Method of producing charcoal from biomass

Abstract

The invention provides a process for the production of charcoal. More particularly, the invention is a process which maximizes the production of charcoal. Of secondary consequence is the production of fuel gasses.

I claim:  
     
         1 . A continuous process for producing charcoal from biomass input material in which the production of charcoal is maximized and the consumption of charcoal is minimized, the process comprising the steps of: 
 a. establishing a charcoal production bed having a biomass upper layer having a top and a charcoal lower layer having a lower layer top; an intermediate layer pyrolysis zone positioned between the upper layer and the lower layer; the charcoal production bed positioned in a single reaction chamber;    b. igniting the lower layer top with ignition means; establishing a pyrolysis zone at the intermediate layer;    c. moving oxygen-containing gas downwardly through the charcoal production bed to sustain the pyrolysis reaction in the intermediate layer and to maintain the temperature of the charcoal in the lower layer, wherein the pyrolysis volatiles from the intermediate layer move downwardly through the hot charcoal in the lower layer, resulting in tar-free fuel gas, which exits from the outlet means, and;    c. removing, by removing means, charcoal in the lower layer; regulating the introduction of additional biomass material so that as charcoal is removed, the level of charcoal comprising the lower layer, and hence the level of the pyrolysis zone comprising the intermediate layer, remain substantially constant within the reaction chamber.    
     
     
         2 . The process of  claim 1 , wherein: 
 a. maintaining the lower layer at a temperature which is sufficiently high to reduce any tars from the pyrolysis zone intermediate layer to carbon monoxide, hydrogen;    c. providing the charcoal production bed with an outlet means for fuel gas; regulating the additional biomass material by regulating at least the quantity and or the moisture content of the additional biomass material.    
     
     
         3 . The process of  claim 2 , including the step of monitoring the level of the pyrolysis zone in the reaction chamber.  
     
     
         4 . The process of  claim 3  wherein the monitoring of the level of the pyrolysis zone in the reaction chamber is by thermocouple means.  
     
     
         5 . The process of  claim 2 , including the step of removing the fuel gas from the reaction chamber.  
     
     
         6 . The process of  claim 1 , wherein the temperature of the pyrolysis reaction zone is in the range of 800.degree. C.-1000.degree.  
     
     
         7 . The process of  claim 1 , wherein the charcoal lower layer is substantially devolatilized.  
     
     
         8 . The process of  claim 1 , wherein the charcoal lower layer is substantially uniform in size.  
     
     
         9 . The process of  claim 2 , wherein: 
 a. establishing the charcoal production bed is commenced by adding a charge of charcoal at the lower layer of the reaction chamber.