Pyrolysis unit EKKO

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Advantages of EKKO unit 

  • High quality at a reasonable price;
  • Compact design and low weight;
  • Energy efficiency: no additional fuel is required to maintain the process;
  • Low power consumption (<0.1 kW / 2.2 kW);
  • Environmental safety: zero harmful emissions during unit operation;
  • Fast startup of the unit into operating mode (<60 minutes);
  • Resistance of the primary thermal oxidizer to thermal shock;
  • Rapid startup of the unit at a “new location”; preparation for startup (< 8 hours);
  • Possibility of transporting two units of unit in a single container or truck;
  • The charcoal preserves the shape of the raw material; the fine fraction (small particles) of the charcoal does not exceed 1%;
  • High unit productivity with relatively small dimensions

Description

Environmentally friendly mobile carbonization unit for carbon-containing biomass, including: firewood, energy wood, wood waste, and fuel briquettes (Pini-Kay, Ruff, Nestro, Nielsen). It is designed for the production of high-quality charcoal or bio-carbon. The core process utilized in the pyrolysis unit is carbonization, or the slow pyrolysis of carbon-containing biomass materials. In addition to charcoal production, thermal energy is generated during the process. This heat can be utilized for the preliminary drying of raw materials or for other purposes.

Charcoal has widespread applications in nearly all sectors of the national economy (read more in Charcoal Applications). The production of high-quality, environmentally friendly charcoal is a critical task for the development of the global economy.

Based on 20 years of experience (since 2001, see the GreenPower history), unique and safe carbonization unit has been developed, taking into account the key requirements of modern consumers: 

  1. The chamber carbonization unit is manufactured using modern insulation materials that can withstand ultra-high temperatures (up to 1300°C), eliminating the need for “ballast” refractory bricks, concrete, and sheet metal. This solution accelerates the technical process and increases the efficiency of the unit. 
  2. The Automated Control System (ACS) allows for the automation of the technical process management and minimizes the influence of the human factor on the unit’s productivity and final product quality. The integration of a feature for saving all production data at every stage into the ACS cloud storage via the Internet enables real-time ONLINE monitoring of the operating personnel and the entire technological process.
  3. A unique, time-tested design guarantees the reliability and maintainability of the unit and its components. The pyrolysis unit will reliably serve for more than 5 years; if necessary, any part or element can be easily and quickly repaired or replaced.
  4. Logistics and Mechanization. Competent and well-thought-out logistics of the charcoal production complex allows for the elimination of expenses that could exceed the cost of the unit itself: the purchase of expensive forklifts and the installation of lifts, crane beams, and the construction of hard surfaces for production, which are required when using a forklift. This advantageously distinguishes us from most manufacturers who typically do not disclose these costs at the stage of unit purchase.
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    Raw materials

    A wide range of raw materials can be subjected to environmentally friendly pyrolysis (read more about the “pyrolysis” process):

    • Firewood, energy wood;
    • Woodworking and logging waste, off-grade wood (including roots, branches, etc.);
    • Various fuel briquettes (Pini-Kay, Ruff, Nestro, Nielsen).
    firewood
    wood waste
    wood log
    roots
    bamboo
    Pini-Kay briquette
    Ruf briquette
    Nestro briquette

    Technical description

    The EKKO pyrolysis unit is manufactured in EKKO-2 and EKKO-4 modifications. The EKKO-2 model includes 2 carbonization chambers, and the EKKO-4 includes 4 carbonization chambers.

    We use a pair of chambers because carbonization occurs in two different reactions: endothermic and exothermic. Therefore, we utilize the exothermic reaction in one chamber to generate excess thermal energy, which is then used to conduct the endothermic reaction in the other chamber and to run the preliminary drying process of the raw material outside the carbonization chambers.

    During charcoal production, the endothermic reaction, which absorbs heat, can occur twice: at the stage of raw material drying and initial pyrolysis, and at the stage of charcoal calcination if a high fixed carbon content is required.

    The main advantage of the EKKO pyrolysis unit is the ability to complete the full carbonization cycle without additional fuel and environmental pollution.

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    Dimensions of the EKKO-2 pyrolysis unit

    EKKO-2
    EKKO-2 with preliminary drying

    Video

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    Have more questions?

    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: 

    1. 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;
    2. Loading feedstock into the trolleys;
    3. Pre-drying of feedstock: forced drying using excess heat from the EKKO-2 process;
    4. Charging the trolley into the chamber and removing the trolley with hot charcoal from the chamber;
    5. Cooling the charcoal in the trolleys without oxygen access;
    6. 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: 

    ModelProductivity (t/month)Productivity (t/year)Energy consumption (kW/h) 
    BIO-CARBON-2 (BС-2)40-70*440-7708
    BIO-CARBON-3 (BС-3)80-120*880-132013.6

    *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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    Discuss Your Carbonization Project

    Our engineering team will review your requirements and propose the appropriate system.