Our plant
for your organic residues
We develop and manage the entire construction project of the carbonisation plant and operate it after completion.
Our plant for your organic residues
A feasibility study is conducted before the construction process starts. Ideally, our plant can be fit in to existing structures at the production site. This allows to connect the streams of organic waste directly to the plant. The recycling process can thereby be integrated on site.
Recycling green energy
Renewable energy is generated as a by-product of biochar. It can be fed into customers’ local production processes either as process steam or as cooling, heating or electricity.
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Product:
Biochar
The biochar obtained is always fully utilised. It can be used in the value chain as required. Alternatively, Circular Carbon can remarket the biochar products.
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Unit 1: Feedstock system
Our industrial client sends the residues through a bridge thanks to a conveyor system. They go through a metal separator and are separated from eventual metals. They are weighed when arriving at Circular Carbon and stored in a silo. From the silo, the residues will be transported via two further conveyor systems to the pyrolysis unit.
Unit 2: Pyrolysis system
The residues are brought to the pyrolysis reactor through a dosing screw. The reactor is filled with nitrogen first to have an inert atmosphere. This prevents the organic compounds from reacting with the Oxygen. The reactor is made of an electrically heated screw and heats at about 600°C. The residence time of the residues in the reactor is approximately 40 minutes. The process forms biochar and pyrolysis gas.
Unit 3: Combustion chamber system
The pyrolysis gas is burnt in a combustion chamber. It is initially fed into the first chamber, where the temperature is around 950°C. This process is called flameless oxidation as there are no visible flames in the combustion chamber. This helps to reduce the formation of nitrogen oxides (NOx) which are pollutants.
Einheit 4: Energy system
The exhaust gas travels into a fire-tube boiler. The thermal energy of the exhaust gas is transferred to the water. The water is heated up to 180°C to produce 11 barg saturated steam. An economiser is installed after the boiler where the remaining energy of the exhaust gas is used to pre-heat the water from 103°C to 150°C. The exhaust gas temperature drops to 200°C after running through the system.
Unit 5: Exhaust gas treatment
The exhaust gas contains sulphur oxides (SOx), a pollutant that must be treated. If SOx are released in the atmosphere, H2SO4 will form, responsible for acid rains. Bicarbonate is injected into the exhaust gas pipe which neutralises the SOx. Finally, the filter traps the particles still in the exhaust gas. The clean exhaust gas is separated in two streams: one stream is released in the atmosphere through the chimney and the second stream is recirculated back into the combustion chamber. This gas recirculation allows to control the temperature in the combustion chamber.
Unit 6: Biochar handling
After the pyrolysis, hot biochar is formed. It comes out of the reactor at about 600°C. It is cooled down with cold water continuously running in the envelope of the cooling screw and moisturised with water to reduce dust development before being stored in big bags.
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