Company Evolution

Technology Evolution

By 2003–2004, it became clear that traditional charcoal kilns could not meet the growing requirements for lump charcoal quality – such as mechanical density and coal dust quantity. Production strongly depended on operator experience, weather conditions, and kiln size, while charcoal wastes remained high, yield low and carbonization was difficult to control.

At the same time, producers faced consistent technical limitations:

• uneven carbonization with underburned and overburned zones
• low mechanical strength and high fines content
• inability to process small-size wood and woodworking residues
• unstable product quality from batch to batch

In response to these challenges, GreenPower initiated the development of a new generation of carbonization equipment in 2003 with a nickname “Bezzolnaya”, focused on controlled process conditions and improved product quality.

In early 2004, the first industrial solution of this mobile type UP-1 “Bezzolnaya” was introduced. The new furnace design ensured:

• uniform heat distribution and stable carbonization
• reduced formation of fines and improved mechanical strength
• the ability to process a wide range of raw materials, including wood waste
• significantly lower emissions compared to traditional furnaces

During further development, the original kiln design was significantly refined and improved. In the following years, GreenPower introduced three upgraded versions of the UP-1, UP-2, and UP-3 “Ugolkov” systems, featuring a simplified and more reliable charcoal unloading mechanism. Between 2004 and 2010, more than 300 units of this type were manufactured and delivered, demonstrating strong market demand and practical efficiency of the design.

At the same time, these systems still operated without automated process control and did not meet modern environmental requirements. The carbonization process remained highly dependent on operator experience, with limited control over emissions and process stability.

This stage clearly indicated the need for the next technological step — the transition toward automated, environmentally compliant, and fully controlled carbonization systems.

First Industrial Pyrolysis Concept

In 2007, GreenPower began the development of a fundamentally new environmentally clean pyrolysis furnace — CK “EURO”. This project became the first practical implementation of a controlled pyrolysis concept based on proprietary engineering solutions. The heating process of raw material from DRYING to PYROLYSIS was achieved through controlled positioning of slide gate-dampers, allowing redirection of the heat carrier and precise regulation of pyrolysis process thermal conditions.

For the first time, it became possible to control the evolution and combustion of pyrolysis gases, enabling stable process management and significantly improving the quality of the final carbon product.

This development marked a critical step toward fully controlled pyrolysis systems, forming the basis for further advancement of fixed bed type carbonization reactors. In early 2008, we began testing CK “EURO”. After numerous design changes as a result of our work, we gained a positive result.

Modular Design and Industrial Readiness

In 2013–2014, a new generation furnace, CK-3 “EURO”, was designed and manufactured. The primary objective of this development was not only to eliminate the structural limitations of previous EURO generations, but also to minimize on-site assembly operations prior to commissioning.

The CK-3 concept introduced a modular, pre-engineered design, allowing most of the system to be manufactured and prepared at the factory. This significantly reduced installation time, simplified on-site works, and minimized dependence on local conditions and assembly personnel.

In 2015, the first serial CK-3 “EURO-m” unit was produced. During its operation, further refinements were implemented, focusing on improving reliability, installation efficiency, and process stability under real industrial conditions.

This stage marked a transition toward standardized, industrial-ready systems with reduced installation complexity and improved environmental performance.

EKKO Furnace Development and EURO Upgrade

In 2016, GreenPower began testing a new generation of equipment — the experimental CK-1 EKKO furnace at the Kharkiv production site. This project was aimed at developing a more advanced, automated, and environmentally compliant carbonization system. Based on the results of these tests, a further evolution of the EKKO line was introduced. In 2017, testing and development continued, as not all engineering objectives had yet been fully achieved. This stage played a critical role in refining the technical solutions that later formed the basis of modern GreenPower furnace systems.

Automation and Modern Carbonization Systems Development 

Between 2019 and 2024, GreenPower focused on the development and optimization of automated carbonization systems for lump charcoal and biochar production. 

This resulted in the release of the EKKO-2 furnace, a fully automated, environmentally compliant solution with remote monitoring and control capabilities. Each furnace can be connected to the Internet, allowing real-time data tracking, centralized supervision, and automated response to emergency conditions. High efficiency is achieved through advanced thermal insulation, rapid transition to operating режим, and utilization of internal process energy, including excess heat for raw material drying. The design minimizes thermal inertia by eliminating unnecessary structural mass, improving cycle time and energy performance. During this period, GreenPower manufactured more than 150 EKKO-2 furnaces.

In parallel, continuous carbonization technology was further developed through the BIO-KILN furnace series, with full automation of raw material feeding, separation, carbonization, cooling, and discharge processes. The system operates on the moving bed-type principle with indirect heating of raw material and automated control, ensuring stable operation and reduced human involvement. Additional improvements included the use of refractory materials and the utilization of excess process heat. A total of 16 BIO-KILN units of various configurations were produced during this stage.

Process Methodology by GreenPower

There is no universal or standard pyrolysis technology applicable to all types of raw materials. Industrial carbon production requires a methodological, feedstock-driven approach, where process design is defined by the physical, chemical, and structural properties of the material.

GreenPower applies a sequential engineering methodology:

feedstock analysis → feedstock preparation → selection of carbonization technology

At the first stage, key parameters are evaluated, including particle size distribution, moisture content, bulk density, structure, and behavior during thermal decomposition. These parameters determine the required preparation strategy.

Feedstock preparation is implemented using a combination of technologies depending on material type:

1. Size reduction: 
   • cutting and splitting for lump charcoal production; 
   • crushing and screening for wood chips and small fractions; 
2. Drying systems 
   • chamber drying for lump wood; 
   • drum drying for chips and small fractions; 
   • drum or aerodynamic drying for low bulk density feedstock
3. Densification for low-density materials: briquetting or pelletizing
4. Carbonization system by GreenPower
   • Fixed-Bed Reactors. These are the simplest type of reactors where the feedstock remains stationary on a grate or inside a container while heat is applied. They are typically used for batch processes and are characterized by slow heating rates, making them more suitable for charcoal production (slow pyrolysis) rather than high-yield oil production.
   • Moving-Bed Vertical Reactors. In a moving-bed vertical reactor, the feedstock is fed from the top and moves downward by gravity as a dense, continuous layer, while heat is typically applied through a counter-current flow of hot gases indirectly. This gravity-fed design is highly valued for its no air thermal efficiency and simplicity, making it ideal for the large-scale processing of coarse materials like wood or bamboo chips, pellets, or briquettes. Because the material remains in the reactor for a relatively long time as it descends, these reactors ensure a high degree of conversion into solid char and heat-energie with minimal mechanical complexity.
   • Auger (Screw) Reactors. Auger reactors use a mechanical screw to move the feedstock through a heated cylindrical tube. They are popular for continuous small scale operations because they offer precise control over the residence time of the material and have possibility for use of low quality biomass.
   • Rotary Kiln Reactors. This type consists of a rotating cylindrical vessel slightly inclined to the horizontal. As the kiln rotates, the feedstock moves through the heated zone. These reactors are highly versatile and can handle varied and “dirty” feedstock (like mixed biomass or low quality biomass) because the mechanical rotation ensures constant raw material mixing. Yield of char will be lower, as from other reactor types.

NOTIFICATION: Only after proper conditioning of the raw material is the carbonization technology selected. The choice of reactor type and process configuration is based on the required heat transfer conditions, material behavior, and target carbon specifications.

This approach ensures controlled pyrolysis, stable process conditions, and predictable carbon quality, which is critical for industrial and metallurgical applications.