Analysis and development services

Our R&D Expertise

GreenPower’s engineering team applies advanced research methods and simulations to develop and refine environmentally safe pyrolysis unit. Our approach integrates design innovation, process analysis, and automation to ensure optimal performance and compliance with global environmental standards. We combine innovation and sustainability to create high-quality pyrolysis unit of various types for the production of biochar and charcoal. Rich experience (since 2001) and a full-fledged Design Working Group allows us to provide analysis and design services, as well as testing of various types of pyrolysis unit.

ENGINEERING

We develop detailed 3D engineering models of pyrolysis unit to optimize structural integrity, check materials strength parameters, and integration of main and critical components. This stage lays the foundation of the construction concept for energy-efficient and durable equipment design.

CFD PROCESSES MODELLING

Our team performs Computational Fluid Dynamics (CFD) simulations to visualize and analyze gas and heat flow within the system. These studies help optimize process stability, improve fuel efficiency, and reduce heat losses.

OXIDATION PROCESSES MODELLING

We model oxidation zones to ensure complete neutralization of pyrolysis gases. These thermal models enable us to minimize emissions and design pyrolysis units that comply with strict environmental regulations and high effective energy balance.

MATERIAL AND HEAT BALANCE CALCULATION

We conduct precise material and heat balance calculations to determine the energy requirements and outputs of each process phase. This ensures efficient energy use and supports accurate system performance predictions.

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Equipment for drying

Which dryers does GreenPower offer?

The design of the drying equipment is determined by the choice of raw materials for drying.

Chamber dryer for drying wood (firewood) and charcoal briquettes.
Drum dryer for small raw materials – sawdust, wood chips, etc.
Shaft dryer can be used for wood chips and wood.

What can a chamber dryer be used for?

Chamber dryer can be used for:

Wood drying, for the carbonization process in carbonization furnace of the ЕККО type.
Pre-drying the wood significantly shortens the carbonization process in the carbonization furnace and improves the quality of the charcoal. Which in general increases the productivity of furnaces. Optimum drying temperature <200°C. The duration of the drying process corresponds to the duration of the carbonization process in the furnace.
Wood drying for fireplaces. Promotes improvement of burning and storage of wood. Typically, the moisture content is adjusted to 15-20%. Optimum drying temperature <150°C.
Drying charcoal briquette for BBQ or hookah. Briquetting line included. Optimum drying temperature <100°C.
Heating of industrial or household premises. It is possible to receive both hot water and hot air.

What is the heat carrier (where does the heat come from) for the chamber dryer?

Separate fire chamber device or a gas (liquid-fuel) burner, for example when using a dryer for fireplace wood
Excess heat from the carbonization furnace EKKO, with a pre-drying system, is used in this case to increase the furnace capacity to pre-dry the wood.
Excess heat from the carbonization furnace BIO-KILN, with system for extracting excess heat from the furnace is used to dry charcoal briquette for BBQ or hookah. It is also possible for heating industrial and household premises.

What is the efficiency of GreenPower dryers?

Drum dryer. The maximum effect of the drying plant is ensured by supplying the same amount of thermal energy to each individual piece of raw material. This process is maximally provided by the design of drum drying, where the raw material is in a pseudo-suspended state. However, the use of drum drying for wood is almost impossible due to large pieces of raw materials.

Chamber dryer. In chamber dryers, this effect is ensured by the efficient mixing of heat in the chamber. And also due to the use of recirculation – the repeated use of heat for the chamber, that is, heat is chasing around, moisture is periodically ejected from the chamber.

EKKO-2 Pyrolysis Unit

Who are the main consumers (Unit buyers) of EKKO-2?

Logging and woodworking enterprises (with their own feedstock or waste products).
Producers of fuel wood and energy crops (eucalyptus, bamboo, energy willow, etc.).
Agricultural enterprises, orchards, and agro-biomass processors (subject to feedstock preparation and applicability for chamber carbonization).
Companies generating plant-based biomass/carbon-containing feedstock (including some lump waste).
Investors/operators of BIOCHAR projects (carbon removal projects, soil improvement, ESG) requiring stable quality and process parameter traceability.

Who are the main consumers of the finished product (charcoal / biochar)?

BBQ/HoReCa and retail market.
Metallurgy.
Silicon production.
Activated carbon production.
BIOCHAR as a soil conditioner/eco-friendly fertilizer (depending on application standards).
Other industries requiring carbon materials (sorbents, filtration, etc. — based on the customer’s technical specifications).

What is EKKO-2 and what is its operating principle?

EKKO-2 is a semi-continuous chamber carbonization (slow pyrolysis) unit equipped with two technological chambers. The process is based on controlled heat supply and the complete neutralization of pyrolysis gases. The thermal energy generated during the neutralization of pyrolysis gases is used for drying the feedstock and maintaining the pyrolysis process, which reduces the need for additional fuel once a stable operating mode is reached.

The main purpose of the EKKO-2 fixed-bed pyrolysis unit is the production of lump charcoal with a minimal content of fine fractions.

What processes take place “outside the Unit” and “inside the Unit”?

A. Processes outside the pyrolysis Unit:

Feedstock size reduction: cutting and splitting, and in some cases crushing and chopping, i.e. reducing the material to an acceptable fraction, which facilitates thermal processes and loading of feedstock into the trolleys;
Loading feedstock into the trolleys;
Pre-drying of feedstock: forced drying using excess heat from the EKKO-2 process;
Charging the trolley into the chamber and removing the trolley with hot charcoal from the chamber;
Cooling the charcoal in the trolleys without oxygen access;
Discharging charcoal from the trolley, and if required, charcoal stabilization and packaging.

B. Processes inside the pyrolysis Unit:

Final drying and initial stage of pyrolysis (100–250°C): removal of moisture and primary pyrolysis products;
Carbonization (250–450°C);
Calcination (approximately 450–550°C): applied when higher fixed carbon content is required (Cfix > 83%).

*Transitions between modes occur according to the ACS algorithms and/or by the operator’s decision;

BIO-CARBON Carbonization Unit

What is BIO-CARBON and what is its purpose?General Questions about BIO-CARBON

BIO-CARBON is a vertical moving-bed unit for continuous dry carbonization of biomass. Based on patented technology and full automation, the unit is an industrial asset that produces:

• High-quality charcoal with fixed carbon content (Cfix) from 82% to 95%
• Biochar for agricultural applications
• Industrial charcoal for metallurgy, activated carbon production, semiconductors, and silicon production
• High-potential thermal energy as a by-product

The unit operates 24/7 without technological shutdowns and ensures environmentally friendly production through full neutralization of pyrolysis syngas.

What are the advantages of BIO-CARBON compared to traditional charcoal production methods?

The main advantages of BIO-CARBON include:

Environmental friendliness: Emissions to the atmosphere consist only of water vapor and CO₂. Pyrolysis gases are fully neutralized at temperatures above 1300°C, eliminating harmful emissions. Compared to traditional methods, which produce up to 4 tons of harmful emissions per 1 ton of charcoal.
100% automation: Minimal personnel involvement (1 operator + 1 assistant per shift). Automatic control of all parameters via the 2026 control system.
Continuous operation: 365 days a year, 24 hours a day, 7 days a week without technological shutdowns.
Stable product quality: The automated control system ensures consistent characteristics of the produced charcoal.
Energy efficiency: The unit operates on its own pyrolysis gas; additional fuel is only required during startup (25–50 liters of propane-butane gas). Generates excess heat of 300–1000 kW.
Low power consumption: BC-2: 8 kW; BC-3: 13.6 kW.
Compactness: Small footprint with high productivity.
High reliability: 100% refractory materials, service life of 5–10 years.

What BIO-CARBON models are available?

There are two main unit models, differing in capacity and dimensions:

Model	Productivity (t/month)	Productivity (t/year)	Energy consumption (kW/h)
BIO-CARBON-2 (BС-2)	40-70*	440-770	8
BIO-CARBON-3 (BС-3)	80-120*	880-1320	13.6

*Note: productivity is specified for a fixed carbon content (Cfix) 82-95%

In which countries are BIO-CARBON unit units used?

GreenPower unit is officially operated in more than 39 countries worldwide, including countries in Europe, Asia, Africa, South America, and North America. The unit has obtained environmental operating permits in all of these regions.

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