Economic analysis and profit potential of a mobile air curtain biochar processor

Authors: Morton, Trent; Kichler, Corey; Torbert Iii, Henry

Submitted to: Meeting Abstract
Publication Type: Research Technical Update
Publication Acceptance Date: 12/5/2025
Publication Date: 12/5/2025
Citation: Morton, T.A., Kichler, C.M., Torbert III, H.A. 2025. Economic analysis and profit potential of a mobile air curtain biochar processor. Technical Report. USDA-ARS National Soil Dynamics Laboratory, Auburn AL, USA. 6 p. https://www.ars.usda.gov/southeast-area/auburn-al/soil-dynamics-research/docs/worksheets/.

Interpretive Summary: Agricultural and forestry waste is typically disposed of using open burn piles. However, this method usually creates a lot of ash and burns up most of the available carbon. Burning waste in low oxygen environment called pyrolysis creates biochar material which leaves most of the carbon in the Biochar residue, resulting in a biproduct that has economic value. An inventive method to achieve pyrolysis while burning organic materials is the use of an air curtain inside of the firebox. By blowing a steady flow of air over the fire pit, the mixing of the air near the burning material is almost entirely removed, resulting in a very low oxygen environment around the burning. Recently, commercially available equipment that uses air curtain technology has been developed that is also portable so that it can be moved to remote sites where the waste is generated. This technical report provides an economic evaluation of using this type of equipment in silvicultural operations typical for the Southeastern US. Results show that for our cost assumptions and equipment choice, the potential total yearly profit of $89,133 could be attained.

Technical Abstract: Agricultural and forestry waste is typically disposed of using open burn piles. However, this method usually creates a lot of ash and burns up most of the available carbon. Burning waste in low oxygen environment called pyrolysis creates biochar material which leaves most of the carbon in the Biochar residue, resulting in a biproduct that has economic value. An inventive method to achieve pyrolysis while burning organic materials is the use of an air curtain inside of the firebox. By blowing a steady flow of air over the fire pit, the mixing of the air near the burning material is almost entirely removed, resulting in a very low oxygen environment around the burning. Recently, commercially available equipment that uses air curtain technology has been developed that is also portable so that it can be moved to remote sites where the waste is generated. This technical report provides an economic evaluation of using this type of equipment in silvicultural operations typical for the Southeastern US. Results show that for our cost assumptions and equipment choice, the potential total yearly profit of $89,133 could be attained.