A. Challenges
Resolving the climate change problem is not just by the reduction / mitigation of carbon emissions. It also depends upon substantial carbon dioxide removal (CDR). Of the several CDR methods, biochar sequestration is currently dominant (87% of delivered durable CDR credits in 2022) but still totally inadequate with less than 1 million tonnes CDR/yr. What is missing are biochar production technologies to reach cumulative gigatonne levels per year with markets and costs that are sustainable to society.
There are at least two major approaches to biochar production. One is “high-tech” with focus on low labor, much mechanization, automation, instrumentation and desired continuous operation, all of which favor large, expensive, fixed-position installations with considerable attention in biomass supply within reasonable distances. In contrast, “low-tech” pyrolysis typically has smaller, less expensive (even cheap), movable devices that can be positioned reasonably close to the biomass sources. The two approaches are different, especially in the initial CAPEX (capital needed to get started), but neither one is better nor worse than the other. Do not expect one solution to serve both approaches.
However, for both high- and low-tech approaches, the desired solutions should ideally:
- dramatically reduce costs (for initial equipment expense and/or per unit of biochar produced),
- substantially increase biochar production capacity (through volume per unit or with more units), and
- be acceptable to society regarding emissions, safety, environment, etc.
Small incremental changes to existing methods are good but generally do not yield major changes. Instead, distinct new innovations can lead to major changes that could eventually be called breakthroughs or paradigm shifts, possibly with patents. Such “new solutions” are first seen by their creators, then by those who know the topic well, and eventually (if successful) by society at large. Such innovation should lead to significant impact even though their initial embodiments are imperfect.
B. Two innovations
I have at least two innovations, one for each of the low- and high-tech approaches to biochar production.
The high-tech innovation is still confidential and will require substantial funding beyond my resources to develop a prototype. To be a competitive alternative to the expensive (US$500,000 and above) rotary kilns and heated auger kilns, at least some of these attributes are expected in addition to lower cost:
- Capabilities of 24/7 continuous operation,
- Low-effort pre-pyrolysis biomass preparations,
- Use of released thermal energy,
- Lower costs per thousand tonnes of biochar,
- Modular or with mobility,
- Several sizes, tending toward large such as in shipping containers as the kiln chamber itself (a “container kiln”), not just as housing for complex kiln components.
But some R&D with smaller size test models should be done before ”super-sizing” the design. This is an ideal opportunity for an impact donor, impact investor, or innovation-seeking established business to accomplish a major change in biochar production. Yes, there are risks, but the rewards and urgency for such a solution require actions. Anyone with access to funding / resources can contact me privately (Send email to: PSA@woodgas.com with Subject: High-tech interest). [My credentials for making such a claim are summarized on the About->Authors page.]
The low-tech innovations (plural) have been combined under the name “Panel Kiln” and have been within my financial and facility capabilities for initial R&D. Other pyrolysis / biochar enthusiasts have certainly touched upon the various topics, as presented in the “review of prior art” in Part II. But my synthesis of many aspects of low-tech pyrolysis pushes the frontiers further, including Panel Kiln capabilities to significantly help resolve serious issues associated with excessive biomass.
- air pollution from field-burning of straw as in India,
- the clearing of invasive species such as prosopis spiny trees and shrubs in Africa,
- value-added disposal of orchard and vine prunings as in Australia and Italy,
- forest improvement and fire safety as in California, and
- waste biomass of coffee farms throughout the tropical uplands.
Each of these issues will receive my (our) focused efforts at advanced levels when working with many mutually collaborating individuals and teams to accomplish these high-priority objectives. Our shared goals include cross-fertilization between the issues and also between national efforts with advanced “Developer Level” efforts.
Being “low-tech” with dispersed biomass supplies, Panel Kiln development will have strong LOCAL implementation, with (we hope) substantial nation-based coordination and support. For example, the field-burning problem in India, Thailand, Kenya, Colombia, California, etc. will be resolved in each location by local participation, whether by farmers, agriculture cooperatives, businesses, NGOs, or government entities. We can share the design and technical solutions at the advanced Levels of Support, but implementation and benefits require success to be on the ground locally, with each location independent of the others.
C. Some words of CAUTION
- CAUTION: Nothing is perfect, and the Panel Kiln technology is in its infancy. Expect good value in our offered support, but not perfection. We are revealing to you the “state of the art” of a new pyrolysis technology intended for achieving high volumes of biochar at substantially lower costs. We are all on the learning curve. There is much to be learned TOGETHER with you.
Panel Kiln technology has the potential to be a breakthrough innovation to achieve high volumes of biochar production and carbon removal (CDR) with low-cost equipment and massively abundant excessive biomass. It has worldwide applications. - CAUTION: You do need to be mature and careful when dealing with metal fabrication and pyrolytic fires. We cannot and do not accept any responsibility or liability for what is done with Panel Kiln technology. This work is at the frontier of pyrolysis R&D. And you can participate. Please be careful.
- CAUTION: Local restrictions need to be followed about burning in side-enclosed open-top configurations / devices. This is especially true when using such a device for the first time. Clean combustion is not automatic simply by using a kiln.
- CAUTION: Biochars are not uniform, and are not immediately ready for placement into soils. Study and learn about biochar characterization and the various methods of preparing appropriate and useful biochar.
D. Some words of HOPE
ALL projections for successful resolution of the climate crisis include assumptions that technology “breakthroughs” will occur in the coming years or decades, hopefully in time for beneficial impacts. Searches for potential breakthroughs are underway for alternative energy (including nuclear fusion), low-carbon replacement products, and many forms of carbon dioxide removal (CDR), whether nature-based or technology-based (including DACS and CCS), or hybrid (such as biochar).
Any potential breakthrough technology must face an undefined period with reviews, rollouts, verifications, adjustments, and (we hope) eventual acceptance that will open doors for possible massive financial / industrial capabilities of society that will make possible great leaps forward.
For a breakthrough in CDR via biochar, two or more of the following would be useful:
- a. Lower cost kilns per tonne of biochar produced.
- b. Scalable from “personal” to “industrial” sizes, including simple “container kilns”.
- c. Much higher production per hour or day of operation.
- d. Cleaner emissions, although already very low emissions are difficult to reduce further.
- e. Significantly easier operations, either manually or semi-mechanized or fully mechanized.
- f. Enhanced mobility of the kiln to be closer to the source of the biomass.
- g. Offer prospects for use of thermal energy or its safe disposal when in fire-prone areas.
The Panel Kiln innovations could offer all the above, but not in one package. There will be many different resultant variations to serve the multitude of situations of place and biomass and economics. Some variations will take years to refine. That is fine as long as we get started now with many hands-on-deck.
Please consider how you can participate and/or be supportive. Register to receive free updates at panelkiln.woodgas.com . Subscribe for the three Levels of Support (as presented in Part IV) with funds or other contributions to make a mark at the very start of Panel Kiln efforts. Be at the frontier.
Best wishes to us all. The world needs success in the realms of carbon removal, and pyrolytic biochar is positioned to remove gigatonnes of CO2e per year while helping build soils and providing energy.
Variations of panel kiln pyrolysis are positioned to alter biochar production at every scale. You will have access to appropriate fabrication designs and operation manuals with batch processing in Support Levels B and C, with appropriate mechanical assistance introduced in LEVELS C and D. Furthermore, currently undisclosed steps to accomplish complete automation and 24/7 operation of very large high-tech facilities are also up for consideration (separate from Panel Kins).
Panel kilns are of INTERNATIONAL interest, resulting in language issues as well as socio-economic issues that include inexpensive labor vs. mechanical assistance vs. full 24/7/365 automation. This is another reason for needing YOUR support to handle biochar production that is close and of interest to YOU.
This is the end of Part I. Please use the “Next” link at the bottom of this page to continue with Part II where the fundamentals and “prior art” of panel kilns are discussed. Part III is where Specific Instructions about Panel Kilns are presented as they become available. Part IV presents an evolving business model. Part V has Participation Reports (case studies).