Abstract:
Processing vessel systems; methods for biochar production; methods for biochar conditioning; methods for cardboard and chipboard biochar blending; and methods for co-generated heat from cardboard and chipboard pyrolysis. Cardboard and chipboard are paper-based products consisting of virgin or post-consumer waste abandoned fibers, repurposed as feedstocks used for thermochemical conversion (pyrolysis) and carbonization of ligno cellulosic biomass. The conditioned cardboard and chipboard biochars improve soil nutrition, improve soil moisture retention, slow soil mineralization, bind or limit heavy metal uptake in soils and plants, improve plant physiological response such as water use efficiency. Co-generation of bioenergy output during pyrolysis is also involved.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    This application claims the benefit of U.S. Provisional Application No. 61/930,569, filed Jan. 23, 2014, which application is incorporated herein by reference in its entirety. 
     
    
     FIELD 
       [0002]    The present invention relates to processing vessels, production (pyrolysis), post-pyrolysis conditioning, testing and application of cardboard and chipboard biochars to resolve agricultural and environmental needs and provide bioenergy. 
       BACKGROUND 
       [0003]    Cardboard (CB) and chipboard (ChB) solid wastes represent between 1-2% of all solid waste in landfills in the United States; 2% of the residential waste stream and 30% of all commercial/industrial solid waste is comprised of these ligno cellulosic-derived materials. Sadly the vast majority of this waste finds its way not to recycling but to abandonment. Removal from waste sites would improve soil and air quality through a reduction in aerobic and anaerobic metabolic microbial processes, reduced atmospheric emissions (CO 2 , CH 4  and N 2 O) and increased carbon (C) sequestration. Even when removed from the post-consumer waste stream, recycling is generally restricted to repurposing through re-pulping and re-fabrication to its original life of cardboard and chipboard. However, conversion to biochar represents a different and significantly beneficial strategy. Biochar production for use as a soil amendment includes products derived from hardwood and paper softwood (W02011014392A4; US20110023566 A1), grass, corn stover (U.S. Pat. No. 8,398,738 B2), sugar cane and animal bone (WO20111097183 A2), hull, shell and food waste (US20110023566 A1), paper waste and sludge (WO2010129988 A1), manure (JP2001252558; U.S. Pat. No. 6,189,463; U.S. Pat. Pub. 2009/0031616), and poultry litter (US20120237994A1). A recent forecast on trends in biochar feedstock sourcing suggests an opportunity to capitalize on recycling of urban waste such as CB and ChB. 
       SUMMARY 
       [0004]    The invention comprises at least the following: processing vessels used to produce CB and ChB biochars; methods for producing, conditioning and testing pyrolyzed CB and ChB biochars before and after addition to soils; benefits of CB and ChB biochars to enhance soil nutrient and moisture holding capacity, enhance plant physiological outcomes such as increased water use efficiency, sorb heavy metals (e.g., Pb, Sb, Cu and As) in soils and plants; and produce co-generated bioenergy as a by-product of CB and ChB pyrolysis in a processing vessel. 
         [0005]    Embodiments of the invention comprise thermochemical conversion of CB and ChB into biocarbon, paperchar or enhanced biochar (individually or collectively sometimes referred to herein as “biochar”). The biochar can be used in situations that include but are not limited to the following: to provide restorative nutrient and moisture to impoverished agricultural land, mitigate depreciating groundwater assets, generate an alternative fuel to deforestation, and comprise an antidote to harmful anthropogenic and environmental factors. Not only are there broad opportunities to collect, produce and distribute CB and ChB biochars but this process can be manifest without the aid of enormous, scaled up production facilities and equipment, though one cascading benefit is comprised of production of CB and ChB biochars in large processing vessels distributed through well-developed networks. The universality of CB and ChB methods described herein, including stacking and dehydrating feedstock and conditioning of post-pyrolysis biochars, is matched by the universality of the feedstocks themselves, namely two well-defined species of universally sourced ligno cellulosic waste which may be processed in a similar manner to that described herein, without regard to geographic location. The same universal characteristic cannot be applied to other cellulosic or ligno cellulosic feedstocks, such as wood, for example, where even a specie may not be considered a unique feedstock depending on its geographical location, or where subspecies exist, for example, or more than one specie is mixed with others to provide multi-feedstock sources. Three micro gasifiers (U.S. Pat. No. 6,830,597) and a retort (e.g., U.S. Pat. No. 6,902,711) (both such patents incorporated herein by reference in their entirety) can be employed herein. Feedstocks are typically batch (not continuous or semi-continuous) fed into the three micro gasifier processing vessels, and hatch or semi-continuous fed into larger retorts or reactors. 
       INCORPORATION BY REFERENCE 
       [0006]    All patents, patent applications, publications and data described in this specification are herein incorporated by reference to the same extent as if each individual publication, patent, patent application or datum was specifically incorporated into this document. 
     
    
     
       BRIEF DESCRIPTION OF FIGURES 
         [0007]    The novel features of the invention are set forth with particularity in the appended claims. A better understanding of the claimed invention (including but not limited to the functionality of the pyrogenic products and their implementation as soil conditioners, benefit to plant performance, or heat output), may be obtained by reference to the following figures which illustrate embodiments of the principles of the invention. 
           [0008]      FIG. 1  is an exploded view of a processing vessel. 
           [0009]      FIG. 2  is an exploded view of another processing vessel. 
           [0010]      FIG. 3  is an exploded view of another processing vessel. 
           [0011]      FIG. 4  shows a power supply-fan-duct device used to increase air for combustion. 
           [0012]      FIG. 5  is a cross-sectional view of feedstock and wood fuel installation in the vessels of  FIGS. 1-3 . 
           [0013]      FIG. 6  compares pyrolysis temperatures and processing vessel type. 
           [0014]      FIG. 7   a  compares outdoor moisture/evaporation test of CB inoculated Entisols. 
           [0015]      FIG. 7   b  compares outdoor moisture/evaporation test of ChB inoculated Entisols. 
           [0016]      FIG. 7   c  compares Atterburg roll (gm H 2 0/3 mm+/−diameter) characteristics following dehydration according to soil type. 
           [0017]      FIG. 7   d  compares shrinkage (gm shrinkage/4.77 cm diameter) characteristics following dehydration according to soil type. 
           [0018]      FIG. 8  illustrates data which compares biochar adsorption rates following GACS testing. 
           [0019]      FIG. 9  compares pyrolysis temperatures according to processing vessel type. 
       
    
    
     BRIEF DESCRIPTION OF TABLES 
       [0020]    The novel features of the invention are set forth with particularity in the appended claims. To gain a better understanding of production, conditioning and functionality of the pyrogenic products and their implementation for soil enhancement, improved plant performance and co-generated energy, these will be obtained by reference to the following tables which illustrate embodiments based on pre- and post-treatment soil and plant physiological outcomes of which: 
         [0000]    TAB. 1 shows Tukey pairs of plasticity results as example of kitchen moisture test.
 
TAB. 2 shows five week nutrient milestones for Entisols treated with CB and ChB biochars.
 
TAB. 3 shows one year follow up nutrient milestones for Entisols treated with CB and ChB biochars.
 
TAB. 4 compares nutrient analysis of CB and ChB biochars.
 
TAB. 5 compares elemental analyses of CB and ChB biochars.
 
TAB. 6 shows heavy metal uptake management via CB biochar soil added to contaminated soils.
 
TAB. 7 shows effect of CB biochar additive on intrinsic WUE determined by δ 13 C 0/00.
 
TAB. 8 shows effect of CB biochar additive on instantaneous WUE determined by seasonal  x  A/g,
 
       DETAILED DESCRIPTION 
       [0021]    Included herein are: (1) design and fabrication of three processing vessels used to produce CB and ChB biochars; (2) methods for producing, conditioning and testing pyrolyzed CB and ChB biochars before and after addition to soils; (3) benefits of CB and ChB biochars to enhance (a) soil nutrient and moisture holding capacity, (b) enhance plant physiological outcomes such as increased water use efficiency and (c) block or reduce uptake of heavy metals (e.g., Pb, Sb, Cu and As) in soils and plants and (4) co-generation of bioenergy as a by-product of CB and ChB pyrolysis in a retort (or reactor). 
         [0022]    Embodiments of the invention include: design, fabrication and use of processing vessels; feedstock arrangement, production and post-pyrolysis conditioning; post-conditioning blending and testing of biochars with soils and plants; and outcomes. In one aspect, three (sizes of) top lit updraft device (TLUD) or micro gasifier processing vessels to thermochemically convert CB and ChB feedstocks were designed and manufactured. The vessels are fabricated from metal parts as shown in  FIGS. 1 ,  2  and  3 . Another aspect is comprised of an air duct assembly  FIG. 4  used with either a 9V battery and low voltage wire or a low voltage power adapter  51  connected to a fan (recycled from a desktop computer)  49  via a connecting section  FIG. 45  for use with the vessels shown in  FIGS. 2 and 3 . Another aspect is a method for installing feedstock and wood fuel; this installation process is similar for embodiments in retorts or processing vessels or reactor other than those described herein. Another aspect is the conversion of cardboard (with fluting and liner board) and chipboard (without fluting) to another solid phase for conditioning soil and co-generated heat resulting from pyrogenic gases. 
         [0023]    To enable a consistent approach to production, conditioning and testing, it was desirable to select universally available feedstocks with generally consistent physical (e.g., thickness), construction (fluted or not fluted) and chemical properties. In another aspect prior to the conditioning phase, raw biochars were pulverized. In a further aspect to characterize and measure the effect of conditioned biochar as a soil 
         [0000]                                            TABLE•1                   •Tukey•pair•comparisons•of•plasticity¶            Null•Hypothesis•(Soil/Biochar•pairs)••••••••••••••••••••••••••••••••••••••••P-value                                             Windsor•255C•CB•-••Windsor•255C•=•0              &lt;0.01                                Windsor•255B•••CB••-•Windsor•255C•=•0              &lt;0.01                                Deerfield••256B/CB•*•-••Windsor•255C•=•0              &lt;0.01                                Deerfield•256B/CB•-••Windsor•255C•==•0••••••••••••••              &lt;0.01                                Deerfield•256B•-••Windsor•255C•==•0•••               0.046                                Quansett•-••Windsor•255C•==•0••••••••••••••••••••••••••••••               0.016                                Quansett•••CB••-••Windsor•255C•==•0•••••               0.018•••                                Windsor•255B•-••Windsor•255C•CB••==•0•••••••••              &lt;0.01                                Windsor•255B••CB••-••Windsor•255C•CB••==•0••••••••               0.010•                                Deerfield•256B/••-••Windsor•255C•CB••==•0•••••••••••              &lt;0.01                                Quansett••262B-••Windsor•255C•CB••==•0•••••••••••••••••••••••              &lt;0.01                                Quansett••262B•/CB•-••Windsor•255C•CB••==•0••••••••••••••              &lt;0.01                                Windsor•255B•••CB••-••Windsor•255B•==•0•••••••••••              &lt;0.01                                Deerfield•256B/CB•Windsor•255B•==•0•••••••••••••              &lt;0.01                                Deerfield•-••Deerfield••256B/CB••==•0••••••              &lt;0.01                                Quansett••262B•-••Deerfield•256B/CB••==•0••••••••••••••••••              &lt;0.01                                Quansett•••262B•/CB••-••Deerfield•256B/CB••==•0              &lt;0.01                                        ¶                    
additive, a set of ‘kitchen’ moisture tests were devised including, evaporation in  FIG. 7   a  and  FIG. 7   b  and plasticity in table 1 as shown on the previous page. Results in those figures and that table denote statistically significant (P=&lt;0.01 and P=&lt;0.05 respectively) moisture holding capacity (plant available water) as a function of statistically significant (P=&lt;0.01) greater plasticity following CB biochar amendment in Atturburg roll tests (tests measured maximum moisture retention at the point of soil contraction contrasting 30 g samples of red oak and CB biochar amended soils). Further demonstration of CB biochar moisture holding capacity was evidenced in “slug” tests where clay shrinkage was measured after evaporation; there is significantly less clay shrinkage for specimens composed of CB biochar additive (P=&lt;0.01) shown in  FIG. 7   c . Another aspect concerns an additional test, not part of the ‘kitchen tests’, portrayed in  FIG. 7   d , which revealed moisture facility of CB biochar additive following soil tension (bar) experiments comparing three biochars with a Quansett 262B control. In six repeated tests, a CB/Quansett 262B blend (10% by volume) exhibited 25% greater soil tension than its nearest cohort. The results illustrate greater capillary induction potential than its three blend test counterparts. Given results from the ‘kitchen’ and soil tension tests, CB biochar was found to exhibit greater global soil moisture
 
         [0000]    
       
         
               
             
               
               
               
               
               
             
               
               
               
               
               
               
               
               
               
               
               
               
               
               
               
             
               
               
               
               
               
               
               
               
               
               
               
               
               
               
               
             
           
               
                 TABLE 2 
               
             
             
               
                   
               
               
                 Five week milestone nutrient analysis 
               
             
          
           
               
                   
                   
                   
                   
                 ppm 
               
             
          
           
               
                 1 year milestone 
                 g/5 cc 
                 CEC 
                 pH 
                 P 
                 K 
                 Ca 
                 Mg 
                 B 
                 Mn 
                 Zn 
                 Cu 
                 Fe 
                 S 
                 Pb 
               
               
                   
               
             
          
           
               
                 Windsor 255B 
                 6.4 
                 8.4 
                 5.4 
                 9.2 
                 58 
                 263.3 
                 16.6 
                 1.8 
                 5.3 
                 2.2 
                 .2 
                 12 
                 7.7 
                 .05 
               
               
                 Windsor 255C 
                 6.6 
                 3.6 
                 6.5 
                 2.5 
                 33.4 
                 523.5 
                 30.6 
                 .05 
                 30.6 
                 .72 
                 .2 
                 16.2 
                 4.5 
                 .53 
               
               
                 Deerfield 256B 
                 7.1 
                 9.4 
                 4.9 
                 6 
                 36 
                 162 
                 14 
                 .1 
                 2 
                 1.3 
                 3. 
                 7.3 
                 4.8 
                 1.1 
               
               
                 Quansett 262B 
                 5.4 
                 7.2 
                 5.4 
                 7.1 
                 49.7 
                 134.8 
                 13.4 
                 0 
                 1.7 
                 .9 
                 .1 
                 5 
                 3.7 
                 .6 
               
               
                 Windsor 255B CB 
                 4.5 
                 6.0 
                 6.8 
                 6 
                 39 
                 621 
                 41 
                 .3 
                 1.4 
                 1.1 
                 .3 
                 3.6 
                 12 
                 .7 
               
               
                 Windsor 255C CB 
                 5 
                 10.7 
                 5.8 
                 16.8 
                 49 
                 504 
                 37 
                 .2 
                 3 
                 3.5 
                 .2 
                 9.4 
                 11.2 
                 1.4 
               
               
                 Deerfield 256B CB 
                 4.95 
                 17.5 
                 5.2 
                 19.7 
                 94 
                 585 
                 55 
                 .2 
                 8.2 
                 10.2 
                 1 
                 17.4 
                 16.6 
                 12.4 
               
               
                 Quansett 262B CB 
                 6 
                 9.2 
                 5.1 
                 8.4 
                 73 
                 277 
                 36 
                 .1 
                 3.3 
                 1.5 
                 .1 
                 7.5 
                 8 
                 .7 
               
               
                   
               
             
          
         
       
     
         [0000]                                                                                                                                                                      TABLE 3                   One year follow up nutrient analysis                            ppm            1 year milestone   g/5 cc   CEC   pH   P   K   Ca   Mg   B   Mn   Zn   Cu   Fe   S   Pb                    Windsor 255B   6.4   8.4   5.4   9.2   58   263.3   16.6   1.8   5.3   2.2   .2   12   7.7   .05       Windsor 255C   6.6   3.6   6.5   2.5   33.4   523.5   30.6   .05   30.6   .72   .2   16.2   4.5   .53       Deerfield 256B   7.1   9.4   4.9   6   36   162   14   .1   2   1.3   3.   7.3   4.8   1.1       Quansett 262B   5.4   7.2   5.4   7.1   49.7   134.8   13.4   0   1.7   .9   .1   5   3.7   .6       Windsor 255B CB   4.5   6.0   6.8   6   39   621   41   .3   1.4   1.1   .3   3.6   12   .7       Windsor 255C CB   5   10.7   5.8   16.8   49   504   37   .2   3   3.5   .2   9.4   11.2   1.4       Deerfield 256B CB   4.95   17.5   5.2   19.7   94   585   55   .2   8.2   10.2   1   17.4   16.6   12.4       Quansett 262B CB   6   9.2   5.1   8.4   73   277   36   .1   3.3   1.5   .1   7.5   8   .7                    
than its red oak biochar counterpart. These findings may be interpreted to inspire the use of CB biochar as a light weight, highly adsorptive additive for soil amendment.
 
         [0024]    Still another indicator of value is found in comparisons of CB and ChB biochar treated Entisols whose results are found in two sets of data in tables 2 and 3. Results of comparisons of organic and inorganic nutrient levels between five and one year milestones illustrate several positive mechanical aspects of CB and ChB biochar interaction with four Entisols. For example while calcium carbonate (CaCO 3 ) generated extremely high, initial Ca status, retesting, following mycorrhizal feeding on these carbonates, subsequent mineralization and sorption, revealed a Ca level suited to planting. P known to be an indicator and correlate of moisture adsorption held steady over the year long period testifying to the power of CB and ChB biochar crystalline structures to adhere moisture much more efficiently than the same soil untreated with the chars. While high pH values as shown below in table 4 may appear to be worrisome, they soon equilibrate, even at the five week milestone depicted in table 2. Elevated CEC in year two reflects greater nutrient sorption. 
         [0000]                                                                                                                                                                      TABLE 4                   CB and ChB biochar nutrient analysis                            ppm            biochars   g/5 cc   OM   pH   P   K   Ca   Mg   B   Mn   Zn   Cu   Fe   S   Pb                    Cardboard biochar   1.4   7.4   7.9   21   1095   3044   1235   70   1.2   13   0   2.1   64.3   70       Chipboard biochar   1.1   32.7   8.7   79   336   4130   1120   16.7   72   13   .8   5.7   83.5   1                    
Additional elemental analysis of CB and ChB found in table 5 below reveal characteristics which compliment earlier results.
 
         [0000]                                                                                                        TABLE 5                   CB and ChB biochar elemental analysis            ID   Yield   Ash   C   H   N   O   O/C   C/N   GACS       biochars   %   %   %   %   %   %   %   %   % (AR)                    CB   21   14.4   72.1   4.8   .2    8.2   11.3   300.4   5.2       ChB   22   19.8   63.2   6.8   .25   10   15.8   252.8   4.1       Red oak   24   1   84.7   5.3   .5    8.5   10   169.4   6.9                    
CB and ChB chars were shown to exhibit (a) higher feedstock to biochar yield, (b) greater ash content during slow pyrolysis, (c) nearly the same C levels as red oak, (d) advantageous O/C ratios (&lt;40% indicates greater stability and aromaticity), (e) high C/N ratios (well above industry requirements [&gt;100] and (f) decent adsorption compared with denser ligno celluslosic red oak in  FIG. 9 . In table 6 results of CB biochar added to four contaminated and one control non-firing range soils samples dug from ‘A’ horizon soil pits located in constructed berms are shown. Preliminary evidence following repeated tests indicated in sample metal sorption was higher in most CB biochar treated contaminated specimens following (10% by volume) an agitated blending procedure from analysis conducted eight weeks after the
 
         [0000]                                                                                                                                      TABLE 6               Evidence of heavy metal uptake by CB biochar                                                Ppm            nutrient   g/5 cc   CEC   pH   P   K   Ca   Mg   B   Mn   Zn   Cu   Fe   S   Pb               Range (D)   7.1   3.6   5.7   .9   12   73   9   .1   1.1   1.1   6.3   3   4.8   170.5       Range (D) with CB   7.2   5.3   5.7   1   21   211   23   .2   .8   2.3   5.1   11.4   6.8   108.3       Range (M)   7.5   5.4   4.9   .6   14   29   13   0   1.9   1.3   4.2   8.7   1.4   14.8       Range (M) with CB   7.2   3.9   5.8   .7   18   164   24   .2   .9   .9   1.8   6.2   4.6   26.8       Range (S)   6.5   6.5   5.9   9.3   55   289   27   .1   4.4   71.8   161   25.8   4.9   29.6       Range (S) with CB   6   8.1   6.2   10.3   70   552   61   .5   4.6   77   174   22   12   68       Background/control   5.2   17.7   4.1   .9   25   182   57   .1   5.7   1.6   .6   4.4   5.5   5.3       Background/control CB   4.2   23   4.2   1.3   51   436   110   .1   8   2.7   .7   5.8   12   27.5                    heavy metal   As   Ni   Sb   Cr   Cu   Pb               Range G Shields   3.58   4.4   26.66   6.89   217   2337       Range G Shields/CB   3.52   6.3   40   8.8   188   2951       Range D Shieldt   2.03   2.4   2.6   4.88   32.2   278       Range D Shields/CB   1.83   2.9   3.4   5.4   36.1   343       Range S Shields   2.08   3.6   .53   8.20   467   47       Range S Shields/CB   1.35   3.1   .84   6.5   267   68       Range M Shields   1.11   1.6   .17   1.97   4   19       Range M Shields/CB   1.23   1.2   .34   2.3   4   24       Control Shields   1.20   1.5   .56   1.68   4   35       Control Shields/CB   .24   1.3   .31   1.08   1.1   12                    
procedure. Typical organic and some inorganic levels (P, K, Ca, Mg) rose in post-inoculation review. However, the most significant results were obtained for cluster analysis of six heavy metals, where
 
         [0000]                                                                TABLE 7                   intrinsic WUE status as determined by δ 13  C ‰ metrics       as an aggregate seasonal value                    June   September           Treatment   Specie   δ 13  C ‰   δ 13  C ‰     x  δ C ‰                    CB Rooflite     Baptisia     −27.50   −28.05   −27.77       Blend     tinctoria         CB Rooflite     Quercus     −29.13   −31.69   −30.41       Blend     ilicifolia         CB Rooflite     Lupinus     −28.75   −31.24   −29.99       Blend     perennis         CB Rooflite     Vaccinium     −30.32   −31.71   −31.01       Blend     angustifolium         Rooflite     Baptisia     −28.75   −31.35   −30.05             tinctoria         Rooflite     Quercus     −29.00   −30.11   −29.55             ilicifolia         Rooflite     Lupinus     −27.44   −30.96   −29.20             perennis         Rooflite     Vaccinium     −28.62   −30.19   −29.48             angustifolium         CB Rooflite   All species   −27.51   −31.71   −29.61       Blend       Rooflite   All species   −29.34   −31.28   −30.31                    
antimony (Sb) and lead (Pb) sorption increases signaled mechanical adherence in the CB biochar portion (with the other 90% contaminated soil) of the blend indicative of a tendency to block metal uptake. Other, different aspects of CB biochar influence on soils and soils inhabited by plant specimens drawn from a pitch pine scrub oak community (found near the military ranges) were studied with regards to the possible effect of CB biochar soil inoculation on plant physiological performance as measured by water use efficiency (WUE). Two tests of WUE were performed on Rooflite® soils (Skyland USA LLC, Avondale, Pa. USA) amended with CB biochar (10% by volume). The first test results appear in table 7 which comprise intrinsic C status as measured by δ 13  C 0/00 as a function of stable isotope analysis. Results indicate elevated post-photosynthate C storage resulting in higher intrinsic WUE. In table 8, results of instantaneous WUE measurements reveal increased C abundance from CB biochar addition interpreted as higher WUE following leaf-level CO 2  readout, as  x  A/g s  through portable photosynthesis.
 
         [0000]                                                        TABLE 8                   Instantaneous measurement of  x  A/g.                Treatment   Specie     x  A/g s                              CB Rooflite Blend     Baptisia tinctoria     48.06           CB Rooflite Blend     Quercus ilicifolia     121.71           CB Rooflite Blend     Lupinus perennis     87.26           CB Rooflite Blend     Vaccinium angustifolium     33.88           Rooflite     Baptisia tinctoria     23.9           Rooflite     Quercus ilicifolia     109.92           Rooflite     Lupinus perennis     120.2           Rooflite     Vaccinium angustifolium     34.02           CB Rooflite Blend   All species   77.10           Rooflite   All species   63.76                        
A final aspect comprises the approximate energy balance achieved following a comparison of retort pyrolysis events. Note cardboard pyrolysis captures 20% of the total heat thrown off in the manufacture of the biochar as opposed to non-pyrolysis heat (100% burnable energy) thrown off by the combustion of cardboard in a non-anoxic vessel producing ash, a process which does not capture energy per se, and does not capture energy as a product of cardboard biochar pyrolysis.
 
       DESCRIPTION OF THE FEEDSTOCKS 
       [0025]    Corrugated cardboard and cardboard box feedstock (ASTM D4727) ranges from 0.25-0.38 cm (single wall)-0.50-0.76 cm thickness (double wall), combining fluting and linerboard, ranging in mass from 0.062 g/cm 2 -0.120 g/cm 2  and chipboard pad and box feedstock ranges from 0.076 cm-0.12 cm in thickness and 0.022 g/cm 2 -0.029 g/cm 2  in mass. Chipboard is typically composed of double kraft paper and coated with resin (ASTM D1037). Due to the worldwide homogeneity of both cardboard and chipboard, and the thickness dimensions (+/−0.508 cm for cardboard and +/−0.254 cm for chipboard) varying little from one geographical location to the next, the procedures described herein are invariably the same based on the non-combustion (anoxic) heating of the feedstocks in such a way as to char without diluting the chemical properties which make it so appealing, namely significant nutrient and moisture holding characteristics. Physical comparisons of CB and ChB with other biomass feedstock sources illustrate their uniqueness in form such as boxes, sheets and pads, produced for commercial consumption, defined by somewhat similar porosity and, as it turns out, similar carbonization outcomes. They are also lighter in pre- and post-pyrolysis mass, as measured by g/cc, than other feedstock types such as hardwood and paper softwood, grass, corn stover, sugar cane, animal bone hull, shell and food waste, paper sludge, manure and poultry litter. 
       Preparation of Feedstocks for Pyrolysis 
       [0026]    CB and ChB feedstocks are dried for a thirty day period (&lt;1% moisture) prior to conversion. Then they are cut, folded, shredded or rolled into 12 cm-0.45 m widths and 12 cm-2.4 m lengths for vertical introduction to a processing vessel. They may also be reduced to circular pieces 2.25-2.85 cm diameter and 0.3 to 0.4 cm thickness through the use of a hammermill press (e.g., pellet mill). 
       Processing Vessels 
       [0027]    A group of 4 L, 20 L and 200 L processing vessels  FIGS. 1 ,  2  and  3  were used to conduct pyrolysis where pyrogenic gases achieve a high temperature treatment (HTT) range between 440-512.4° C. see  FIG. 9 . Though the three processing vessels comprise different sizes, similar pyrolysis of the same feedstocks produces similar outcomes, i.e., pyrogenically propagated sheets still manifesting a patina comprised of either slightly ridged (fluted) in the case of the cardboard or non-ridged (non-fluted) appearance in the case of the chipboard (lacking fluting). 
         [0028]    A 4 L aluminum TLUD  4 ,  FIG. 1 , is fabricated from a used 4 L stainless steel paint can  3  with 27 cm height and 17 cm diameter with an inner aluminum can  5  (e.g., recycled aluminum can which housed fruits or vegetables). Multiple holes are cut into the bottom of the outer can  3  which induces air flow through the bottom and into the outer combustion chamber of the outer can. A portion of a second, aluminum can is cut out to form a “crown”  7  (3 cm in depth and 17 cm in diameter) having a semi-diagonal tooth shape side and solid top. The center of the solid top of the crown  7  is removed to form a 7.5 cm wide hole or opening. When pyrolysis is initiated, a sheet metal chimney  9  (measuring 30 cm height and 7.75 cm diameter) is placed over the opening. After pyrolysis is complete, the chimney  9  is removed and a “damper” (separate flat 8 cm circular piece of aluminum) is placed over the opening; then the processing vessel is lifted from the ceramic “feet”  1  and placed on a non-flammable surface. The pyrolytic event ranges between fifty minutes and one hour. Maximum temperature (HTT) for the 4 L pyrolysis is recorded at 440° C. measured by inserting an EXTECH K-type single pole temperature thermocouple into the chimney and vertically downward into the middle of the feedstock. After cool down, between two and a half to three hours duration, the cover is removed from the micro gasifier and the biochar contents are scooped out (with scoops, pans, shovels, brooms, dustpans and similar tools) and placed temporarily in a 17 L plastic bucket. 
         [0029]    Another embodiment of the invention is a steel 20 L TLUD  16 ,  FIG. 2 . The main portion of the unit is fabricated from a commercial steel canister  15  and  59  (38 cm in diameter and 54 cm in height) placed on ceramic block  11  and  55  with five 1.25 cm holes  18  spaced 2 cm apart around the center. Within that canister is placed a smaller 11 L aluminum (37.5 cm in diameter and 2 cm in depth) feedstock holder  17  and  61 . It is covered with a circular aluminum cover  19  with five 1.25 cm holes  18  spaced 2 cm apart around the center. The canister  15  is covered with a 38 cm diameter and 1.6 cm thick stainless steel top  20  with a 7.5 cm diameter aperture. A 9 cm diameter×40 cm long chimney  21  is placed over the hole or opening during pyrolysis. As with the methods described previously, fuel is placed in the void between the outer and inner canisters  57 . CB and ChB feedstock is rolled or folded and inserted vertically in the inner canister  63   FIG. 5 . Unlike the method used with the smaller 4 L processing vessel, the larger 20 L vessel utilizes an air ducting feature  46 , FIG.  47 —to pump air from a battery operated fan  49  through a duct  47  to a 3.75 cm aperture  13  in the side of the bottom portion of the vessel  15  via a nozzle adapter  43 . The fan-duct device allows the operator to add air flow as desired using a ‘D’ cell battery (not shown) or plug in power unit  51  to power the fan whose nozzle fits into the aperture  13 . Air is added to the combustion chamber (to increase combustive gas rate) by engaging or disengaging battery  51 . When the fan/duct is not in use, a 5 cm×3.75 cm plug fashioned from aluminum is inserted into the aperture  13 . In the 20 L processing vessel, firewood is ignited, as with the previous embodiment, with an isopropyl alcohol or similar accelerant. Note, experiments with vertical as opposed to horizontal loading demonstrate greater air flow and carbonization. The pyrolytic event ranges between one hour and one hour and fifteen minutes. Maximum temperature (HTT) range during pyrolysis was recorded at 498.9-508.6° C. for CB and ChB measured by inserting an EXTECH K-type single pole temperature thermocouple into the chimney and vertically downward into the middle of the feedstock. After cool down, which is typically two and a half to three hours, the cover is removed from the micro gasifier and the biochar contents are scooped out (with scoops, pans, shovels, brooms, dustpans and similar tools) and placed temporarily in a 17 L plastic bucket. 
         [0030]    A 200 L steel “double barrel” TLUD processing vessel  32 ,  FIG. 3 , is a further embodiment of the invention. It comprises 200 L outer  25  and  59  and 170 L inner  31  and  61  steel barrels. The outer barrel  25  (measuring 120 cm in height and 66 cm in diameter) is comprised of one open and one closed end and is situated on top of four ceramic bricks  23  and  55  (18 cm×3 cm×9 cm). The closed end, or bottom of the outer barrel, features twelve 1.25 cm holes  53  cut into the bottom, spaced 2 cm apart, in a concentric orientation to allow air entry into the bottom of the outer barrel. The top lid  37  serves as a cover for the outer barrel after pyrolysis is complete. The outer barrel is placed on top of four strategically arranged ceramic bricks  23  situated to support the undercarriage of the outer barrel. Around the bottom amongst the bricks and up the sides of the space between the inner and outer barrels are placed wood fuel (typically 2.5 cm×4 cm×15 cm pieces)  29  and  57  for combustion in a 6 cm void (chamber). Inner barrel  31  is inserted into the outer barrel  25 . Barrel  31  is comprised of an enclosed bottom and a lid  33  (which has eight 1.25 cm holes  35  spaced 2 cm apart around the center of the lid). Four ceramic bricks  27  are placed below the bottom of the inner barrel. Either CB and ChB feedstocks are placed inside the inner barrel  63 ,  FIG. 5 , with space between feedstock pieces to allow gas movement. After an accelerant has been applied to the wood fuel  57  in the void between barrels  25  and  31 , the inner barrel cover  33  is placed on the top of the inner barrel  31 . Then the cowling  39  and chimney  41  are placed on top of the outer barrel  25 . After the start of combustion, an air duct ( 46 ,  FIG. 4 ) is again used to feed air into the bottom barrel through holes in the bottom of the outer barrel. In this instance, the duct is placed between the brick ‘feet’  23 , centered under the holes in the bottom of the outer barrel. After completion of pyrolysis the cowling  39  and chimney  41  are removed and the outer barrel steel cover is placed over the chimney hole during the post-pyrolysis, cool down process. Maximum temperature (HTT) is recorded at 522.4-550° C. for CB and ChB pyrolysis measured by inserting an EXTECH K-type single pole temperature thermocouple through a tiny peephole in the outer and inner barrels into the middle of the feedstock. After two hours to two hours and twenty-five minutes, the pyrolytic event is concluded and biochar is produced. After pyrogenic gases dissipate, the material is allowed to air cool for twenty-four hours, after which it is removed from the inner chamber as before using scoops, pans, shovels, brooms, dustpans and similar tools. 
         [0031]    In a larger 3000 L non-TLUD processing vessel, a retort (as described by Adams (2002), Anderson (2004), McLaughlin (2006) and Wells (2006)), is an embodiment reduced to practice as a subset of pyrolysis processing, comprising biochar and heat energy production. A retort of this type is used worldwide for the purpose of small to mid-scale manufacture of biochar and production of bioenergy. This embodiment produces CB and ChB biochars in an efficient fashion. A further embodiment is comprised of still greater production output via a commercial grade reactor which follows from the same principles. Such larger production could be increased if one pelletized (approx. 3 mm thick and approx. 12 mm in length and width) the CB or ChB with a hammer mill (as noted previously) or larger device. The retort described here is constructed of steel. It features a 2.5 m 3  feedstock chamber with 0.18 m thick walls and a 2.76 m×1.46 m×1 m combustion chamber with two attached chimneys and a firebox, all totaling an area of around 3.7 m. The sequence for loading the retort is thus: first a cover latch attached to the feedstock chamber is opened and feedstock (cardboard or chipboard) is loaded, preferably in rolls so as to make volume more compact. This procedure also enables a quicker and more effective pyrolysis. As before, with other embodiments described earlier, starter wood is used to initiate the gasification process which precedes pyrolysis in this style retort. There are four valves mounted on the device which control a pump, fan, air and gas blowers. At the start of the combustion process, blowers and the fan are left in the “off” position until gasification sequence has started. Once combustion begins (ignition of the firewood fuel), a chamber cover is placed over the top (opening) of the device wherein a sealing gasket fixes the lid to another gasket at the top of the chamber walls; four bolts are used to fasten down the lid. After primary ignition has occurred, a gas pipe feeds gas to the gasifier. A thermocouple attached to the chamber reveals when a minimal 250-300° C. temperature is achieved wherein gasification is said to be established; at that time the combustion blower is turned off, the gasifier lid is removed and more wood fuel is added. Then the lid is replaced as before and the combustion blower is turned back on. This process is repeated wherein sufficient wood fuel is made available to maintain sufficient heat for pyrolysis. Another thermocouple (there are four in all) is used to maintain readout of temperature during pyrolysis of the feedstock. A temperature of 615° C. is maintained in order to ensure complete pyrolysis. When gas exhaust has transitioned from smoke to clear fumes, it is time to turn on the gas blower which circulates hot exhaust gas to rinse through the pyrolyzed feedstock and accelerate completion of the heating process. After a time, the retort manufactures its own flammable gas and the gas blower is used continuously from this juncture until such point where further wood fuel is required. During pyrolysis, steam is created and distillates from that steam are created using a condenser after which they are drained down. Some of the distillates form vinegar and vinegar oil which may be used to coat firewood for future retort events. The retort uses a water supply for cooling down just-made biochar. Total pyrolysis time ranges from 4.5 to 6 hours depending on temperatures achieved following initiation of gasification and amount of wood fuel added during that process. The same would apply to ranges for HTT and total pyrolysis for larger processing vessels such as reactors which are not described herein. After cool down, the char is removed from the chamber and readied for inoculation as described earlier. All of the retort processing vessels behave in a similar way; though geometry of the retorts may be different the basic results are similar with regards to venting of gasses and uniform chemical activity. Biosynthetic gas produced from cardboard and chipboard pyrolysis is characterized through estimated maximum redox potential, biochemical oxygen demand, chemical oxygen demand, volatile fatty acids and other factors which generate estimated biogas yield. 
       Conditioning and Charging Biochars 
       [0032]    After removal from processing vessels, CB and ChB biochars were conditioned by the same method. This consists of three stages: conditioning, charging and inoculation. To begin conditioning, 15 L of each type of biochar particles were saturated with 13 L water and placed in a 40 L plastic tub. In this step, saturation drove off tars, sugars, ash and lime from the biochar. The same process was used to saturate the peat moss, an organic blended with the raw char to quickly activate mycorrhizal activity after wetting. After a week, as part of a charging process the two materials were mixed into a single slurry 1:1 and poured into two 40 L tubs; as the blended material was solubilized equilibration of inorganic nutrient and trace elements began to take place. In the third week, 75 mL Peters 5-10-5 fertilizer was mixed into each tub. Fertilizer inoculation added additional nutrient to increase amount of sugars for microbes to feed on. As biochar sugars were used up through microbial action, mobile matter became leachable carbon accompanied by an increase in water uptake. In the fourth week, the charging process continued; each slurry mixture was removed from the tubs and shoveled onto a wire mesh attached to a wooden frame with the screen suspended over two empty 20 L tubs. Approximately 2 L of water were drained from the slurries, after which the remaining non-liquified material was removed and air dried in a separate dry container. By week five, sufficient drying occurs for the biochars to be blended with soil. 
       Blending and Post-Treatment Results 
       [0033]    After conditioning, biochars are blended with soils of various kinds including calcined clay, sandy loams and sandy clays. Prior to blending, soil and biochar are kept in moisture free containers, most often in 16 L plastic buckets, and then transferred using scoops of various sizes depending on whether blends are poured into pots or extracted as samples (ranging from 2 mg to 300 mg) for laboratory analysis. When prepared for pot use, 10% biochar volume and 90% soil volume samples are blended in plastic tubs (generally 35 L in volume). Blends are mechanically stirred to ensure even distribution of the biochar particulate. Then each blend is poured into the appropriate sized pot and labeled, or extracted for analysis and labeled. For that purpose, untreated soils and conditioned biochars are sieved through a #10 sieve before blending using a 1.5 L aluminum bowl followed by further reduction. As a field application, a conditioned biochar may be tilled into an existing field at the rate of 1:10 biochar to soil within the a to b soil horizons (to a depth no greater than 30.48 cm). 
       Applications and Outcomes 
       [0034]    As discussed earlier, observations and measurements of specific outcomes follow application of embodiments of the biochar which include laboratory elemental and nutrient analyses, adsorption capacity scanning (GACS) as shown in  FIG. 8 , portable photosynthesis and mass spectrometry as shown in tables 7 and 8 yielding metrics of plant physiological response to CB in pitch pine scrub oak species. Standard nutrient analysis performed using typical ICP testing yielded results of eastern U.S. grassland species ( Panicum, Festuca, Helichtrichon, Schizachrium  and  Chasmantium ) Prior to and Subsequent to exposure to CB soil additive. The effect of CB as a blocking (sorption) agent with regards to uptake of heavy metals in treated contaminated (firing range) soils was described previously. 
         [0035]    The use of CB biochar intervention as a soil conditioner may mitigate problems associated with recalcitrant urban waste, worldwide disappearance of standalone or networked biomes and depredation of isolated and sometimes networked man-made landscape features which have induced undesired anthropogenic effects. In terms of impact on crops, there is preliminary evidence by the claimants, based on earlier heavy metal sorption research, that CB biochar soil amendment may achieve sorption and improved growth of potentially hyperaccumulating crops such as  Brassica oleracea  (cabbage),  B. oleracea  (var. kale),  Lactuca saliva  (lettuce) and  Cucumis saliva  (cucumber).