Flame Cap 'Algorithm' Panel Kiln

This design compared to other kilns on the medium scale can reduce kiln cost, save feedstock processing time, can be easily manufactured, is feedstock agnostic, wins on logistics, is more easily assembled and can be adapted to feedstock/Biochar requirements with modular expandable volume.
It's generic panel design and predicted reliable performance could be suitable for generating Biochar Carbon Removal credits from possibly a variety of CRM platforms.

TECH SPECS
- South Australian available steel:
    - 1.55mm (or 2mm) HW350 Corten 'Weathering steel', 1210 x 2440 standard sheets
    - Durable structural steel, weathering for outdoors (can be left assembled), no steel rot
- Standard 'V panel' sides 1150x1150 with 4 x 30mm 90 degree folds
- Standard Panel for Ends, 1160x1180, with 3 x 30mm 90 degree folds, dual prongs for anchoring into soft ground/earth
- both end and side panels will use 25x25x2 square tube 'X reinforcement' using a laser stitch weld (or MIG/TIG) on same side as folds

- Modular/Expandable

    - Volume for base unit (2 ends, 4 side panels, with no truncation is 1322.5 litres) then add volumes per additional V panel pairs (could add truncation to increase overall volume too)
    - length also determined by the length of the biomass feedstock eg.bamboo, hemp straw, kelp et al.
- Weight: 35kg/sheet, so, just under 17.5kg per panel + weight of 'X reinforcement ' (should be OK for Oz Workplace, Health & Safety as there are now no upper weight limits). Heavy but can be managed by one person.

- Panels will fit on a standard 1165x1165 Oz pallet - perfect for logistics

Assembly
- Drop the first end panel in
    - Folds pointed away from the V panels/fuel chamber footprint
    - pound the top of the end to drive the prongs in (with the club hammer)
- pound in 2 star pickets per side, 60cm apart (with the club hammer), lining up with edge of end panel, first one 30cm away
- assemble the sides/V panel pairs
    - first V panel pairs, leaned against star pickets (with optional truncation)
    - 2 steel 'C clamps' per outward facing and sloping adjacent V panel folds for additional stability
- drop in and pound the second/last end panel in, folds facing outwards

Operation
- fill the kiln half full with thin biomass waste
- light at the top (using firelighter gel if you can get it)
- create a bed of coals
- add the first layer
- wait until top ashes a little
- add next layer and repeat until the top of the panel module is full
- flame almost goes completely out
- quench
    - carefully remove one side of the V panels
    - rake out the biochar
    - use water, urine, soil, manure etc.
    
DONE

R&D cluster

As the Algorithm is at the build phase of R&D (I'm building one for the 2025 biochar season) this design may need to be modded for future iterations/generations. For eg., I can't guarantee the panels won't warp for a given (?any) feedstock although I have tested 1.55mm Corten panels in the Flat Modular Biochar kiln which were smaller without X reinforcement but did not warp. Any feedstock with a moisture content below 15% is going to test the engineering limits of this kiln. Mistakes lead to more learning, so if you can access manufacturing and are prepared to lose some money if some/all the panels warp, go for it - but I doubt they will warp. You can always mod the panel(s) design for stronger reinforcement (or for future variations if the initial design fails) -  if we can get a group working on the same tech, it will be much faster R&D and perhaps even getting the kiln to a commercial footing with a new commercial license that could be shared with early movers. But - really, the main bucks will be in kiln manufacturing, kiln sales, biochar sales by Charistas and Biochar Carbon Removal credits for Charistas (pending approval once a commercial design is finalised).

 

Anyone interested in joining an R&D cluster please get in touch on the 'Contact' form and we can get the ball rolling on this one.