Pyrolysis unit BIO-Carbon

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Key Benefits

  • Environmental friendliness: Emissions into the atmosphere are only water vapor and CO₂. Pyrolysis gases are completely neutralized at temperatures above 1300°C, which eliminates harmful emissions. Compared to traditional methods, which produce 4 tons of harmful emissions per 1 ton of coal.
  • 100% automation: Minimal personnel participation (1 operator + 1 assistant worker per shift). Automatic control of all parameters through the automated control system 2026.
  • Continuity of production: Operation 365 days a year, 24 hours a day, 7 days a week without technological stops.
  • Consistent product quality: The automatic control system ensures constant characteristics of the finished coal.
  • Energy efficiency: The installation runs on its own pyrolysis gas; additional fuel is required only at startup (25-50 liters of propane-butane gas). Produces excess heat 300-1000 kW/hour.
  • Low energy consumption: BC-2: 8 kW/h; BC-3: 13.6 kW/h
  • Compact: Small dimensions with high performance.
  • High reliability: 100% fireproof materials, service life 5-10 years.

Description

The Bio-Carbon pyrolysis unit is designed taking into account the key engineering requirements used in the certification systems for pyrolysis units and final products (biochar), namely regarding the prevention of harmful emissions into the soil and atmosphere, as well as the prevention of injury to operating personnel. The installation is designed and manufactured taking into account the basic safety and health requirements provided for by Machinery Directive 2006/42/EC and Machinery Regulation (EU) 2023/1230, including requirements for:

  • preventing injuries to service personnel when contacting or approaching surfaces with elevated temperatures;
  • ensuring safe operation of technological equipment;
  • preventing the risks of burns, fire and uncontrolled release of hot gases;
  • restricting access to hazardous areas of equipment;
  • the use of thermal insulation, protective screens and fences;
  • ensuring safe maintenance, cleaning and inspection of the installation;
    integration of emergency stop and overheating control systems;
  • safety of automated control systems and actuators;
  • reducing risks associated with the accumulation of dust, pyrolysis gases and high-temperature process products;
  • ensuring safe removal and neutralization of pyrolysis steam and gas products;
  • compliance with industrial, fire and environmental safety requirements;
  • minimizing residual risks by applying technical, design and organizational measures to protect personnel.

BIO-Carbon – continuous system for dry pyrolysis of biomass to obtain high-quality biochar with a fixed carbon content (Cfix) from 85 to 95%, then installation. The installation is the central unit of the biochar production system, the production complex using the installation also includes additional units of equipment to ensure the processes of preparing raw materials for the process (drying, crushing, separation) and handling the resulting final product (cooling and packaging of biochar). The stability of production processes is ensured through the use of industrial automation, with mandatory temperature control.

An automated control system (ACS) ensures control of the non-volatile carbon content in the biochar, a carbonization reactor ensures the absence of external atmospheric oxygen, and a secondary thermal oxidizer ensures the environmental friendliness of the process, which allows the biochar to be successfully certified (EBC, IBI, WBC, Puro Earth, Vera).

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    Raw materials for processing

    The raw materials for the installation are various biomass, which corresponds to the following characteristics: humidity < 10-15%, fraction 3-40 mm.

    Most raw materials require certain preparation, which is determined by the characteristics of the raw material. Conventionally, raw materials for installation can be divided into two types:

    1. Requires preliminary compaction (pelletizing or briquetting);
    2. Requires preliminary crushing and drying;
    Coconut shell
    Walnut shell
    Hazelnut shell
    Wood chips
    Bamboo
    Almond shell
    Palm kernel shell
    Pistachio shell
    Argan shell
    Pits of date
    Pits of olives
    Peach Shell
    Hawthorn Seed
    Bagasse

    Technical description

    Basic elements of Bio-Carbon

    1. Belt/screw conveyor
    2. Storage hopper
    3. Loading auger
    4. Bucket Elevator
    5. Loading Hopper
    6. Pyrolysis Chamber
    7. Unloading hopper with air cooling system
    8. Screw unloading conveyor
    9. Unloading devices of the pyrolysis chamber
    10. Secondary Thermal Oxidizer
    11. Chimney

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    Overall dimensions of the installation

    BIO-Carbon-2
    BIO-Carbon-3

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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.