FLAME CARBONIZERS

In Practice and Theory

Kelpie Wilson
Wilson Biochar Associates
kelpiew@gmail.com

Japanese Cone Kiln Moki Co.

Our inspiration comes from Japan where these simple cone-shaped

kilns were developed and sold by the Moki Company. They are
bottomless, and you simply roll them away when you are done.

Flame as Heat Exchanger

With the pan excluding air from the bottom and the flame
excluding air from the top, the Flame Cap Kiln acts like a retort
with the flame as a heat exchanger transferring heat efficiently
by radiation.

Limits of Heat Transfer through Metal

In theory, Stirling Cycle engines approach Carnot efficiency. In practice,

exergy loss from heat transfer across metal reduces efficiency. Thats
why we use the internal combustion engine, despite its lower theoretical
efficiency. For similar reasons we may prefer a flame carbonizer to an
externally heated retort

Basic Flame Types

Flames can be divided into categories:
Pre-mixed vs Diffusion
Laminar vs Turbulent
Concurrent flow (axial) vs Counter-current flow or Cross-current flow

The cone kiln works with crosscurrent flow that generates countercurrent vortex flows

Concurrent Axial Flow

No external limits on air
entrainment
Lean mixture cools the
flame, producing soot
Flame length limits
radiative heat transfer
to fuel bed

Counterflow combustion laminar flame

For Best Heat Transfer:

Shorten the Flame Length
Flame length is a function of mass flow rate and fuel bed

diameter
Open sided piles entrain more air than enclosed piles
giving higher air mass flow rate and higher flame length
High flow rate flames cool faster and radiate less heat to
the fuel bed
Piles enclosed by a surrounding cylinder have shorter,
more turbulent flames due to less entrained air

Buoyant diffusion flames: Some measurements of air entrainment, heat transfer and flame
merging. Thomas, et al. Fire Research Note. 1964

Flame Carbonizer Flame Types

TLUDs* and Ricks
Con-current Axial Flow
Flame Kilns
Shallow Kilns
Cross-current vortex generation
Deep Kilns
Passive Counter-current flow
Air Burners
Active Counter-current flow

*TLUD: Top-Lit Up-Draft gasifier

Ways to Tame a Flame

Jack Daniels Rick with Hood

The Jack Daniels Company has made charcoal for

filtering whisky this way for decades. When the rick
collapses into glowing coals, they quench it with water

Optimizing TLUDs as Flame Carbonizers

TLUDs are Flame
Carbonizers
Not very different from
a rick in a cylinder
Design Parameters:
Primary Air
Secondary Air
Flame stabilization
with swirl or tertiary air
Burner plenum space
Stack effects

Rick inside a ring - Ring of Fire

If bottom is not sealed, can burn like a TLUD. Can operate in dual mode:
TLUD for startup
Deep Kiln for later stages

Deep Kiln - Counter-current flow

Passive counter-current flow as burning fuel draws air downward

Active counter-current flow uses a blower

Ring of Fire Kiln - vortex generation

Reflected (re-radiated) heat and thermal gradients

produce vortex flows

Kon Tiki cross-current vortex generation

Rim shield around the cone draws air to feed the flames, generating
cross-current vortex flows

Flame Carbonizers vs Pile Burning:

The Fuel Problem in Oregon

Tight pile construction is standard

Tight piles dont fall apart

Burn hot in the center
Burn completely to ash
Generate smoke
Burn forest soil

Top lit makes a difference

But to save any char you need water to quench

Very Loose Open Pile Top Lit

Concurrent axial flow burns fast, hot and clean, but pile falls
apart and needs tending. Can make a lot of biochar if quenched.

Open Ricks

Rick in Pan

Design Parameters for Oregon Kiln

Sized for feedstock
Logs 4 to 5 feet long
Up to 6 diameter
Log rick fits better in pyramid shape than cone
Portable but Durable
Less than 200 lbs
14 gauge steel

Ergonomic for loading

Only 2 feet high
Economical
Pyramid shape cheaper to fabricate than cone
$600 for Kiln 5 top base, 4 bottom base, 2 high

Oregon Kiln

Oregon Kiln in the Backyard

Oregon Kiln in the Woods

Grayback Forestry Crew

Working in the Rain

Dumping

Time and Water Needed to Quench

Willow Witt Ranch

Quenching Time

Using the jib crane to dump

Next Christmas

Giant Slash Pile

Its a HUGE problem! We need bigger kilns, but they need to be

mobile.

Air Curtain Burner Counter-flow

Active counter-current flow using a blower

Air Burner with blower off like Deep Kiln

Air Burner Biochar - Ashland Watershed

Air Burner Char

Air Burner Char

Left: char chunks. Right: mineral soil

Trees planted in Air Burner char

Left: light granitic soil. Right: soil with char mixed in.

More Ideas for Flame Carbonizing

Burner Design tangential air & baffles

Burner Design Electromagnetism

Controlling the flame with an electromagnetic field

Burner Design - Coanda Effect

Can we create curved surfaces that exploit the Coanda Effect?

Container Design -Tents and Wigwams

Left: Carbon Cultures biochar kiln.

Right: WigWam biochar kiln by Scott McKain of UBET

Container Design Coking Ovens

Non-Recovery Coking Oven

Channels flue gas underneath for more heat transfer

Container Design - Cob Ovens

Make a little biochar with your pizza or make a little pizza

with your biochar!

Wilson Biochar
Associates
Wilson Biochar Associates specializes
in biochar technology and market
development. We provide strategic
advice and services to businesses and
organizations.

Technology Assessment
Research and Analysis
Project Development

Kelpie Wilson
Wilson Biochar Associates
Home office: 541-592-3083
Mobile: 541-218-9890
kelpiew@gmail.com
www.wilsonbiochar.com

Kelpie Wilson and Carol Ann Perkins

with Stirling Engine at CSU, Chico.
Wilson, K. & Perkins, C. (1987). Approximating
the Ideal Stirling Cycle Through Discontinuous
Motion of the Displacer Piston. Senior Project
Report and Second Prize Winner, ASME Power
Division, Student Paper Competition.