Biochar reactor is an advanced system designed for the pyrolysis of biomass in a controlled environment. This thermal decomposition process produces biochar—a lightweight, highly porous carbon-rich material with remarkable properties. Biochar has gained widespread recognition for its valuable applications, including soil enhancement, carbon sequestration, and environmental sustainability. Curious to learn more about how a biochar reactor can benefit your business or the environment? Read on!
What Is A Biochar Reactor? – The Core of Biomass Pyrolysis
The biochar reactor is the heart of biochar production equipment and biomass pyrolysis process. It provides a controlled high temperature and low oxygen environment to produce high-quality biochar. Its design and function influence the efficiency, yield, and quality of the final products, as well as the overall sustainability and economic viability of the biomass pyrolysis operation.
- Phase 1: Dehydration: The biomass will remove excess water inside as the temperature gradually rises.
- Phase 2: Demethylation: As the reaction temperature continues to rise, the methyl groups in the biomass are removed. As a result, it releases combustible gases such as hydrogen and methane.
- Phase 3: Release of Organic Volatiles: The increase in temperature will cause some organic volatile substances to be released. These gaseous volatiles can form wood vinegar and tar after condensation.
- Phase 4: Biochar formation: As volatile substances continue to precipitate, biomass is eventually converted into carbon-rich biochar.
Types of Beston Biochar Reactor for Sale
| Model | BST-06 | BST-50 |
|---|---|---|
| Input Capacity | 0.3-0.5m³/h | 10-15m³/h |
| Reactor Size | φ820mm*L11200mm | φ2000mm*L14260mm |
| Land for Equipment (L*W*H, Standard Configuration) | 25m*15m*8m | 35m*18m*9m |
| Weight (Standard Configuration) | 21T | 49T |
| Energy Consumption (Standard Configuration) | 153kw/h*0.7 | 191kw/h*0.7 |
| Working Method | Fully continuous | |
| Feeding Requirement | Size: ≤20mm; moisture: ≤15%; strong liquidity | |
| Structure | Double barrel double hearth | |
| Speed | 1-9RPM | |
| Control Method | PLC control | |
| Reactor Material | Stainless steel 304 | |
| Pressure | Micro negative pressure | |
| Heating Material | Diesel, natural gas, heavy oil, biomas, etc. | |
| Heating Method | Direct heating | |
| Noise (dB) | ≤80 | |
| Condenser | Circulating water cooling | |
| Rotation Method | External gear rotation | |
Specific Design/ Specific Components of Beston Biochar Reactor
01Main Roller – Reactor Core
The main roller is the core component of the entire biochar reactor. Its manufacturing directly affects machine safety and workers’ safety.
Function: The main roller rotates to evenly heat raw materials, producing biochar and syngas once the pyrolysis temperature is reached.
The choice of reactor material directly impacts the achievable pyrolysis temperature, which indirectly impacts the fixed carbon content of the resulting biochar. The material selection depends on customer requirements, and the options below are available for customization.
- Q245R + 310S: Allows pyrolysis temperatures up to 650°C.
- SS304 or SS316: Allows reaction temperatures between 600-650°C.
- 310S: Supports reaction temperatures as high as 750-850°C.
02Casing – Thermal insulation effect
03Drive Wheel – Power unit
Components: Motor, gearbox, transmission belt, base.
Function: Provides power for the rotation of the main furnace.
The carbonization reactor allows flexible adjustment of the material’s residence time inside the furnace by regulating the motor’s operating speed according to the pyrolysis condition of the material.
04Burning Room
Function: The fuel burns inside the base to provide heat for the main furnace.
Beston Group can design customized heating solutions based on the specific conditions of the customer’s site. Commonly used fuels include coal, wood, fuel oil, natural gas, and non-condensable combustible gas recovered during production. The structure of the base varies depending on the type of fuel used.
05Inlet and Outlet Seal Head
It is the passage for materials to enter and exit the biomass pyrolysis reactor. Its highly-sealed structure prevents gas leakage and outside air from entering the reactor. Thus, this ensures that the whole machine completes biomass pyrolysis in a strictly oxygen-free or low-oxygen environment.
Unique Design of Biochar Reactor
Three-point Support Design
The drive unit features a three-point support structure, consisting of one main drive wheel and two auxiliary drive wheels. This design offers several benefits:
- Enhanced stability: This design evenly distributes the load and pressure generated during operation, ensuring stable operation of the main furnace. This ensures full heat exposure for the biomass, enabling complete pyrolysis.
- Extended service life: The weight of the equipment is effectively distributed, preventing tilting or wear caused by uneven load, thereby improving the durability of the equipment.
- Easy maintenance: With evenly distributed support points, maintenance is more convenient and quicker when issues arise.
Double Cylinder Design
Biomass first enters the inner cylinder, where it is dried in a relatively high-temperature environment to prepare for pyrolysis. A spiral device moves the material into the outer cylinder, which applies higher temperatures in a sealed environment to efficiently pyrolysis and produce high-quality biochar. This design offers several benefits:
- Enhance Thermal Efficiency: This segmented processing doubles heat utilization compared to single-layer external heating systems.
- Enhance Biochar Quality: The separation of the inner and outer cylinders allows for precise temperature control, improving biochar quality.
- Save Space: The dual-cylinder design is more compact, significantly reducing space occupation.
How Much Does a Biochar Reactor Cost?
The cost of a biochar reactor can vary widely depending on its size, design, and features. Larger commercial-scale biochar reactors can cost anywhere from tens of thousands of dollars. These types of reactors are typically more sophisticated and include features such as automated temperature control, air and fuel injection systems, and advanced filtration systems.
Please note that biochar reactor cost is just one aspect of the overall cost of producing biochar. Other costs to consider include the cost of other devices, the cost of biomass materials, labor costs, and maintenance costs. If you want to get a detailed price list, contact Beston Group.
Traditional Biochar Kilns VS Beston Biochar Reactors
For centuries, people use traditional biochar kilns to produce biochar, but modern Beston biochar reactors offer more advantages over traditional kilns. These Beston machines represent a significant advancement in biochar production technology and offer a promising solution for reducing greenhouse gas emissions and promoting sustainable agriculture.
| Comparison Dimension | Traditional Biochar Kilns | Beston Biochar Reactors |
|---|---|---|
| Technology | Simple carbonization process relying on natural combustion | Utilize modern pyrolysis technology with precise control of temperature and pressure |
| Applicable Materials | Limited to a few types of biomass, such as wood and crop residues. | Process a wide range of biomass, including rice husks, sawdust, coconut shells, etc. |
| Automation Level | Rely on manual operation and experience; lack precise control. | High automation with intelligent control and remote monitoring, reducing manual intervention. |
| Thermal Efficiency | High thermal energy loss | Effectively recycle and reuse heat energy |
| Safety | Prone to fire hazards and high-temperature burns, posing safety risks to operators. | Features multiple safety systems, such as temperature and pressure monitoring and emergency shutdown, for enhanced safety. |
| Product Quality | Inconsistent biochar quality, often containing impurities, unsuitable for high-end markets. | Controlled carbonization temperature and time ensure high purity and stable quality, meeting the demands of agricultural and industrial markets. |
| Equipment Lifespan | Short lifespan, susceptible to high-temperature and humidity damage, with frequent maintenance required. | Made from high-quality, heat-resistant materials, offering a long lifespan, simple maintenance, and stable operation. |
| Installation & Mobility | Typically fixed, requiring substantial civil works and lacking mobility. | Modular designs for allow for easy installation and even mobility, suitable for various scenarios. |
| User-Friendliness | Require specialized skills and relatively complex operation | Easy to learn and get started |
| Environmental Performance | Produce much smoke and harmful gas, polluting the environment | Exhaust treatment systems to minimize emissions, ensuring clean production |
| Economic Benefits | Low initial investment, but inefficient with limited product value, resulting in lower overall profitability. | Higher initial investment, but low operational costs, high efficiency, and high product value offer significant long-term benefits. |
| Efficiency | Long processing time and low material conversion rate | High material utilization rates and large throughput |
Conclusion: Traditional biochar kilns are suitable for low-cost, basic carbonization needs with minimal environmental considerations. In contrast, Beston Biochar Reactors leverage modern technology to enhance efficiency, environmental performance, and economic benefits, making them ideal for industrial-scale production and sustainable development.
Overview of Beston Biochar Reactor Projects in Different Parts of the World
Beston has completed a number of biochar reactor projects in different parts of the world, such as Indonesia, Vietnam, and Thailand. These projects have involved the installation of large-scale biochar reactors, which are capable of processing large volumes of organic waste. These projects have focused on converting agricultural waste(crop residues and industrial biomass waste and others) into biochar. The biochar produced by these reactors can improve soil health, increase crop yields, and reduce greenhouse gas emissions.
Contact Beston Group to Get Biochar Reactor
At Beston Group, we provide biochar reactors that stand out for their efficiency, ease of use, and affordability. Whether you’re a seasoned professional or new to the industry, Beston reactors are user-friendly and require minimal maintenance. Ready to take the next step? Contact Beston today and discover how our biochar reactors can elevate your business. For more insights, don’t forget to check out our latest videos on Youtube!