Mobile kiln system

An example mobile kiln system includes a mobile platform. A frame is mounted to the mobile platform. At least one kiln is rotatably mounted to the frame. The kiln is movable between a first operational position for loading a feed material into the at least one kiln, and a second operational position for unloading a biochar product from the at least one kiln following processing of the feed material. In an example, the mobile kiln system includes at least one stack assembly for the kiln. The stack assembly has a lid to cover the kiln to retain heat and a chimney to release emissions from the kiln during processing of the feed material.

BACKGROUND

Biochar is taking on increased interest with the abundance of source material (e.g., beetle kill forests) and new innovations for the end product (e.g., environmental clean-up, agricultural uses, etc.). However, it can be expensive to transport the source material to a processing facility. As such, these facilities have to be constructed at least somewhat near the source material to reduce these costs and make biochar production cost-effective. When the source material runs out, the facility has to be dismantled and moved to a new location, or abandoned. Both options leave an undesirable footprint on the landscape.

DETAILED DESCRIPTION

A mobile kiln system is disclosed as it may be operated to produce a biochar product from feedstock, such as beetle kill pine trees or other plant material. An example mobile kiln system includes a mobile platform. A frame is mounted to the mobile platform. At least one kiln is rotatably mounted to the frame. The kiln is movable between a first operational position for loading a feed material into the at least one kiln, and a second operational position for unloading a biochar product from the at least one kiln following processing of the feed material. In an example, the mobile kiln system includes at least one stack assembly for the kiln. The stack assembly has a lid to cover the kiln to retain heat and a chimney to release emissions from the kiln during processing of the feed material.

The example mobile kiln system is shown as it may be configured for transport by a “lowboy” trailer for use on-site (e.g., where trees or other biochar source product is available). Other transport mechanisms (e.g., trailers, or built-on the truck) are also contemplated. The mobile kiln system thus reduces time and costs associated with transporting the biochar source product to the biochar kilns.

In an example, the system is self contained. That is, it can be fully isolated from “shore” power, with both power and fuel for the conversion process. A frame subsystem can be easily lowered on and off of a trailer. In an example operating configuration, the frame subsystem also provides the option to be permanently attached to a dedicated trailer.

Before continuing, it is noted that as used herein, the terms “includes” and “including” mean, but is not limited to, “includes” or “including” and “includes at least” or “including at least.” The term “based on” means “based on” and “based at least in part on.”

It is also noted that the examples described herein are provided for purposes of illustration, and are not intended to be limiting. Other devices and/or device configurations may be utilized to carry out the operations described herein.

FIG.1is a perspective view of an example mobile kiln system10.FIG.2is a back view of the example mobile kiln system10shown inFIG.1. An example of a mobile kiln system10includes a mobile platform12, and a frame14mounted to the mobile platform12. The mobile platform12may be a trailer (e.g., a flatbed or “lowboy” trailer), a truck (e.g., a flatbed truck or a specially designed truck including the mobile platform), a skid, a float, or any other platform for transporting the frame and mobile kiln system10between sites for processing and/or delivering biochar.

In an example, the frame14is removable from the mobile platform12and remains fully operational apart from the mobile platform12for biochar production.

In an example, a fuel supply16may be provided on the mobile platform so that the mobile kiln system is self-sustained. The fuel supply16(e.g., propane) may be connected to one or more of the kiln(s)18, at least during a burn phase of biochar production.

At least one kiln18is rotatably mounted to the frame14. The kiln18is mounted to the frame14to be movable between a first operational position for loading a feed material into the kiln18(e.g.,FIG.7), and a second operational position for unloading a biochar product from the kiln18following processing of the feed material (e.g.,FIG.8).

In an example, the kiln18is mounted to an elevated support axis20rotatably mounting the kiln (or kilns)18to the frame14. The elevated support axis20supports the kilns on the frame14in the first operational position and the second operational position.

In an example, the elevated support axis20includes a first shaft hub22mounted to a cross member21on the frame14, and a second shaft hub24mounted to either side of the kiln18. A shaft extends between the shaft hubs22and24to enable rotation.

A drive system26may be operated to rotate one or more kiln18on the elevated support axis20between the first operational position and the second operational position. In an example the drive system26includes a motor. Examples of the motor include but are not limited to a direct drive, gear driven, chain or belt driven motor.

In an example, the mobile kiln system10includes at least one stack assembly30for the at least one kiln18. An example stack assembly30has a lid32to cover the kiln body to retain heat therein, and a chimney or other exhaust port34to release emissions from the kiln18during processing of the feed material. In an example, the stack assembly30is positionable on the kiln18in an operating configuration (e.g., chimney up as seen inFIG.3), and a transport configuration (e.g., chimney down as seen inFIG.1). The chimney34moves about 180 degrees (e.g., upright to upside down) between the operating configuration and the transport configuration.

In an example, the mobile kiln system10includes a dedicated stack assembly30for each of a plurality of kilns mounted to the frame. In another example, a single stack assembly30is provided on a guide track to move between a plurality of kilns mounted to the frame. The guide track may have one or more rail and corresponding rail engagement device. The corresponding rail engagement device may include at least one wheel to roll on the at least one guide track. In another example, the corresponding rail engagement device includes at least one slider to slide on the guide track.

In an example, a drive mechanism automatically moves the stack assembly between the plurality of kilns. The drive mechanism may include one or more motor and drive chain or drive belt to move the stack assembly30.

FIG.3is a perspective view of the example mobile kiln system10showing a stack assembly30on a first kiln18.FIG.4is a perspective view of the example mobile kiln system10showing the stack assembly30moved to a second kiln18. The stack assembly30may also be moved to the third kiln18, or some or as many kilns as provided.

In an example, a three kiln18configuration (such as that shown in the drawings) is best suited for the most efficient processing of the biochar burn cycle and subsequent cooling cycle of the biochar production. The configuration is laid out in a line so that it fits within standard shipping requirements for transportation on highways, rail, or ship.

The frame14may be structured to support the kiln rotation pins22of the support axis20, and the overall outside geometry of the frame14, so that the kilns18can be suspended from the frame14. This structure allows for the lower portion of a traditional kiln18to be removed and all kilns18to be supported by the frame14for transport via the mobile kiln system10. The frame14also allows for the kilns18to be rotated and emptied within the frame structure14, together or each independently, after the completion of the cooling cycle of the biochar.

FIG.5is a perspective view of the example mobile kiln system10showing the first kiln18in a tipped position to empty biochar from the first kiln18. Biochar may be emptied onto the ground, e.g., for pickup using a frontend loader, or emptied directly into a transporter (e.g., frontend loader, truck, railcar, etc.).FIG.6is a back view of the example mobile kiln system10corresponding toFIG.5.FIG.7is a close up view of the example mobile kiln system10showing the first kiln18in an upright position to load with feedstock and processing operations.FIG.8is a close up view of the example mobile kiln system10showing the first kiln18in a tipped position to empty processed biochar.

In this example, the kilns18are pivoted from a middle pin22on the frame14to enable the kiln18to tip and dump from the trailer or frame14. An automated system enables emptying the kilns18with little to no human involvement, making the mobile kiln system fully or at least partly automated. In addition, no external equipment is necessary for the dumping of the kilns18, making the mobile kiln system10fully or at least partly self-contained. An automated system enables the entire process, from burn, dump and moving the stack assemblies30during the production of char material with little to no human interaction, with the use for little or no external equipment.

The operations shown and described herein are provided to illustrate example implementations. It is noted that the operations are not limited to the ordering shown. Still other operations may also be implemented.

It is noted that the examples shown and described are provided for purposes of illustration and are not intended to be limiting. Still other examples are also contemplated.