powder form through mechanical size reduction processes that achieve desired particle size distributions for specific end-use applications. The pulverizing means (116) operates with variable grinding intensity to produce different particle size ranges from coarse granular material with particle sizes exceeding 1 millimeter to fine powder with particle sizes below 100 micrometers. The pulverizing process includes pulverizer equipment specifically designed for processing activated carbon materials while preserving their surface characteristics and porosity.
[0038] (g) A vibro-sieving unit (118) for segregating larger pieces of pulverized activated biochar receives the pulverized material from the pulverizing means (116). The vibro-sieving unit (118) separates oversized particles from the desired powder fraction and provides particle size classification capability through controlled sieving operations. The vibro-sieving unit (118) utilizes screens with mesh sizes ranging from 20 mesh to 400 mesh that correspond to particle size separations from 850 micrometers down to 38 micrometers. The vibration frequency parameter ranges from 1000 vibrations per minute to 3000 vibrations per minute, while the vibration amplitude parameter ranges from 1 millimeter to 10 millimeters.
[0039] (h) The blending and packing unit (120) for packaging the powdered activated charcoal receives the sized activated charcoal powder from the vibro-sieving unit (118). The blending and packing unit (120) homogenizes the product and packages the powdered activated charcoal for distribution and storage. The blending and packing unit (120) incorporates mixing equipment that ensures uniform product characteristics throughout the packaged material and includes automated weighing systems that ensure accurate product quantities in each package according to market requirements.
[0040] (i) A syngas generation capability (122) with both the pyro gasifier unit (104) and rotary/activation unit (114) for generating syngas comprising carbon monoxide, hydrogen, methane, nitrogen, and carbon dioxide from the bamboo biomass, which produces combustible gases during the gasification and activation processes. The syngas generation capability (122) operates from gasifier under the same controlled thermochemical conditions as the gasifier unit (123) that collects and directs the syngas to downstream processing equipment. Syngas flows to the gas cleaning system (124) that purifies the produced gases before utilization for on-site energy production, making the process self-sustaining while producing high-quality activated biochar and creating surplus energy through electricity generation from syngas without any other by-products.
[0041] (j) The gas cleaning system (124) including cyclones and scrubbers for purifying the syngas before electricity generation receives the raw syngas from the syngas generation capability (122). The gas cleaning system (124) removes particulates, tar compounds, and other impurities from the syngas stream through multiple stages of purification. The cyclones utilize centrifugal force to separate solid particles from the gas stream with ash collection points, while the scrubbers employ liquid contact methods to remove soluble contaminants and remaining particulates. The system includes a secondary scrubber followed by a primary scrubber, then a course filter and fine filter in sequence to ensure comprehensive contaminant removal for downstream applications. The gas cleaning system incorporates cyclone for enhanced particulate removal and includes specialized tar removal equipment to ensure high-quality syngas for electricity generation. Each stage includes ash collection points for proper waste management throughout the purification process.
[0042] (k) A waste heat recovery boiler (126) configured to recover heat from the syngas receives the syngas from the activation kiln (114). The waste heat recovery boiler (126) captures thermal energy from the hot syngas stream and generates steam. The waste heat recovery boiler (126) enhances overall system efficiency by capturing energy that would otherwise be lost through exhaust gases, thereby reducing the external energy requirements for activayed biochar production operations. The waste heat recovery system includes preheating water (heat transfer) capabilities that utilize recovered thermal energy for multiple process applications including steam generation for the activation process and hot water production for system operations. The preheating water system connects with hot air distribution for enhanced heat utilization throughout the process.
[0043] (l) An electricity generation means (128) for converting the syngas to electricity receives the cleaned and heat-recovered syngas from the gas cleaning system (124). The electricity generation means (128) is configured to utilize the syngas composition comprising carbon monoxide, hydrogen, methane, nitrogen, and carbon dioxide for on-site energy production. The electricity generation means (128) combusts the syngas in engines or turbines to produce electrical power for system operation and external supply, with the system configured to produce surplus energy through electricity generation from clean syngas. The electricity generation means (128) includes control systems for operational safety and flexibility, allowing for controlled shutdown and startup operations as required for system maintenance and safety management. The exhaust gas discharge (high temperature exceeding 400 degree) from gas generator is used for various heating applications. The surplus exhaust gas connects to chimney for exhaust gas discharge.
[0044] In an exemplary embodiment, the activated biochar production system provides a configuration for producing surplus energy through electricity generation from syngas without generating other by-products. The system operates in a mode where the primary focus shifts to maximizing energy output while maintaining activated biochar production as the main product stream. The syngas generated during the gasification process and steam activation process serves as the sole feedstock for electricity generation and other heating requirements, eliminating the need for additional fuel sources or supplementary materials and enhancing the efficiency of the complete system.
[0045] In an exemplary embodiment, the syngas composition comprises carbon monoxide, hydrogen, methane, nitrogen, and carbon dioxide in varying proportions depending on the gasification conditions and bamboo feedstock characteristics. The electricity generation means utilizes this syngas composition for on-site energy production through controlled combustion processes that convert the chemical energy stored in the gas components into electrical energy.
[0046] In an exemplary embodiment, the activated biochar production system provides a self-sustaining configuration that achieves energy independence through comprehensive energy recovery from syngas utilization while generating surplus power for external applications. The self-sustaining system configuration operates by capturing and converting all available energy from the syngas stream into useful forms including thermal energy, mechanical energy, and electrical energy that meet the complete energy requirements of the biochar production process.
[0047] In an embodiment, Figure 1, illustrates a flowchart of a biochar production and syngas generation system. The bamboo material first enters a chipper for size reduction to uniform pieces (10-50 mm), then proceeds to storage. From storage, the material follows the main processing path where the chipped bamboo enters a dryer that utilizes hot air supplied from exhaust of air generator powered by LPG/diesel (for initial iginition purpose only) as alternate fuel for initial ignition. The hot air generator produces heated air at 80-120°C to reduce moisture content from 40-60% to 10-20% by weight. After drying, the material undergoes sieving and moves to storage. The system includes a chimney with cyclone for ash collection from the drying process. The prepared bamboo then enters the pyro gasifier which operates under controlled thermochemical conditions at 600-700°C with 30-60 minutes residence time and regulated air flow including pre-heating air systems to maintain an oxygen-limited environment. This gasification process simultaneously produces biochar and syngas (comprising CO, H₂, CH₄, and CO₂). The biochar output undergoes sieving to separate powdered biochar from crystal biochar, with the crystal fraction directed to a rotary/activation unit supplied with diesel (for initial iginition purpose only) and steam operating at 800-900°C for 20-30 minutes with a heating rate of 10-20°C per minute. This activation process enhances surface area and porosity by creating micro- and mesoporous structures, producing activated lumps that proceed to storage. The activated biochar crystals then undergo de-stoning operations to remove/reduce ash before entering the pulverisor to reduce particle size, followed by vibro-sieving to achieve precise particle classification. The final powdered activated charcoal moves to blending and packing for distribution. Meanwhile, the syngas stream from both the gasifier and rotary/activation unit passes through a chamber, then flows through a waste heat recovery boiler that captures thermal energy followed preheating water (heat transfer) capabilities with hot air connections for process heating requirements. The syngas then undergoes multiple cleaning stages including cyclones for particulate removal with ash collection points, followed by a secondary scrubber, primary scrubber, course filter, and fine filter for comprehensive purification. The cleaned syngas flows to a gas generator that converts the gas to electrical power for system operation and surplus energy production, with control systems for operational safety and flexibility. The integrated system incorporates multiple ash collection points throughout the process, heat recovery mechanisms, and multiple storage stages to ensure efficient material flow and energy utilization throughout the process.
[0048] In an exemplary embodiment, as shown in Figure 1, the present invention also relates to a method for activated biochar production using modified gasifier and steam activation. The method comprises the following steps:
[0049] (a) preparing bamboo biomass by chipping the bamboo material into uniform pieces suitable for gasification processing, where the chipping process reduces raw bamboo feedstock into controlled dimensions that facilitate uniform heat transfer during subsequent processing operations;
[0050] (b) drying the chipped bamboo material using hot air supplied from exhaust of gas generator or a hot air generator to remove moisture content from the bamboo chips, where the drying process reduces moisture levels from initial values of 30% to 50% down to target levels of 10% to 20% by weight through controlled temperature exposure, and includes preheating air systems to improve thermal efficiency;
[0051] (c) feeding the dried bamboo material to a gasifier unit through biomass input means that regulate the flow rate of feedstock material into the gasification chamber while maintaining controlled processing conditions;
[0052] (d) processing the bamboo biomass in the gasifier unit under controlled thermochemical conditions to produce biochar and syngas, where the processing operates at maximum temperatures of 600°C to 700°C with residence times of approximately 30 to 60 minutes while maintaining air flow regulation to create an oxygen-limited environment;
[0053] (e) generating syngas comprising carbon monoxide, hydrogen, methane, nitrogen, and carbon dioxide during the gasification process through thermochemical conversion reactions that decompose the bamboo material into combustible gas components and solid biochar residue;
[0054] (f) sieving the gasification products to separate powdered biochar from crystal biochar using a sieving system that classifies the biochar output based on particle size characteristics ;
[0055] (g) performing steam activation of the crystal biochar produced during gasification processing using a rotary activation unit, where the steam activation operates at temperatures of 800°C to 900°C for durations of 20 to 30 minutes with heating rates of 10°C to 20°C per minute to enhance surface area and porosity characteristics;
[0056] (g) destoning the granular activated biochar to remove/ reduce its ash content, wherein the methods employed include physical separation techniques such as segregation and elutriation.
[0057] (h) pulverizing the activated biochar to convert crystal forms into powdered activated charcoal through mechanical size reduction processes that achieve desired particle size distributions for specific end-use applications;
[0058] (i) vibro-sieving the pulverized activated biochar to segregate larger pieces from the desired powder fraction before final product preparation, where the vibro-sieving operation utilizes controlled vibration parameters to achieve precise particle size separation;
[0059] (j) blending and packing the powdered activated charcoal for distribution and storage, where the blending process homogenizes the product characteristics while the packing operation prepares the material for commercial applications;
[0060] (k) cleaning the syngas through multiple cyclone separation stages and scrubbing processes to remove particulates, tar compounds, and other impurities from the gas stream before utilization in downstream applications;
[0061] (l) recovering waste heat from the syngas during processing through a waste heat recovery boiler captures thermal energy from hot gas streams and converts the recovered heat into steam. Also use thermal energy of syngas and hot exhaust of gas generator for process heating requirements, including preheating water and air heat transfer applications;
[0062] (m) converting the cleaned syngas to electricity using electricity generation means including a gas generator that combusts the gas mixture in engines, turbines, or fuel cells to produce electrical power for system operation and external supply, with control systems for operational flexibility;
[0063] (n) supplying hot air to the dryer using a hot air generator powered by syngas with alternate fuel sources including LPG or diesel (for initial ignition/startup only), where the hot air generator utilizes the combustible syngas as the primary fuel source while maintaining backup fuel capability for system startup operations;
[0064] (o) producing surplus energy through electricity generation from syngas without generating other by-products, where the method configuration enables conversion of all available syngas into electrical energy through complete combustion processes that eliminate secondary waste materials while maximizing energy recovery from the biomass feedstock.
[0065] In an embodiment, the advantages of the present invention are discussed herein:
• The present invention is to provide operational flexibility by accommodating different biomass feedstock materials including agricultural waste, wood chips, and other organic materials through adjustable processing parameters that optimize conversion efficiency for varying feedstock characteristics.
• The present invention is to incorporate energy recovery mechanisms that achieve self-sustaining operation by utilizing syngas for all thermal and electrical energy requirements while generating surplus power for external applications.
• The biochar production system using modified gasifier and steam activation technology provide numerous advantages that enhance the economic viability, environmental sustainability, and operational efficiency of biomass processing operations.
• The system achieve energy self-sufficiency through comprehensive syngas utilization that eliminates dependency on external energy sources during normal operation. The energy recovery mechanisms capture thermal energy from gasification processes, steam activation operations, and electricity generation systems to provide heating for biomass drying, process steam generation, and facility heating requirements.
• The present invention is to provide dual product output capability that generates both biochar and electrical energy from the same biomass feedstock, maximizing the value extraction from agricultural and forestry waste materials. The electricity generation provides additional revenue streams while contributing to renewable energy production goals and carbon emission reduction targets.
• The present invention is to enhance the surface area and porosity characteristics of biochar products through steam activation process to create activated carbon materials with superior adsorption capacity compared to conventional biochar production methods. The activated biochar products achieve surface areas exceeding 500 to 1000 square meters per gram, enabling high-performance applications in water treatment, air purification, and industrial separation processes.
• The present invention is to provide multi-feedstock processing capability that accommodates diverse biomass materials including bamboo, agricultural waste, wood chips, and other organic materials through adjustable processing parameters that optimize conversion efficiency for different feedstock characteristics.
• The present invention is to provide comprehensive gas cleaning systems that produce high-quality syngas enabling efficient electricity generation while minimizing environmental emissions from combustion processes. The gas purification stages remove tar compounds and particulates that could cause equipment fouling or environmental compliance issues. The clean syngas utilization reduces maintenance requirements for electricity generation equipment while extending service life and improving operational reliability.
• The present invention is to provide waste heat recovery systems that capture thermal energy from multiple process streams to improve overall energy efficiency and reduce environmental heat discharge. The heat recovery mechanisms utilize waste heat for biomass drying, steam generation, and facility heating applications that reduce external energy consumption while improving process economics. The comprehensive heat utilization minimizes thermal pollution and enhances the environmental sustainability of biochar production operations.
• The present invention is to provide continuous or batch operation flexibility that accommodates different production scales and operational preferences while maintaining product quality and system efficiency. The operational flexibility enables optimization of production schedules based on feedstock availability, market demand, and facility constraints while maximizing equipment utilization. The flexible operation modes provide adaptability to changing market conditions and business requirements throughout the operational lifetime of the production facility.
• The present invention is to provide environmental benefits including reduction of agricultural waste burning, greenhouse gas emission reduction through carbon sequestration in biochar products, and renewable energy generation that displaces fossil fuel consumption.
[0066] While this invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not limited to the disclosed embodiments, but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the scope of the appended claims. , Claims:We Claim,
1. A biochar production system (100), comprising:
i) a biomass input means (102) feeding bamboo material to the gasifier unit;
ii) a gasifier unit (104) configured for processing bamboo biomass to produce biochar and syngas;
iii) a sieving system (112) for separating powdered biochar from crystal biochar ;
iv) a steam activation means (114) activating the biochar produced in the gasifier unit;
v) a pulverizing means (116) for pulverizing the activated biochar to powder activated charcoal produced after steam activation of biochar;
vi) a vibro-sieving unit (118) for segregating larger pieces of pulverized activated biochar;
vii) a blending and packing unit (120) for packaging the powdered activated charcoal;
viii) a syngas generation capability (122) integrated with the gasifier unit for generating syngas comprising CO, H₂, CH₄, N2 and CO₂ from the bamboo biomass;
ix) a gas cleaning system (124) including cyclones and scrubbers for purifying the syngas before electricity generation;
x) a waste heat recovery (126) boiler configured to recover heat from the syngas;
xi) an electricity generation means (128) for converting the syngas to electricity; and
xii) a hot air generator (130) powered by syngas with alternate fuel for initial ignition as LPG or diesel for supplying hot air to the dryer;
2. The biochar production system as claimed in claim 1, wherein the system is configured to produce surplus energy through electricity generation from syngas without any other by-products.
3. The biochar production system as claimed in claim 1, wherein the biomass preparation means includes a chipper for chipping the bamboo material into pieces suitable for gasification processing, and a dryer for drying the chipped bamboo material to prepare the feedstock for gasification processing.
4. The biochar production system as claimed in claim 1, wherein a syngas composition comprises carbon monoxide (CO), hydrogen (H₂), methane (CH₄), nitrogen (N₂) and carbon dioxide (CO₂) in varying proportions depending on the gasification conditions and bamboo feedstock characteristics
5. The biochar production system as claimed in claim 1, wherein the steam activation means is configured to operate at 800 - 900°C for 20 - 30 minutes with a heating rate of 10 – 20 °C per minute to enhance surface area and porosity of the biochar;
6. The biochar production system as claimed in claim 1, wherein the gasifier unit is configured to operate under controlled thermochemical conditions with air flow regulation to maintain an oxygen-limited environment at a maximum temperature of 600 – 700 °C with a residence time of approximately 30 -60 minutes;
7. The biochar production system as claimed in claim 1, wherein the system is configured to be self-sustaining along with surplus power generation through energy recovery from syngas utilization.
8. A method of biochar production comprising step of:
a) preparing bamboo biomass by chipping the bamboo material into uniform pieces suitable for gasification processing, where the chipping process reduces raw bamboo feedstock into controlled dimensions that facilitate uniform heat transfer during subsequent processing operations;
b) drying the chipped bamboo material using hot air supplied from exhaust of gas generator or a hot air generator to remove moisture content from the bamboo chips, where the drying process reduces moisture levels from initial values of 30% to 50% down to target levels of 10% to 20% by weight through controlled temperature exposure, and includes preheating air systems to improve thermal efficiency;
c) feeding the dried bamboo material to a gasifier unit through biomass input means that regulate the flow rate of feedstock material into the gasification chamber while maintaining controlled processing conditions;
d) processing the bamboo biomass in the gasifier unit under controlled thermochemical conditions to produce biochar and syngas, where the processing operates at maximum temperatures of 600°C to 700°C with residence times of approximately 30 to 60 minutes while maintaining air flow regulation to create an oxygen-limited environment;
e) generating syngas comprising carbon monoxide, hydrogen, methane, nitrogen, and carbon dioxide during the gasification process through thermochemical conversion reactions that decompose the bamboo material into combustible gas components and solid biochar residue;
f) sieving the gasification products to separate powdered biochar from crystal biochar using a sieving system that classifies the biochar output based on particle size characteristics ;
g) performing steam activation of the crystal biochar produced during gasification processing using a rotary activation unit, where the steam activation operates at temperatures of 800°C to 900°C for durations of 20 to 30 minutes with heating rates of 10°C to 20°C per minute to enhance surface area and porosity characteristics;
h) destoning the granular activated biochar to remove/ reduce its ash content, wherein the methods employed include physical separation techniques such as segregation and elutriation.
i) pulverizing the activated biochar to convert crystal forms into powdered activated charcoal through mechanical size reduction processes that achieve desired particle size distributions for specific end-use applications;
j) vibro-sieving the pulverized activated biochar to segregate larger pieces from the desired powder fraction before final product preparation, where the vibro-sieving operation utilizes controlled vibration parameters to achieve precise particle size separation;
k) blending and packing the powdered activated charcoal for distribution and storage, where the blending process homogenizes the product characteristics while the packing operation prepares the material for commercial applications;
l) cleaning the syngas through multiple cyclone separation stages and scrubbing processes to remove particulates, tar compounds, and other impurities from the gas stream before utilization in downstream applications;
m) recovering waste heat from the syngas during processing through a waste heat recovery boiler captures thermal energy from hot gas streams and converts the recovered heat into steam. Also use thermal energy of syngas and hot exhaust of gas generator for process heating requirements, including preheating water and air heat transfer applications;
n) converting the cleaned syngas to electricity using electricity generation means including a gas generator that combusts the gas mixture in engines, turbines, or fuel cells to produce electrical power for system operation and external supply, with control systems for operational flexibility.