Method of producing charcoal from biomass

A continuous process for producing charcoal from biomass input material in which the production of charcoal is maximized and the consumption of charcoal is minimized, the process comprising the steps of:

• a. establishing a charcoal production bed having a biomass upper layer having a top and a charcoal lower layer having a lower layer top;
• an intermediate layer pyrolysis zone positioned between the upper layer and the lower layer;
• the charcoal production bed positioned in a single reaction chamber;
• b. igniting the lower layer top with ignition means;
• establishing a pyrolysis zone at the intermediate layer;
• c. moving oxygen-containing gas downwardly through the charcoal production bed to sustain the pyrolysis reaction in the intermediate layer and to maintain the temperature of the charcoal in the lower layer, wherein the pyrolysis volatiles from the intermediate layer move downwardly through the hot charcoal in the lower layer, resulting in tar-free fuel gas, which exits from the outlet means, and;
• c. removing, by removing means, charcoal in the lower layer;
• regulating the introduction of additional biomass material so that as charcoal is removed, the level of charcoal comprising the lower layer, and hence the level of the pyrolysis zone comprising the intermediate layer, remain substantially constant within the reaction chamber.