HIGH PRODUCTIVITY THERMO ENERGY SIMPLIFIED BIO-COKES FURNACE AND METHOD FOR PRODUCING HIGH CARBON CHARCOAL

A process and a business method for converting wood waste to charcoal have been invented. Multiple high productive thermo energy simplified bio-cokes furnaces create an outlet discharging the earned volatile gas and the wood tar from the carbonization device. By taking back the gas and the wood tar mixed with the air into the furnace, the present invention produces evenly distributed heat with higher energy productivity. The present invention adopts different Coefficients of Thermal Expansion (CTE) for the top opening zone and the carbonization chamber, to avoid transmittal of oxygen from outside the furnace. Charcoal produced with a reduced energy use by the present invention can replace bio-cokes produced from general waste incineration. Through the creation of higher carbon charcoal, the present invention introduces a source of environment-friendly, cost effective and sustainable heat use. Accordingly, the present invention proposes promising business models both to the suppliers and the consumers.

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Description
RELATED APPLICATION

This application claims the benefit of priority to U.S. Provisional Application Ser. No. 61/596,717, entitled “High Productivity Thermo Energy Simplified Bio-Cokes Furnace and Method” filed on Feb. 8, 2012, and currently co-pending.

FIELD OF THE INVENTION

The present invention pertains generally to processes and business methods for wood waste treatment units for converting the waste to charcoal. The present invention is more particularly, though not exclusively, useful as a system of multiple high productive thereto energy simplified bio-cokes furnaces configured for use with recycled thereto energy, volatile gas, and wood tar. By adopting methods with less auxiliary combustion and without using produced charcoal, and by requiring a shorter period of production time, the charcoal produced by the process of the present invention can be used as a replacement for bio-cokes of general waste incineration or other incineration process for reduced energy use.

BACKGROUND OF THE INVENTION

In the United States, roughly 160 Mt of wasted wood is produced every year, however only 19% of such 160 Mt of wasted wood is recycled. Accordingly, approximately 130 Mt of the wasted wood is treated for disposal in landfill each year. The average fee for disposing of a ton of waste in California is between $30 and $40. Thus, disposal of waste wood in landfills costs companies in California over $390 millions every year.

The primary market for the waste wood comprises the recycling for use of lumber, engineered wood products, mulch or compost feedstock, daily landfill cover, animal bedding, wood flour filler for plastic products, and a source of biomass fuels and chemicals. In addition, since a large quantity of waste materials are reproductive plant resources, many researchers have researched these wastes for renewable energy such as carbonization and pyrolysis (the thermochemical decomposition of organic material that occurs at elevated temperatures without the participation of oxygen) for years. However, even though the Rotary kiln has been well-known for large industrial carbonization equipment for timbers, the produced charcoal is costly because of the requirement for a massive facility, and the significant transportation costs required for the raw materials that need to be brought to a Rotary kiln.

As one of the ways in making effort to recycle wood waste, small carbide furnaces have long been introduced to the market in Japan. However, small carbide furnaces need 66 pounds of roast material for the production of only 44 pounds of charcoal. Therefore, due to the relatively small yield of charcoal, small carbide furnaces have been recognized as inappropriate for the industrial use. Furthermore, small carbide furnaces do not contain re-burning systems that can repeatedly uptake volatile gases that are produced while carbonization is ongoing. The volatile gases, such as methane, carbon monoxide, and hydrogen, have been known to have higher global warming potential and thus, instead of utilizing an auxiliary flame, a middle-sized carbide furnace wastes heat and produces more environmentally damaging gases.

In a typical small carbide furnace system, the basic heat balance calculations are adopted to use sawdust, which contains 24 percent moisture as an auxiliary combustion, even though natural dry wood waste usually contains approximately 30 percent of moisture, and broad leaf tree wood material contains approximately 70 percent of moisture. However, it has been determined that when the heat balance is calculated with 30 percent of moisture-containing materials, the furnace cannot provide sustainable operation since the output heat is higher than the input heat. As a result, the small carbide furnace systems are deemed inefficient and environmentally damaging.

It has also been known that pyrolysis of lignin and hemicelluloses creates the exothermic reaction after the endothermic reaction of the thermal degradation of cellulose, when timbers are carbonized. The carbonization of timbers results in the production of carbon monoxide, methane, carbon dioxide, hydrogen gas and wood tar, which are environmentally hazardous. Currently, wood tar is burned at the end of the flue in order to prevent smoke pollution. However, this process only wastes the energy and is not deemed efficient.

In light of the above, it would be advantageous to provide a carbide furnace which is configured to perform continuous carbide production from waste wood, through interconnecting multiple furnaces, and carbonization chambers inside the furnaces, through pipes for controlling the produced volatile gases such as carbon monoxide, hydrogen gas, and methane, and to eject and recycle to burn at the next furnace. It would further be advantageous to produce bio-coals by using the mid-sized carbide furnaces with less auxiliary combustion and without using produced charcoal, thus requiring a shorter period of production time. It would be further advantageous to provide for the creation of high carbon charcoal which can be replaced with cokes, coals, and pellet, in a short production time would provide financial and environmental benefits. It would be additionally advantageous to provide processes and business methods for wood waste treatment units that convert waste to charcoal, where the volatile gases and wood tar formed during cokes creation from wood and other Cellulosic waste, are used in a subsequent burn.

It would also be advantageous to provide a system such that when wood is used to displace high sulfur bituminous coal, sulfur emissions can be reduced by more than 80%. Moreover, using the wasted wood would free up the landfill space, contribute to sequestering of carbon, reduce carbon dioxide emissions from processing raw materials, and contribute to the sustainable use of natural resources. Landfill costs can be avoided by recycling wood wastes, along with revenue from sale of recovered wood waste materials, and such costs can be credited toward the processing costs. Instead of spending money on the landfill, the suppliers may even earn the revenues from recycling.

SUMMARY OF THE INVENTION

The present invention includes a process and a method for wood waste treatment units for converting waste to charcoal. The process provides multiple, highly productive, thereto energy simplified bio-cokes furnaces that utilize bio-gas from wood and wood tar which are formed from wood and other Cellulosic waste, during the bio-coke creation. The bio-cokes furnace of the present invention first creates an outlet to discharge the earned volatile gas and wood tar from heated lower carbonization area at the carbonization device. Then, by taking the volatile gas and wood tar mixed with a suitable quantity of air for the combustion chamber, and directing it back into the furnace, the system in the present invention results in evenly distributed heat with higher energy productivity, without emitting greenhouse effect gas (GHG) from the chimney.

The middle-sized furnaces adopted in the present invention are not restricted as to the location or number of connections. The charcoal produced by the process of the present invention can be used as a replacement for bio-cokes from general waste incineration or other incineration process for reduced energy use. Through the creation of higher carbon charcoal of 88-91% of carbon therein, the present invention introduces a source of more sustainable heat use, which is environmentally friendly and cost effective. Accordingly, the present invention proposes a promising business model which is applicable both to the suppliers and the consumers.

BRIEF DESCRIPTION OF THE DRAWING

The nature, objects, and advantages of the present invention will become more apparent to those skilled in the art after considering the following detailed description in connection with the accompanying drawings, in which like reference numerals designate like parts throughout, and wherein:

FIG. 1 is a vertical cross-sectional view of a portion of the carbonization furnace system of the present invention, showing two (2) furnaces connected each other, while the number of the furnaces connected together and the specific connections between furnaces can actually be unlimited in the present invention and each furnace is equipped with a carbonization chamber and a combustion chamber;

FIG. 2 is a vertical cross-sectional view of a single carbonization furnace of the present invention, wherein the furnace is fully covered with firebricks and rock wool double insulators to improve the heat insulating effect, and the gas is supplied for the furnace's own volatile gas burner or the adjacent furnace's volatile gas burner which is controlled by the reversible valves such that the volatile gas can be transmitted to the adjacent furnace;

FIG. 3(A) is a cross-sectional view of the carbonization chamber showing a silo container equipped with a tuyere, a carbonized chamber hook and a grid lid, when the Coefficient of Thermal Expansion (CTE) of the material on the carbonization chamber is higher than that of the material on the top opening zone;

FIG. 3(B) is a cross-sectional view of the carbonization chamber showing a silo container equipped with a tuyere, a carbonized chamber hook and a grid lid, when the CTE of the material on the top opening zone is higher than that of the material on the carbonization chamber;

FIG. 4 is a diagrammatic view of the air intake system of the present invention, for mixing the volatile gas and the air within the furnace;

FIG. 5 is a top view illustrating a bottom zone in a carbonized furnace;

FIG. 6 is a graph showing the timeline of a single cycle of creation of charcoal by a single furnace, comprising its initialization, carbonization, cool-down, release and refill phases;

FIG. 7 is a diagrammatic view of multiple furnaces connected in series showing their connection through pipes and valves;

FIG. 8 is a diagrammatic view of multiple furnaces connected in a continuous series configuration where the thermo energy loss is at its minimum status;

FIG. 9 is a graph illustrating the timeline of multiple furnaces connected in series, for a single cycle of creation of charcoal by each furnace in which a subsequent furnace is initialized as soon as the prior furnace begins the carbonization phase; and

FIG. 10 is a table illustrating the chemical composition from the analysis of the carbonated wood scrap produced by the method in the present invention.

 DETAILED DESCRIPTION OF THE INVENTION High Productive Thermo Energy Simplified Bio-Cokes Furnace Method

Referring initially to FIG. 1, a cross-sectional view of the carbonization furnace of the present invention is depicted. It describes the two (2) furnaces connected each other; however, it should be noted that this is merely an example, and the number of the furnaces connected together and the specific connections between furnaces can actually be unlimited in the present invention. The furnace may be configured as either a cylinder or a box as is known in the industry, and the furnace 100 has a carbonization chamber 102 inside. The bottom of the furnace has a combustion chamber 104 with a volatile gas burner 106. FIG. 2 is an exaggerated view of the furnace 100 in FIG. 1.

Referring to FIG. 2, the furnace 100 is fully covered with firebricks 134 and rock wool double insulators 110 to improve the heat insulating effect. The furnace has a joint on the top and provides for the installation and withdrawal of materials within the carbonization chamber 102. The top opening zone 112, or top generally, in FIG. 2 has a hook 114 to lift and the joint 116 between the top opening zone 112 and the furnace 100 is insulated with powder insulator as it seals like silica sand and aluminum oxide. Although the furnace 100 can vary in its shape, from straight, double row, to an arc type as are known in the art, an arc-shaped arrangement is preferred because all the connecting valves and tubes can be shortest when used for the arc-shaped furnace. In this case, the furnace can increase the regenerative effect and avoid unwanted thermal segregation at the upper area of the furnace with the aid of a dome-shaped top made from fireproof bricks. The dome-shaped top is preferred for an efficient creation of high temperature air circulation and insulation.

Carbonization chamber 102 is located on the stand 118 on the furnace 100, and the guide pipe 108 for volatile gas under the carbonization chamber 102 leads the volatile gas to the outside of the furnace 100. The gas is supplied for the furnace's own volatile gas burner 106 or the adjacent furnace 200's volatile gas burner which is controlled by valves 122, 124(A) and 124(B). The valves are reversible such that the volatile gas can be transmitted to any adjacent furnace. The pipe for the volatile gas is located outside the furnace, and it prevents heat loss since the pipe is covered with insulating materials, such as rock wool. Flue 126 is located at 25-75% of the height of furnace 100 and connected to the bottom of the adjacent furnace 200, by valves 128(B) and 128(C) (shown in FIG. 1), and also connected to Chimney 150 through a valve 128(B). Flue 126 is also covered by rock wool insulator to prevent the heat loss. Tuyere 132 is set at the front of the furnace 100, for blowing and supplying combustion gas during the start-up auxiliary combustion. The combustion chamber 104 is needed only at the first furnace because the present invention does not need any assistant flame. Therefore, the present invention can avoid the occurrence of oxide scales during decarburization at the carbonized chamber 102 and the top opening zone 112, because the chance for consuming extra oxide at the combustion chamber 104 is deemed very low. The carbonization process in the present invention can easily be controlled since the temperature of carbonization area is controllable with the valves which are monitored, such as with a thermo-coupled methane sensor.

As to the specific aspects of the embodiment of the present invention, any kind of cellulose waste can be used for the carbonization chamber 102, which is set in the furnace 100. Indeed, given that all trees, tree barks, woods, grass, flower, and natural fibers (hereinafter, “wood waste” for all of these) contain cellulose, virtually all types of cellulose may be used.

At the same time, furnace 200 (shown in FIG. 1) which is adjacent to the furnace 100, may also be set with the same setting. As will be discussed in conjunction with FIG. 6, this process may be repeated with a number of interconnected furnaces. After the valves 124(C) (shown in FIG. 1) and 128(C) (shown in FIG. 1) are closed, the charcoal waste as well as the ignite wood are placed at the carbonization chamber 202 (shown in FIG. 1) of the furnace 200 (shown in FIG. 1), before start-up of carbonization of the furnace 100. When the internal temperature of the guide pipe 108 for heated gas reaches 230-250° C. (446-482° F.) the furnace 100 starts to catch fire, due to the auxiliary combustion heating. At the time the internal temperature of the carbonization chamber 102 reaches over 400° C. (752° F.), the furnace 100 starts to create sufficient amount of volatile gas to supply the adjacent furnace. Then, a valve 122 at the thermo-coupled guide pipe 120 for volatile gas is open and the volatile gas burner 106 at the furnace 100 is switched on for the continued heating. After then, the air emission valve 130 (shown in FIG. 1) is closed, the valve 128(C) (shown in FIG. 1) that is connected to the furnace is open, and the heating of the connected furnace 200 (shown in FIG. 1) is initiated.

Referring back to FIG. 1, the connected furnace 200 repeats the same process as the furnace 200 turns on the volatile gas burner 106, once the guide pipe 108 for heated gas reaches 230-250° C. (446-482° F.), as the same temperature of the furnace 100. If the furnace 100 is heated for two (2) to three (3) hours, the top of the furnace reaches 950° C. (1,742° F.) and maintains the temperature for 10-20 minutes. Once the air emission valve 130 is open, the valves 124(A), 124(C) and 128(A), 128(C) are closed, and then the natural air starts blowing for cooling. After the carbonization chamber 102 gets cooled down to below 500° C. (932° F.), for safety and workability, the chamber 102 is taken out from the furnace 100, and is then put on the floor with silica sand. Silica sand creates the safety for cooling down and shuts down the backflow of the air from the guide pipe 108 for volatile gas at the bottom of the carbonization chamber 102. The same process is repeated for the entire system of connected furnaces and back to the furnace 100 at the end.

In a preferred embodiment of the present invention, the entire process including carbonization and the cooling down process, takes approximately six (6) hours per furnace. Accordingly, the facility can produce cokes four (4) times a day when it runs for 24 hours. The re-burning of a product into the carbonization chamber can completely prevent the chamber from being pulled out of the floor and stop the air from refluxing out of the volatile gas tubes at the bottom.

FIG. 3 illustrates a longitudinal cross-sectional view and an outlook of the carbonization chamber 102 in the furnace 100, depending on different Coefficient of Thermal Expansion (hereinafter, “CTE”). The carbonization chamber 102 in the furnace 100 has a top opening zone 152, a hook 136, and a guide pipe 108 for heated gas at the bottom. In order to earn thermo energy for the furnace, the carbonized room has a top opening zone 152 and a perfect fit structure at the door for higher air tightness since the carbonization chamber 102 uses different CTE. The top opening zone 152 is generally made of carbon steel that has lower CTE and the bottom part of the carbonized chamber 102 is generally formed with stainless materials having a higher CTE. For example, when the size of an outer diameter of the carbonization chamber 102 is 1600 mm and the heat temperature reaches 950° C. (1742° F.), the thermal expansion of the bottom material can be 17.3×10−6×(950−20)×1600=25.74 mm and the thermal expansion of the top opening material can be 14.2×10−6×(950−20)×1600=21.13 mm. Accordingly, as illustrated in FIG. 3(A), when the CTE of the material on the carbonization chamber 102 is higher than that of the material on the top opening zone 152, the connection part 156 will be shaped as depicted in dashed lines 158, due to the higher expansion of the carbonization chamber 102. On the other hand, as illustrated in FIG. 3(B), when the CTE of the material on the top opening zone 152 is higher than that of the material on the carbonization chamber 102, the connection part 160 will be shaped as depicted in dashed lines 162, due to the shrinkage on the carbonization chamber 102.

The expanded parts at the bottom and on the top are completely sealed each other. Thus, the outside air and oxygen cannot come into the carbonized room. The volatile gas, such as hydrogen, carbon monoxide, and methane, earned in the furnace, is discharged from the bottom and used for its own thermo energy and supplied to the next furnace. In addition, the bottom of the guide pipe 108 for heated gas has a grid lid 138 that prevents falling of the hydrocarbons material and retrieves the volatile gas such as hydrogen, carbon monoxide, and methane only.

Referring now to FIG. 4, a diagrammatic view of an air intake system is depicted. In FIG. 4, the air intake passing through the air intake valves 140(A) and 140(B) and the air intake system 146, can be anywhere between the valves 142(A) and 142(B). Even though the air pressure can be a natural pressure, a higher pressure (for example 0.1-0.5 MPa) is preferred for the better efficiency. Generally, in combustion engineering, furnace needs more air because of the difference between the density of volatile gas (H2, CH4 and CO) and the air, when the volatile gas is mixed with the air. Slanted plate 144, the same as Sirocco Fan, is movable and connected to the inverter motor, working like a windmill in a cylinder. At the front of the volatile gas burner 106, there is a swirl generator for perfectly mixing the volatile gas and the air, in order to prevent the incomplete combustion. Thus, if there is no slanted plate 144 between the valves 142(A) and 142(B), the warmed volatile gas and the air in room temperature cannot be completely mixed.

One of the functions of the forced air is to create a constant air condition for combustion. To accomplish this, the volatile gas burner 106 has a Sirocco Fan for introducing a perfect mixture of the air and the volatile gas. Volatile gas has higher pressure because of a Sirocco Fan which is controlled by the inverter motor and a gate opening volume of the valves 124(A), 124(B) and 124(C) (shown in FIG. 1). The air intake system 146 at the valves 142(A) and 142(B) and the air intake valves 140(A) and 140(B) can also be automatically controlled. Each valve contains inverter control motor to control the pressure level of the volatile gas. Pressure level is set by a speed of temperature change and a degree of temperature. For example, when either the speed of elevating temperature is too slow or the temperature does not reach the set point, the valve 124(B) (shown in FIG. 1) will completely be open and starts a Sirocco Fan to add pressure. Both the Sirocco Fans at the valves and the valves are monitored and controlled by electronic monitors.

Combustion related control in the present invention is automated. Usually the butterfly valves 122 and 124(B) (shown in FIG. 1) are opened, and the air intake valves 140(A) and 140(B) are closed. First, the temperature of volatile gas is measured at the air intake system 146 and the volume of the gas is measured by the shaft speed of Sirocco Fan that is connected to the inverter control motor. Second, the air intake valves 140(A) and 140(B) are open and the inverter controlling the Sirocco Fan provides the air theoretically containing more amount of oxygen level by 10-20%. Therefore, the present invention avoids the creation of white smoke which is produced from incomplete combustion of wood gas in existing furnaces and keeps the local environment clean, accordingly.

Discharging gas path is also automated. Usually, referring back to FIG. 1, the valves 128(5) and 128(C) are open and the air emission valve 130 is closed. The opening angles of the valves 123, 124(A) and 124(B) are calculated when the measured gas at the sensor 148 is completely combusted and overflows air volume at the sensor 148 (shown in FIG. 4). From such two (2) result combinations, the valves are computer controlled. The completed combusted air which does not contain any harmful materials passes either from the valve 122 that is controlled by a thereto-coupled monitor or from the valves 124(A) and 124(C), to an adjacent furnace.

FIG. 5 illustrates a bottom zone in the carbonized furnace which is equipped with valves, burner, air intake system, guide pipe for combustible gas, and a support of carbonized room. The valves 122 and 123 in FIG. 5 are capable of controlling air/fuel rate and transmitting the excessive amount of gas into the volatile gas burner of the next furnace. The method adopted in the present invention has a unique character such as a volume controller of the air flow. In order to control the volume, the facility is equipped with a tuyere 132 and a volatile gas burner 106 at the bottom of the furnace and controls the air flow volume through a blower at the tuyere 132. The volatile gas such as hydrogen, carbon monoxide, and methane, are supplied to the volatile gas burner 106 as spiral mixed air through the whirlpool air intake system 146, and it results in perfect combustion. The guide pipe 108 for heated gas under the carbonization chamber leads the volatile gas to the outside the furnace.

Referring ahead to FIG. 6, the furnaces are connected each other through the pipes and each pipe can be open and closed with the butterfly valves. The valves are controlled by a computer program and thermo sensors.

FIGS. 6 and 9 graphically illustrate the function of the furnaces according to the timeline necessary for the operation. The carbonization cycle of an individual furnace in a single cycle of creation of charcoal, comprising the time for initial combustion, carbonization, opening top to cool down, releasing, and refilling the furnace, is depicted through the line 301, in FIG. 6. Line 301 begins at time zero at the room temperature. At the beginning of each carbonization cycle, the carbonization chamber 102 (shown in FIG. 1) is loaded with wood waste to be carbonized. Immediately at time zero, heat is applied to the carbonization chamber 102 (shown in FIG. 1) to initiate the heating of the carbonization chamber 102 (shown in FIG. 1). As the temperature rises to a required temperature, usually around 150° C. (302° F.), the butter fly valves 128(B) and 128(C) (shown in FIG. 1) will be open, while valve 122 (shown in FIG. 1) will be closed, and carbonization begins at point 302.

About 20 minutes after the carbonization cycle starts, the temperature within the carbonization chamber 102 (shown in FIG. 1) reaches a temperature sufficient to provide heated volatile gas to an adjacent furnace, if desired. At 304, usually around 300° C. (572° F.), the volatile gas comes into the existence and it starts combustion. As the furnace continues to heat, no new external gas or thermo energy is provided since the carbonization within the carbonization chamber 102 (shown in FIG. 1) occurs entirely within the chamber, due to the heat produced from the burning cellulose within the carbonization chamber 102 (shown in FIG. 1). The temperature of the heat within the carbonization chamber 102 (shown in FIG. 1) continues to rise until it reaches the maximum temperature 306 which occurs at two (2) to three (3) hours after time zero and maintains the same temperature for 10 to 20 minutes. At that time, the thermo energy sources to the chamber are closed off, and the carbonization chamber 102 (shown in FIG. 1) is open to initiate a cooling period 310.

From FIG. 6, it can be appreciated that carbonization 308 occurs from the minimum carbonization temperature 302 until the maximum carbonization temperature 306 is reached after two (2) to three (3) hours. It is to be appreciated that a longer or a shorter carbonization period 308 may be adopted without departing from the present invention.

Cooling period 310 allows the carbonized wood waste and the carbonization chamber 102 (shown in FIG. 1) to be cooled. Once cooled to a temperature that is suitable for interaction, at time period 310, the now-carbonized cellulose is removed from the chamber 102 (shown in FIG. 1). The now-cooled chamber 102 (shown in FIG. 1) is refilled at time 314 and the furnace 100 is ready for another carbonization cycle.

FIG. 7 depicts an example of the multiple furnaces connected in series, through the valves 124(A), 124(8), and 124(C), and 128(A), 128(8), and 128(C). Theoretically, the multiple furnaces can be connected in any number, from two (2) even to the infinite number, in any shape. As depicted in FIG. 7, the furnaces can be connected in series through the valves. However, the empirical data for the present invention has proved that the connection of the multiple furnaces in a hexagonal shape would minimize the thermo energy loss. Through the numerous experiments, it has been turned out that six (6) furnaces in hexagonal connection would be most efficient both in cost and energy, by minimizing the thermo energy loss, as illustrated in FIG. 8.

FIG. 8 illustrates an example of six (6) furnaces hexagonally connected through the valves 124(A), 124(3), and 124(C), and 128(A), 128(B), and 128(C) (shown in FIG. 1). The number of furnaces that can be connected together needs not be limited since thermo energy loss can be at its minimum, with an aid of volatile gas and thermo energy between connected furnaces. However, so far, the empirical data through the experiment has proved that the connection of six (6) furnaces is optimal for the purpose of efficiency by reducing the energy loss. The furnace can reuse the remaining thermo energy from the next furnace connected and chimneys, through the valves connected to the adjacent furnaces. The connecting chimney and volatile gas outlet tubes for the adjacent furnaces can be covered with rock wool or other insulators. In addition, the shorter the distance of the connection between furnaces, the better the furnaces' efficiency in reducing and/or avoiding the heat loss. However, the length for the connection between furnaces can be varied depending on the circumstances and the length for the connection does not have to be identical between the furnaces. Furthermore, in addition to the use of six (6) furnace system, virtually any number of furnaces in the system can be used without departing from the present invention, to customize the user's need.

Referring now to FIG. 9, as illustrated in FIGS. 7 and 8, six (6) furnaces connected to each other in creation of charcoal, according to the timeline as follows: once the first furnace, furnace 100 is fired, 10-20 minutes later, the temperature of flue 126 (shown in FIG. 1) will amount to 150° C. (302° F.), the temperature at which the valve 128(B) (shown in FIG. 1) is open to lead the thermo energy to an adjacent furnace 200. The butterfly valve 128(C) (shown in FIG. 1) will then be open and the thermo energy starts being transmitted to the adjacent furnace, furnace 200, as depicted in FIG. 9, when the furnace 100 reaches over 230-250 CC (446-482° F.), After 45-60 minutes of the combustion, the volatile gas comes into the existence in the guide pipe 108 (shown in FIG. 1) for heated gas of furnace 100 and starts carbonating. By then, valve 122 (shown in FIG. 1) will be open and the volatile gas spreads into the furnace 200. This process also is controlled by a computer program, using the temperature sensor 148 (shown in FIG. 4).

When the temperature of the flue 126 (shown in FIG. 1) in furnace 100 reaches over 500° C. (932° F.), after 60-90 minutes of the combustion, the adjacent furnace 200 reaches about 230-250° C. (446-482° F.). Then the furnace 200 starts carbonating and producing volatile gas by itself.

Another furnace 300, adjacent to the furnace 200, then turns on its combustion system in the same way, and so the other furnaces do. Total time for the carbonization is three (3) hours to three (3) hours and 30 minutes per each furnace. The time will vary depending on the condition of the wood waste, the temperature and the humidity near ambient. Furnace 200 starts to be heated 10-20 minutes after the furnace 100 is fired, and the furnace 300 starts to be heated 20-40 minutes after the furnace 100 is fired.

The time taken for the carbonization depends on the percentage of moisture within the wood waste. After carbonization is completed, the furnace needs to be cooled down to below 500° C. (932° F.), before being refilled with new wood waste. It generally takes an hour to get cooled down, and the replacement of charcoal for the waste wood takes another hour. Accordingly, total time for the creation of charcoal is the six (6) hours per furnace. At the end of the first cycle of charcoal creation by sixth furnace 600, furnace 100 starts its second cycle of charcoal creation, as depicted in FIG. 9. Throughout the entire process, neither any new energy input nor any assistant flame from outside the furnaces is needed. With the six (6) furnace-embodiments in the present invention, each furnace can produce four (4) cycles or more than four (4) cycles of charcoal per day.

Referring to FIG. 10, a table illustrating the chemical composition from the analysis of the carbonated wood scrap produced by the method in the present invention is shown. The chemical composition was measured based on the dried status of the carbonated wood scrap, for the better comparison of the chemical composition, regardless of the temperature and the humidity near ambient where the present invention is used. Specifically, the total carbon content of carbonated wood scrap produced in each of the furnaces is over eighty percent (80%). The refining level by the electrical resistance for the analysis is from 100 to 101 ohm per centimeter (1 cm).

While there have been shown what are presently considered to be preferred embodiments of the present invention, it will be apparent to those skilled in the art that various changes and modifications can be made herein without departing from the scope and spirit of the invention.

Business Application

There are five (5) ways of business application through the present invention for the suppliers. Any business entities which have waste wood to dispose of and/or recycle are deemed suppliers.

First, the suppliers can be part of the business in the present invention, without any cost incurred, merely by disposing of wasted wood. Once the suppliers bring the wasted wood to the factory of the operator in the present invention, the waste wood would be disposed of and handled by the operator perfectly for free.

Second, the suppliers can be part of the business in the present invention by creating its own charcoal factory. The suppliers may purchase the furnaces in the present invention, and set up the charcoal factory for their own. The operator in the present invention may provide consultants in installation and organization of the charcoal factory for the suppliers. Thus, the suppliers can create and sell the charcoal wherever, through any methods they may wish. If the suppliers need help in selling the charcoal, the operator in the present invention would be able to buy high quality charcoal from the suppliers, and sell, based upon the advice, research and analysis of the market specialist, hired by the operator.

Third, a business form of a joint venture can be considered, by the contribution of the space in the facility and waste wood from the suppliers, and the operator's supply of furnaces and professionals to the supplier. After the creation, both the suppliers and the operator of the present invention share a right to sell the charcoal, and the profits gained from the creation and sale of charcoal.

Fourth, the suppliers can be part of the business in the present invention, by renting a space to the operator of the present invention. While the suppliers may provide a space in its facility, they would not get involved with how and where the charcoal being sold. The operator would pay the suppliers for enting the space, and provide the furnaces and professionals to the suppliers and sell the charcoal. In this situation, the profits gained from the creation and sale of charcoal would not be split between the suppliers and the operator.

Fifth, the suppliers can be part of the business in the present invention, by licensing and franchising. The suppliers and the operator in the present invention can enter into the contract that a license would be granted to the suppliers to create a factory in its facility, and to use the marketing methods of the operator as to how and where to create and sell the charcoal, and the suppliers would pay a license fee to the operator of the present invention. A certain percentage of revenues or profits made through the sale of charcoal will be deemed a license fee, upon agreement, and will be paid to the operator of the present invention.

A business in the present invention can also be applied for the carbon credit, which is a component of national and international attempts to mitigate the growth in concentrations of greenhouse gases (GHGs). One carbon credit is equal to one metric ton of carbon dioxide, or in some markets, it is deemed carbon dioxide equivalent gases. With an aid of a replacement from any combusted material to the charcoal in the present invention, the company providing for wood and/or cellulose waste, may be able to reduce its emission of CO2 to a much lower level than the level it used to be at. Then the company providing for wood and/or cellulose waste can use the leftover of reduced CO2 as a carbon credit, and for cap and trade.

Finally for the benefits of the consumers, charcoal created from the present invention may be used for the various purposes. It can be sold as a replacement of cokes, coal, or pellet as heat use. The heat use from the high carbon charcoal can be power plant, certain metallurgical processing of clarification, general waste treatment or any other types of heat. These consumers can also apply for the carbon credit, which is part of the national and international attempts to mitigate the growth in concentrations of greenhouse gases (GHGs). Such a carbon credit will locally apply to the cap and trade system and internationally, to the Clean Development Mechanism (CDM). In addition, the charcoal can be used as non-smoke BBQ charcoal, as well as a filter, to remove organic structures, such as chlorine, gasoline, pesticides, and other poisonous chemicals in water and air. Especially in the State of California, people are required to remove any wood waste within 90 days from the day they leave or store the wood waste, due to the pesticide problem. Through the process of creating high carbon charcoal from the wood waste adopted in the present invention, this invention would dramatically help the problems related to pesticide get resolved. Moreover, high carbon charcoal can be used as a reducing agent to maintain a proper pH level in agriculture, to alkalize soil or neutralize the chemical imbalance therein. Furthermore, high carbon charcoal can even be used for the medical purpose in absorbing any toxics or improper materials in human body and purifying it.

Charcoal quality generally depends on two (2) factors: kind of source and temperature selected in the creation of charcoal. By creating charcoal, which will result in neither SOX nor NOX, but CO2, at the high temperature maintained without fluctuation in its temperature, the present invention enables the production of charcoal in high quality. Especially, by creation of higher carbon charcoal comprising between 88% and 91% of carbon, while the standardized carbon charcoal contains only around 80% of carbon, the present invention proposes a source of more sustainable heat use.

As one of the examples in the business application, in one embodiment, a revenue stream can be generated by contracting with the company providing for wood and/or cellulose waste, to set up and operate a charcoal producing process. The managing company provided with wood and cellulose waste would pay the consultants and the operator of the present invention a fee which is lower than the usual operating cost of a conventional waste treatment process, in this manner, the managing company reduces waste treatment costs, disposal costs, while the operator of the present invention obtains two (2) treatment fees and the profits from selling the bi-product, which is charcoal here. Alternatively, in another embodiment, the managing company would provide the zero emission to the operator of the wood waste treatment plant, which would then derive revenues from sale of the recycled materials obtained through the treatment process.

Due to the porosity, the produced charcoal sensitive to the air flow and burns at a various range of temperatures, up to 2700° C. (4892° F.). The generated heat can be moderated by controlling the air flow. For this reason, charcoal is an ideal fuel replacement for gas and cokes of general waste incineration or other incineration process, such as refinement of metals, general waste treatment, and an electronic power plant, for reduced energy use.

The principles disclosed herein are described in detail above, and partially summarized below. The summary is intended solely as a summary of some features of the preferred embodiments of the present invention and is not intended in any way to limit the disclosure in any way, decrease the scope of the invention, or the provide any limitations whatsoever to the appended claims. The High Productivity Thermo Energy Simplified Bio-Cokes Furnace and Method for Producing High Carbon Charcoal of the present invention includes:

A process and method for wood waste treatment units of converting charcoals comprising multiple high productive thermo energy simplified bio-cokes furnaces creating charcoal with reused polluted gas and wood tar, and business application through the creation of charcoal by the use of multiple bio-cokes furnaces in the present invention.

Is The process further includes the bio-cokes furnace being fully covered with firebricks and double insulators to improve the heat insulating effect.

The process further includes the bio-cokes furnace having an arc-shaped arrangement to minimize the length of connecting valves and tubes.

The process further includes the valves in the bio-cokes furnace being reversible, rendering the volatile gas be transmitted to any adjacent furnaces.

The process further includes the bio-cokes furnace first creating an outlet to discharge the said volatile gas and wood tar from the heated lower carbonization area at the carbonization device.

The process further includes the bio-cokes furnace then taking the volatile gas and wood tar mixed in a suitable quantity of air for the combustion chamber, resulting in evenly distributed heat, with higher energy productivity.

The process further includes the path and the volume for the discharged gas coming in and out from the bio-cokes furnace being computer controlled.

The process further includes the valves used in conjunction with discharge of gas coming in and out from the bio-cokes furnace being controlled by a computer program and thereto sensors.

The process further includes the number of the bio-cokes furnaces connected together can be unlimited.

The process further includes optimizing a configuration, through experimentation, of six (6) furnaces in hexagonal connection to be most efficient both in cost and energy, for the multiple connection of the bio-cokes furnaces.

The process further includes the bio-cokes furnace being equipped with valves and burners which are capable of controlling air/fuel rate and transmitting the excessive amount of gases into the said burner of the next furnace, being monitored by a thereto-coupled methane sensor.

The process of creation of charcoal from the wasted wood through the bio-cokes furnaces further includes steps that once the first bio-cokes furnace of claim 1 is fired, the temperature of the flue will go up to 150° C. (302° F.), at which the butterfly valve will be open and the air starts being transmitted to the second furnace adjacent, and then when the first bio-cokes furnace reaches over 300° C. (572° F.), the volatile gas comes into the existence in the air of the furnace and starts carbonating and by then, the said volatile gas spreads into the second furnace adjacent, and then when the first bio-cokes furnace reaches over 500-600° C. (932-1112° F.), the second furnace adjacent starts carbonating and producing volatile gas and the other furnaces connected together are turned on to be carbonized in the same way, and then after carbonization is completed, the bio-cokes furnace needs to be cooled down before being refilled with new wood waste.

During the entire process for creation of charcoal through the multiple furnaces connected each other, neither assistant flame nor additional resources outside is needed, since the bio-cokes furnace adopts different Coefficients of Thermal Expansion (CTE) for the automatic seal avoiding transmittal of oxygen from outside. Different CTEs of for the material on the carbonization chamber and the material on the top opening zone adopted for the bio-cokes furnace result in a higher expansion of the carbonization chamber when the CTE of the material of carbonization chamber is higher, and a shrinkage on the carbonization chamber when the CTE of the material of the top opening zone is higher.

Total time for the creation of charcoal is generally 6 hours per furnace and each furnace can produce 4 cycles or even more than 4 cycles of charcoal per day, depending on the percentage of moisture within the fuel sources.

A business application for the present invention utilizing the creation of charcoal through the use of multiple bio-cokes furnaces includes business application to the suppliers, business application of carbon credit, and business application to the consumers. Specifically, these business applications to the suppliers can include the suppliers' disposal of wasted wood, suppliers' creation of its own charcoal factory, suppliers' contribution of the space in the facility and wasted wood, and the operator of the present invention brining furnaces and professionals to the suppliers, suppliers' rental of a space to the operator of the present invention, and suppliers' licensing and franchising.

The business application related to the carbon credit further includes the company providing for wood and/or cellulose waste can then use the leftover of reduced CO2 and use for cap and trade. Moreover the business application to consumers further includes a replacement of cokes, coal, or pellet as heat use, the sustainable use of heat use from the creation of higher carbon charcoal, between 88% and 91% of carbon, power plant use, certain metallurgical processing of clarification, general waste treatment, non-smoke BBQ charcoal, filter to remove organic structures, reducing agent, and a variety of medical purposes.

While there have been shown what are presently considered to be preferred embodiments of the present invention, it will be apparent to those skilled in the art that various changes and modifications can be made herein without departing from the scope and spirit of the invention.

Claims

1. A bio-coke furnace comprising:

a carbonization chamber formed with an opening sized to receive cellulose waste;
a top sized to seal said carbonization chamber;
a combustion chamber within said carbonization chamber and having a volatile gas burner;
a guide pipe passing from the atmosphere to said carbonization chamber;
a first valve along said guide pipe configured to selectively interrupt passage of gasses therethrough;
a flue extending from said combustion chamber and in gaseous communication with an adjacent furnace; and
a second valve along said flue configured to selectively interrupt passage of combustion gasses therethrough.

2. The bio-coke furnace of claim 1, further comprising a tuyere configured to supply combustion gas to said combustion chamber during combustion.

3. The bio-coke furnace of claim 1, further comprising said carbonization chamber having an outer surface; and

an insulation later covering said outer surface of said carbonization chamber.

4. The bio-coke furnace of claim 3, wherein said insulation layer further comprises firebricks and rock wool double insulators to improve the heat insulating effect.

5. The bio-coke furnace of claim 1 wherein said top further comprises a dome-shaped top.

6. The bio-coke furnace of claim 5, wherein said top is made from fireproof bricks.

7. The bio-coke furnace of claim 1, wherein said first valve is reversible and configurable to transmit volatile gas to any adjacent furnace.

8. The bio-coke furnace of claim 1, wherein said second valve is reversible and configurable to transmit volatile gas to any adjacent furnace.

9. The bio-coke furnace of claim 1, wherein said flue is insulated.

10. The bio-coke furnace of claim 1, wherein said guide pipe is insulated.

11. The bio-coke furnace of claim 1, wherein said gas burner within said combustion chamber is configured to receive volatile gasses from an adjacent furnace.

12. A bio-coke furnace assembly, comprising:

six furnaces, each of said six furnaces comprising: a carbonization chamber formed with an opening sized to receive cellulose waste; a top sized to seal said carbonization chamber; a combustion chamber within said carbonization chamber and having a volatile gas burner; a guide pipe in gaseous communication with said carbonization chamber; a first valve along said guide pipe configured to selectively interrupt passage of gasses therethrough; a flue extending from said combustion chamber; and a second valve along said flue configured to selectively interrupt passage of combustion gasses therethrough;
wherein the carbonization chamber of each said furnace is in gaseous communication with the carbonization chamber of at least one adjacent furnace through said guide pipe;
wherein the combustion chamber of each said furnace is in gaseous communication with the combustion chamber of at least one adjacent furnace through said flue; and
wherein said first valve and said second valve are configurable to control the flow of gasses between adjacent furnaces.

13. The bio-coke furnace of claim 12, further comprising a tuyere configured to supply combustion gas to said combustion chamber during combustion.

14. The bio-coke furnace of claim 12 further comprising said carbonization chamber having an outer surface; and

an insulation later covering said outer surface of said carbonization chamber.

15. The bio-coke furnace of claim 14, wherein said insulation layer further comprises firebricks and rock wool double insulators to improve the heat insulating effect.

16. The bio-coke furnace of claim 12 wherein said top further comprises a dome-shaped top.

17. A method of creating high carbon coal, comprising the steps of:

providing a first furnace, said furnace having a carbonization chamber having a top, a combustion chamber, a guide pipe having a first valve and a flue having a second valve;
loading said carbonization chamber with cellulose waste;
applying heat to said carbonization chamber to initiate the heating of the carbonization chamber to a required temperature;
opening said first valve and said second valves to facilitate carbonization;
monitoring the temperature within said carbonization chamber until said temperature reaches a carbonization temperature generating volatile gasses;
closing said first valve and said second valve;
waiting for carbonization to occur; and
cooling said carbonization chamber.

18. The method of claim 17, further comprising removing said high carbon charcoal from said chamber.

19. The method of claim 18, further comprising:

refilling said combustion chamber with cellulose waste; and
initiating another carbonization cycle.

20. The method of claim 17, further comprising:

Providing multiple furnaces, each said furnace of said multiple furnaces in gaseous communication with at least one other adjacent furnace;
initiating carbonization in said first furnace;
transmitting volatile gasses from said first furnace to an adjacent furnace once said first furnace reaches a carbonization temperature; and
initiating carbonization in an adjacent furnace to said first furnace.
Patent History
Publication number: 20130219779
Type: Application
Filed: Aug 25, 2012
Publication Date: Aug 29, 2013
Inventors: Natsumi Komatani (Oakland, CA), Tetsuo Fujimori (Kita Ku)
Application Number: 13/594,802
Classifications
Current U.S. Class: From Vegetation Or Refuse (44/605); Apparatus For Making Or Treating Fuel Composition (44/629)
International Classification: C10B 21/18 (20060101);