Description:FIELD OF THE INVENTION

[0001] The present invention relates to an automated bio-coal production device that efficiently processes sugarcane bagasse through a series of mechanically integrated stages, for ensuring optimal conversion into bio-coal while maintaining safety, efficiency, and environmental compliance.

BACKGROUND OF THE INVENTION

[0002] Bio-coal production involves converting organic materials, such as agricultural waste, wood, or other biomass, into a solid fuel that serve as an alternative to traditional coal. This process helps reduce dependence on fossil fuels and lowers environmental impact. Traditionally, bio-coal was produced using simple methods like furnaces or kilns, where biomass was heated in low-oxygen environments to produce the fuel. These methods, though functional, were labor-intensive and required constant monitoring. The equipment was usually basic, leading to inefficiencies in energy use and inconsistent quality of the final product. Additionally, the process often resulted in higher emissions, contributing to pollution. As a result, while the traditional techniques were effective to some extent, by these lacked environmental sustainability and operational efficiency.

[0003] Traditionally, bio-coal was produced in simple, open kilns and pits. These methods were rudimentary and relied heavily on manual labour, with workers stacking biomass such as wood, agricultural residues, and other organic matter in a pit or kiln. The biomass was then slowly heated in a low-oxygen environment, a process known as carbonization. However, these early methods were very labour-intensive, requiring significant human effort to gather and load biomass into the kilns. So, people also use retort kilns, batch ovens, and horizontal and vertical carbonization reactors. These equipment’s allowed for better control over the temperature and pressure, leading to more consistent bio-coal production. However, these industrial methods still involved a lot of manual input and did not address all the environmental and efficiency issues.

[0004] WO2023135445A1 discloses about an invention that includes a method for producing bio-coal, in which discarded plant parts are used as a raw material, sintering is carried out in a vacuum and in a high temperature environment, and bio-coal having a high calorific value, low emissions, and a low price is produced. Compared with currently used coal, pollution gases, such as sulfur dioxide, hydrogen sulfide, nitric oxide and the like, that are generated during combustion can be greatly reduced, so that combustion is cleaner. In another aspect, the calorific value generated by the combustion of the obtained finished product is 15-20% higher than the calorific value of coal, so that said method can be widely applied to steel smelting, thermal power generation and the like and is a more ideal and environmentally friendly coal-substituting source of energy.

[0005] CN111892967A discloses about an invention that includes an equipment for producing biological coal by crop straws and a preparation process thereof, and relates to the technical field of biological coal. According to the invention, the airflow pipe is arranged, so that the organic acid in the heat flow is cooled and remained in the wood acid liquid collecting barrel, the cooled reducing gas enters the combustion chamber to be mixed and combusted with natural gas, and the purpose of heat recovery of waste gas is achieved.

[0006] Conventionally, many devices have been developed that are capable of producing bio-coal. However, these devices involve a high level of manpower for converting sugarcane bagasse into bio-coal that not only increases the labour cost but also makes the process labour dependent. Additionally, these existing devices also lack in efficiently separating and collecting fine particles and gases generated during the production of bio-coal.

[0007] In order to overcome the aforementioned drawbacks, there exists a need in the art to develop a device that is capable of receiving organic waste like sugarcane bagasse and efficiently converting it into bio-coal through a series of controlled stages, thereby ensuring optimal quality and energy efficiency. In addition, the developed device also ensures that efficient separation and collection of fine particles and gases is carried out during the processing, thereby optimizing the end product and reducing potential pollutants.

OBJECTS OF THE INVENTION

[0008] The principal object of the present invention is to overcome the disadvantages of the prior art.

[0009] An object of the present invention is to develop a device that is capable of receiving organic waste like sugarcane bagasse and efficiently converting it into bio-coal through a series of controlled stages, thereby ensuring optimal quality and energy efficiency.

[0010] Another object of the present invention is to develop a device that is capable of continuously monitoring and controlling environmental conditions, such as temperature and gas emissions, throughout the bio-coal production process to ensure safety and compliance with environmental standards.

[0011] Yet another object of the present invention is to develop a device that is able to ensure the efficient separation and collection of fine particles and gases generated during the processing, thereby optimizing the end product and reducing potential pollutants.

[0012] The foregoing and other objects, features, and advantages of the present invention will become readily apparent upon further review of the following detailed description of the preferred embodiment as illustrated in the accompanying drawings.

SUMMARY OF THE INVENTION

[0013] The present invention relates to an automated bio-coal production device that is capable of facilitating the efficient processing of sugarcane bagasse through a series of mechanically integrated stages, in order to ensure optimal conversion into bio-coal while upholding safety, operational efficiency, and environmental compliance.

[0014] According to an embodiment of the present invention, an automated bio-coal production device comprises of, a housing developed to be positioned on a ground surface, installed with a first chamber for receiving sugarcane bagasse, a pair of calendar motorized rollers is attached on a bottom portion of the first chamber to rotate for cutting the bagasse into smaller pieces, via sharp-edged blades fabricated with the rollers, a second chamber containing a motorized grinder installed underside the first chamber for receiving smaller bagasse, a primary Peltier unit is attached to the second chamber and integrated with a primary temperature sensor to monitor and regulate the temperature inside the second chamber, a mesh is attached to bottom surface of second chamber, the mesh acting as a filtration element to filter dust particles and very fine pieces of sugarcane bagasse, that are transferred to a waste storage chamber located adjacent to the second chamber, the first and second chambers are equipped with vibration units and accelerometers, the vibration units facilitate cutting and grinding to ensure sugarcane bagasse particles are within an optimal size range, and the accelerometers provide real-time data on vibration patterns to detect potential blockages, a conveyor belt attached vertically to the second chamber, configured to transfer small-sized sugarcane bagasse particles into a pyrolysis reactor unit installed inside the housing, and multiple plates are connected to the conveyor belt via a motorized ball-and-socket joint, enabling angle of the plates to be adjusted during transfer process, thereby optimizing flow and alignment of bagasse particles as they are dispensed into the pyrolysis reactor.

[0015] According to another embodiment of the present invention, the proposed device further comprises of, a motorized hinge attached to a top portion of the pyrolysis reactor to tilt and deploy a cap attached with the hinge over mouth portion of the pyrolysis reactor, multiple infrared heaters are installed inside the pyrolysis reactor to raise temperature and make the sugarcane bagasse more carbon-rich, to convert the bagasse into bio-coal, a gas sensor installed inside the pyrolysis reactor to continuously monitor gas levels, a horizontal conduit is attached to the reactor wall, incorporating an iris hole, which allows gas to flow out of the reactor and collect inside a reservoir connected with the conduit, in case the gas levels exceed a predefined threshold, multiple activated carbon packets are placed inside the conduit by a motorized clamping unit to capture unwanted gases, such as carbon monoxide and volatile organic compounds, a cooling chamber positioned below the pyrolysis reactor to regulate temperature of the bio-coal, the cooling chamber is equipped with a secondary Peltier unit and a secondary temperature sensor, which work together to maintain optimal cooling conditions for the bio-coal, preventing overheating and ensuring that bio-coal reaches desired temperature for safe handling and storage and an iris unit provided on bottom of the cooling chamber connects the cooling chamber to a third chamber, where the cooled bio-coal is stored.

[0016] While the invention has been described and shown with particular reference to the preferred embodiment, it will be apparent that variations might be possible that would fall within the scope of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0017] These and other features, aspects, and advantages of the present invention will become better understood with regard to the following description, appended claims, and accompanying drawings where:
Figure 1 illustrates a perspective view of an automated bio-coal production device.

DETAILED DESCRIPTION OF THE INVENTION

[0018] The following description includes the preferred best mode of one embodiment of the present invention. It will be clear from this description of the invention that the invention is not limited to these illustrated embodiments but that the invention also includes a variety of modifications and embodiments thereto. Therefore, the present description should be seen as illustrative and not limiting. While the invention is susceptible to various modifications and alternative constructions, it should be understood, that there is no intention to limit the invention to the specific form disclosed, but, on the contrary, the invention is to cover all modifications, alternative constructions, and equivalents falling within the spirit and scope of the invention as defined in the claims.

[0019] In any embodiment described herein, the open-ended terms "comprising," "comprises,” and the like (which are synonymous with "including," "having” and "characterized by") may be replaced by the respective partially closed phrases "consisting essentially of," consists essentially of," and the like or the respective closed phrases "consisting of," "consists of, the like.

[0020] As used herein, the singular forms “a,” “an,” and “the” designate both the singular and the plural, unless expressly stated to designate the singular only.

[0021] The present invention relates to an automated bio-coal production device that is designed to receive organic waste, such as sugarcane bagasse, and convert it into bio-coal through a sequence of controlled stages, for ensuring high-quality output and energy efficiency. Additionally, the device effectively separates and collects fine particles and gases produced during the conversion process, thereby enhancing the quality of the final product while minimizing environmental pollutants.

[0022] Referring to Figure 1, a perspective view of an automated bio-coal production device is illustrated, respectively, comprising a housing 101 developed to be positioned on a ground surface, installed with a first chamber 102 for receiving sugarcane bagasse, a pair of calendar motorized rollers 103 is attached on a bottom portion of the first chamber 102, a pair of sharp-edged blades 104 fabricated with the rollers 103, a second chamber 105 containing a motorized grinder 106 installed underside the first chamber 102, a mesh 107 is attached to bottom surface of second chamber 105, a waste storage chamber 108 located adjacent to the second chamber 105, a conveyor belt 109 attached vertically to the second chamber 105, a pyrolysis reactor unit 110 installed inside the housing 101, multiple plates 111 are connected to the conveyor belt 109 via a motorized ball-and-socket joint 112, a cap 113 attached over mouth portion of the pyrolysis reactor, a horizontal conduit 114 is attached to the reactor wall, a reservoir 115 connected with the conduit 114, a cooling chamber 116 positioned below the pyrolysis reactor, a motorized clamping unit 117 placed inside the conduit 114, a third chamber 118 arranged inside the housing 101, an iris unit 119 provided on bottom of the cooling chamber 116.

[0023] The device disclosed herein comprising a housing 101 which is designed to be placed on a ground surface, serving as the structural base for the device. Within this housing 101, a first chamber 102 is installed, specifically intended for the reception and containment of sugarcane bagasse. The chamber is designed to handle the initial stage of processing, where sugarcane bagasse, a fibrous by-product of sugar extraction from sugarcane, is introduced.

[0024] A pair of calendar motorized rollers 103 are mounted on the bottom portion of the first chamber 102, specifically designed for cutting the sugarcane bagasse into smaller, more manageable pieces. As the rollers 103 rotate, they engage sharp-edged blades 104 that are attached to the rollers 103. These blades 104 are specifically fabricated to efficiently cut through the bagasse, breaking it down into smaller fragments. The microcontroller precisely controls the rotation speed and timing of the rollers 103 to ensure uniform cutting of the bagasse, thereby optimizing the size and consistency of the pieces for further processing.

[0025] The calendar motorized rollers 103 are driven by a motor controlled by the microcontroller. Upon activation, the microcontroller initiates rotation of the rollers 103, which are equipped with sharp-edged blades 104. As the rollers 103 rotate, these moves the sugarcane bagasse towards the blades 104. The sharp blades 104 cut the bagasse into smaller pieces as it passes through. The microcontroller regulates the speed and timing of the rollers 103 rotation to ensure uniform cutting of the bagasse. This controlled movement continues until the bagasse is reduced to the required size, enabling efficient preparation for subsequent processing.

[0026] A second chamber 105 is positioned beneath the first chamber 102, specifically designed to receive the smaller bagasse that has been processed by the calendar motorized rollers 103. Within this second chamber 105, a motorized grinder 106 is installed, which is responsible for further processing the bagasse by grinding it into finer particles. The motorized grinder 106 is regulated by the microcontroller, for ensuring precise control over the grinding speed and process duration. Once the smaller bagasse is introduced into the second chamber 105, the grinder 106 is activated, and the bagasse is subjected to grinding until it reaches the desired consistency.

[0027] The motorized grinder 106 is powered by a motor and works in the second chamber 105, where the bagasse is introduced after being cut. The grinding unit's mechanism involves rotating grinding elements such as blades 104 or rollers 103 that crush and grind the bagasse, reducing it to the desired particle size.

[0028] A primary Peltier unit is attached to the second chamber 105, designed to regulate the temperature within the chamber. The primary Peltier unit functions by transferring heat from the interior of the second chamber 105 to its exterior, thereby cooling the chamber as needed. This primary Peltier unit is integrated with a primary temperature sensor, which continuously monitors the temperature inside the second chamber 105. The sensor provides real-time data to the microcontroller, which, in turn, controls the activation and operation of the primary Peltier unit. When the temperature deviates from the desired range, the microcontroller adjusts the primary Peltier unit to either increase/decrease the cooling effect, for maintaining a stable temperature for optimal grinding and processing of the bagasse.

[0029] The temperature sensor comprises crucial components such as an infrared sensor, an optical arrangement, and a detector. It functions on the principle of detecting infrared radiation emitted by the surrounding. When the temperature exceeds absolute zero, it emits infrared radiation. The sensor captures this radiation using its optical arrangement, directing it onto a detector. Common detectors, like thermopiles or pyroelectric sensors, then convert the received infrared energy into an electrical signal. This signal undergoes processing by electronic components, translating it into a temperature reading of the surroundings.

[0030] The primary Peltier unit consists of two semiconductor plates, known as Peltier plates, connected in series and sandwiched between two ceramic plates. When an electric current is applied to the Peltier unit, one side of the unit absorbs heat from its surroundings, while the other side releases heat, thereby regulating the temperature inside the second chamber 105.

[0031] A mesh 107 is securely attached to the bottom surface of the second chamber 105, functioning as a filtration element. As the smaller pieces of sugarcane bagasse undergo processing, the mesh 107 filters out dust particles and any very fine pieces of bagasse that may be produced during the grinding process. These fine particles, along with any unwanted dust, pass through the mesh 107 and are directed into a waste storage chamber 108 located adjacent to the second chamber 105. This filtration ensures that only the properly ground and processed bagasse is retained for further use, while the waste is efficiently separated and stored, minimizing contamination and enhancing the quality of the final product. The waste storage chamber 108 is designed to contain the filtered dust and fine particles until they can be disposed of or further processed.

[0032] The first and second chamber 105 are each equipped with vibration units and accelerometers to enhance the efficiency of the cutting and grinding processes. The vibration units generate controlled vibrations within the chambers, facilitating the cutting of sugarcane bagasse in the first chamber 102 and the grinding in the second chamber 105. These vibrations help ensure that the bagasse particles are broken down to an optimal size range, enhancing the overall processing efficiency.

[0033] The accelerometers monitor the vibration patterns in real-time, providing continuous feedback on the system’s operation. If the accelerometers detect irregular or abnormal vibration patterns, this may indicate a potential blockage or disruption in the process. In such cases, the microcontroller automatically adjusts or halt operation to prevent damage or inefficiency, ensuring that the cutting and grinding processes proceed smoothly and without obstruction.

[0034] The vibration units consist of motors or actuators mounted inside the first and second chamber 105. When activated, these generates oscillatory movements that cause the chamber walls or internal structures to vibrate. These vibrations assist in the cutting and grinding processes by helping to move and agitate the sugarcane bagasse, ensuring it remains evenly distributed and is broken down into smaller pieces or finer particles.

[0035] The accelerometers consist of modules that are mounted inside the first and second chamber 105. These modules detect the frequency, amplitude, and direction of vibrations. When irregular vibration patterns are detected, such as those caused by blockages or imbalances, the accelerometers transmit real-time data to the microcontroller to trigger necessary adjustments or alerts to maintain optimal processing conditions.

[0036] A conveyor belt 109 is vertically attached to the second chamber 105 and is designed to transport the small-sized sugarcane bagasse particles from the chamber into a pyrolysis reactor unit 110. The conveyor belt 109 is powered by an integrated motor, which is regulated by the microcontroller to ensure smooth and continuous operation. Upon activation, the conveyor belt 109 moves the processed bagasse particles upward, transferring them into the pyrolysis reactor unit 110. This process is essential for preparing the bagasse for pyrolysis, where it will undergo thermal decomposition to produce bio-coal or other by-products. The conveyor belt 109 is designed for efficient material handling, preventing delays or blockages while ensuring a consistent flow of material to the reactor.

[0037] Multiple plates 111 (preferably 2 to 6 in numbers) are connected to the conveyor belt 109 via a motorized ball-and-socket joint 112, which allows for the dynamic adjustment of the angle of the plates 111 during the transfer process. The motorized ball and socket joint enables the plates 111 to tilt or reposition, optimizing the flow and alignment of the small-sized sugarcane bagasse particles as these are dispensed into the pyrolysis reactor unit 110. By adjusting the angle of the plates 111, the bagasse particles are evenly distributed and directed into the reactor, preventing blockages, uneven feeding, or spillage. This adjustment is controlled by the microcontroller, for allowing precise positioning to maximize the efficiency of the transfer process and optimize the pyrolysis reaction.

[0038] The motorized ball and socket joint mentioned here consists of a ball-shaped element that fits into a socket, which provides rotational freedom in various directions. The ball is connected to a motor, typically a servo motor which provides the controlled movement. The plates 111 is attached to the socket of the motorized ball and socket joint, the microcontroller sends precise instructions to the motor of the motorized ball and socket joint. The motor responds by adjusting the ball and socket joint and rotates the ball in the desired direction, and this motion is transferred to the socket that holds the plates 111. As the ball and socket joint move, it provides the necessary movement to the plates 111 for enabling angle of the plates 111 to be adjusted during transfer process.

[0039] A motorized hinge is attached to the top portion of the pyrolysis reactor, for enabling controlled tilting and deployment of a cap 113 over the mouth portion of the reactor. The motorized hinge is powered by an integrated motor and is controlled by a microcontroller, allowing the cap 113 to be accurately positioned over the reactor's opening. When activated, the hinge tilts the cap 113 into place, for ensuring a secure closure of the reactor's mouth during the pyrolysis process. This sealing is crucial for maintaining the necessary internal conditions for pyrolysis, such as temperature and pressure control, and preventing the escape of gases or by-products.

[0040] Multiple infrared heaters (preferably 2 to 6 in numbers) are installed inside the pyrolysis reactor to raise the temperature within the reactor, facilitating the transformation of the sugarcane bagasse into bio-coal. These heaters emit infrared radiation that heats the bagasse directly, accelerating the pyrolysis process by raising the temperature to the required levels.

[0041] The heat from the infrared heaters causes the bagasse to undergo thermal decomposition, removing moisture and volatile compounds, and resulting in a carbon-rich product. The combination of controlled heating and the elevated temperature within the reactor enables the conversion of the bagasse into bio-coal, which is more energy-dense and suitable for use as a fuel source. The infrared heaters are regulated by the microcontroller to ensure optimal heating and maintain the required temperature range for effective bio-coal production.

[0042] A gas sensor is installed inside the pyrolysis reactor to continuously monitor the levels of gases produced during the pyrolysis process. The sensor detects and measures various gases, such as carbon dioxide, carbon monoxide, methane, and other volatile organic compounds that are released when the sugarcane bagasse undergoes thermal decomposition. The data from the gas sensor is transmitted to the microcontroller, which analyzes the gas composition and concentration in real time.

[0043] The gas sensor is equipped with chemical sensing elements that detect and measure the concentration of gases inside the pyrolysis reactor. As gases are released during the pyrolysis process, the sensor reacts with the gas molecules, producing a measurable electrical signal. This signal is proportional to the concentration of specific gases, such as carbon dioxide, carbon monoxide, or methane. The sensor continuously transmits this data to the microcontroller, which processes the information in real-time.

[0044] A horizontal conduit 114 is securely mounted on the wall of the pyrolysis reactor, designed to manage the flow of gases produced during the pyrolysis process. This conduit 114 is integrated with an iris hole, a valve mechanism that regulates the release of gas from within the reactor. The iris hole is designed to open and close based on specific conditions, thereby allowing the gas to flow out of the reactor when the internal gas levels exceed a predetermined threshold. Once the gas exits through the iris hole which gets opened/closed as per requirement. As per the requirement the iris hole is directed by the microcontroller to get opened into a reservoir 115 connected to the conduit 114.

[0045] The reservoir 115 is designed to collect and store the excess gas, thereby preventing the buildup of pressure within the reactor and ensuring the process remains within safe operational parameters. The iris hole operates in response to sensor data, ensuring automatic and precise control of gas release based on the real-time conditions monitored within the reactor. This is crucial for maintaining the safety, efficiency, and regulatory compliance of the pyrolysis process, preventing potential hazards related to excessive gas accumulation.

[0046] Multiple activated carbon packets are placed inside the horizontal conduit 114 by a motorized clamping unit 117, which is specifically designed to secure and position the packets at optimal locations within the conduit 114. These activated carbon packets serve to adsorb unwanted gases, such as carbon monoxide and volatile organic compounds (VOCs), that are released during the pyrolysis process. The activated carbon material has a high surface area, which allows it to trap and retain these gases, preventing their release into the environment.

[0047] The motorized clamping unit 117 ensures that the packets are precisely placed and securely held within the conduit 114, maintaining effective filtration throughout the gas flow. The process is automated, and the placement of activated carbon packets is adjusted based on real-time monitoring of gas levels and the specific filtration needs. This method effectively mitigates hazardous emissions, ensuring the safety and environmental compliance of the pyrolysis process.

[0048] The motorized clamping unit 117 consists of a motor-driven mechanism that moves along a predefined path within the conduit 114. When activated, the unit positions activated carbon packets inside the conduit 114 at designated locations. The motor drives a set of clamps that securely hold the packets in place, ensuring these remain fixed during the gas flow process. The clamping unit 117 operates based on commands from the microcontroller, which controls the precise timing and placement of the packets. Once in position, the unit ensures that the packets remain effectively secured, allowing the activated carbon to capture unwanted gases as they flow through the conduit 114.

[0049] A cooling chamber 116 is positioned below the pyrolysis reactor to regulate the temperature of the bio-coal produced during the pyrolysis process. The cooling chamber 116 is equipped with a secondary Peltier unit which works in similar manner as of primary Peltier unit and a secondary temperature sensor which works in similar manner as of primary temperature sensor, and function collaboratively to maintain optimal cooling conditions.

[0050] The secondary Peltier unit actively cools the bio-coal by transferring heat away from the material, while the secondary temperature sensor continuously monitors the temperature of the bio-coal within the cooling chamber 116. Based on the data received from the temperature sensor, the microcontroller regulates the operation of the Peltier unit to prevent overheating, ensuring the bio-coal reaches the desired temperature for safe handling and storage. This cooling ensures that the bio-coal is cooled efficiently, avoiding any risk of excessive heat or potential hazards, and ensuring it is at a safe and stable temperature for further use or storage.

[0051] An iris unit 119 is installed at the bottom of the cooling chamber 116, facilitating the connection between the cooling chamber 116 and a third chamber 118, wherein the cooled bio-coal is stored after the cooling process is completed. The iris unit 119 functions as a controlled, motorized mechanism that regulates the flow of bio-coal from the cooling chamber 116 into the third chamber 118. Upon activation, the iris unit 119 opens to allow the transfer of cooled bio-coal, for ensuring a smooth and efficient passage of the material.

[0052] This transfer is executed in a controlled manner, with the iris unit 119 closing once the required amount of bio-coal has been released into the third chamber 118, thereby preventing any spillage or contamination. The iris unit 119, being an automated component, is controlled by the microcontroller, which ensures precise timing and coordination of the transfer process. The third chamber 118, where the cooled bio-coal is ultimately stored, is designed to maintain the integrity and quality of the bio-coal, ensuring that the material remains in optimal condition for subsequent use or packaging.

[0053] Moreover, a battery is associated with the device for powering up electrical and electronically operated components associated with the device and supplying a voltage to the components. The battery used herein is preferably a Lithium-ion battery which is a rechargeable unit that demands power supply after getting drained. The battery stores the electric current derived from an external source in the form of chemical energy, which when required by the electronic component of the device, derives the required power from the battery for proper functioning of the device.

[0054] The present invention works in the best manner, where the housing 101 developed to be positioned on the ground surface, installed with the first chamber 102 for receiving sugarcane bagasse. Then the pair of calendar motorized rollers 103 rotate for cutting the bagasse into smaller pieces, via sharp-edged blades 104 fabricated with the rollers 103. Now the second chamber 105 containing the motorized grinder 106 installed underside the first chamber 102 for receiving smaller bagasse. Thereafter the primary Peltier unit is attached to the second chamber 105 and integrated with the primary temperature sensor to monitor and regulate the temperature inside the second chamber 105. Then the mesh 107 is attached to bottom surface of second chamber 105, where mesh 107 acting as the filtration element to filter dust particles and very fine pieces of sugarcane bagasse, that are transferred to the waste storage chamber 108 located adjacent to the second chamber 105. Afterwards the first and second chamber 105 are equipped with vibration units and accelerometers, to facilitate cutting and grinding to ensure sugarcane bagasse particles are within the optimal size range. Thereafter the accelerometers provide real-time data on vibration patterns to detect potential blockages. Then the conveyor belt 109 attached vertically to the second chamber 105, configured to transfer small-sized sugarcane bagasse particles into the pyrolysis reactor unit 110 installed inside the housing 101. Thereafter multiple plates 111 are connected to the conveyor belt 109 via the motorized ball-and-socket joint 112, enabling angle of the plates 111 to be adjusted during transfer process, thereby optimizing flow and alignment of bagasse particles as they are dispensed into the pyrolysis reactor. Now the motorized hinge attached to the top portion of the pyrolysis reactor to tilt and deploy the cap 113 attached with the hinge over mouth portion of the pyrolysis reactor.

[0055] In continuation, then multiple infrared heaters raise temperature and make the sugarcane bagasse more carbon-rich, to convert the bagasse into bio-coal. Thereafter the gas sensor continuously monitors gas levels. Synchronously, the horizontal conduit 114 is attached to the reactor wall, incorporating the iris hole, which allows gas to flow out of the reactor and collect inside the reservoir 115 connected with the conduit 114. In case the gas levels exceed the predefined threshold, multiple activated carbon packets are placed inside the conduit 114 by the motorized clamping unit 117 to capture unwanted gases, such as carbon monoxide and volatile organic compounds. Then the cooling chamber 116 positioned below the pyrolysis reactor to regulate temperature of the bio-coal. Where the cooling chamber 116 is equipped with the secondary Peltier unit and the secondary temperature sensor, which work together to maintain optimal cooling conditions for the bio-coal, preventing overheating and ensuring that bio-coal reaches desired temperature for safe handling and storage. Moreover, the iris unit 119 provided on bottom of the cooling chamber 116 connects the cooling chamber 116 to the third chamber 118, where the cooled bio-coal is stored.

[0056] Although the field of the invention has been described herein with limited reference to specific embodiments, this description is not meant to be construed in a limiting sense. Various modifications of the disclosed embodiments, as well as alternate embodiments of the invention, will become apparent to persons skilled in the art upon reference to the description of the invention. , Claims:1) An automated bio-coal production device, comprising:

i) a housing 101 developed to be positioned on a ground surface, installed with a first chamber 102 for receiving sugarcane bagasse, wherein a pair of calendar motorized rollers 103 are attached on a bottom portion of said first chamber 102 that are actuated by an inbuilt microcontroller to rotate for cutting said bagasse into smaller pieces, via two or more sharp-edged blades 104 fabricated with said rollers 103;
ii) a second chamber 105 containing a motorized grinder 106 installed underside said first chamber 102 for receiving smaller bagasse, wherein a primary Peltier unit is attached to the second chamber 105 and integrated with a primary temperature sensor to monitor and regulate the temperature inside said second chamber 105;
iii) a mesh 107 is attached to bottom surface of second chamber 105, said mesh 107 acting as a filtration element to filter dust particles, that are transferred to a waste storage chamber 108 located adjacent to the second chamber 105;
iv) a conveyor belt 109 attached vertically adjacent to said second chamber 105, configured to transfer sugarcane bagasse particles into a pyrolysis reactor unit 110 installed inside said housing 101, wherein multiple plates 111 are connected to said conveyor belt 109 via a motorized ball-and-socket joint 112, enabling angle of the plates 111 to be adjusted during transfer process, thereby optimizing flow and alignment of bagasse particles as they are dispensed into said pyrolysis reactor;
v) a motorized hinge attached to a top portion of said pyrolysis reactor to tilt and deploy a cap 113 attached with said hinge over mouth portion of said pyrolysis reactor, wherein multiple infrared heaters are installed inside said pyrolysis reactor to raise temperature and make said sugarcane bagasse more carbon-rich, to convert said bagasse into bio-coal;
vi) a gas sensor installed inside said pyrolysis reactor to continuously monitor gas levels, wherein a horizontal conduit 114 is attached over a wall of said reactor unit 110, incorporating a motorized iris hole, which transfers the gas inside a reservoir 115 connected with said conduit 114, in case said gas levels exceed a predefined threshold; and
vii) a cooling chamber 116 positioned below said pyrolysis reactor to regulate temperature of said bio-coal, wherein said cooling chamber 116 is equipped with a secondary Peltier unit and a secondary temperature sensor, which work together to maintain optimal cooling conditions for said bio-coal, preventing overheating and ensuring that bio-coal reaches desired temperature for safe handling and storage.

2) The device as claimed in claim 1, wherein multiple activated carbon packets are placed inside said conduit 114 by a motorized clamping unit 117 to capture unwanted gases, such as carbon monoxide and volatile organic compounds.

3) The device as claimed in claim 1, wherein an iris unit 119 provided on bottom of said cooling chamber 116 that connects said cooling chamber 116 to a third chamber 118, where said cooled bio-coal is stored.

4) The device as claimed in claim 1, wherein said first and second chamber 105 are equipped with vibration units and accelerometers, wherein said vibration units help in agitating said particles which aids in proper cutting and grinding to ensure sugarcane bagasse particles are within an optimal size range, and said accelerometers provide real-time data on vibration patterns to detect potential blockages.