Laboratory and applied research on biomass, polymer waste, and end-of-life tire (ELT) processing

Find out the price

GreenPower provides laboratory and applied research services aimed at identifying effective technological solutions for the processing of biomass and other carbon-based materials.

We believe that technology selection should be based not only on the type of feedstock but also on the requirements for the final product. Therefore, our research covers the entire process chain—from the analysis of the raw material and its preparation for processing to the determination of optimal operating parameters and the evaluation of the properties of the resulting product.

This approach helps reduce technological risks during project implementation, improve the predictability of outcomes, and identify solutions that meet the customer’s objectives within the framework of modern circular economy principles and resource-efficiency strategies.

What types of raw materials do we research?

Agricultural, woody, and other types of biomass;
Lignin-containing waste materials;
Polymer waste, including polyethylene, polypropylene, polystyrene, and other plastics;
Rubber waste, including end-of-life tires (ELTs);
Sewage sludge and sludge-derived waste;
Other carbon-based materials.

Scope of Our Research

Characterization and analysis of feedstock properties;
Assessment of feedstock suitability for thermal processing;
Development of feedstock preparation recommendations;
Modeling and optimization of process operating conditions;
Determination of solid, liquid, and gaseous product yields;
Evaluation of carbonaceous solid residue quality;
Preparation of recommendations for technology scale-up and industrial implementation.

Feedstock Preparation for Processing

Size Reduction and Comminution – Selection of the optimal particle size and evaluation of the impact of particle size distribution on downstream processing performance.
Feedstock Drying – Determination of initial and target moisture content and selection of the most suitable feedstock pre-treatment approach.
Briquetting – Assessment of feedstock suitability for densification, evaluation of binder requirements, and analysis of briquette properties after compaction.
Mechanical Feedstock Preparation – Evaluation of material structure, bulk density, and processing behavior prior to thermal treatment.

Thermal Process Modeling

Torrefaction – Selection of optimal temperature profiles, residence time, and processing conditions to achieve the desired product characteristics.
Pyrolysis – Determination of optimal process parameters, carbonaceous solid residue yield, and the properties of liquid and gaseous products.
Activation – Assessment of the suitability of feedstock and carbonaceous residue for the production of activated carbon and sorbent materials.

Comprehensive Feedstock and Product Analysis

Moisture content determination;
Ash content determination;
Volatile matter analysis;
Higher Heating Value (HHV) determination;
Particle size distribution analysis;
Lignin content analysis;
Evaluation of briquetting suitability;
Assessment of binder requirements;
Mechanical strength testing;
Bulk density determination of feedstock, briquettes, and carbonaceous residue;
Evaluation of the efficiency of size reduction, drying, and thermal processing operations.

Quality Control and Environmental Assessment

Heavy metals analysis;
Determination of polycyclic aromatic hydrocarbons (PAHs) content;
Analysis of organochlorine compounds and other potentially hazardous substances;
Assessment of compliance with end-product specifications and quality requirements;
Preliminary evaluation of certification potential according to applicable international frameworks and standards, including IBI, EBC, REACH, and other relevant regulatory requirements.

Deliverables Provided to the Customer

Upon completion of the research program, the customer receives:

A technical assessment of feedstock suitability for processing;
Recommendations for feedstock preparation and pre-treatment;
Recommendations on torrefaction, pyrolysis, briquetting, and activation operating parameters;
An evaluation of carbonaceous residue yield and its key quality characteristics;
An analysis of process energy efficiency;
Recommendations for the selection of the most appropriate process configuration;
Technical data and engineering insights required for scaling up from laboratory studies to pilot-scale and industrial implementation.

Business Benefits

Our research helps businesses to:

Reduce the risk of selecting an inappropriate technology;
Understand the actual value and processing potential of a specific feedstock;
Identify material limitations and advantages before investing in equipment;
Define requirements for feedstock preparation systems and thermal processing units;
Improve consistency and repeatability of final product quality;
Accelerate the transition from concept validation to commercial-scale operation.

GreenPower as a Technology Partner

We view the research phase as the foundation for the successful design and implementation of a processing solution. For this reason, GreenPower can support customers not only during the evaluation stage but throughout subsequent project phases—from process design and technology development to equipment selection, commissioning, and ongoing process optimization.

Would You Like to Assess the Processing Potential of Your Feedstock?

Share information about your feedstock and project objectives with us, and we will propose a research program tailored to your needs. Our studies help identify the most effective processing pathway, define feedstock preparation requirements, and establish the operating parameters needed to achieve the desired end-product characteristics.

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:

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.

View all