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<p>This study focuses on the development of a movable fixed-bed pyrolyzer and investigates biochar production from three agricultural residues: paddy straw, barley straw, and corn cob kernels. The pyrolysis process was conducted at temperatures between 300 and 600&#xa0;°C, with a heating rate of 3–5&#xa0;°C per minute and a residence time of 30–60&#xa0;min, resulting in an average biochar yield of 39.84%. The system recorded an overall efficiency of 29.59%, 26.34% and 29.06% for paddy straw, barley straw and corn cob kernels residues, respectively. Over 20 days, 130&#xa0;kg of biomass produced approximately 52–53&#xa0;kg of biochar, demonstrating the system’s capability to process up to five batches daily. Among the feedstocks, corn cob kernels demonstrated the highest thermal stability, while paddy straw yielded the highest biochar output of 40.67%, followed by barley straw (39.89%) and corn cob kernels (38.89%). Fuel characterization revealed that biomass had a low fuel ratio of 0.134–0.261 and high volatile matter of 64–68%, indicating rapid combustion, while their derived biochar shows higher fuel ratio of 2.4–4.84 and reduced volatile matter of ~ 15%, enhancing thermal stability and fixed carbon. Corn cob kernel biochar (BCS) exhibits the highest stability (FR 4.84), while barley straw biochar (BSB) has the lowest combustibility index (6.22&#xa0;MJ/kg), making biochar more suitable for stable fuel and specialized applications. SEM analysis showed structural changes, including a porous architecture suitable for adsorption and microbial growth. The TGA curves demonstrate distinct thermal degradation profiles for the raw biomass samples (PS: Paddy Straw, BS: Barley Straw, CS: Corn Cob Kernels) and their corresponding biochar derivatives (BPS, BSB, BCS), highlighting variations in thermal stability and decomposition characteristics. The statistical analysis indicated significant differences in biochar production parameters among selected biomass feedstocks, with high F-values (101.59 to 192.21) and low p-values (<i>p</i> &lt; 0.05), confirming the robustness of the observed transformations. These findings underscore the potential of biochar, with enhanced fuel properties, electrical conductivity, and alkalinity, for applications in energy, agriculture, and environmental remediation.</p> Graphical Abstract <p></p>

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Design and performance evaluation of movable fixed-bed type pyrolyzer for biochar production from agricultural residues

  • 期刊论文

  • 发表日期：

    2026年5月11日

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  • Revathi Kommarla,
  • Pradip Digambar Narale,
  • Mahendra Singh Seveda

摘要

This study focuses on the development of a movable fixed-bed pyrolyzer and investigates biochar production from three agricultural residues: paddy straw, barley straw, and corn cob kernels. The pyrolysis process was conducted at temperatures between 300 and 600 °C, with a heating rate of 3–5 °C per minute and a residence time of 30–60 min, resulting in an average biochar yield of 39.84%. The system recorded an overall efficiency of 29.59%, 26.34% and 29.06% for paddy straw, barley straw and corn cob kernels residues, respectively. Over 20 days, 130 kg of biomass produced approximately 52–53 kg of biochar, demonstrating the system’s capability to process up to five batches daily. Among the feedstocks, corn cob kernels demonstrated the highest thermal stability, while paddy straw yielded the highest biochar output of 40.67%, followed by barley straw (39.89%) and corn cob kernels (38.89%). Fuel characterization revealed that biomass had a low fuel ratio of 0.134–0.261 and high volatile matter of 64–68%, indicating rapid combustion, while their derived biochar shows higher fuel ratio of 2.4–4.84 and reduced volatile matter of ~ 15%, enhancing thermal stability and fixed carbon. Corn cob kernel biochar (BCS) exhibits the highest stability (FR 4.84), while barley straw biochar (BSB) has the lowest combustibility index (6.22 MJ/kg), making biochar more suitable for stable fuel and specialized applications. SEM analysis showed structural changes, including a porous architecture suitable for adsorption and microbial growth. The TGA curves demonstrate distinct thermal degradation profiles for the raw biomass samples (PS: Paddy Straw, BS: Barley Straw, CS: Corn Cob Kernels) and their corresponding biochar derivatives (BPS, BSB, BCS), highlighting variations in thermal stability and decomposition characteristics. The statistical analysis indicated significant differences in biochar production parameters among selected biomass feedstocks, with high F-values (101.59 to 192.21) and low p-values (p < 0.05), confirming the robustness of the observed transformations. These findings underscore the potential of biochar, with enhanced fuel properties, electrical conductivity, and alkalinity, for applications in energy, agriculture, and environmental remediation.

Graphical Abstract