Wood Pyrolysis to Biochar

Submitted To: Engineering Physics Review Board

Submitted By: Chris Alkire
Embry-Riddle Aeronautical University
600 S. Clyde Morris Blvd. Box 4243
Daytona Beach Florida
September 15 2016
Chris Alkire
Principal Investigator/Team Leader
Phone:
Email:
Co-Investigators/Team Members:

___________________________________
________________________

Myriah Wilson (Structures)

________________________
Chris Alkire (Team Leader)

Jessica Hagan ( )

Abstract

1 Introduction
There is a global concern about the impacts of excessive carbon dioxide emissions and pollution
in our atmosphere, bodies of water, and our land. In previous generations, large quantities of
smoke and construction were a sign of progress and applauded. Now, we have a better
understanding of the cost that this progress had on our environment. With a growing concern
regarding the effects of carbon emissions the public demand for change has risen sharply.
Governments around the world have been implementing new regulations companies are required
to abide by in order to produce less harm to our environment. If a company were to exceed the
amount of carbon dioxide production, or pollute an area they would receive a substantial fine or
even risk their company being shut down. Whether inspired to help the planet or to provide a fix
for companies, there is a demand for newer technology and processes that either limit or
completely eliminate the involved emissions and pollutants.
Gasification is a process that converts organic carbonaceous material into basic carbon and
hydrogen compounds and has been around since the early 1700s. Gasifying a product includes
drying, pyrolysis, combustion, and reduction. Drying a feed is true to its name. Its a basic
process that removes the moisture from the feed at temperatures ranging from 100-200 degrees
Celsius allowing the following processes to perform at a higher quality. Pyrolysis breaks down
carbonaceous material through thermal decomposition with temperatures ranges of 200-500
degrees Celsius producing various energy carriers such as volatile gases, also known as synthetic
gas or syngas, and biochar with bio-oil. Combustion is as well true to its name where the feed is
brought to a maximum temperature ranging from 600-1200 degrees Celsius. Reduction then
strips the oxygen atoms off combustion products to manufacture the molecules to forms that can
burn at temperatures ranging from 600-900 degrees Celsius.
The products of pyrolysis have various uses that make the process convenient. The syngas
produced has a high amount of combustibles such as hydrogen, carbon monoxide, and methane.
Once refined, the gas can be put through various processes in order to create an assortment of
fuels. The bio-oil, or pyrolysis oil, is currently under investigation for its ability to become a
substitute for petroleum, while also being used as fuel sources for boilers, furnaces, hot water/air
generators, electric generators and diesel pumps. Biochar has numerous applications. Similarly to
the syngas and bio-oil, it can be used like coal and burn o produce heat. However, it can also be
used for soil amendment, a sand-charcoal water filtration system, and is currently being
investigated as an approach to carbon sequestration.
Biochar is the desired product and will affect the decisions made in the design and experiment.
The creation of a cost efficient pyrolysis chamber would aid in multiple Earth projects while also
benefitting the Martian Space Missions by providing a reliable, renewable resource for a Martian
base when the time comes. The biochar would be able to provide options for nutrient rich soils
for plant growth decreasing the need for food supply missions. Also by providing recycling
options for organic waste produced while occupying the planet to aid in the riddance of waste
and abide by space laws.
Carbon Terrra is focusing on the market with biochar as a feed supplement. Research shows that
adding 20g/day of biochar to young livestock (80-100kg) increased their growth during the study
period of 21 days with 25% and simultaneously reduced methane emissions from the animals by
22%. Also, other studies demonstrate a reduced methane production by using biochar as feed

supplement
to
ruminants
% of biochar in the feed [7].

by

10%

when

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2 Literature Review
2.1 Heat Transfer Rate
Depending on the conditions that a feedstock goes through, the product of pyrolysis can differ in
quantity ratios. Different operating conditions produce different products in pyrolysis. These
conditions are temperature, heating rates, residence time, biomass size etc. There are two main
types of pyrolysis processes that a feed can go through, slow and fast pyrolysis.
2.1.1 Slow Pyrolysis
During slow pyrolysis, thermal decomposition occurs in an inert atmosphere with a slow heating
rate of 5-10 degrees Celsius per minute to a maximum temperature of 300-600 degrees Celsius.
This is the ideal process to produce biochar because the components in the vapor phase continue
to react with each other. This reaction results in the formation of solid char and other liquids [19].
The liquid produced separates into two phases, pyrolygneous water and decanted oil [1]. Any
reactor that utilizes particles larger than 2 mm in diameter is considered a slow pyrolysis reactor.
Some examples are kilns, retorts, and converters [18].
Vacuum Slow Pyrolysis
This is a section of slow pyrolysis where the organic material is heated in a vacuum to decrease it
boiling temperature, avoiding adverse chemical reactions [21].
2.1.2 Fast Pyrolysis
During fast pyrolysis, the feedstock is heated at high ramp rates of over 300 degrees Celsius per
second to a maximum temperature range of 600-1000 degrees Celsius. Typically fast pyrolysis
produces 60-75% liquids, 15-25% solids, and 10-20% gases, depending on the feedstock used
[19]. It uses small particles due to the low thermal conductivity of lignocelluloses materials [18].
High heat transfer and heating rate, very short vapor, residence time, rapid cooling of vapors and
aerosol for high bio-oil yield and precision control for reaction temperature are the basic
characteristics of fast pyrolysis. A disadvantage is that the char accumulates quickly and must be
removed quickly.
Flash Fast Pyrolysis
A subsection below Fast Pyrolysis, Flash pyrolysis has a ramp rate greater tank 800 degrees
Celsius per second to a maximum temperature of 1200 degrees Celsius. This process is
characterized by rapid devolatilization in an inert atmosphere, high heating rate of the particles,
high reaction temperatures, and very short gas residence time. However, with poor thermal
stability and corrosiveness of the oil, solids in the oil, increase of the viscosity over time by
catalytic action of char, alkali concentrated in the char dissolves in the oil and production of
pyrolysis water, its not (word here I cant think of) [19].
Ablative Pyrolysis

Pressure is applied to biomass to increase speed of decomposition through use of centrifugal or

mechanical force [20]. It uses larger particles through fast removal of the low thermal
conductivity layer of biochar that forms around the particle [18].
Cyclinic Pyrolysis
This process is also called the cortex fast pyrolysis, where at the end of pyrolysis the system
separates the solids from the liquids and returns them to the mixer [20]
Rotating Cone Pyrolysis
Uses a compact high intensity reactor in which biomass at ambient temperature is mixed with hot
sand. When mixing, the biomass decomposes into 70% gas, 15% liquids, and 15% char [20].
2.2 Mode of Operation
Batch Pyrolysis
Typically for small scale systems, a batch operation is preferred. Batch reactors are mainly used
for the production of biochar, while the recovery of the other byproducts is often a secondary
mission. First the units are loaded with the biomass and sealed properly to keep oxygen from
entering into the system. Once sealed, the chamber is heated to initiate the pyrolysis reaction.
Once the process of heating the product is complete, a nonproductive cool down period occurs
before extraction, and before the equipment can be ready to heat another batch. Once the entire
system is cooled down, the biochar and other vapors can be extracted and the system can run
again. Advantages rely with the systems simplicity and easy operation, however this cool down
period can take hours depending on the initial temperature and there is a large amount of labor
that undergoes loading and unloading the system. It also has a significant energy loss during this
cool down period. [1]
Continuous Pyrolysis
Continuous pyrolysis systems are designed to operate nearly continuously with only occasional
downtime during maintains. The operating system allows for a continuous addition of biomass
without stopping. Often used for large scale production of biochar, a typical unit has a capacity
of over 2.75 tons/hour [6]. The designs include intake and extraction subsystems to maintain
operating conditions within the chamber. The complexity of the system shows in its designs and
can become a disadvantage when building and operating it, however when it comes to thermal
losses it tends to be more efficient than the batch operation. [1]
2.3 Feed Stock
In the process of slow pyrolysis char can contain 25-35% of the original feed stock and up to
50% of the original carbon [5]. With the chamber under pressure, the process produces more char
when the moisture content is lower so it is important to keep the biomass dry. However, in
general slow pyrolysis is more tolerant to the moisture content being high although it will result
in the efficiency of the reactor to decrease [7].
Despite which of the above methods of pyrolysis are used, the final product's yield and
characteristics are determined by the properties of the feed stock used [22]. The characteristics
of the feed stock that will have the greatest impact on the product is where the biomass is grown,
climatic conditions, soil type and cultivation practices [7]. The preferred type of feed stocks are

plant biomass, human wastes, food scraps, paper, cardboard [13], garden waste, untreated textile,
paper fibers, plant based packaging materials, bio manure, slaughterhouse waste, and plants
growing in water [7]. Plant biomass and paper have a large amount of oxygen in the
composition of the material. This will result in a production of large amounts of water being
from the produced as steam, which can be capture and passed through a condenser to produce
water [14].
2.3.1 Pre-treatment
Regardless the pyrolysis method used, pre-treating the feed stock will increase the efficiency of
the process. Pre-treating the feed stock is done by drying, shredding, sorting, alkali compound
removal or any combination thereof [6].
Drying
Drying the feed stock will increase the efficiency of the process [7] by reducing the moisture to
10-20% of the biomass. However, since it takes a lot of energy to dry the feedstock within the
pyrolysis unit, the biochar production will be reduced. Some of the energy loss can be managed,
during the drying process, by directing the waste heat that is produced into the drying units [6].
Shredding
Shredding is a pre treatment that will decrease the size of the material. This is important because
both fast and slow pyrolysis requires different size particles in order to be effective. Fast
pyrolysis requires the size of a feedstock particle to be smaller than 2 mm, while in slow
pyrolysis the particles can be larger than 2 mm [7]. Two common devices that are used in order
to reduce the size of the particles are knife chippers and hammer mills. Knife chippers are high
speed rotary blades that are best for grinding wood. Hammer mills crush any falling biomass on
a breaker plate. The crushed biomass is then put onto screen while a hammer pulverizes the
particles. The size of the finial product is determined by the diameter of the bottom screen [6].
Sorting
In order to prevent damage to the equipment or contaminating the final produce the feed stock
must first be clear of stones, metal, or any loose objects [7]. For example, if there is any metal
fragments present in the feed stock while it is going through the knife chippers the metal will
dull the blades of the chippers and also has the possibility of causing pieces to break off [6].
Alkali compound removal
When there is a high level of alkali compounds present in feed stock, extra char will be
produced. This is good if bio char is the desired ended product, however, no if the desire product
is a high percent of bio oil. Leaching the biomass will remove up to 80% potassium, sodium,
and 90% chlorine. Leaching is a process of washing the biomass in water, and then
mechanically dewatering the waterlogged feed stock [6].
Feed Input
The loading of the pyrolysis unit with feed stock can be accomplished in one of three ways:
manually, mechanically, and with the use of wagons. Manual loading is done by workers putting
feed stock in and taking it out of the unit through a door. This method is labor intensive and
expensive because of the danger it poses to the workers. Mechanical loading has advantages
when the pyrolysis unit is at a large plant. The use of conveyer belts, bucket elevators, and
tractor scoops allows the product to be moved efficiently and quickly while the risks to workers

are low. Wagon cars carry the feed stock into the oven directly by the use of tracks, and then
come out the opposite side with the resulting biochar. This method cut costs considerably.
However, due to the thermal fatigue of the carts, maintaining and replacing them are a major
factor in the operating cost [6].
2.4 Pyrolysis Chamber
An effective pyrolysis chamber must meet all of the safety requirements, must be able to reach
and maintain at least 400C, maintain a consistent temperature and pressure, and use any type of
feed stock stated above.
2.5 Heating Unit
2.5.1 The Mitsui Rotary Drum Pyrolyzer

Figure 1: The Mitsui Rotary Drum Pyrolyzer

Consisting of an externally heated rotating horizontal cylindrical shell the biomass is moved
from inlet to outlet through mechanical paddles that push the biomass. The material is heated
indirectly with hot gases, and after the starting phase the gases produced from the pyrolysis can
be heated and used as fuel. This makes the unit energy independent. A disadvantage is that this
type of pyrolyzer can cause the pyrolysis vapors to overheat resulting in the change of the vapors
into solid carbon and non-condensable gases. To fix this, multiple burners at uniform
temperatures are used with the rotary drum to maintain an optimum wall temperature. However,
this also requires two sets of blowers to recycle product gas and supply air to the burners
respectively. This type of pyrolyzer is complex to build due to the heat circulation and is
composed of elements that increase the risk of hazard.

2.5.2 The Inclined Rotary Kiln Pyrolyzer

Figure 2: The Inclined Rotary Kiln Pyrolyzer

The inclined rotary pyrolyzer is an externally heated rotating inclined cylindrical shell operating
at atmospheric pressure. Similar to the drum except that the inclination allows gravity to draw
the biomass from the inlet to the outlet instead of using paddles. In Figure #, the burner at the
lower end provides auto-thermal heating, where the hot gases flow counter current of the moving
biomass. With is being simple in design and lack of moving parts, it has the same disadvantages
as the rotary drum pyrolyzer, which include the difficulty in controlling the process temperature
accurately.
2.5.3 The Screw Pyrolyzer

Figure 3: The Screw Pyrolyzer

This type uses an Archimedes screw to move the biomass continuously along a heated cylindrical
vessel with indirect heating through the walls by use of gas burners. The gases and vapors are
taken to a condenser to produce bio-oil, non-condensable gases and biochar, which fall out from
the vessel through an extraction system. The heating system is place at bottom of the system so it
can provide heat to the area that most of the material is touching. This unit type is relatively
simple and has been proven to function for small and large scale operations.

2.5.4 The Vessel Pyrolyzer

The vessel pyrolyzer is fundamentally a pressure vessel that is loaded, sealed, and then heated.
Once the process of pyrolysis is completed the system is cooled, unloaded, and the vessel is
ready to start the process again. This simple process makes it great for a batch fed system. Vessel
pyrolyzers are very easy to build and very simplistic in design having no problem maintaining
temperature and pressure inside the chamber, however the unit typically entails a significant
thermal loss during the heating and cooling cycles with no ability to generate power
continuously.
2.6 Cooling System
In order for the syn-gas and bio oil to be handled after pyrolysis it must first be cooled. The most
effective method is having the vapors pass through a series of condenser containing water of
about 20C. The condensers will reduce the vapors into condensable (bio oil) and noncondensable gases (syn-gas). Once the vapors have reached either bio oil or syn-gas form, they
are ready to remove and analyze [22]. The biochar must be separated from the heating unit in the
pyrolysis chamber in order to start the cooling phase. While, the method of moving the biochar
is left up to the design and efficiency of the pyrolysis chamber; all of the biochar must be cooled
gradually and for large batches this process could take up to 48 hours a load to cool [6].

3 Mission Objectives
The primary objective of this project is to design and build a working pyrolysis chamber that can
produce a significant amount of biochar. The secondary objective would be to conduct successful
experiments with the system.
3.1 Primary Objective
The figure below outlines a basic block diagram of how the pyrolysis process will work. The
feed will be pre-dried and kept in a desiccators to keep the feed from absorbing the atmospheric
moisture. Each batch will be of the same mass so there is no bias in biochar production. The feed
will then be entered into the system where it will become exposed to the thermal temperature of
375 degrees Celsius. The pyrolysis chamber will have the feed move along at a speed
proportional to the residence time of pyrolysis. As the process continues, the gases produced will
be able to move up and into a gas cooling chamber. This chamber will have the capability of
sealing from the rest of the system to move the gas to any area for analysis. As the feed becomes
char it will reach the end of the pyrolysis chamber where it will be moved into the solid cooling
chamber. In here, a separate compartment will be held so liquids will have the ability to be
drained as well as the ability to seal from the solid cooling chamber and be moved for analysis.
Once the entire system in complete the biochar will be extracted and analyzed for its color,
weight, density, and other properties.

Figure 4: Basic Pyrolysis Diagram

3.2 Secondary Objective

The secondary objective of this experiment will be to measure both the temperature and pressure
of the system while it is working.
Temperature
The type of biochar produced from pyrolysis has a factor of temperature. The starting experiment
will have a temperature of 375 degrees Celsius. This was determined after extensive research on
similar experiments and what temperatures they used.
If time permits, multiple experiments dealing with temperature differences would be performed
with a temperature range from 300-400 degrees Celsius increasing in increments of 25 degrees.
This will give a nice color change and char difference to visually see. Also, it will provide some
insight into the different steps pyrolysis takes.
Pressure
Pressure has been known to play a role in the char produced in pyrolysis. The starting
experimental pressure will be at atmospheric pressure.
If time permits, a second and third
experiment will be conducted with low and high pressure respectively.

4 Management Plan
Each task will be divided up as equally as possible. Jessica Hagan will be responsible with
communication to the current contacts Dr. Robert Baldwin, and various other companies. She
will be in charge of final decisions regarding the design of the Pyrolysis system. Co-

manufacturer of parts when necessary. Reports and reviews will be written with team member.
She will have the responsibility of performing the experiments when necessary
Myriah Wilson will be responsible for communication to future contacts regarding parts and
donations. She will be in charge of all ordered parts and making sure they ship to the school
when necessary. Co-manufacturer of parts when necessary. Reports and reviews will be written
with team member. She will have the responsibility of making sure the equipment needed before
experiments at the experiment location (feed, tools, measurements, etc.).
Chris Alkire

5 Schedule and Milestones

6 Cost Estimate
Parts
Temperature Gauge $60
The temperature gauge needs to have the ability to give measurements in real time and can
withstand temperatures of 450 degrees Celsius
Pressure Gauge $50
The pressure gauge needs to have the ability to give measurements in real time and cn withstand
temperatures of 450 degrees Celsius.

Desiccator $45-$70
The device needs to provide an air tight moisture free environment to store the batches of dried
material.
Electrically heated augers $150-$600
The equipment needs to have the ability to reach and maintain high temperatures.
Software packet

7 Safety Elements
In order to design an environmentally friendly pyrolysis reactor it must follow a set of several
guidelines set by the Ecology Waste to Resources Program.
Pyrolysis unit should be net exporters of energy and only operate on renewable energy
without reliance on fossil fuels or any sort of remote energy generation.
The heating process must be efficiently incorporated into the design and be generated
from renewable resources.
The entire design process must use water carefully and conservatively.
Short term environmental impacts must be considered during the design process.
Designs must be flexible enough to accommodate several different production needs.
Not only are there environmental concerns when operating a pyrolysis there are also many safety
concerns. While the reactors are simply to use and operate, carelessness and complacency can
lead to a loss of product and endanger the operators.
The operators of the reactors should always be aware of explosion hazards. The pyrolysis
system can explode burn or collapse when it is improperly used. Explosions can also happen if
methane, hydrogen and air mix inside of an air inlet. These explosions might not hurt the
operators, but it could cause damage to the structure of the reactor. In order to prevent these
explosions a method called puffing which is the release of pressure is used and can be controlled
with temperature regulation through air inputs. If a fire should happen it normally will lead to a
fire. Thus, biochar production should occur a proper distance away from buildings, brush, and
anything else that might be flammable [6].
The temperature of the pyrolysis system has to be monitored at constant intervals. Intake and
vent closure plates should be consider in order preventing explosion or fire hazards. Also, water
should be available the entire time the system is in operation. The water should be kept in
storage containers and remain on the burn site within reach should a fire or explosion happen.
Other safety equipment that would useful is large capacity fire extinguisher and a hose with a
nozzle will provide an extra measure of fire protection. A first aid kit should be kept on the site,
along with the operators should wear gloves while opening the door and falling or tripping
should be avoided while the system is in operation. Fuels with low flash points should never be
used. Once the system has cooled, gases may still be in the reactor so operators should wear
masks in be in a well ventilated area to prevent the inhalation of harmful gas [6].
The process of moving and storing the biochar require a different set of safety standards. Once
biochar is removed it could absorb oxygen which would lead to combustion. The biochar fines
should be removed before the biochar is stored. If any burning materials where missed during
the removal process, do not let the hot coals near the storage area. Allow the hot coals to sit in
an open and dry area for at least 24 hours before it is put into storage. Biochar fines should be

placed in a separate pile from the biochar for at least five days. While the biochar and biochar
fine are cooling they should be kept in a well ventilated area and out of the rain [6].

References
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Tull. "Proof of Concept Pyrolysis System Design."Proof of Concept Pyrolysis System
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Statements of Support

Team Mr. Pyro

September 12, 2016
To whom it may concern,
I acknowledge that I am a co-investigator to the Engineering Physics (EP) Senior Design team
using pyrolysis in order to monitor the effectiveness of biochar production. I intend to carry out
all responsibilities that are identified as being mine in the project proposal to the Engineering
Physics Review Board.
Specifically, I will be responsible as the Co-Investigator for the design and building of the
pyrolysis system including the reactor. I will make sure that safety and environmental
requirements are met. I will also be responsible for any chemistry that is required for the
collection and analyzation of the biochar. If there is adequate time in the spring 2017 semester, I
will participate in analyzing any bio oil and syngas that is produced and collected alongside of
the biochar. Additionally, I will assist in writing the reports and participating in the presentation
to the EP reviewing committee. As a member of this team I will attend all designated meeting
times, and work closely with Jessica Hagan in order to meet the deadlines set by ourselves and
the faculty.
______________________
Myriah Diane Wilson
Engineering Physics Senior
Embry Riddle Aeronautical University
600 S. Clyde Morris Blvd.
Daytona Beach, FL. 32114

Team Mr. Pyro

September 12, 2016

To whom it may concern,

I acknowledge that I am identified as Co-Investigator to the investigation entitled Green

Trash Disposal for the Engineering Physics (EP) senior design project. I intend to carry out all
responsibilities identified in this proposal. I understand the extent of my participation according
to the proposal and will be considered during the peer review. I agree that this proposal correctly
describes my duties during the course of my senior year.
Specifically, I will be responsible as the Co-Investigator for the design and building of
the pyrolysis system including the reactor. I will make sure that safety and environmental
requirements are met. I will also be responsible for any chemistry that is required for the
collection and analyzation of the biochar. If there is adequate time in the spring 2017 semester, I
will participate in analyzing any bio oil and syngas that is produced and collected alongside of
the biochar. Additionally, I will assist in writing the reports and participating in the presentation
to the EP reviewing committee. As a member of this team I will attend all designated meeting
times, and work closely with Myriah Wilson in order to meet the deadlines set by ourselves and
the faculty.
______________________
Jessica Hagan
Engineering Physics Senior
Embry Riddle Aeronautical University
600 S. Clyde Morris Blvd.
Daytona Beach, FL. 32114