PORTABLE BIOCHAR KILN

Abstract

A portable biochar kiln and system is disclosed. An example of a portable biochar kiln system includes a kiln body. A ridge is provided around an outside perimeter of the kiln body. A removable lid is provided to cover and uncover an opening in the top of the kiln body. An edge is provided around an outside perimeter of the removable lid. The example portable biochar kiln system also includes a gripper attachment for heavy machinery. The gripper attachment is configured for engagement with the ridge to raise and lower the kiln body. The gripper attachment is also configured for engagement with the edge of the lid to cover and uncover the kiln body.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the priority benefit of U.S. Provisional Patent Application No. 62/317,573 filed Apr. 3, 2016 for “Biochar Kiln,” hereby incorporated by reference in its entirety as though fully set forth herein.

BACKGROUND

Biochar is made from biomass (trees, agricultural waste, etc.) in an oxygen deprived, high temperature environment. Quality biochar has high purity, absorptivity and cation exchange capacity. This can provide significant benefits to several large markets including agriculture, pollution remediation, odor sequestration, separation of gases, oil and gas clean up, and more.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an example portable biochar kiln.

FIGS. 2-3 illustrate lifting and moving the example portable biochar kiln shown in FIG. 1.

FIGS. 4-5 illustrate removing a lid from the example portable biochar kiln.

FIGS. 6-7 are perspective views of an example lid of the portable biochar kiln.

FIGS. 8-10 illustrate replacing the lid from the example portable biochar kiln.

FIGS. 11-12 illustrate covering an opening in the lid for a stack assembly.

FIGS. 13-17 illustrate transporting the lid of the example portable biochar kiln.

FIG. 18 illustrates assembling the lid and stack assembly on the portable biochar kiln.

DETAILED DESCRIPTION

A biochar kiln and system is disclosed, including construction of the kiln and various subsystems such as, but not limited to, ventilation, stack, control, insulation, and ember suppression. The kiln may be implemented to produce biochar.

The biochar kiln is configured to support slow pyrolysis and can accommodate a number of variables. Variables include, but are not limited to, a “green” and/or dry feedstock, large and/or small pieces of the feedstock, various and multiple different species of the feedstock, and operation according to variable processing times. The biochar kiln is robust in that it may be operated under a number of variable operating conditions, while still producing a consistent and high quality biochar product.

An example portable biochar kiln includes a body having a one-piece rolled wall, a curved floor attached to a sidewall. The example portable biochar kiln also includes a ridge around an outside perimeter of the body. The ridge is configured for engagement with a gripper attachment for heavy machinery to raise and lower the body. The example portable biochar kiln also includes a removable lid. An edge is provided around an outside perimeter of the removable lid. The edge is configured for engagement with the same gripper attachment for heavy machinery to cover and uncover the lid on the body.

An example of a portable biochar kiln system includes a kiln body. A ridge is provided around an outside perimeter of the kiln body. A removable lid is provided to cover and uncover an opening in the top of the kiln body. An edge is provided around an outside perimeter of the removable lid. The example portable biochar kiln system also includes a gripper attachment for heavy machinery. The gripper attachment is configured for engagement with the ridge to raise and lower the kiln body. The gripper attachment is also configured for engagement with the edge of the lid to cover and uncover the kiln body.

In an example, the kiln has a removable lid to permit easy loading of feedstock and unloading of biochar. The kiln may also have removable stacks and a stack hole sealing mechanism. In an example, the kiln is transportable and can travel to workstations, instead of making the workstations travel to the kilns.

Before continuing, it is noted that as used herein, the terms “includes” and “including” mean, but is not limited to, “includes” or “including” and “includes at least” or “including at least.” The term “based on” means “based on” and “based at least in part on.”

FIG. 1 is a perspective view of an example biochar kiln 10. The biochar kiln 10 may include a main body portion 12 and a lid 14. The main body portion 12 is configured to receive a feedstock (not shown) by removing the lid 14 and loading the feedstock before replacing the lid 14. In an example, the biochar kiln further includes a base portion 16. The base portion 16 may be configured such that it is raised off of the ground. This enables airflow under the main body portion 12. A ring 18 may also be implemented to lift the biochar kiln 10, e.g., using a loader tractor, forklift or other suitable machinery.

In an example, the kiln wall 20 may be made of a one-piece, rolled wall. Body welds, where needed (e.g., between the floor 222 and wall 20, and various ports), are made on curved surfaces to lower structural and thermal stress to those joints.

The floor 24 may also be a one-piece heavy gauge, high strength steel. The floor 24 may be downward elliptical-shaped (the shape being visible in FIG. 1 and FIG. 5) to withstand heavy falling wood chunks during filling. The surface of the floor 24 is curved and has only one weld joint along the perimeter where it joins with the wall 20. In an example where the kiln floor is curved or substantially elliptical shaped and cannot balance the kiln, a multi-legged stand 16 with circular base 18 may be attached (e.g., welded) to the kiln body 12, which travels with the kiln body 12 as it is being transported.

Before continuing, it should be noted that the examples described above are provided for purposes of illustration, and are not intended to be limiting. Other devices and/or device configurations may be utilized to carry out the operations described herein.

FIGS. 2-3 illustrate lifting and moving the example portable biochar kiln 10 shown in FIG. 1. The kiln body 12 may include a ridge. In an example, the ridge 24 may be provided as a heavy gauge, rolled gripper angle iron is provided on the outside perimeter of the body, e.g., around the walls 20. The ridge 24 may be substantially L-shaped, such that one leg of the L is mounted (e.g., welded or otherwise) to the wall 20 and the other leg of the L provides a lip. However, other configurations are also contemplated, such as a T-shape or other shape ridge that provides the lip around all or a portion of the perimeter of the wall 20.

This configuration enables structural durability, and the ridge 24 provides an interface for grasping with a heavy machinery arm. In an example, the heavy machinery may include a forklift. Other machinery (stationary or mobile) may also be provided to raise and lower the kiln, e.g., for transport.

In the example shown in FIGS. 2-3, a front-end loader 1 is implemented to raise and lower the kiln 10. The front-end loader 1 is shown as it may be specially configured with a gripper attachment 26.

The gripper attachment 26 may be attached to the front-end or “wheel” loader 1 where a bucket or other tooling may typically be installed, e.g., at the ends of arms 2. The gripper attaches to the wheel loader using a JRB style quick attach interface which is standard or a factory option on many brands of wheel loaders.

Movement of the arms 2 enables raising, lowering, and tilting of the gripper attachment 26, and as such, anything grasped by the gripper attachment 26, such as the kiln 10.

In an example, the gripper attachment 26 is configured as a pincher. That is, the gripper attachment has two arms 28a-b pivotally mounted to the gripper attachment such that the arms 28a-b can be opened (or loosened) and closed (or tightened).

In an example, a hydraulic rotor motor (not shown) is provided for the gripper attachment 26. The hydraulic rotor motor may be mounted to the gripper attachment 26, and wired into the cab of the front-end loader 1 so that it can be controlled by the operator/driver. The hydraulic rotor motor may be provided to open and close the arms 28a-b and/or rotate the arms 28a-b. As such, the hydralic rotor motor may enable to the gripper attachment 26 to operate as a pincher. The hydraulic rotor motor may also enables a wheel loader to raise a kiln over a hopper and then dump its load (e.g., like a can of spaghetti into a saucepan). The dumping operation takes less than a minute during which the kiln remains attached to the wheel loader.

It is noted that the same hydraulic rotor motor may be implemented for both rotation and pincher operation, or a separate motor(s) can be provided.

During operation, the front-end loader 1 may approach the kiln 10 as shown in FIG. 2. The gripper attachment 26 may be raised off of the ground at about the same height as the ridge 24. As the front-end loader moves toward the kiln 10, a channel 30 formed in each of the arms 28a-b may be slid onto the ridge 24.

After positioning at the desired location, the arms 28a-b of the gripper attachment 26 may be closed against the ridge 24 to secure the kiln body 12 within the gripper attachment. It is noted that the structure of the ridge 24 may assist in preventing damage to the kiln wall 20, e.g., by providing additional support at the point(s) of engagement between the arms 28a-b and the kiln 10.

After engaging the arms 28a-b with the ridge 24, the arms 2 of the front-end loader 1 may be raised and/or tilted, depending on the desired operations, e.g., as shown in FIG. 3. As such, the front-end loader 1 may be used to transport the kiln 10 to any desired location. By tilting the gripper attachment 26, contents can be emptied from the kiln 10.

The process described above can be reversed to lower and release the kiln 10. This will be readily understood by those having ordinary skill in the art after becoming familiar with the teachings herein, and therefore a full description is not included.

FIGS. 4-5 illustrate removing a lid from the example portable biochar kiln. The lid 14 of the kiln 10 may include an edge 32. In an example, the edge 32 may be provided as a heavy gauge, rolled gripper angle iron is provided on the outside perimeter of the lid 14. The edge 32 may be substantially L-shaped, such that one leg of the L is mounted (e.g., welded or otherwise) to the lid 14 and the other leg of the L provides a lip. However, other configurations are also contemplated, such as a T-shape or other shape ridge that provides the lip around all or a portion of the perimeter of the lid 14

This configuration enables structural durability, and the edge 32 provides an interface for grasping the lid 14 with a heavy machinery arm. As noted above, the heavy machinery may include a forklift or other machinery (stationary or mobile). In the example shown in FIGS. 4-5, the front-end loader 1 is implemented to raise and lower and thus attach and detach lid 14 from the kiln 10. The front-end loader 1 is shown as it may be specially configured with the same gripper attachment 26 described above for FIGS. 2-3.

During operation, the front-end loader 1 may approach the lid 14 of kiln 10. The gripper attachment 26 may be raised off of the ground at about the same height as the edge 32. As the front-end loader moves toward the kiln 10, a channel 30 formed in each of the arms 28a-b of the gripper attachment 26 may be slid onto the edge 32.

After positioning at the desired location, the arms 28a-b of the gripper attachment 26 may be closed against the edge 32 to secure the lid 14 within the gripper attachment. It is noted that the structure of the edge 32 may assist in preventing damage to the lid 14, e.g., by providing additional support at the point(s) of engagement between the arms 28a-b and the lid 14.

After engaging the arms 28a-b with the edge 32, the arms 2 of the front-end loader 1 may be raised and/or tilted, depending on the desired operations, e.g., as shown in FIG. 4. As such, the front-end loader 1 may be used to cover and uncover the kiln 10, and to transport the lid 14 to any desired location. FIG. 5 shows the inside of the kiln 10 after the lid has been removed. By tilting the gripper attachment 26, the ash, snow or debris can be removed from the lid 14.

FIGS. 6-7 are perspective views of an example lid 14 of the portable biochar kiln 10. The lid 14 is shaped similar to the kiln floor 22. In an example, the lid 14 is a one-piece elliptical or curved heavy gauge, high strength steal. The lid 14 may anneal with use (e.g., it gets stronger over time).

In an example, a diameter of the edge 32 of the lid forms a lip which is about two inches greater than the outer perimeter of the kiln wall 20. As such the edge 32 of can sit on the kiln's top rim without falling in. In an example, the outer rim 34 of the lid 14 may seat within an inner perimeter of the kiln wall 20. In another example, the outer rim 34 may be larger than the kiln wall 20 such that the outer rim 34 sits on top of the kiln wall 20. A gasket (not shown) may be provided between the lid 14 and the kiln wall 20.

In an example, a circular, downward flange is installed under the lid to block condensed creosote from migrating to the lid's lip (it drips down onto the wood for reprocessing). If the creosote was allowed to migrate to the lip, it would make a hard, uneven interface with the seating angle iron. The resulting gaps would result in difficult to manage air leaks.

FIGS. 8-10 illustrate replacing the lid from the example portable biochar kiln. During operation, the front-end loader 1 carrying the lid 14, may approach the kiln 10 as shown in FIG. 8. The gripper attachment 26 may be raised off of the ground at about the same height or slightly higher than the top rim of the kiln 10. As the front-end loader moves toward the kiln 10.

After positioning at the desired location as shown in FIG. 9, the arms 28a-b of the gripper attachment 26 may lower the lid 14 onto the kiln 10. After lower the lid 14, the gripper attachment 26 may release from the edge 32 to release the lid 14 on top of the kiln 10, as shown in FIG. 10.

FIGS. 11-12 illustrate covering an opening 38 in the lid 14 for a stack assembly (see, e.g., stack 15 in FIGS. 1 and 18). When the burn is complete, the stack 15 is removed from the lid 14 and a gasket cover 36 is positioned to seal the opening 38 in the kiln lid 14. With the stack opening 38 and the bottom vent pipes sealed, the biochar embers self-extinguish due to lack of oxygen. The cover 36 may be positioned manually by an operator, or using the gripper attachment 26 or other machinery.

It is noted that a lighter duty gripper (or “mini-gripper”) may be provided for low weight applications, such as lid and stack removal. FIGS. 13-17 illustrate transporting the lid 14 of the example portable biochar kiln 10. FIG. 18 illustrates assembling the lid 14 and stack assembly 15 on the portable biochar kiln 10.

The mini-gripper 26′permits use of smaller-weight machinery (e.g., front-end loader 1′) which can result in cost savings (e.g., 60% to 70% over the cost of larger loaders 1). In an example, the mini-gripper 26′ can be readily mounted to smaller machinery such as skid-steer-type of equipment.

In FIG. 13, the front-end loader 1′ is shown as it may approach the lid 14 (e.g., in this case the lid 14 is laying on the ground). The gripper attachment 26′ may be at about the same height as the edge 32 of the lid 14. As the front-end loader moves toward the lid 14, a channel 30′ formed in each of the arms 28a′-b′ of the gripper attachment 26′ may be slid onto the edge 32.

After positioning at the desired location, the arms 28a′-b′ of the gripper attachment 26′ may be closed against the edge 32 to secure the lid 14 within the gripper attachment 26′. After engaging the arms 28a′-b′ with the edge 32, the arms of the front-end loader 1′ may be raised, as shown in FIGS. 15-16. As such, the front-end loader 1 may be used to transport the lid 14 (as shown in FIG. 17) to any desired location, such as to a kiln 10 shown in FIG. 18.

The gripper 26′ may also be operated as shown in FIG. 18 to add the stack 15 on top of the lid 14. The gripper 26′ may engage a ring 40 of the stack 15. Operation to engage ring 40 is similar to that already described for engaging edge 32 of the lid 14. In an example, the stack 15 may be assembled prior to positioning the lid 14 onto the kiln 10. In another example, the stack 15 may be assembled after positioning the lid 14 onto the kiln 10.

The mini-gripper 42 also can be manufactured with less material, has a simplified arm actuator, and may have a limited rotor (e.g., for leveling only). Again, the mini-gripper 40 may include an industry-standard attachment.

It is noted that the examples shown and described are provided for purposes of illustration and are not intended to be limiting. Still other examples are also contemplated.

Claims

1. A portable biochar kiln, comprising:

a body having a one-piece rolled wall, a curved floor attached to a sidewall;

a ridge around an outside perimeter of the body, the ridge configured for engagement with a gripper attachment for heavy machinery to raise and lower the body; and

a removable lid;

an edge around an outside perimeter of the removable lid, the edge configured for engagement with the same gripper attachment for heavy machinery and to cover and uncover the lid on the body.

2. The portable biochar kiln of claim 1, wherein the ridge has a substantially L-shaped profile.

3. The portable biochar kiln of claim 1, wherein the edge has a substantially L-shaped profile.

4. The portable biochar kiln of claim 1, wherein the ridge is attached to the lid by a plurality of legs.

5. The portable biochar kiln of claim 1, wherein the lid is substantially dome shaped.

6. The portable biochar kiln of claim 1, further comprising a stack.

7. The portable biochar kiln of claim 6, wherein the stack is removable from the lid.

8. The portable biochar kiln of claim 7, further comprising an opening formed in the lid, the opening configured to receive the stack.

9. The portable biochar kiln of claim 1, further comprising a removable cover for the opening formed in the lid.

10. The portable biochar kiln of claim 9, wherein the cover is operable by the heavy machinery.

11. A portable biochar kiln system, comprising:

a kiln body;

a ridge around an outside perimeter of the kiln body

a removable lid to cover and uncover an opening in the top of the kiln body;

an edge around an outside perimeter of the removable lid;

a gripper attachment for heavy machinery, the gripper attachment configured for engagement with the ridge to raise and lower the kiln body, and the gripper attachment configured for engagement with the edge of the lid to cover and uncover the kiln body.

12. The portable biochar kiln system of claim 11, wherein the ridge has a substantially L-shaped profile.

13. The portable biochar kiln system of claim 11, wherein the edge has a substantially L-shaped profile.

14. The portable biochar kiln system of claim 11, wherein the ridge is attached to the lid by a plurality of legs.

15. The portable biochar kiln system of claim 11, wherein the lid is substantially dome shaped.

16. The portable biochar kiln of system of claim 11, further comprising a stack.

17. The portable biochar kiln of system of claim 16, wherein the stack is removable from the lid.

18. The portable biochar kiln system of claim 17, further comprising an opening formed in the lid, the opening configured to receive the stack.

19. The portable biochar kiln system of claim 11, further comprising a removable cover for the opening formed in the lid.

20. The portable biochar kiln system of claim 11, wherein the gripper attachment is substantially C-shaped, the gripper attachment contracts to engage the edge and the ridge for lifting, and the gripper attachment expands to release the edge and the ridge.