Description:FIELD OF THE INVENTION
The present invention broadly relates to sustainable energy storage material production. More particularly, the present invention relates to an apparatus/system and method for producing biochar hard carbon with bio synthesis gases from agricultural waste (biowaste). Especially, the produced biochar hard carbon (biocarbon) exhibits superior quality to be applied as energy storage materials in rechargeable (sodium ion, lithium ion, etc.) batteries.

BACKGROUND OF THE INVENTION
As the demand for electricity and the use of electric vehicles (EVs) continue to rise, the search for clean and dependable energy sources becomes increasingly crucial. While renewable energy from sources like solar and wind is eco-friendly, it isn't always available when needed, especially during high-demand times or for charging EVs. That's where batteries step in. Lithium-ion batteries, widely used in EVs and grid energy storage, have revolutionized the energy solutions. However, there's a challenge: these batteries rely on lithium, and there are concerns about its scarcity and rising costs. To address this, scientists and engineers are exploring alternatives, like sodium-ion batteries. Sodium is more abundant and affordable than lithium. Yet, making sodium-ion batteries work efficiently, especially the part called the "anode," is a puzzle. Here's where the narrative becomes truly captivating: scientists are delving into the realm of a natural substance known as biochar, meticulously crafting it into a unique form of carbon meticulously tailored for battery applications. Through the gentle alchemy of heating, they mold biochar's structure into an exquisite carbon material ideally suited for batteries. This bespoke carbon innovation finds its purpose in empowering electric vehicles and bolstering the resilience of grid applications, ushering in an era of cleaner and more sustainable energy storage.

Biochar, a carbon-rich material derived from pyrolysis of biomass, serves as an intriguing starting point for the creation of hard carbon: an essential component for advanced energy storage technologies. To harness its potential, biochar undergoes a transformation process known as carbonization. This entails subjecting biochar to elevated temperatures within an oxygen-deprived environment, typically around 500°C to 1200°C. During carbonization, volatile components are driven off, and biochar's structure is refined into a more organized and graphitic carbon form.
Once the transformation is complete, the resulting hard carbon material is milled into a fine powder and processed into the desired electrode form. This may involve mixing it with binders and conductive additives before coating it onto a current collector to create the anode. This journey from biochar to hard carbon represents a sustainable and eco-friendly approach, repurposing a product of biomass pyrolysis to serve the evolving needs of clean and efficient energy storage systems.

Conventionally, the hard carbon is produced using raw materials such as sucrose, glucose, petroleum coke or pitch coke mixed with a thermoplastic binder such as coal tar, petroleum pitch or synthetic resin, which is then heated to around 1200 ?. However, although better than graphite, such hard carbon material suffers from slow insertion kinetics and low volumetric energy density.

On the other hand, in agriculture-based countries like India where huge amount of agricultural waste (such as husk, straw, leaves, shells, woods, fibres, etc.) are discarded or dumped throughout the year. In many places such biowastes are burnt uncontrollably, thus emitting carbon dioxide to the atmosphere causing air pollution. Further, such biowastes are used in many ways to produce bioenergy, biogas, and biochar or biocarbon.

One reference may be made to CN213803653U that discloses a downdraft biomass gasification furnace having a feeding port, an air distribution system, a material stirrer, a gasification reaction chamber, a furnace grate, a gas discharge system, and a biochar discharge system. However, the biochar (carbon enriched ash) produced therefrom cannot be used battery application.

Another reference may be made to CA2777339A1 that discloses an apparatus for producing biocarbon product from bio-based raw stock. The apparatus has a fluidized-bed reactor for producing a biocarbon product and a combustion boiler for producing energy fractions and warm up a heat transfer material, these two being integrated together, and sorting means for the bio-based raw stock in order to sort the bio-based raw stock into a desired and undesired fraction in terms of the production of biocarbon, feeding means for feeding the desired fraction into the fluidized-bed reactor and the undesired fraction into the combustion boiler, means for leading the warmed-up heat transfer material from the combustion boiler to the fluidized-bed reactor, means for separating the heat transfer material from the biocarbon product that has been formed, and means for circulating the heat transfer material back to the combustion boiler for warming up the heat transfer material.

However, all the existing biocarbon/biogas production mechanism have many constructional/operational limitations with respect to their sustainable design, configurational/control complexity, installation, maintenance, and economical feasibility, there exists a need to develop an improved approach, system/apparatus and method/process which would in turn address a variety of issues including, but not limited to, controlled oxidation/reduction/exfoliation of agricultural waste, production of high quality biocarbon with biosynthesis gas, and reducing air pollution in user friendly, cost effective and expedient manner. Moreover, it is desired to develop technically advanced apparatus/system and method for producing biochar hard carbon with biosynthesis gas, which includes all the advantages of the conventional/existing techniques/methodologies and overcomes the deficiencies of such techniques/methodologies.

OBJECT OF THE INVENTION
It is an object of the present invention to overcome deficiencies of conventional approaches used in energy storage (battery) material production.

It is another object of the present invention to produce biochar hard carbon with improved quality using various agricultural waste (biowaste) through a sustainable approach.

It is one more object of the present invention to produce various bio synthesis gases as byproduct in energy efficient and cost-effective manner.

It is a further object of the present invention to devise apparatus/system and method for producing biochar hard carbon with bio synthesis gases.

SUMMARY OF THE INVENTION
In one aspect, the present invention provides an apparatus/system for producing biochar hard carbon with biosynthesis gas product. The apparatus comprises a vertical hollow body, a motorized agitator mounted along central axis of the vertical hollow body; at least two exfoliation enclosures adjacent to peripheral wall of the vertical hollow body; a gas/biochar collection chamber; a water circulating device; and a sensor enabled control unit. The vertical hollow body has an upper part for receiving biowaste, a lower part for releasing intermediary gas/biochar, and a core reactor therebetween for causing oxidation/reduction. An air sealed cover is attached on top of the upper part, and an air/fire injection device is coupled to the core reactor. The lower part of the vertical hollow body is introduced into the gas/biochar collection chamber. Each exfoliation chamber has a bottom provided with biochar exit door, a top provided with a biowaste entry door and a gas outlet, and a peripheral wall provided with at least one heat balancing electrode. The gas/biochar collection chamber has a biochar release door, and gas/steam release channels extended into the bottom of the exfoliation chambers. The water circulating device includes pipes coiled up around peripheral wall inner surfaces of the collection chamber, the exfoliation enclosures, and the upper part of the vertical hollow body.

Other aspects, advantages, and salient features of the present invention will become apparent to those skilled in the art from the following detailed description, which delineate the present invention in different embodiments.

BRIEF DESCRIPTION OF DRAWINGS
These and other features, aspects, and advantages of the present invention will become better understood when the following detailed description is read with reference to the accompanying figures.

Fig. 1 is a schematic diagram illustrating whole construction of an apparatus for producing biochar hard carbon with biosynthesis gas from agricultural biowaste, in accordance with an embodiment of the present invention.

Fig. 2 is a bottom view of gas/biochar collection chamber of the apparatus, in accordance with an exemplary embodiment of the present invention.

Fig. 3 illustrates arrangement of water circulating device/pipes and water flow directions in various components of the apparatus, in accordance with an embodiment of the present invention.

Fig. 4. illustrates air/fire injection device/holes configuration inside core reactor of the apparatus, in accordance with an embodiment of the present invention.

Fig. 5. shows top (Fig. 5a) and bottom (Fig. 5b) views of vertical hollow body (without air sealed cover) of the apparatus, in accordance with an exemplary embodiment of the present invention.

Fig. 6. illustrates various method steps of producing biochar hard carbon with biosynthesis gas from agricultural biowaste, in accordance with an embodiment of the present invention.

List of reference numerals
100 vertical hollow body
102 upper part
102a air sealed cover
104 core reactor
104a air/fire injection device
104b fire grate plate
104c inclined slopes above air/fire injection holes
104d air injection holes
106 lower part
106a spiral cuts/holes
200 motorized agitator
202 blades
204 motor
300 exfoliation enclosures/chambers
302 exit doors for releasing final hard carbon output
304 entry doors for filling first biowaste input
306 gas outlets for releasing final biosynthesis gas output
308 heating device (electrodes)
400 gas/biochar collection chamber
402 exit door for releasing biochar
404 gas/steam release channels
500 water circulating device
502 pipes
600 control unit integrated with sensors
AF air flow from air injection holes
UF upward flow of water through water circulating pipes
DF downward flow of water through water circulating pipes
GF gravitational force

DETAILED DESCRIPTION OF THE INVENTION
Various embodiments described herein are intended only for illustrative purposes and subject to many variations. It is understood that various omissions and substitutions of equivalents are contemplated as circumstances may suggest or render expedient, but are intended to cover the application or implementation without departing from the scope of the present invention. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.

The use of terms “including,” “comprising,” or “having” and variations thereof herein are meant to encompass the items listed thereafter and equivalents thereof as well as additional items. The terms, “an” and “a” herein do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced items. Further, the term ‘biowaste’ is used herein to refer all kind of discarded agricultural products or dried wastes including but not limited to husk, straw, leaves, shells, woods, coconut shell, pecan nut shell, macadamia nuts shell, hickory nut shell, brazil nut shell, prosopis juliflora, bamboo, fibres, peanut shell, pistachio shell, walnut, almond, pine, pine needle, pine cone or organic hydrocarbon enriched agricultural waste material left out after harvesting etc. Furthermore, the term ‘biosynthesis gas’ is used herein to refer a mixture of hydrogen and carbon monoxide, carbon dioxide, and other trace gases in various ratios.

In accordance with an embodiment of the present invention, as shown in Fig. 1, an apparatus for producing biochar hard carbon with bio-synthesis gas is depicted. The apparatus comprises a vertical hollow body (100), an agitator (200), at least two exfoliation enclosures/chambers (300) mounted around or adjacent to peripheral wall of the vertical hollow body (100), a gas/biochar collection chamber (400), a water circulating device (500), and a control unit (600). A first biowaste material is filled into the exfoliation enclosures (500) and a second biowaste material is conveyed to fall into vertical hollow body (100). The final product (hard carbon) is produced through pyrolysis of the first biowaste material due to combinative effect of heat leaching from internal components and purging of oxygen inside the exfoliation enclosures (500). Such hard carbon is used in battery manufacturing. Simultaneously, as a result of exfoliation the biosynthesis gaseous content is produced as byproduct in the exfoliation enclosures (500). The biochar (carbon enriched ash) and intermediate hot gases are produced due to oxidation/reduction of the second biowaste material in the vertical hollow body (100) and collected into the gas/biochar collection chamber (400). Such biochar can be used as fertilizer in agricultural field and the hot gas is diverted into the exfoliation enclosures (500), thus minimizing use of external energy/power source, and consumption of the biosynthesis gas generated by the system. A small portion of the biosynthesis gas generated therefrom can be used as primary energy/power source to run various power consuming components of the apparatus.

In accordance with an embodiment of the present invention, the flow of the first biowaste under gravitational force (GF) inside the vertical hollow body (100) from top towards bottom is indicated as arrow mark. The water flow direction inside pipes (502) of the water circulating device (500) is indicated as dotted arrow mark such as upward flow (UF) and downward flow (DF). The vertical hollow body (100), the agitator (200), the exfoliation enclosures (300), the gas/biochar collection chamber (400), the water circulating pipes (502) are formed of metal. The control unit (600) is configured with the sensors to measure a plurality of parameters to be compared with set values, based on which appropriate signals are generated to operate the air/fire injection device (104a), the agitator (200), the electrode (308), and the water circulating device (500).

In accordance with an embodiment of the present invention, the vertical hollow body (100) has an upper part (102), a lower part (106), and a core reactor (104) therebetween. On top of the upper part (102) there is provided an air sealed cover (102a) having a passage/hole to receive the second biowaste (input) thereinto from a feeder/hopper (not shown in figure for simplicity). The lower part (106) is dimensioned to remain inside the gas/biochar collection chamber (400) and discharge the biochar with hot gas thereinto. The air/fire injection device (104a) is coupled to the core reactor (104) that is adapted to cause oxidation/reduction of the second biowaste material therein. The oxidation/reduction criteria (temperature, pressure, heating/steaming duration, gaseous contents, etc.) also vary depending on natural properties of the biowaste. Therefore, the automation for monitoring and controlling the whole operations inside the vertical hollow body (100) (especially inside the core reactor) with minimal human interference are essentially required for improved optimization.

In accordance with an embodiment of the present invention, the agitator (200) is mounted along central axis of the vertical hollow body (100). The agitator (200) comprises a vertical rotating rod and a plurality of blades (202) horizontally attached to the rod. The rotating rod is operatively coupled to a motor (204) arranged at bottom of the gas/biochar collection chamber (400) or at top of the vertical hollow body (100). The agitator (200) may be sensor driven that helps in turning on/off the motor (204) and regulating its speed/motion as per the oxidation/reduction criteria set in the control unit (600).

In accordance with an embodiment of the present invention, the exfoliation enclosures (300) act as secondary reactors. Each exfoliation enclosure (300) has a bottom, a top, an internal space, and peripheral wall. The number exfoliation chambers (300) may vary depending on the shape, size, and dimensions of the whole setup. The exfoliation chamber (300) may have inclined bottom for ease for collecting the final hard carbon, and a common (sharing) peripheral wall along the peripheral walls of the vertical hollow body (100) and the gas/biochar collection chamber (400). The exfoliation enclosures (300) may be positioned very close or adjacent to the vertical hollow body (100) and the gas/biochar collection chamber (400) in contact or non-contact manner. The exfoliation (pyrolysis) criteria (temperature, pressure, heating/steaming duration, gaseous contents, etc.) also vary depending on natural properties of the first biowaste and the desired properties of the hard carbon output. As indicated in arrow mark in Fig. 1, the top has an entry door (304) for filling the first biowaste material, and a gas outlet (306) for releasing the biosynthesis gas (output) to be transferred to a dedicated filtration/storage system (not shown in figure for simplicity) for further processing. The bottom has an exit door (302) for releasing the hard carbon (output) to be transported to a dedicated storage system (not shown in figure for simplicity). There is at least one heating electrode or an industrial microwave or induction apparatus coupled on peripheral wall of the exfoliating enclosures (308) for uniformly spreading/balancing heat as per the exfoliation (pyrolysis) criteria set in the control unit (600). The heating electrode (308) may be formed of graphite or tungsten or other materials depending on the heat requirement. The exit/entry doors (302, 304), the gas outlet (306), and the electrode (308) are sensor operated.

In accordance with an embodiment of the present invention, the gas/biochar collection chamber (400) has a biochar release door (402) for releasing the biochar (to be used as fertilizers), and gas/steam release channels (404) extended into the bottom of the exfoliation enclosures (300). The door/channels (402, 404) are sensor operated. The collection chamber (400) has guide bars (406) fixed on its peripheral wall inner surface (at lower end) to guide the hot gas flow (produced in the core reactor) into the gas/steam release channels (404). The water flowing through the pipes (502) along the core reactor region (104) gets heated and produces pressure steam which can be utilized by introducing into the exfoliation enclosures (300) through the same channel (404) or a dedicated route. Additionally, if required, some essential gasses such as nitrogen, sulphur from an external gas source are introduced into the exfoliation enclosures (300) through the same channel (404) or a different route. Addition of steam and/or external gases imparts a porous nature to the carbon, enhancing its electrochemical properties, which is highly advantageous for its application in batteries and auxiliary industries .

In accordance with an embodiment of the present invention, as shown in Fig. 2-3, the water circulating device (500) comprises metal pipes spirally embedded (like a coil) around peripheral wall inner surfaces of the gas/biochar collection chamber (400), the exfoliation enclosures (300), and the upper part (102) of the vertical hollow body (100). The metal pipes are coupled to a sensor driven water pump to cause flow the water from a water tank (not shown in figures for simplicity) into the peripheral walls. One or more valves are fitted at entry/exit points of the water along the metal pipe. The water flows from the gas/biochar collection chamber (400) upto the upper part (102) through the core reactor (104) of the vertical hollow body (100) [indicated as the upward flow (UF) in Fig. 1 and 3], then from the top upto the bottom of the exfoliation enclosures (300) [indicated as the downward flow (DF) in Fig. 1 and 3]. The steam produced from the water circulating pipes (502) is also introduced into the exfoliation chamber (300) through the gas release channels (404) as per the exfoliation requirements. This coiled shaped water circulation pipes (502) helps in controlling temperature as well as capturing heat to create high pressure steam, causing crackling and exfoliating the materials present in the core reactor (104) and the exfoliation enclosures (300).

In accordance with an embodiment of the present invention, the lower part (106) of the vertical hollow body (100) has downwardly inclined spiral cuts/holes (106a) around its peripheral wall to release the hot gas into the collection chamber (400) from where the hot gas flows into the exfoliation enclosures (300) through the gas release channels (404).

In accordance with an embodiment of the present invention, as shown in Fig. 4-5, the air/fire injection device (104a) includes air pump, fire generator, and metal pipes. The metal pipes are introduced into the core reactor (104) through air injection holes (104d) provided on the peripheral wall of the core reactor (104). Each injection hole (104d) has a double wall jacket with vortex like fins to evenly/uniformly spread air flow (AF) inside the core reactor (104) for causing (partial pyrolysis) simultaneous oxidation and reduction of the biowaste falling from the upper part of the (102) of the vertical hollow body (100). A fire grate (104b) is horizontally fitted along inner circumference of the core reactor (104) just below the air injection holes (104d). The fire grate (104b) is concave shaped plate formed of curved rods connected in circular/oval shape with a central passage that allows the rotation of the agitator rod therein. The fire grate plate (104b) and the agitator (200) help in controlling falling speed of the biowaste in the core reactor (104), thereby providing sufficient time to oxidation/reduction take place effectively. The wall of the core reactor (104) has inner surface formed of inclined slopes (104c) above the air injection holes/openings (104d). These inclined/protruding slopes (104c) prevent accumulation of the biowaste in the core reactor (104).

In accordance with an embodiment of the present invention, the control unit (600) is configured with one or more sensors and a user interface for giving access to operators. The sensors include temperature/thermal sensor, pressure sensor, water/steam sensor, gas/air sensor, and speed sensor. These sensors are adapted to measure various parameters (temperature, steam pressure, vapour/gas content, motor speed, air/water/stem flow etc.) during oxidation/reduction/exfoliation operations in the apparatus and report to the user interface of the control unit (600). The required parameters of the biowaste to be processed are set in the user interface of the control unit (600). The measured parameters are compared with the set parameters, and if any deviation is observed, then the control unit (600) automatically generates appropriate signals to operate various components of the apparatus. For example, if the temperature inside the exfoliation enclosures (300) is below the set values, then the electrode (308) is turned on to increase the temperature. Similarly, if the steam/vapour/water or external gas is required, then the valves of the steam release channel (404), the water circulating channel (500) and the external gas tanks are opened. Further, the valves of the gas outlets (306) and the air injection pipe (104a), and the exit/entry doors (302/402, 304) are tuned on/off automatically or under input commands received from operators via the control unit (600).

In accordance with an embodiment of the present invention, the control unit (600) comprises a processor/controller, a memory, an input/output operator interface. The control unit (600) may be a remote monitoring device including but limited to personal computer, laptop, tabloid etc. The operation status/condition (including various parameter values) can be easily monitored in real-time and all the necessary actions can be taken to optimize the whole operations to produce quality biocarbon (biochar hard carbon) with biosynthesis gas.

In accordance with an embodiment of the present invention, as shown in Fig. 6, the method for producing biochar hard carbon with bio-synthesis gas is depicted. The method employs a vertical hollow body (100), a motorized agitator (200), at least two exfoliation enclosures (300) mounted around or adjacent to peripheral wall of the vertical hollow body (100), a gas/biochar collection chamber (400), a water circulating device (500) having pipes (502), and a control unit (600).

In accordance with an embodiment of the present invention, the method comprises a step (S1) of filling a first biowaste into the exfoliation enclosures (300).

In accordance with an embodiment of the present invention, the method comprises a step (S2) of conveying a second biowaste to gradually fall into the vertical hollow body (100) through opening of an air sealed cover (102a) attached on its top, whereas the vertical hollow body (100) has a core reactor (104) between its upper part (102) and lower part (106).

In accordance with an embodiment of the present invention, the method comprises a step (S3) of injecting air and fire into the core reactor (104) by an air/fire injection device (104a) coupled thereto along with simultaneous rotation of the agitator (200) mounted therein.

In accordance with an embodiment of the present invention, the method comprises a step (S4) of circulating water through the water circulating pipes (502) around peripheral wall inner surfaces of the collection chamber (400), the exfoliation enclosures (300), and the upper part (102) of the vertical hollow body (100).

In accordance with an embodiment of the present invention, the method comprises a step (S5) of receiving in the collection chamber (400) gas and biochar produced through oxidation/reduction of the second biowaste at a temperature range of 600 oC - 1200 oC in the core reactor (104)

In accordance with an embodiment of the present invention, the method comprises a step (S6) of diverting the hot gas from the collection chamber (400) into the exfoliation enclosures (300) through the gas channels (404), whereas the steam produced from the water circulating pipes (500) and external gas (nitrogen and sulphur) from an external gas source are introduced into the gas channels (404), if required. The steam creates crackling while causing exfoliation of the first biowaste, thus generating hydrogen-rich gases. The nitrogen and/or sulphur doping further improves the electrochemical properties the final hard carbon. The hard carbon produced therefrom may be 8-15% nitrogen doped, or sulphur doped, or nitrogen-sulphur co-doped, which can be used in different types of battery manufacturing.

In accordance with an embodiment of the present invention, the method comprises a step (S7) of exfoliating the first biowaste in the exfoliation enclosures (300) at a temperature range of 400 oC - 1200 oC using a heating electrode (308) coupled to its peripheral wall and combinative heat leaching from the vertical hollow body (100) and the collection chamber (400) to produce biosynthesis gas and hard carbon (final output).

In accordance with an embodiment of the present invention, the method comprises a step (S8) of transporting the biosynthesis gas and the hard carbon from the exfoliation enclosures (300) into corresponding storage units through a gas outlet (306) provided at top and an exit door (302) provided at bottom of the exfoliation enclosures (300), respectively.

In accordance with an embodiment of the present invention, the method comprises a step (S9) of monitoring and controlling operation the air/fire injection device (104a), the agitator (200), the heating electrode (308), and the water circulating device (500) through a sensor enabled control unit (600).

Working of Invention

The biowaste are also fed into the exfoliation chambers (300) through the entry doors (304). The dried biowaste are gradually fed into the vertical hollow body (100) from its top, and allow them to fall controllably under the action of gravitation force (GF), rotation of agitator (200) and air flow (AF) from the air injection device. The water pump/valve is turned on to start circulating water through the water circulating pipes (502) along the peripheral wall inner surfaces of the collection chamber (400), the exfoliation enclosures (300), and the upper part (102) of the vertical hollow body (100), so that steam pressure is produced and injected into the exfoliation enclosures (300) causing crackling. If required the heat balancing electrode (308) is turned on for increasing the temperature/heat therein. The biowaste processing parameters are set in the control unit (600). All the components are monitored remotely and sensor controlled. The exfoliation enclosures (300) can be operated in batch by batch.

The hot syngas (synthesis gas) is produced inside the core reactor (104) at the temperature of 600 oC - 1200 oC depending on the nature biowaste materials. The hot syngas flows towards bottom of the gas/biochar collection chamber (400) from where it flows into the exfoliation enclosures (300). Thus, the combinative effect of heat leeching from the core rector due to proximity of the exfoliating enclosures, hot syngas, the heat emitted from the water circulating channel (500), hot steam flow being pressurized, and the turned-on electrode (308) makes it possible to significantly save external energy source (fuels) and achieve the required amount heat/steam to cause pyrolysis towards production of the biochar hard carbon inside the exfoliation enclosures (300). The temperature inside the exfoliation enclosures (300) remains at 400 oC - 1200 oC depending on the nature biowaste materials, and quality and character of the final product i.e., biocarbon). The biochar hard carbon (final output) is collected via the exit doors (302) and transported into the storage unit/system. The biocarbon/biochar is also collected from the collection chamber (400) via its exit door (402) and transported into the storage unit/system. The biosynthesis gas produced inside the exfoliation enclosures (300) flows out via the gas outlet (306) and transported into the filtration system for further processing.

For example, approximately 100 kg of biowaste can produce around 50-60 kg of biosynthesis gas, 5-15 kg of biochar ash, while the core reactor reaches temperature of 400-1200 degrees Celsius during oxidation. From the core reactor the waste heat is recovered/harvested to power at least two secondary reactors (exfoliating enclosures), achieving temperatures of 200-600 degrees Celsius from that waste heat to facilitate pyrolysis.

Electricity from an onboard gas generator is used supply power to various components (air/fire injection device, electrode, agitator motor, water/gas pumps, valves, sensors, control unit etc.) of the apparatus. A small portion of the biosynthesis gas can fulfill the energy need of the apparatus. Therefore, it makes the proposed apparatus/method self-sustaining and suitable for remote and completely off-grid locations.

The foregoing descriptions of exemplary embodiments of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teaching. The exemplary embodiment was chosen and described in order to best explain the principles of the invention and its practical application, to thereby enable the persons skilled in the art to best utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated. It is understood that various omissions, substitutions of equivalents are contemplated as circumstance may suggest or render expedient, but is intended to cover the application or implementation without departing from the scope of the claims of the present invention. , Claims:We claim:

1. An apparatus for producing biochar hard carbon, the apparatus comprises:
a vertical hollow body (100) having an upper part (102) for receiving a second biowaste, a lower part (106) for releasing hot gas and biochar, and a core reactor (104) therebetween for causing oxidation/reduction, wherein an air sealed cover (102a) is coupled on top of the upper part (102), and an air/fire injection device (104a) is coupled to the core reactor (104);
a motorized agitator (200) mounted along central axis of the vertical hollow body (100);
at least two exfoliation enclosures (300) mounted around peripheral wall of the vertical hollow body (100), wherein each exfoliation enclosure (300) has a bottom provided with an exit door (302) for hard carbon output, a top provided with an entry door (304) for a first biowaste input and a gas outlet (306) for biosynthesis gas output, and a peripheral wall provided with a heating device (308) for balancing heat therein;
a gas/biochar collection chamber (400) into which the lower part (106) of the vertical hollow body (100) is introduced, wherein the collection chamber (400) has a biochar release door (402), and gas/steam release channels (404) extended into the bottom of the exfoliation enclosures (300);
a water circulating device (500) including pipes (502) coiled up around peripheral wall inner surfaces of the collection chamber (400), the exfoliation enclosures (300), and the upper part (102) of the vertical hollow body (100); and
a control unit (600) configured with one or more sensors to measure a plurality of parameters to be compared with set values, based on which appropriate signals are generated to operate the air/fire injection device (104a), the agitator (200), the heating device (308), and the water circulating device (500).

2. The apparatus as claimed in claim 1, wherein the core reactor (104) has a fire grate plate (104b) horizontally fitted along its inner circumference, air injection holes (104d) circumferentially formed of double wall jacket with vortex like fins to evenly spread air injected therefrom, and inclined wall inner surface (104c) formed above the air injection holes.

3. The apparatus as claimed in claim 1, wherein the lower part (106) of the vertical hollow body (100) has downwardly inclined spiral cuts/holes (106a) around its peripheral wall to release the hot gas into the collection chamber (400).

4. The apparatus as claimed in claim 1, wherein the collection chamber (400) has guide bars (406) fixed on its peripheral wall inner surface to guide gas flow into the gas/steam release channels (404).

5. The apparatus as claimed in claim 1, wherein the heating device (308) includes a graphite or tungsten electrode, or a microwave device or an induction device.

6. The apparatus as claimed in claim 1, wherein the control unit (600) is configured to control/regulate motor speed (204) of the agitator (200), and air flow from the air/fire injection device (104a) into the core reactor (104) as per oxidation/reduction set values of the second biowaste while passing therethrough.

7. The apparatus as claimed in claim 1, wherein the control unit (600) is configured to turn on/off the electrode (308) as per exfoliation set values of the first biowaste filled in the exfoliation enclosures (300).

8. The apparatus as claimed in claim 1, wherein the control unit (600) is configured to turn on/off valves of the gas outlets (306), the gas/steam release channels (404), the water circulating device (500), and the entry/exit doors (304, 302/402) as per a set of commands inputted thereinto via a user interface.

9. The apparatus as claimed in claim 1, wherein the exfoliation enclosures (300) are adapted to receive the hot gas produced from the core reactor (104), steam produced from the water circulating pipes (502), and external gas (nitrogen and sulphur) from an external gas source via the gas/steam releasing channels (404).

10. A method for producing biochar hard carbon, the method comprises step of:
filling (S1) a first biowaste into exfoliation enclosures (300) mounted around peripheral wall of a vertical hollow body (100) below which is provided a collection chamber (400);
conveying (S2) a second biowaste to gradually fall into the vertical hollow body (100) through opening of an air sealed cover (102a) attached on its top, wherein the vertical hollow body (100) has a core reactor (104) between its upper part (102) and lower part (106);
injecting (S3) air and fire into the core reactor (104) by an air/fire injection device (104a) coupled thereto along with simultaneous rotation of a motorized agitator (200) mounted therein;
circulating (S4) water through a water circulating device (500) having pipes (502) coiled up around peripheral wall inner surfaces of the collection chamber (400), the exfoliation enclosures (300), and the upper part (102) of the vertical hollow body (100)
receiving (S5) in the collection chamber (400) gas and biochar produced through oxidation/reduction of the second biowaste at a temperature range of 600 oC - 1200 oC in the core reactor (104);
diverting (S6) the hot gas from the collection chamber (400) into the exfoliation enclosures (300) through gas channels (404), wherein steam produced from the water circulating pipes (502) and external gas (nitrogen and sulphur) from an external gas source are introduced into the gas channels (404) as per need;
exfoliating (S7) the first biowaste in the exfoliation enclosures (300) at a temperature range of 400 oC - 1200 oC using a heating device (308) coupled to its peripheral wall and combinative heat leaching from the vertical hollow body (100) and the collection chamber (400) to produce final biosynthesis gas and hard carbon;
transporting (S8) the biosynthesis gas and the hard carbon from the exfoliation enclosures (300) into corresponding storage units through a gas outlet (306) provided at top and an exit door (302) provided at bottom of the exfoliation enclosures (300), respectively; and
controlling (S9) operation the air/fire injection device (104a), the agitator (200), the heating device (308), and the water circulating device (500) through a sensor enabled control unit (600).