Biochar training for environmental sustainability and

development
SANTIAGO DE COMPOSTELA, SPAIN: JUNE 26 - 28, 2014

Biochar production
FRAUNHOFER INSTITUTE FOR ENVIRONMENTAL, SAFETY AND ENERGY TECHNOLOGY
UMSICHT

Technologies
Feedstock
Processes and parameters
Costs and constraints
Fraunhofer
UMSICHT

Fabian Stenzel, Samir Binder

Folie 1
Fraunhofer UMSICHT

Fraunhofer
UMSICHT

Table of Contents
Technologies

Charcoal pile
Torrefaction
Pyrolysis

Gasification
Feedstock
Examples

Feedstock
Technology
Processes and parameters

Costs and constraints

Folie 2
Fraunhofer UMSICHT

Old charcoal pile

Ground coal piles are still used in rural
areas of developing countries.
They are covered with leaves (so that
the inside is not contaminated by the
earth) and covered with earth. In the
middle of a pile a chimney-area remains
free. In addition, a few small holes must
be dug in the covering layer of soil, so
that the carbonization gases can escape.
They yield from 20-25 % of the dry mass
of the wood.

Folie 3
Reference
Fraunhofer UMSICHT
picture:

http://de.wikipedia.org/wiki/Kohlenmeiler

Classical charcoal production (Brazil)

air inlet holes

This construction is called a "beehive"

kiln.

chimney

20 t of wood can be per batch. Such a kiln

can be used for about 5 years.
A char cycle takes about 11-13 day (1-2
days are for the loading and unloading)

air inlet holes

Coal yield is about 25% of the dry wood

mass.

air inlet holes

Round, brick kilns are still in operation in

Brazil, Argentina and South East Asia.

gate

Folie
4
Reference:
Energie
Fraunhofer UMSICHT

aus Biomasse; Kaltschmitt, Hartmann,Hofbauer; 2.edition; 2009 Springer publishing company

Charcoal piles (Brazil)

REUTER
S

Reference : newspaper Frankfurter Allgemeine 16. december 2007

klimapfennig-fuer-den-urwald-1488091.html
Folie 5
Fraunhofer UMSICHT

http://www.faz.net/aktuell/wissen/natur/umweltschutz-der-

Torrefaction
Torrefaction is a thermal process to convert biomass into a coal-like material,
which has better fuel characteristics than the original biomass. Torrefied biomass
is more brittle, making grinding easier and less energy intensive. Compared to
fresh biomass, storage of the torrefied material can be substantially simplified
since biological degradation and water uptake is minimized.
Torrified wood is not usually considered biochar.
Torrefaction involves the heating of biomass in the absence of oxygen to a
temperature of typically 200 to 400C. The structure of the biomass changes in
such a way, that the material becomes brittle, and more hydrophobic. Although
the weight loss is about 30%, the energy loss is only 10%. Main product is the
solid, torrefied biomass. During the torrefaction process a combustible gas is
released, which is utilized to provide heat to the process. In the figure below the
energy and mass yields are shown for auto-thermal operation as a function of the
moisture content in the feedstock. With increasing moisture content more gas is
required to achieve auto-thermal operation and as a consequence the degree of
torrefaction will increase.

Folie 6
Fraunhofer UMSICHT

Mechanical fluidization
Torrefaction / Rotation cone BTG (The Netherlands)

Temperature: 200 400 C

Reference: http://www.btgworld.com/en/rtd/technologies/torrefaction

Folie 7
Fraunhofer UMSICHT

Pilot plant BTG (The Netherlands)

Note Pilot plant for 100 150 kg/hour input

Reference: http://www.btgworld.com/en/rtd/test-facilities/torrefaction
Folie 8
Fraunhofer UMSICHT

Pyrolysis
Various reactors and three main pyrolysis procedures in practice
1. Fast pyrolysis
2. Intermediate pyrolysis
3. Slow pyrolysis
Most significant difference is the residence time of the solid phase within the
reactor seconds, minutes, up to hours and correlated energy transfer and
temperature distribution

Folie 9
Fraunhofer UMSICHT

Slow pyrolysis
The slow pyrolysis is known as carbonization. It is used to maximize the solid
products. The method has been practiced for many centuries in the context of the
charcoal production. The residual time could be hours and days [Mahmood2012]. The process is often used in developing countries to produce charcoal for
coking.
Advantageous of slow pyrolysis:
Simple plant design
Easy handling of the process
Disadvantageous of slow pyrolysis:

Discontinuous processes
Toxic exhaust gases, pollution of the environment and affect for the climate
Only wood with a water content of 26 wt.-% and less can be used

Long residence times

Only production of solid charcoal
Very seldom in combination with combustion for heat and power production.
Folie 10
Fraunhofer UMSICHT

Fast and flash pyrolysis

Fast pyrolysis leads generally to a maximum amount of liquid and minimum
amount of gas, while wood is used as feedstock . The temperature reaches
during the fast pyrolysis over 500 C. The feed for the fast pyrolysis must be
dried to less than 10 wt.-% water. With an absence of oxygen the reaction time is
below 2 seconds. To prevent cracking the vaporized pyrolysis oil and the char is
removed quickly form the reacting zone. The dark brown pyrolysis oil has with
16 - 19 MJ/kg approximately half the low heating value of conventional fuel oil.
Depending of the feedstock about 75 wt.-% of the dry feed will be converted to
bio-oil. In the literature various reactors like the bubbling fluid bed, the circulating
fluid bed and the transported bed are named. From all the reactor systems the
ash and char must be removed during the pyrolysis process.
For non woody feedstock the fast pyrolysis produces high reactive liquids which
can contain a high value of tars. Therefore fast pyrolysis is not the optimum
system for the treatment of bio-geneous residues.
A demonstration plant for the usage of straw was built by the KIT called Bioliq in
Karlsruhe. Another demonstrator for the flash pyrolysis from PYTEC for the
thermal conversion of wood was built. Although internationally there are many
researching groups who developing fast pyrolysis system.
Folie 11
Fraunhofer UMSICHT

Advantages/Disadvantages of fast pyrolysis:

Advantages of fast pyrolysis:
Production of liquids with high quantity
Disadvantages of fast pyrolysis:
High tar formation during pyrolysis

Especially for non woody feed the liquids are higher in viscosity and tar
content
Fine grounded material is needed for a fast thermal energy transfer
Water content of the feedstock below 10 wt.-% necessary
High cooling rates for the vapors necessary to reduce decomposition
Liquids containing usually high amounts of ash and char

Folie 12
Fraunhofer UMSICHT

Intermediate pyrolysis

A special kind of pyrolysis is the intermediate pyrolysis. The process is operating

with reaction conditions between slow and fast pyrolysis.
The reaction temperature is around 350 - 450 C. The reaction conditions
prevent the forming of long chain tar molecules. The produced char can be used
for fertilization or combustion.

The typical product yield of the intermediate pyrolysis is 40 - 60 % liquids, 15 25 % gases and 20 - 30 % solid char.

Folie 13
Fraunhofer UMSICHT

Advantages/Disadvantages of intermediate pyrolysis:

Advantages of intermediate pyrolysis:

Better control of the chemical reactions

Moderate heating rates
Water content of the feedstock up to 40 wt.-%
Coarse, shredded, chopped or fine grounded materials can be used as single feed or in
mixtures. Particles of several cm down to dust can be used.
Optimized reforming process alongside the pyrolysis
Better gas quality, liquids nearly free of tar
No hot gas filtration needed
Proofed principle
Flexibility for larger size feedstock
Steady char separation
Great diversified feedstock (algae, residuals of digestion, energy grass, wood residues,
sewage sludge, other residues from agriculture)
Direct usage of liquids in engines and boilers
Most promising biochar for application as fertilizer
Disadvantages of intermediate pyrolysis:

Less production of liquids in comparison with fast pyrolysis

Folie 14
Fraunhofer UMSICHT

Fast Pyrolysis Reactors

Rotating cone

Fluidised bed
HeissZyklon
Sand-Loop
Biobrennstoff

l
Gas

Heiss-Zyklon
Kondensator

Biobrennstoff

kalter
Biobrennstoff
Dampf

Koks

Sand
Bett

l, Gas

heisse Scheibe

Sand Loop
Koksverbrennung

zum
von
Koksverbrennung

siehe auch
Vortex Reaktor

rotierende, heisse
Scheibe, Zylinder,
Messer

Gas-Loop

Circulated fluidised bed

HeissZyklon

SandLoop

Koks

Koksverbrennung
Gas-Loop

Folie 15
Fraunhofer UMSICHT

Twin screw

l
Gas

zirkulierende Wirbelschicht
Bio brennstoff

Ablative reactor

Heizer im Sand-Loop

LR-Mischreaktor
Kondensator

Biobrennstoff

Heiss-Zyklon

Gas
l
Koks

Vakuumpyrolyse

Some Examples of Technologies

Folie 16
Fraunhofer UMSICHT

PYREG 500 Carbonization plant (Germany)

Biomass reactor:
Biomass
storage
tank

input rotary
valve

about 800 C

Burning chamber: about 1250 C

Energy extraction
Exhaust fan

PYREG double auger reactor

chimney

flue gas
fuel gas
Burning chamber

discharge
rotary valve

Ignition boiler

Combustion air
Reference: brochure about PYREG 500 kW carbonisation plant http://www.pyreg.de/website/resources/documents/pyreg_dt.pdf

Folie 17
Fraunhofer UMSICHT

The PYREG Unit

A PYREG machine works on the principle of dry carbonization. The fuel

(biomass) enters into the reactor via a dosing feeder, where it is heated up to 800
C. The material is not burned, but carbonized.
This produces syngas which is then burned completely in a combustion chamber
by a high efficiency FLOX burner up to 1250 C. This type of technology
produces very low exhaust emissions, which by todays standards cannot be
achieved by any other industrial method.
The recovered heat from the combustion chamber is used to power the PYREG
reactors in a continuous cycle. Roughly one third of the total heat energy
generated is then available for other forms of external use.

Folie 18
Fraunhofer UMSICHT

PYREG 500 Carbonization plant (Germany)

Burning
Chamber

Ash discharge

Reactor

Feedstock
distributor

Control box

Flue gas pipe with

optional heat extraction
Reference: brochure about PYREG 500 kW carbonisation plant http://www.pyreg.de/website/resources/documents/pyreg_dt.pdf

Folie 19
Fraunhofer UMSICHT

PYREG 500 Carbonization plant (Germany)

Feedstocks:
Green cuttings, leaves, Sieve residues,
willow, miscanthus, brewer's grains,
pulp, rapeseed cake, grain husks,
Coffee residues, digestate from biogas
plants, organic waste containers,
domestic waste, horse manure, chicken
manure, slaughterhouse waste,
sewage sludge, paper fiber sludge,
leather sludge
Minimum calorific value: 10 MJ / kg and
humidity below 100%, ie at least 50%
dry matter content

Reference: brochure about PYREG 500 kW carbonisation plant http://www.pyreg.de/website/resources/documents/pyreg_dt.pdf

Folie 20
Fraunhofer UMSICHT

Pyrolysis rotary kiln RWE Contherm plant (Germany)

Pyrolysis with high heat value feedstock
waste gas
to boiler
pyrolysis gas
to boiler

1. Waste/Feedstock storage
2. Shredder
3. Second storage
4. Crane
5. Material valve

6. Pyrolysis rotary kiln

7. Heating system
8. Discharge of solid
pyrolysis residues
9. Fan
10. Cyclon dust filter

Reference: http://www.techtrade.de/de/index.html

Folie 21
Fraunhofer UMSICHT

Pyrolysis rotary kiln RWE Contherm plant in Hamm

(Germany)
Operating from 2001 -2010

Throughput 70.000 tons/year

(planned 100.000 t/y)
Plant Temperature 700C
Problems: Fouling of gas
pipes, not economic

Folie 22
Fraunhofer UMSICHT

Ablative flash pyrolysis

Principle: contact of the biomass
with a hot surface (rotating disk)
with additional rotation "scraping")
Biomass is applied to a hot disk,
gets hot, and the pyrolysis starts.
80 rpm, the pressure on the
biomass is controlled here by a
spring.

Reactor wall temperature is 300400 degrees (to condense the

pyrolysis gases) for this type of unit.

Reference: Fast pyrolysis processes for biomass, Bridgwater, Peacocke, in Renewable and Sustainable Energy Rewiews Volume 4
March 2000
Folie 23
Fraunhofer UMSICHT

Ablative flash pyrolysis (Germany)

hydraulic control unit

condensation unit

oil and charcoal (output)

wood (input)
Hot rotary ablation disc

about 500 C for 1 second

100 kg wood
fused wood

70 kg oil
15 kg coke
15 kg gas

Reference: http://www.furgy.eu/fileadmin/downloads/veranstaltungen/workshops/deutsch/Vortrag_Josef_Robert.pdf

Folie 24
Fraunhofer UMSICHT

Ablative flash pyrolysis (Germany), Umsicht Oberhausen

Temperature about 500 C

Retention time < 1 s
Yield: 1000 g wood delivers approximately 500-700 g of pyrolysis oil (residues:
pyrolysis coke and pyrolysis gas)
Pretreatment of biomass: granulators, shredders (crushing); Briquetting and
pelleting presses (shaping); Rotary kiln and drying ovens (therm. treatment)

Reference:
http://www.umsicht.fraunhofer.de/content/dam/umsicht/de/dokumente/OE300prozesse/250313-innoclusterFolie
25
flashpyrolyse.pdf
Fraunhofer UMSICHT

Haloclean: Pyrolysis of 19 t of straw in 2005,

production of 6 t of biochar slurries to be gasified for
syngas production!

Folie 26
Fraunhofer UMSICHT

Haloclean
Haloclean, co-financed by European Commission, together with a prestigious pool of
other research partners. Sea Marconi, coordinator of the project since the beginnings,
patented Haloclean in the 2002.
The original idea of the project was to deal with the problem of electronic wastes.
Subsequently Sea Marconi started to investigate other feasible applications for the
Haloclean technology. The most promising are agricultural or forestry residues, given
their intrinsic low value, easy availability and because they usually represent a burden.
This new research area have given life to Haloclean BioEnergy, targeted to the
production of liquid fuels from biomasses for joint power and heat generation
(cogeneration), on a small scale using, properly modified internal combustion diesel
engines.
The conversion of biomass is realized by means of a peculiar pyrolysis process
(normally defined as termo-chemical cracking in the absence of oxygen).
Typical examples of residues that could be treated are wheat or rice straw, rapeseed
residues, corn and cotton stalks, rice husk and bran, olive stones, sawmill waste, etc.

Folie 27
Fraunhofer UMSICHT

Intermediate Pyrolysis

Folie 28
Fraunhofer UMSICHT

Pyroformer Intermediate Pyrolysis and combined

Reforming
Biomass

Pyrolysis vapours

Biomass IN

Char back

Biochar
Drying - Torrefaction - Pyrolysis Reforming - Char Conditioning

Folie 29
Fraunhofer UMSICHT

Pyroformer
The European Bioenergy Research Institute (EBRI) at Aston University has
developed an innovative bioenergy solution a Pyroformer unique in its use
of multiple waste feedstocks to generate cost-effective heat and power. The
Pyroformer uses a patented heat transfer mechanism to pyrolyze and
chemically process waste material in a single step using a dual Archimedes
screw system and an externally heated jacket, and works in contrast to existing
slow and fast pyrolysis techniques.
The reaction temperature for this process is around 450-500C, with a greatly
reduced vapor residence time of a few seconds the solids residence time can
be varied as desired. As the reaction occurs under controlled heating levels it
avoids the formation of tar which is problematic for other forms of pyrolysis as
clogging occurs and prevents the machinery from working. The Pyroformer
also allows the more efficient coupling with gasifier equipment (already
commercially available) to produce a consistent gas output that can be mixed
with biodiesel to drive combined heat and power (CHP) engines. The units could
be scalable to 5 -10MW of electrical power. The Pyroformer is capable of
processing up to 100 kg/h of biomass feed and when coupled with a Gasifier it
will have an output of 400 kWe
Folie 30
Fraunhofer UMSICHT

Pyroformer Detail

Pyroformer

Prof. Dr. A. Hornung

EBRI/Aston University
Folie 31
Fraunhofer UMSICHT

Technology can be simplified and at low cost!

Folie 32
Fraunhofer UMSICHT

Containerized mobile Pyroformer unit with engine

Folie 33
Fraunhofer UMSICHT

Pyroformer

Folie 34
Fraunhofer UMSICHT

A. Hornung, Aston Universitiy

A. Hornung, Aston Universitiy

A. Hornung, Aston Universitiy

A. Hornung, Aston Universitiy

MILENA Gasification plant (The Netherlands)

Reference: http://www.milenatechnology.com/

Folie 35
Fraunhofer UMSICHT

The MILENA gasification process

The MILENA gasification process converts biomass into a combustible product
gas with high efficiency. After cleaning, this gas can be used to generate power
with gas engines, gas turbines or fuel cells. The gas produced by the MILENA
gasifier is very suitable for application in a gas engine or gas turbine because of
the higher calorific value of the gas (typical 16 MJ/mn3 dry, compared to 4 7
MJ/mn3 for a conventional air blown gasifier) and the complete conversion of the
fuel (typical fuel conversion for downdraft or fluidized bed gasifiers is 85 - 95%).
The MILENA producer gas is also suitable for conversion of (woody) biomass
into sustainable Synthetic Natural Gas (SNG), also referred to as Bio-Methane or
Biomethane. SNG has the same properties as conventional natural gas and can
be used to replace natural gas in all applications. SNG is CO2 neutral, which
means that no extra CO2 is added to the natural environment.

Folie 36
Fraunhofer UMSICHT