WO2008076944A1

WO2008076944A1 - Pyrolysis biomass chain reactor for clean energy production in closed loop

Info

Publication number: WO2008076944A1
Application number: PCT/US2007/087676
Authority: WO
Inventors: Philippe R. Murcia
Original assignee: Ecoem, Llc
Priority date: 2006-12-15
Filing date: 2007-12-14
Publication date: 2008-06-26

Abstract

An apparatus and methods and processes for producing in closed loop charcoal having an high Fix Carbon Content and by so doing using the exhaust gases from a Pyrolysis process for producing Electricity and Thermal Heat in form of Steam directed for producing Ethanol fuel, Methane Gas, Hydrogen, Extracting Oil, Acids and Tars from Coal Mining and finally Composts and Liquid Fertilizers. The apparatus is preferably made out of metal sheets and refractory concrete cement and is composed of kilns disposed on parallel line or on daisy form having on its center at equidistance an exhaust/incinerator to which are specially positioned flues and ducts to drive the smoke and tars, eliminating all polluting gases otherwise present. The method includes sequential, combined operations that generate the chain reaction.

Description

PYROLYSIS BIOMASS CHAIN REACTOR FOR CLEAN ENERGY PRODUCTION IN CLOSED LOOP

BACKGROUND OF THE INVENTION FIELD OF THE INVENTION

[0001] The present invention relates to pyro lysis biomass chain reactor equipment layout and operation.

DISCUSSION OF RELATED ART

[0002] Conventionally, charcoal is made by using either an earth pit or a brick kiln, which, most of them would be closed by 2008 year end in Missouri due to their high polluting process. Most of the cost in the manufacture of charcoal is associated with the multiple shipping and handling of the raw wood & domestic and/or industrial waste to the central processing site. For example, a train or truck transports cut trees and domestic and/or industrial wastes to a centralized processing site, where the charcoal is manufactured.

[0003] Approximately more than half of the volume of trees cut down is not transported to the central processing site, meaning that loggers must cut down fifty percent (50%) more trees than if the entire tree is used. Thus, more trees are cut down because the centrally located sawmill does not utilize the leftover. Also, the planting of new trees is also inhibited because of the abundance of wood waste on the ground forest floor.

[0004] The leftover wood is typically discarded and left on the forest floor. While the leftover wood is still moist, new types of fungi and insect species appear on the leftover wood, which can ruin new tree generation and may adversely affect human health. In addition, once the leftover wood becomes dry it becomes extremely combustible. The presence of combustible matter throughout the forest is a significant reason for increased wild forest fires. [0005] Such leftover wood turns the forest into a carbon dioxide (CO2) supplier, instead of a natural "sink" that soaks up gases responsible for the "greenhouse" effect that causes global warming, and thereby jeopardizes the balance of the existing ecosystem. On the other hand, usable wood, which is not of sufficient volume to be transported cost effectively is either disposed of, or salvaged by, expensive and time consuming techniques. However, it never gets used in a charcoal making process.

[0006] The traditional method of making charcoal in an earth pit or brick oven requires several days, or even weeks, for the wood to be properly seasoned and dried prior to being heated. Furthermore, the charcoal and by-products, which are tar and ash, can not be fully recovered because they all seep into the earth. Another disadvantage is that the recovered charcoal is often contaminated with earth and stones. Making charcoal using this method can often take more than one week after the wood is dried and polluting air, soil and water resources.

[0007] The traditional method of making charcoal in brick kilns or earth pit on the other hand, pollute the soil, air and water because, with all of them, tar and acid condensation aren't collected. However, brick kilns require constant supervision.

[0008] The carbonization stage may be decisive in charcoal production, unless it is carried out as efficiently as possible, it puts the whole operation of charcoal production at risk since low yields in carbonization reflect back through the whole chain of production as increased costs and waste of resources, without assessing here the carcinogen effects for human health.

[0009] Wood consists of three main components: cellulose, lignin and water.

[0010] The cellulose and lignin and some other materials are tightly bound together and make up the material we call wood. The water is absorbed or held as molecules of water on the cellulose/lignin structure. Air dry or "seasoned" wood still contains 12 to 18% of absorbed water. Growing and freshly cut or "unseasoned" wood contains, in addition, liquid water to give a total water content of about -40 to 60% expressed as a percentage of the oven dry weight of the wood.

[0011] The water in the wood has to be driven off as vapor before carbonization can take place. Water evaporation requires a lot of energy so that using the sun to pre-dry the wood as much as possible before carbonization greatly improves efficiency. At the same time, it requires two processing steps: the storing and seasoning stage and the second handling for carbonization. [0012] The water remaining in the wood to be carbonized must be evaporated in the kiln or pit and this energy must be provided by burning some of the wood itself which otherwise would be converted into useful charcoal.

[0013] The first step in carbonization in the kiln is drying out of the wood at 100⁰C or below to zero moisture content. The temperature of the oven dry wood is then raised to about 28O⁰C. The energy for these steps comes from partial combustion of some of the wood charged to the kiln or pit and it is an energy absorbing or endothermic reaction, which release the harmful gases on the traditional brick oven or earth pit contaminating the soil, air and water resources. [0014] When the wood is dry and heated to around 28O⁰C, it begins to spontaneously break down to produce charcoal plus water vapor, methanol, acetic acid and more complex chemicals, chiefly in the form of tars and non-condensable gas consisting mainly of hydrogen, carbon monoxide and carbon dioxide at a rate within a range of 4 to 10 tons per hour. Air is admitted to the carbonizing kiln or pit to allow some wood to be burned and the nitrogen from this air will also be present in the gas. The oxygen of the air is sued up in burning part of the wood charged. [0015] The spontaneous breakdown or carbonization of the wood above a temperature of 28O⁰C liberates energy and hence this reaction is said to be exothermic. This process of spontaneous breakdown or carbonization continues until only the carbonized residue called charcoal remains. Unless further external heat is provided, the process stops and the temperature reach about 400⁰C. This charcoal, however, on traditional brick oven or earth pit will still contain appreciable amounts of tarry residue, together with the ash of the original wood. The ash content of the charcoal is about 3 to 5%; the tarry residue may amount to about 30% by weight and the balance is fixed carbon - about 65 to 70%.

[0016] Further, heating increases the fixed carbon content by driving off and decomposing more of the tars. A temperature of 500⁰C gives a typical fixed carbon content of about 85% and a volatile content of about 10%. The yield of charcoal at this temperature is about 33% of the weight of the oven dry wood carbonized - not counting the wood, which was burned to carbonize the remainder. Thus the theoretical yield of charcoal varies with temperature of carbonization due to the change in its content of volatile tarry material. [0017] Low carbonization temperatures give a higher yield of charcoal but this charcoal is low grade, is corrosive due to its content of acidic tars, and does not burn with a clean smoke- free flame. Good commercial charcoal should have a fixed carbon content of about 85% and this call for a final carbonizing temperature of above 500⁰C.

[0018] The yield of charcoal also shows some variation with the kind of wood. There is evidence that the lignin content of the wood has a positive effect on charcoal yield. High lignin content gives a high yield of charcoal. Therefore, mature wood in sound condition is preferred for charcoal production. Dense wood also tends to give a dense, strong charcoal, which is also desirable. However, very dense woods sometimes produce a friable charcoal because the wood tends to shatter during carbonization. The friability of charcoal increases as carbonization temperature increases and the fixed carbon content increases as the volatile matter content falls. A temperature of 450 to 500⁰C gives an optimum balance between friability and the desire for high fixed carbon content.

[0019] The many variables possible in carbonization make it difficult to specify an optimum procedure - generally the best results will be obtained by using sound hardwood of medium to high density. The wood should be as dry as possible and usually be split to eliminate pieces more than 20 cm thick. Firewood, which will be burned up inside the kiln or pit to dry out and start carbonization of the remainder, can be of inferior quality and temperature. One should try and reach a final temperature of around 500⁰C through the whole of the charge. With brick kilns or earth pits this is difficult since the air circulation and cooling effects are irregular and cold spots occur. These produce "brands" of non-carbonized wood. Trying to reach a final overall temperature of 500⁰C with an earth pit or brick kiln having poor and irregular air circulation usually results in burning part of the charcoal to ashes, while leaving other parts of the charge only partly carbonized. Hence the importance of using kilns properly operated for an efficient charcoal operation with computerized control of each step of the process is preferable. [0020] Carbonization produces substances, which can prove harmful, and simple precautions should be taken to reduce risks.

[0021] The gas produced by carbonization has a high content of carbon monoxide, which is poisonous when breathed. Therefore, when working around the brick kiln or earth pit during operation and when the kiln is opened for unloading, care must be taken that proper ventilation is provided to allow the carbon monoxide, which is also produced during unloading through spontaneous ignition of the hot charcoal, to be dispersed.

[0022] The tars and smoke produced from carbonization from brick kiln or earth pit, although not directly poisonous, may have long-term damaging effects on the respiratory system. Housing areas should, where possible, be located so that prevailing winds carry smoke from charcoal operations away from them and batteries of kilns should not be located in close proximity to housing areas.

[0023] Wood tars and pyroligneous acid can be an irritant to the skin and care should be taken to avoid prolonged skin contact by providing protective clothing and adopting working procedures that minimize exposure.

[0024] The tars and pyroligneous liquors can also seriously contaminate streams and affect drinking water supplies for humans and animals. Fish may also be adversely affected. Liquid effluents and waste water from medium and large scale charcoal operations should be trapped in large settling ponds and allowed to evaporate so that this water does not pass into the local drainage system and contaminate streams.

[0025] Unfortunately brick kilns and earth pits, as distinct from retorts and other sophisticated systems, normally produce liquid effluent, which are mostly dispersed into the air as vapors or seep into the ground. Precautions against airborne contamination of the environment are of greater importance in this case.

[0026] Charcoal ready for use by the consumer implies a certain sequence of steps in a production chain all of which are important and all of which must be carried out in the correct order. They have varying incidence on production cost. Noting these differences enables the importance of each step or unit process to be assessed so that attention may be concentrated on the most costly links of the production chain.

[0027] Charcoal is the solid residue remaining when wood is "carbonized" or "pyrolysed" under controlled conditions in a closed space such as a charcoal kiln. Control is exercised over the entry of air during the pyrolysis or carbonization process so that the wood does not merely burn away to ashes, as in a conventional fire, but decomposes chemically to form charcoal. [0028] Air is not really required in the pyrolysis process. In fact, advanced technology methods of charcoal production do not allow any air to be admitted resulting in a higher yield, since no extra wood is burned with the air and control of quality is facilitated. [0029] The pyrolysis process once started, continues by itself and gives off considerable heat. However, this pyrolysis or thermal decomposition of the cellulose and lignin of which the wood is composed does not start until the wood is raised to a temperature of about 300° Celsius. [0030] In the traditional brick kiln or earth pit some of the wood loaded into the kiln is burned to dry the wood and raise the temperature of the whole of the wood charge so that pyrolysis starts and continues to completion by itself. The wood burned in this way is lost. By contrast, the success of sophisticated continuous retorts in producing high yields of quality charcoal is due to the ingenious way in which they make use of the heat of pyrolysis, normally wasted to raise the temperature of the incoming wood so that pyrolysis is accomplished without burning additional wood. Although some heat impact is needed to make up for heat losses through the walls and other parts of the equipment. The combustible wood gas given off by the carbonizing wood can be burned to provide this heat and to dry the wood. All carbonizing systems give higher efficiency when fed with dry wood since removal of water from wood needs large inputs of heat energy.

[0031] The pyrolysis process produces charcoal which consists mainly of carbon together with a small amount of tarry residues, the ash contained in the original wood, combustible gases, tars, a number of chemicals - mainly acetic acid and methanol - and a large amount of water which is given off as vapor from the drying and pyrolitic decomposition of the wood. [0032] When pyro lysis is completed, the charcoal that has arrived at a temperature of about

500⁰C is allowed to cool down without access of air. It is then safe to unload and ready for use.

[0033] The overwhelming bulk of the world's charcoal is still produced by the simple process briefly previously described. It wastefully burns part of the wood charge to produce initial heat and does not recover any of the by-products or the heat given off by the pyrolysis process.

[0034] Other woody materials such as nutshells and bark are sometimes used to produce charcoal. Wood is, however, the preferred and most widely available material for charcoal production. Many agricultural residues can also produce charcoal by pyrolysis but such charcoal is produced as a fine powder, which usually must be briquetted at extra cost for most charcoal uses. In any case, encouraging the wider use of crop residues for charcoal-making or even as fuel is generally an unwise agricultural practice although the burning of sugar cane bagasse to provide heat in sugar production and the burning of cornstalks and coarse grasses as domestic fuel in some regions do provide an overall benefit where carried out as part of a national agricultural policy.

[0035] On the grounds of availability, properties of the finished charcoal, and sound ecological principles wood remain the preferred and most widely used raw material and there appears to be no reason why this should change in the future.

Charcoal making can be divided into several stages or unit operation. They are: a- growing the fuel wood and/or organizing ecologically the harvesting for future trees generation; b- wood harvesting ecologically for future trees generation; c- drying and preparing the wood for carbonization; d- carbonizing ecologically the wood to charcoal.

[0036] It would be desirable to provide a method and apparatus for making charcoal in a

PYROLYSIS BIOMASS CHAIN REACTOR unit that can use all wood and domestic and/or industrial waste cost effectively. It is further desired to provide a method and apparatus for making charcoal in PYROLYSIS BIOMASS CHAIN REACTOR unit with minimal need for supervision. It is a further desired to provide a method and apparatus for making charcoal in PYROLYSIS BIOMASS CHAIN REACTOR unit that does not emit or discharge pollutants at levels that would harm or damage the environment.

SUMMARY OF THE INVENTION

[0037] One aspect of the invention resides in a PYROLYSIS BIOMASS CHAIN

REACTOR for making charcoal from wood and domestic and/or industrial waste. The wood waste employed is any part of a cut tree that has not been used, including portions of the tree trunk, large branches, small branches, bark and cutoff from wood industry as well as peat or demolition residues if not contaminated with lead paint and/or other chemicals. The PYROLYSIS BIOMASS CHAIN REACTOR, which in its preferred embodiment includes of three main parts - various numbers of kilns, an exhaust/chimney and an amount of ducts and flues related to the number of kilns, being loaded with the wood waste. [0038] Another aspect is for producing in closed loop Charcoal having an high Fix

Carbon Content and by so doing using the exhaust gases from such a Pyrolysis process for producing Electricity and Thermal Heat in form of Steam directed for producing Ethanol, Methane Gas, Hydrogen and finally Composts and Liquid Fertilizers is provided. The apparatus is preferably made out of metal sheets and refractory concrete cement and is composed of Kilns disposed on parallel line or on daisy form having on its center at equidistance an exhaust/incinerator to which are specially positioned flues and ducts to drive the smoke and tars, eliminating all polluting gases from the pyrolysis process.

[0039] Another aspect of the present invention is a method that includes sequential combined operations in a kind of chain reaction.

BRIEF DESCRIPTION OF THE DRAWING [0040] For a better understanding of the present invention, reference is made to the following description and accompanying drawing, while the scope of the invention is set forth in the appended claims.

[0041] Fig. 1 is a schematic diagram showing operation process # 1 of pyrolysis biomass chain reactor in accordance with the invention.

[0042] Figs. 2-8 are schematic flow diagrams of processes #2 - # 8, respectively, that use the operation of the pyrolysis biomass chain reactor of Fig. 1 to generate electricity (Fig. 2), to produce ethanol fuel (Fig. 3), to make methane gas (Fig. 4), to make methane gas and cleanse water (Fig. 5), to yield hydrogen and/or extract oil, acids and tars from coal mining (Fig. 6), to make composts (Fig. 7) and to make liquid fertilizer (Fig. 8);

[0043] Fig. 9 is a schematic flow diagram of a process of operation of the pyrolysis biomass chain reactor of the present invention to show the application of the processes #1 - #8 of

Figs. 1-8.

[0044] Fig. 10 is an overall front view of the pyrolysis biomass chain reactor of Fig. 1.

[0045] Fig. 11 is an aerial view of the pyrolysis biomass chain reactor of Fig. 10.

[0046] Figs. 12-14 are front, side and top views respectively of the pyrolysis biomass chain reactor of Figs. 10-11.

DESCRIPTION OF THE PREFERRED EMBODIMENT

[0047] The invention produces in closed loop charcoal having a relatively high fixed carbon content and by so doing uses the exhaust gases from a pyrolysis process for producing electricity and thermal heat in form of steam. The steam is directed for producing ethanol fuel, methane gas, hydrogen, extracting oil, acids and tars from coal mining and finally composts and liquid fertilizers. The apparatus in accordance with the invention is preferably made out of metal sheets and refractory concrete cement and is composed of kilns disposed in parallel lines or in a daisy form having on its center at equidistance an exhaust/incinerator to which are positioned flues and ducts to drive the smoke and tars, eliminating al polluting gases otherwise present.

[0048] The method includes sequential, combined operations that generate the chain reaction. The primary processing includes loading and igniting the load of biomass into the kilns in sequential manner, when the temperature reaches over 150 degrees Celsius within 45 minutes.

The secondary processing starts when the gases and acid begin to run to the Exhaust/Incinerator in which the gases are ignited and reach a temperature of an average of 750 degrees Celsius within 15 minutes. Such heat is directed to a boiler, which generates steam and starting the chain reaction for the other following processes:

[0049] Fig. 2 - Process # 2. Electricity is produced through a conventional multi-input turbine and a conventional generator,. Later on, in the following processes as part of the chain reaction, part of the methane gas produced by Processes # 4 & # 5 ( see Figs. 4 & 5) are also directed to such conventional multi-input turbine and a conventional generator;

[0050] Fig. 3 - Process # 3. Ethanol fuel is produced by directing part of the steam and/or heat from Process # 2 to a central steam switchboard. Part of the left over from such ethanol production will then be directed to Process # 4;

[0051] Fig. 4 - Process # 4. Steam and/or heat from Process # 2 are directed to a conventional digester for maintaining the loaded organic residues from sewer, household organic wastes, oil cake from ethanol and manures from chicken, lamb and cow farms for making methane, then part of the left over from such methane gas production is directed to Process # 7;

[0052] Fig. 5 - Process # 5. Steam and Heat from Process # 2 are directed to a conventional digester for maintaining the loaded organic residues from sewer, household organic wastes, oil cake from ethanol and manures from pig farms for making methane gas, then part of the left over from such Methane production is directed to Process # 8;

[0053] Fig. 6 - Process # 6. Electricity from Process # 2 is directed to a Catalytic

Processor for making Hydrogen and/or Extracting Oil, Acids and Tars from Coal Mining;

[0054] Fig. 7 - Process # 7. Left over from processes # 3 & # 4 are stored for making

Composts;

[0055] Fig. 8 - Process # 8. Left over from process # 5 are stored for making liquid

Fertilizers.

TECHNICAL DISCUSSION AND OPERATION

[0056] The present invention relates mainly to a method and apparatus for the production of Charcoal from biomass and particularly to the production, in chain reaction, of other clean energy related products as well as other by products, all deriving from organic products and/or organic residues which are renewable, sustainable and storable.

[0057] The pyro lysis biomass chain reactor of the present invention operates in the same way that would a conventional central thermal device suited for electricity production, which uses biomass as a fuel generator to produce only electricity. The present inventor discovered that additional processes may be utilized to enhance the economics favoring biomass pyrolysis by enhancing the efficiency of electricity generation; generating end products such as ethanol fuel, methane gas, composts, and liquid fertilizer; cleanse water; and yield hydrogen and/or extract oil, acids and tars from coal mining.

[0058] PROCESS # 1 (Fig. 1). The chain reaction of the Biomass Chain Reactor in accordance with the invention operates differently in the sense that all kilns are being loaded. Each kiln, when ignited, needs exactly 8 hours to complete its endothermic and exothermic processes and thereafter 11 to 14 hours to cool off. This means that when Kiln # 1, after being ignited, achieves the endothermic timing after 1 hour and 12 minutes, its exothermic process starts for the remaining time of 6 hours and 30 minutes.

[0059] The temperatures in the chimney reached during such endothermic period are

352° C and 119° C in the incinerator and 462° C and 236° C in the following 6 hours and 15 minutes during its exothermic process. When the second kiln is ignited 2 hours and 38 minutes after the first one, the temperatures in average are, in the chimney, 569° C, and, in the incinerator, 282° C, during all processes. The average temperatures obtained when igniting the Kilns # 3, 2 hours and 4 minutes after kiln #2 are, in the chimney 559° C, and, in the incinerator, 512° C during all processes. Such results are obtained by igniting the kilns one after the other within a 2 and half hours of time interval. That way, the successive kiln to be ignited doesn't have to undergo the same time to complete the endothermic process as was necessary for the initially ignited one. All gases, other acids and tars are immediately processed in the exothermic mode in accordance with the invention.

[0060] Furthermore, during the exothermic processes of the kilns # 2 and 3, the kiln # 1 is cooling off, unloaded and reloaded for being again ignited without undergoing such long endothermic process anymore.

[0061] PROCESS # 2 (Fig. 2). By achieving this amount of heat (average during the 24 hours basis, in the chimney 450° C and 311° C in the incinerator) with the pyrolysis biomass chain reactor process from the main apparatus, part of such heat is diverted to a steam plant for generating pressured steam to a conventional multi input turbine and generator for producing electricity on 24 hours basis. The other part of the heat is directed for serving the PROCESSES # 3, 4, 5, 7 and 8 either by pulsed hot air or regular steam on the same 24 hours basis. PROCESS # 6 will be fueled either by electricity generated on site, for instance, if not hooked up on an electric utility grid or part of it. By having a conventional multi input turbine and generator on site, part of the production of the PROCESSES # 3, 4, 5 may be diverted to such conventional multi input turbine and generator.

[0062] PROCESSES # 3 - # 8 (Figs. 3-8). Schematic process of the chain reactor production is depicted, in which the kilns of the pyro lysis reactors for making charcoal are built, either in line and/or circular form around a steady smoke exhaust/incinerator which eliminate all pollutant green house gases arising during the pyrolysis process.

[0063] The dimensions of the kilns, flues, ducts, exhaust/incinerator are calculated for eliminating such pollutant green house gases.

[0064] By arranging the kilns and/or pyrolysis reactors as described in the Figs. 10-14, one may monitor by computer the temperatures of the kilns. By comparing the monitored temperatures, the computer may send instructions that direct the heating of the kilns to stay within desired ranges for carrying out pyrolysis. For instance, the temperatures may be influences by changes in the surrounding environmental temperatures and kiln exposure to solar radiation and thus the amount of heating may be varied to compensate accordingly. [0065] While the conventional producers of electricity use biomass as a fuel generator produce only electricity, the present invention produces biomass charcoal or wood charcoal, which, during the process of making it, generates thermal heat, Such thermal heat may be conveyed to a boiler to generate steam directed to a conventional multi input turbine and generator allowing production of electricity and high volume of steam. Indeed, the present invention may allow one to produce charcoal having a relatively high fixed carbon content and yet respect the most stringent environmental regulations in term of curtailing green house gases as compared with the conventional ways of yielding peat or making charcoal that discharge green house gases.

[0066] The present invention uses co-generated steam and/or part of the produced electricity to produce a closed loop, ethanol fuel and/or methane gas and/or hydrogen gas and/or extracting oil, acids and tars from coal mining and/or composts and/or liquid fertilizers. During these chain reaction processes, one can drive back part of the yield of methane gas to the exhaust/ incinerator, which will increase the yield of co-generating electricity and the steam. The co-generated electricity could either be directed to an electric grid or be used for electrolytic and/or catalytic processing to generate hydrogen gas and/or extracting oil, acids and tars from coal mining at lesser cost.

[0067] The PYROLYSIS BIOMASS CHAIN REACTOR of the present invention is in effect a closed loop multi clean energy production system.

[0068] The PYROLYSIS BIOMASS CHAIN REACTOR of the present invention is modular, which means, that one may build or use a unit production starting with 6 Kilns and increase the amount of them to 9, 12, 18 or more. The size of the unit is assessed according to the availability of discarded wood from logging left over; cutoff from sawmills; amount of sludge from sewers'; amount of organic wastes from households; amount of fats and/or organic wastes and residues from food industries and farms; manures from chicken farms, pig farms, cow farms and other breeders; water proximity.

[0069] Instead of burning the biomass for obtaining only electricity, the present invention produces charcoal having relatively high fixed carbon content, which has usage in many market segments, such as smelters industries, pharmaceutical industries, chemical industries, water purification and distillation industries, activated charcoal industries and barbecue (BBQ) industries.

[0070] As it can be seen in Fig. 1 concerning Process # 1 :

[0071] 1. One loads the Kiln 1 , 2, 3, η with prepared discarded wood from logging left over and/or Cutoff from sawmills;

[0072] 2. In parallel the receptacle tanks are loaded on daily basis of Various Organic

Wastes for Methane gas production and/or Ethanol production and/or fertilizers and/or composts silos and/or other tanks with coal mining for Extracting Oil, Acids and Tars from Coal Mining;

[0073] 3. Sequentially ignite the Kiln 1 to η for starting the pyro lysis process. At this point the chain reactor process starts as follows:

[0074] 4. The temperature in the kilns jumps from 0 degree Celsius to over 150 degrees

Celsius within 45 minutes;

[0075] 5. The moisture contained in the biomass as well as the gases and acid, during the endothermic phase, starts to run through the ducts and flues to the Exhaust/Incinerator in which the gases are ignited reaching a temperature of an average of 750 degrees Celsius within 15 minutes; [0076] 6. At this point, the exothermic cycle starts the chain reaction directing hot air and/or steam and/or pressured steam to the Receptacle tank of Organic Wastes for Methane gas production and/or Ethanol production and/or fertilizers and/or composts silos and/or other tanks with coal mining for Extracting Oil, Acids and Tars from Coal Mining;

[0077] 7. During these operations, the steam and/or the pressured steam starts to reach a conventional multi input turbine and generator and electricity starts to be produced and can be directed either to the ELECTRIC GRID and/or to a ELECTROLYTIC and/or CATALYTIC

CONVERTER for Hydrogen production;

[0078] 8. The chain reaction is now complete and we can start to send into the turbine and generator, simultaneously with the steam and/or the pressured steam, part of the methane gas produced and/or Ethanol and/or Hydrogen and/or oil and tar from the extracted coal mining process;

[0079] 9. The process is now launched and can be run on 24/7 (hour/week day) basis.

[0080] The present invention and its embodiment apparatuses allow the following yields:

(1) Charcoal having the highest Fix Carbon Content up to 89% and plus for use as Activated

Charcoal, which is at the present moment imported to a large extent from China (180,000 tons per year subject of 248% duties from November '06); (2) Clean and renewable Energy in form of Electricity and Thermal Heat; (3) Oil and Tar from the Coal Mining to be send to refinery for process; (4) Clean Coal free of pollutants; (5) Methane Gas as a minimum production of 180 to

200 Cubic meters per ton of residues maintained at 55 degree Celsius; (6) Ethanol fuel at more economical costs; (7) Hydrogen production using our electricity from closed loop; (8)

Organically fertilizer and/or composts maintained at 65 to 70 degree Celsius and free from any polluting substances or pathogens contaminants made from the organic residues from which

Methane gas and/or Ethanol fuel had been extracted before.

[0081] The following table shows the effect of final carbonization temperature on the yield and composition of the charcoal.

[0082] The effect of carbonization temperature on yield and composition of charcoal on traditional brick ovens or earth pits are:

Carbonization Chemical analysis of charcoal Charcoal yield based on

Temperature oven dry wood

⁶O øf fixed charcoal % volatile material (0% moisture) 300 68 31 42 δoo 86 13 33

700 92 7 30

[0083] Compared with the charcoal from the pyrolysis biomass chain reactor:

[0084] Pollutant gas emissions from furnaces. Incinerator and chimney temperatures

Pollutant gas emission factors in relation to current standards

* According to the ministerial order of France of February 2, 1998 ** undetected

FURNACE N⁰ 1

Incinerator and chimney temperatures

9 00 9 30 10 00 10 30 11 00 11 30

Time

CO, CO₂, NO_x and O₂ emissions

9 00 9 30 10 00 10 30 11 00 11 30

Time FURNA vo _raon.CE N⁰1 + 2

Incinerator and chimney temperatures

11:45:16 12:45:16 13:45:16 14:45:16 15:45:16

Time

CO, CO₂, NO_x and O₂ emissions

NOx en^tra_tim

11:45:16 12:45:16 13:45:16 14:45:16 15:45 16

Time SUO _cen_ra

FURNACE N⁰ 2 + 3

Incinerator and chimney temperatures

CO, CO₂, NO_x and O₂ emissions

cen_{t r}a_tion

15:50 16:00 16: 10 16:20 16:30 16:40 16:50 17 00

Tim e FURNACE N⁰ 7

Incinerator and chimney temperatures

15:40 15:50 16:00 16:10 16:20

Time

CO, CO₂, NO_x and O₂ emissions

₎

FURNACE N⁰ 7 + 8

Incinerator and chimney temperatures

16:25 16:35 16:45 16:55 17:05 17:15 17:25 Time

CO, CO₂, NO_x and O₂ emissions

ncen_{ti r}a_tim

16:25 16:35 16:45 16:55 17:05 17: 15 17:25

Tim e C_tons _raone_*

FURNACE N⁰ 7 + 8 + 9 Incinerator and chimney temperatures

17 30 17:40 17:50 18:00 18:10 18:20 18:30

Time

CO, CO₂, NO_x and O₂ emissions

17:30 17:40 17:50 18:00 18: 10 18:20 18:30

Tim e FURNACE N⁰ 7 + 8 + 9 + 10

Incinerator and chimney temperatures

CO, CO₂, NO_x and O₂ emissions

[0084] Figure Legends

[0085] Fig. 3: Grain silo 1; milling-processor 2; mashing processor 3; fermenting processor

4; distillation 5; dehydration 6; fuel ethanol 7; rectification process 8; industrial alcohol 9; valves and/or pump 10; centrifuge processor 11; central steam switchboard 12; evaporator 13; dryer 14; dried distillers grains 15; carbon dioxide plant 16; compressed carbon dioxide 17.

[0086] Fig. 4: Organic residues silo 1; grinding processor; three manure silos 3; mixer processor 4; methane digester 5; methane gases 6; sludge dehydration; cleansing water treatment

8; valves and/or pump 9.

[0087] Fig. 5: Manures silo 1; mixer processor 2; methane digester 3; methane gasses 4; valves and/or pump 5.

[0088] Fig. 6: Water pretreatment tank 1; catalytic processor 2; hydrogen gas tank 3; hydrogen gas tank 4; hydrogen fuel 5 (to market). [0089] Fig. 7: Storage silo 1 (of leftovers from process #3); storage silo 2 (of leftovers from process #4); grinding facility 3; mixing processor 4; laboratory 5; maturing fields 6; packaging facility 7.

[0090] Fig. 8: Storage silo 1 (of leftovers from Process #5); laboratory 2; standardizing dosage

3; packaging facility 4.

[0091] Figs. 10-11: Ref. Letter, Item Description

A; Kilns, chimney / incinerator, Ducts and Flues; B: Pipes driving heat to steam plant

C; Steam plant; D: Pipes driving the steam from steam plant; E: Conventional Turbine; F: Pipes and Rod of produced electricity; G: Conventional generator; H: Electric grid of the substation; I:

Electric grid to catalytic converter; J: Hydrogen Tanks; K: Pipes for water exchange; L: Pipes driving Hot Air or steam to methane tanks; M: Conventional digester for methane gas production; N: Pipes for residues exchanges; O: Kilns, chimney / incinerator, ducts and flues; P:

Pipes for Residues exchanges; Q: Pipes for sending methane Gas and / or Ethanol to Turbine; R:

Plant & silo for compost and liquid fertilizer production

[0092] Figs. 12-14: Ref.No, Item Description (Quantity)

1 : Incinerator (1) ; 2: Flues (2); 3: Kilns (12): 4: Metallic ducts (12): 5: Evacuation (12); 6:

Containers Trolley (1): 7: Extinguishers (20); 8: Container lifter (1): 9: Upper walkways (1); 10:

Protection set (1); 11 : Catwalks access (1); 12: Rails (1) ; 12: Building (1)

[0093] While the foregoing description and drawings represent the preferred embodiments of the present invention, it will be understood that various changes and modifications may be made without departing from the scope of the present invention.

Claims

WHAT IS CLAIMED IS:

1. A method of building and assembling a pyro lysis biomass chain reactor to turn biomass into charcoal, comprising loading a plurality of kilns each with biomass; sequentially igniting the kilns to start pyro lysis of the biomass in each; discharging, during an endothermic phase of the pyro lysis, moisture in the biomass as well as gases and acid that are byproducts from the pyrolysis into a common incinerator exhaust so as to heat the moisture and the air within the common incinerator exhaust; igniting the gases in the common incinerator exhaust; producing at least one of heated air, steam and pressurized steam as a result of the heating of the moisture and the air within the common incinerator; directing at least one of the heated air, steam and pressurized steam into a receptacle tank, extracting charcoal from within the kilns after an exothermic phase of the pyrolysis ends.

2. The method of claim 1 , further comprising depositing wastes in the receptacle tank and heating same to generate at least one of methane gas, ethanol, compost, fertilizer and an extraction of oil, acids and tars from coal mining.

3. The method of claim 2, further comprising directing the at least one of the heated air, steam and pressurized steam to also reach a turbine generator, generating electricity with the turbine generator by passing the at least one of the heated air, steam and pressurized steam through the turbine generator.

4. The method of claim 3, further comprising directing the electricity to at least one of an electric utility power grid, an electrolytic converter that yields hydrogen, and a catalytic converter that yields hydrogen.

5. The method of claim 3, further comprising sending part of the at least one of methane gas, ethanol, compost, fertilizer and extraction simultaneously with the at least one of the heated air, steam and pressurized steam to the turbine generator.

6. The method of claim 1, further comprising directing the at least one of the heated air, steam and pressurized steam to also reach a turbine generator, generating electricity with the turbine generator by passing the at least one of the heated air, steam and pressurized steam through the turbine generator.

7. The method of claim 1 , wherein the receptacle is a digester loaded with contents at least one of which being selected from a group consisting of organic residues from sewer, household organic wastes, oil cake from ethanol and farm manures, the digester forming methane gas from the contents being heated from the at least one of heated air, steam and pressurized steam.

8. The method of claim 7, further comprising directing part of leftover from the forming of methane gas to the turbine generator.

9. The method of claim 1 , further comprising monitoring thermal parameters during the pyro lysis and adjusting thermal conditions of the kilns as warranted to compensate for deviations between the monitored thermal parameters and norms for same to effect the pyrolysis.

10. A pyrolysis biomass chain reactor, comprising a plurality of kilns each configured to be loaded with biomass, the kilns each discharging moisture, gases and acids that are byproducts of the pyrolysis into a common incinerator exhaust whose internal temperature is sufficiently high to ignite the gases and produce at least one of heated air, steam and pressurized steam, a receptacle tank arranged to receive the at least one of the heated air, steam and pressurized steam.

11. The reactor of claim 10, wherein the kilns are substantially equidistant from the common incinerator exhaust.

12. The reactor of claim 10, wherein the kilns are arranged in a daisy wheel circle with the common incinerator exhaust located substantially at a geometric center of the daisy wheel circle.

13. The reactor of claim 10, wherein the kilns are arranged in parallel lines.

14. The reactor of claim 10, further comprising computerized controls configured to direct sequential igniting of the kilns to start pyrolysis of the biomass in each.

15. The reactor of claim 10, wherein the receptacle is configured to have contents that transform due to presence of the at least one of the heated air, steam and pressurized steam into at least one of methane gas, ethanol, compost, fertilizer and an extraction of oil, acids and tars.

16. The reactor of claim 15, further comprising a turbine generator arranged to receive also at least one of the heated air, steam and pressurized steam so as to generate electricity in response to passing the at least one of the heated air, steam and pressurized steam through the turbine generator.

17. The reactor of claim 16, further comprising a power lines arranged to route the electricity to at least one of an electric utility power grid, an electrolytic converter that yields hydrogen, and a catalytic converter that yields hydrogen.

18. The reactor of claim 16, further comprising a flow guide arranged to direct part of the at least one of methane gas, ethanol, compost, fertilizer and extraction simultaneously with the at least one of the heated air, steam and pressurized steam to the turbine generator.

19. The reactor of claim 10, further comprising a turbine generator arranged to receive also at least one of the heated air, steam and pressurized steam so as to generate electricity in response to passing the at least one of the heated air, steam and pressurized steam through the turbine generator.

20. The reactor of claim 1 , wherein the receptacle is a digester loaded with contents at least one of which being selected from a group consisting of organic residues from sewer, household organic wastes, oil cake from ethanol and farm manures, the digester forming methane gas from the contents being heated from the at least one of heated air, steam and pressurized steam.

21. The reactor of claim 20, further comprising a passage configured to direct part of leftover from the forming of methane gas to the turbine generator.

22. The method of claim 1, further comprising monitors of thermal parameters during the pyro lysis and a control suited to adjust thermal conditions of the kilns as warranted to compensate for deviations between the monitored thermal parameters and norms for same to affect the pyrolysis.