Our Technology Solutions
We are enablers of torrefaction and carbonisation processing facilities. Together with our European parent Polytechnik we are able to provide you with Cutting Edge process solution for the transformation of biomass residues into high value products that serve as a renewable energy source and CO2 storage solutions.
Torrefaction
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Carbonisation
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Torrefaction
carbon-neutral fuel
Carbona and its parent Polytechnik together with its partners offer solutions for the entire torrefaction process, from biomass preparation (storage and drying) to reactors, combustion chambers and even waste heat utilisation.
With an annual production of 60.000t per line these plants are able to convert Biomass residues into a valuable commodity.
Torrefied Biomass can be used in different applications where as the substitution of coal in various processes is currently the most effective one with the decarbonisation of major industries.
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What is torrefaction?
Torrefaction is a method of roasting biomass. It is a thermal treatment that eliminates volatile components from the biomass and increases its carbon content. Depending on the process temperature and duration, the torrefaction degree rises and the product becomes similar to bio coal. The process runs similar to pyrolysis but in a lower temperature range of around 300°C. The Torr-Gas is used in a circular approach to generate the process energy for the system including feedstock drying.
02
How does torrefaction work?
The feedstock is heated in a reactor with flue gases until the volatile components are expelled. The gases produced in this process are redirected into a combustion chamber, where they are burnt. The resulting heat is used to heat the reactor. As the process is exothermic (ie. more heat is released than consumed), the excess heat is used in a waste heat boiler. Any heat transfer medium (hot water, steam, thermal oil) can be applied and used in subsequent processes.
The torrefied product has a higher carbon content than the feedstock. It is cooled and then compacted into briquettes. This process increases its energy density again. The result is a high-quality biomass product. This process typically results in a mass yield of around 66% and a product with an energy content of around 75%.
03
Why Carbona torrefaction?
The resulting product has very favourable fuel properties. For example, its energy density is much higher than raw biomass, meaning transport costs can be reduced. Furthermore, the existing infrastructure for loading and unloading of coal can be used. The product can be stored outside. This results in a product, which can be used as a carbon-neutral fuel substitute in power plants to create electricity or process heat for industrial processes.
Carbonisation
The Clean Answer To Carbon Negative Energy
Using our own group technology we are enablers of build production facilities that can produce Biochar with Carbon contents up to 97%. Our batch process runs on pyrolysis under an low oxygen environment, continuously and fully automated. The pyrolysis gas is fully used in a circular approach to generate the systems own thermal energy demand. Any surplus energy can be used for either drying applications or for electricity production. The facility and its logistics are automated in such a way that they can be operated 24/7. Carbona is able to offer Carbonisation plants with a yearly biochar output from 3.000 up to 9.000t per line.
01
What is carbonisation?
Carbonisation is is the process by which organic matter, including biomass is converted into carbon or a carbon-containing residue through a pyrolysis or destructive distillation process.
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How does carbonisation work?
Carbonisation involves subjecting organic material to high temperatures in the absence of oxygen within a kiln or specially designed carbonisation retorts. This thermal decomposition leads to the breakdown of complex organic molecules into simpler carbon-based compounds. The result is the formation of solid carbon or carbonaceous residues.
The Carbona process involves:
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Drying. Storage containers are filled with organic raw material and dried with hot air (waste energy from the pyrolysis process).
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Retort Filling. After drying, the raw material (feedstock) is tipped into a receiving hopper and transported to the retort filling station, where an empty retort is waiting.
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Preheating. The filled retorts are automatically transported to a connected preheating station to prepare the raw material for carbonisation. Here, the feedstock is heated with hot air. This reduces the time required in the pyrolysis station and increases the output of the plant.
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Automated Material Transport. A crane equipped with two independently operated lifting devices transports the retorts quickly and safely from station to station. The material movements are optimised to ensure continuous efficient operation of the energy plant and the pyrolysis station. Advanced automation ensures operational flexibility.
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Furnace. The pyrolysis station is supplied with energy from a custom-built combustion system with a water- cooled reciprocating grate for the combustion of the automatically fed feedstock. The combustion of the pyrolytic gases takes place in a specially designed combustion chamber via gas burners. Advanced controls, primary and secondary air systems and an adiabatic combustion chamber ensure complete oxidation of both biomass fuel and pyrolytic gases – resulting in high efficiency and low emissions.
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Reaction Process. After preheating, the retorts are closed with airtight covers. Once the reaction process has completed carbonisation, the retort is opened and the crane removes the retort. The pyrolytic gases are directed to the burners of the combustion system, providing clean energy for the pyrolysis process.
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Cooling. After pyrolysis, the hot retorts are stored in a cooling station and brought to ambient temperature with cool air. To prevent further oxidation of the charcoal produced, the openings of the retorts are sealed with sand.
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Discharging. The cold retorts are transported to an unloading station at the end of the process. A conveyor brings the charcoal to a screening or crushing station, allowing the customer to produce different product sizes. It is then transferred to the packaging station (e.g. bulk bags).
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Why Carbona carbonisation?
Carbona’s carbonisation process can transfer approximately 50% of the plant’s carbon into an inactive carbon pool, which means it is not released. This is done by processing it through pyrolysis under low-oxygen conditions. The remaining 50% of the carbon can be used for heat or electricity production – enabling you to produce biochar with up to 97% carbon and carbon negative energy at the same time (provided sustainable sources are used).
