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Biochar Production Technologies

Technology for making biochar can be as simple as a pit fire or as complex as a modern bio-refinery, making biochar production an appropriate technology for smallholder farmers as well as industries with thousands of tonnes of biomass and net zero goals to reach.

Learn more about biochar production technologies with IBI’s Biochar Technology Podcast

The basic process to create biochar is pyrolysis.

Pyrolysis is the breaking down (lysis) of a material by heat (pyro). As the material is broken down, it releases gas. This is the first step in the combustion or gasification of biomass.

All the processes involved in pyrolysis, gasification, and combustion can be seen in the flaming match. The flame provides heat for pyrolysis, and the resulting gasses and vapors burn in the luminous zone in a process called flaming combustion, leaving behind char. After the flame passes a given point, the char may or may not continue to burn. When the match is put out, the remaining wood continues to bake, or pyrolyze, releasing a smoke composed of condensed tar droplets as it cools.

Biochar production systems are generally classified as either pyrolysis or gasification systems.

Production Systems

Pyrolysis Systems

Pyrolysis systems use kilns and retorts and other specialized equipment to contain the baking biomass while excluding oxygen. The reaction vessel is vented, to allow pyrolysis gasses to escape. Pyrolysis gasses are often called “syngas”. The process becomes self-sustaining as the syngas produced is combusted, and heat is released.

There are two types of pyrolysis systems in use today: fast pyrolysis and slow pyrolysis. Fast pyrolysis tends to produce more oils and liquids while slow pyrolysis produces more syngas.

gasification

Gasification Systems

Gasification systems produce smaller quantities of biochar in a directly-heated reaction vessel with introduced air.

The more oxygen a production unit can exclude, the more biochar it can produce. Biochar production is optimized in the absence of oxygen.

Biochar Producing Stoves

An estimated two billion people in the developing world cook and heat their homes with primitive stoves or open fires through the burning of wood, straw, dung, or coal. These inefficient stoves emit air pollution that can harm respiratory and cardiac health and exacerbate the climate crisis. Biochar producing stoves offer a solution. For decades, a small group of researchers and development advocates have worked to improve household biomass energy technologies. Newer stove designs can create heat for cooking while also producing biochar for carbon sequestration and soil building. Testing indicates that these stoves are much more efficient and emit less pollution, while the need for less wood can lead to decreased deforestation.

There are, however, many challenges that face biochar stove designers.

  1. Ensuring that biomass consumption is lowered.
  2. Producing an affordable, durable stove that is easy to operate and maintain.
  3. Producing a stove whose efficiency doesn’t decrease over time.
  4. Understanding the potential added burdens of producing and distributing
  5. biochar—especially for women.
  6. Understanding behavioral and sociological barriers to new technologies.

Potential Benefits of Biochar Producing Stoves

User Health

Biochar-producing stoves can potentially create a much cleaner environment for users with lower emissions of carbon monoxide, hydrocarbons, and fine particles.

Climate Change Mitigation and Soil Health

Biochar-producing stoves have lower greenhouse gas emissions (carbon dioxide and methane) and black carbon emissions. The biochar created during the heating process can be used to sequester carbon in soils, increase soil fertility and productivity, and reduce the need for fossil-fuel based fertilizers.

Reduced Deforestation

Biochar-producing stoves use less fuel. They can also use a wider variety of fuels and can replace inefficient charcoal production technologies.

Income Generation

Biochar-producing stoves can accommodate many forms of agricultural residues—some without further treatment. Collecting and selling this residue is an income-generating opportunity not presently available for most other stoves since they can’t operate on those types of fuels.

Black Carbon and Biochar-Producing Stoves

The UN Environment Program now recognizes that Atmospheric Brown Clouds (ABCs) are a major contributor to climate change (UNEP, 2008). ABCs are caused by particulate emissions from inefficient combustion of biomass and fossil fuels and they include both black particles (soot) that heat the atmosphere by absorbing sunlight, and white particles that reflect sunlight and contribute to cooling.

Black carbon has a significant effect on global warming, second only to carbon dioxide (CO2) (V. Ramanathan & G. Carmichael, 2008). However, the atmospheric residence time of black carbon is only a few weeks, while CO2 emissions stay in the atmosphere for more than a century. This means that we have an opportunity for immediate action to decrease climate forcing by reducing black carbon emissions.

While much of the black carbon is emitted by forest fires and diesel fuel used in industrialized nations, between 25 and 35 percent comes from household energy use in China and India (V. Ramanathan & G. Carmichael, 2008). Unfortunately, even some improved (non-biochar-making) cookstoves that are otherwise efficient users of wood still emit large amounts of black carbon. One study comparing improved cookstoves showed that a common design, the rocket stove, had black carbon emissions equal to those of an open fire (MacCarty & Bond, et al, 2008). The study found that gasifier stoves, both natural draft and fan-assisted, had very low black carbon emissions. These are the types of stoves that can be configured to produce biochar.

Biochar-producing stoves are not yet a mature technology, and indeed, the emissions from the few designs that have been developed have not yet been systematically tested. However, there are good reasons to believe that they will be as clean as or cleaner than other gasifier stoves that do not retain the biochar but combust it (P. Anderson, 2009).

The Status of Stove Technology

A number of researchers and programs world wide are devoted to producing efficient and cost-effective biochar-producing stoves. However, as yet there has been very little in the way of funding for these projects. Explore some of the stove designs and programs that are in operation below.

Top-Lit Updraft Gasifier (TLUD) Stoves

There are many variations on the TLUD, but the biggest distinction is between natural draft TLUDs and fan-forced TLUDs. The TLUD operates as a gasifier by creating a stratified pyrolysis/combustion regime with four basic zones: raw biomass, flaming pyrolysis, gas combustion and charcoal combustion (see diagram to the right, modified from Anderson & Reed, 2004).

Anila-type Stoves

The modern Anila stove was developed by U.N. Ravikumar, an environmentalist and engineer with the Director of the Centre for Appropriate Rural Technologies (CART) at India’s National Institute of Engineering. Anila-type stoves use two concentric cylinders of different diameters (see diagram). Biomass fuel is placed between the two cylinders and a fire is ignited in the center. Heat from the central fire pyrolyzes the concentric ring of fuel. The gasses escape to the center where they add to the cooking flame as the ring of biomass turns to char. The center combustion chamber can be configured as either a rocket stove design (with a side opening door) or as a TLUD with primary combustion air entering from the bottom. (Anila diagram courtesy of Stephen Joseph).

Scale and Variety of Units

Gasification and pyrolysis production systems can be mobile or stationary units.

At the local or regional level, pyrolysis and gasification units can be operated by co-operatives or larger industries, and can process up to 4,000 kg of biomass per hour. Small scale gasification and pyrolysis systems that can be used on farms or by small industries are commercially available with biomass inputs of 50 kg/hr to 1,000 kg/hr.

Biochar ovens are low tech biochar production units with a primary design function of producing biochar. This category of biochar production unit can be suitable for clean, healthy, distributed low tech biochar production (DLT) of by developing country smallholders and micro-entrepreneurs; “backyard” producers utilizing yard waste; small and urban farmers; nurseries; communal gardens; etc to convert the thinly distributed feedstock (TDF) available to them. The feedstock ‘chamber’ of these units will usually be in the range of very small to 4-500 liters. The primary functional design of these units is to produce biochar. To date, the primary technologies used in units that fall within this category are retorts; Top Lit Up Draft (TLUD) units and TLUD/retort hybrids; and Top Fed Open Draft (TFOD) units such as cones and pyramids (metal & pit) and rings. Other functional designs may fall within this category (based on size, primary design function, and technology level) as they are developed. The name of this category is based on the metaphor that, as a bread oven is a unit used to bake dough to produce bread, a biochar oven is unit used to bake feedstock to produce biochar. Open-source designs for ovens can make them a very economical choice.

Charcoal-making stoves show promise of bringing low-cost biochar to rural areas. Biochar production can help build soils and provide households with new opportunities to earn income.

There is also potential to develop stoves and furnaces for urban and suburban use that gasify biomass and leave behind charcoal. Such stoves could cook food and heat water while they make biochar for gardens and landscaping.

Opportunities for Advanced Production

Continuous feed pyrolyzers to improve energy efficiency and reduce pollution emissions associated with batch kilns. Exothermic operation without air infiltration to improve energy efficiency and biochar yields. Recovery of co-products to reduce pollution emissions and improve process economics. Control of operating conditions to improve biochar properties and allow changes in co-product yields. Feedstock flexibility allows both woody and herbaceous biomass (like crop residues or grasses) to be converted to biochar. Some technologies that hold promise for helping achieve these goals include drum pyrolyzers, rotary kilns, screw pyrolyzers, the flash carbonizer, fast pyrolysis reactors, gasifiers, hydrothermal processing reactors, and wood-gas stoves, all of which produce varying quantities of gas and liquids along with biochar.