We build pyrolysis plants at industrial scale.
The CarbonHub formula
What is a CarbonHub? It’s a cutting-edge solution for carbon transformation. Each CarbonHub is a dedicated facility where we process carbon-rich biomass, converting it into renewable energy to reduce reliance on natural gas while producing biochar for carbon removal.
By generating Carbon Dioxide Removal (CDR) Credits, our CarbonHubs actively contribute to negative emissions, supporting global climate goals. Every new plant we build is a CarbonHub, driving sustainable energy innovation and creating a cleaner, greener future.
Scalable biochar plants driving industrial decarbonization
We develop and manage the entire construction project of the carbonization plant and operate it after completion.
Industrial symbiosis
We develop, design, and implement projects tailored to the industrial needs of our partners. We own and operate our systems.
By providing green energy on site, we step into an industrial symbiosis with our partners, securing a long term partnership.
Versatile solutions for industries
We bring a global perspective to a wide range of industries, including district heating, industrial steam, and more. With expertise in sustainable energy solutions and advanced industrial technologies, we help businesses optimize efficiency, reduce environmental impact, and achieve long-term success.
Whether you’re looking for innovative heating solutions or industrial steam applications, our tailored approach ensures cutting-edge solutions designed to meet industry demands.
Global growth
As part of our global expansion strategy, we want to extend our operations worldwide. This expansion underscores our commitment to sustainable practices and its role in advancing the circular economy on an international scale.
Each examined location has specific needs which we are prepared to satisfy: energy, better soils, better air and better environment.
Project timeline: Building an industrial scale pyrolysis plant
Feasibility study and/or Basic Engineering
Realization
(Detail Engineering, Permitting, Procurement, Construction)
Commissioning and Start of Production
The CarbonHub
Ever wondered how a pyrolysis plant is constructed? Find a detailed explanation for every unit – from registration to truck loading – in this slideshow.
Unit 1: Registration and weighting
Incoming trucks, either for delivery of feedstock, the pick-up of biochar, or other purposes will be registered here. This ensures safety and tracability of all vehicles entering the facility.
The initial quality check of incoming material is also performed here.
Unit 2: Feedstock handling
Depending on the properties of the delivered feedstock, the material gets either directly stored or further processed before storage.
Coarse material is unloaded separately and undergoes several steps of crushing and grinding to the needed properties before storage.
Unit 3: Wet feedstock storage
The feedstock from direct delivery or from pre-processing is transferred into the storage. The storage bunker is equipped with different compartments to store different qualities.
The storage can be designed with a capacity for several days of production.
Unit 4: Drying
Before entering the pyrolysis process, the wet feedstock needs to be dried to approx. 10 % moisture content.
From the storage it is passing a belt drying system, before entering the intermediate storage for the pyrolysis unit.
Unit 5: Buffer tanks
Each pyrolysis unit is equipped with a intermediate storage silo which acts as a buffer for several hours of production.
This ensures the availability of the plant in case of a technical incident in the feedstock system.
Unit 6: Pyrolysis
The two pyrolysis units are the heart of the plant. Using part of the energy from the combustion process, the feedstock gets converted into biochar and syngas.
At the outlet of the unit, the hot biochar is being cooled down and transported to further processing.
Unit 7: Combustion chambers
The extracted syngas from the pyrolysis process is burned in the combustion chamber. The hot flue gas is partly used to fuel the pyrolysis process, the main part is directed to the energy system.
Unit 8: Energy system
Using the hot flue gas from the combustion chamber outlet, steam generators use the energy to generate process steam to be used by the customer. Optionally part of the steam can be used to generate electricity.
The exact use case depends on the steam demand and properties.
Unit 9: Flue gas treatment
The cooled down flue gas from the energy system is finally processed in the flue gas treatment system to extract dust and harmful compounds before the remains get extracted into the atmosphere with minimal environmental impact.
Unit 10: Recycling center
Central in the plant layout, the recycling center is mainly used to safely store the filtered dust from the flue gas treatment.
It also contains facilities for any other type of material to ensure that everything is disposed of properly.
Unit 11: Biochar post treatment
The cooled biochar is either directly stored in silos or can be further treated by grinding and sieving to create different kinds of biochar products for different markets.
For the final packaging big bags or smaller bags are possible.
Unit 12: Biochar bulk storage
The storage silos are used to store raw biochar directly from the reactor, as well as treated biochar which has been already grinded.
A sufficient number of silos ensures the availability of different fractions of biochar.
Unit 13: Truck loading
For direct truck loading, one of the silos is equipped with a truck loading station. A bulk material truck can there be loaded directly with biochar.
The truck-silo can also be filled with different kinds of biochar from the other silos before unloading.
Our pioneer plant in Hamburg
Turning cocoa waste into clean energy and biochar
Track record
In partnership with one of the world’s leading producer of premium cocoa products, we’ve developed a tailor-made biochar facility at industrial scale in Hamburg, Germany—one of Europe’s largest. This innovative plant is designed for seamless integration into an existing brownfield site, showcasing a first-of-its-kind approach that utilizes purely biomass residues.
The facility transforms waste cocoa shells into renewable process steam, which powers the biomass supplier’s factory operations. The carbonization process produces biochar, designed specifically to meet the unique demands of diverse biochar applications and markets.
With this cutting-edge plant, we’re achieving a reduction of 5,000 t/a CO2 by replacing steam generated from fossil fuel gas and a removal of 5,800 tCO2e/a, significantly contributing to sustainability and advancing the circular economy.
From organic waste to clean energy, biochar and CO2 credits
Nominal figures of our pioneer plant
Biomass
8,000 t/a cocoa shells
Energy
21,000 t/a process steam
Biochar
3,300 t/a high quality biochar (25 % moisture)
Carbon Credits
5,800 tCO2e/a carbon removal certificates
Climate impact:
5,000 t/a CO2 reduction by replacing steam from fossil fuel gas
The figures provided reflect a base case scenario and are subject to variation, depending on the specific project characteristics, including the type of biomass and the energy supplied.
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