Biochar pyrolysis equipment provides an innovative solution for recyclers. The equipment can improve production efficiency while promoting environmental sustainability. As global attention to carbon emissions and resource reuse continues to increase, biochar pyrolysis machines can not only bring considerable economic returns to companies. The solution can also find the best balance between sustainability and profitability while promoting sustainable development goals.
Biochar Pyrolysis Process: Step by Step
The process involves heating biomass in a high-temperature, low-oxygen environment in biochar pyrolysis equipment. During this process, organic matter such as lignin, cellulose and hemicellulose in biomass undergoes property changes:
- Preheating Stage: The internal water in the biomass begins to evaporate and become loose. The volatile components in cellulose and hemicellulose begin to release slowly.
- Devolatilization Stage: Cellulose and hemicellulose release a large amount of volatile substances, such as water vapor, methane, ethylene, alcohols, ketones, etc.
- Cracking Stage: Cellulose and hemicellulose are completely decomposed. Meanwhile, the aromatic ring system of lignin gradually breaks, generating small molecular gases such as benzene, toluene, xylene, etc.
- Carbonization Stage: With the release of volatiles, biochar is gradually formed. High temperature makes the aromatic structure of biochar more perfect, and the proportion of carbon further increases.
- Stable Stage: Inside biochar equipment, the structure of biochar tends to be completely carbonized, becoming more stable. Thus, the carbon content reaches the maximum value.
Applications of Biochar in Various Fields
Soil Improvement
Biochar can significantly improve the physical, chemical and biological properties of soil. Thus it improves the moisture holding capacity, aeration and fertility of the soil. In addition, biochar improves the soil environment by adsorbing nutrients, improving soil pH, and promoting microbial activity.
Carbon Sequestration
Biochar pyrolysis machine locks the naturally degraded carbon in biomass into a stable form. Therefore, the carbonaceous material in biochar will not be oxidized to form CO2 in its natural state. Biochar’s persistence and stability allow it to persist in the soil environment for hundreds of years.
Animal Feed Additive
As a feed additive, biochar can improve the intestinal environment of animals. In turn, this improves feed utilization. On the other hand, it can also reduce methane emissions from ruminants. This reduces greenhouse gas emissions while also reducing the carbon tax burden on the livestock industry.
Building Material Additive
In the construction industry, biochar is used as an additive to concrete. This enhances the concrete’s compressive strength, toughness and durability. Its porous structure improves the thermal insulation properties of concrete. By reducing cement usage, it contributes to a sustainable construction industry.
What is Biochar Pyrolysis Equipment?
Pyrolysis machine for biochar can efficiently and continuously convert biomass into biochar. The continuous operation mode can continuously feed and discharge materials without stopping. As a result, this equipment can achieve long-term stable operation. In addition, the equipment can achieve self-supply of operating energy consumption through the reuse of combustible gas. Multi-stage tail gas treatment facilities can ensure clean emissions. Therefore, this equipment is an excellent choice for large-scale production of biochar. The following is a diagram of the equipment components for your reference.
Parameter Table of Biochar Pyrolysis Equipment 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 | |
Innovative Solutions through Biochar Pyrolysis Machine
Waste Resource Management
Climate Change Mitigation
Sustainable Income Generation
- Large-Scale Reduction: Pyrolysis converts waste into useful biochar and combustible gas. Through large-scale processing, biomass pyrolysis plant can effectively reduce the volume of waste biomass. As a result, this alleviates the space occupation problem caused by biomass landfill and accumulation.
- Reducing Treatment Costs: Some regions have strict environmental regulations on the incineration and composting of waste biomass. Non-compliant treatment results in fines or governance fees. However, third-party treatment fees are extremely high. Biochar pyrolysis equipment can reduce these costs.
- Reducing Greenhouse Gas Emissions: Traditional waste incineration and composting processes release a large amount of greenhouse gases (such as CO2, CH4, etc.). In contrast, biochar pyrolysis is a micro-oxygen, closed combustion environment. In addition, the equipment adopts strict emission controls.
- Promoting Carbon Neutrality: From the perspective of carbon footprint reduction, pyrolysis biochar production converts atmospheric carbon dioxide into solid carbon form to achieve carbon storage. Together with the reduction of greenhouse gas emissions, it forms a negative carbon effect. This helps achieve global carbon neutrality goal.
- Biochar Trading: Due to its wide range of applications, biochar is a product with growing market demand. For some areas with high demand for biochar, producers can enter into long-term trade cooperation with them. Through the sale of biochar, producers can have a stable and sustainable source of income.
- Carbon Credit Trading: The carbon sequestration capacity of biochar makes it an important part of carbon credit trading. Producers can obtain carbon credits through the carbon sequestration effect of biochar pyrolysis machine. Through the sale of these carbon credits, producers can also obtain considerable income.
Operation Stages of Pyrolysis Machine for Biochar
01 Feeding Stage
The biomass size of the feed is no larger than 20mm, the moisture content is no higher than 15%, and it has good fluidity. This avoids feed blockage caused by material sticking or agglomeration. You can ensure that the waste meets the feed conditions through drying, crushing and screening systems. Beston Group provides the corresponding equipment.
02 Pyrolysis of Biochar Stage
- Preheating: The burner starts to preheat the biochar reactor, which is driven to rotate by drive device. The preheating stage of the main furnace ensures that the material can quickly enter the pyrolysis reaction.
- Further Drying: The material first enters the inner barrel, where it is initially dried to remove the internal moisture in the material. Excessive moisture content will cause energy loss and affect the carbonization effect.
- Deep Carbonization: After drying, the material enters the outer barrel through the guide plate and enters the deep carbonization stage. At this time, the temperature and oxygen-deficient conditions contribute to the thermal decomposition of the biomass. Finally, biochar is formed.
03 Combustible Gas Reuse Stage
- Gas Generation: During the pyrolysis process, the organic components in the material will decompose and produce combustible gases (such as carbon monoxide, methane, etc.). These gases enter the dust removal device to remove solid particles and impurities.
- Fuel Recovery: The combustible gas after dust removal enters the combustion system through the pipeline. It serves as fuel to further provide the heat energy required in the pyrolysis process.
- Excess Gas Treatment: Excess combustible gas enters the exhaust combustion chamber and is directly burned. Or you can use a special device to collect it.
04 Biochar Collection Stage
The biochar is usually discharged from biochar pyrolysis reactor by a screw conveyor. Too high a temperature of the biochar can lead to a reduction in quality or the risk of spontaneous combustion. Therefore, the screw conveyor is water-cooled. In addition, this prevents the biochar from coming into contact with hot flue gases, thus ensuring the purity of the biochar.
05 Gas Treatment Stage
The waste flue gas that no longer participates in the reaction will be cooled and dust-removed. The waste gas undergoes a series of treatments: heat exchanger → bag filter → desulfurization tower → activated carbon dust collector. The treated waste flue gas is discharged through the chimney. This not only meets environmental protection standards, but also reduces the impact on air quality.
How Beston Biochar Pyrolysis Equipment Ensures Operation Efficiency?
Reasonable Raw Material Properties
Maintaining the appropriate dryness and moisture of the raw materials improves the efficiency of the carbonization furnace. In addition, each run processes a single material. This avoids the mixing of different raw materials that affects the reaction effect. You can conduct experimental tests in advance to evaluate the pyrolysis characteristics of different raw materials.
Accurate Parameter Control
The PLC system can accurately control the pyrolysis process. The system ensures that key parameters such as temperature and wind speed are always kept in the optimal range. In addition, the application of variable frequency fans makes airflow and temperature control more flexible, improving the uniformity and thermal efficiency of the biochar pyrolysis equipment.
Durable Main Furnace Material
The pyrolysis process involves high temperature and chemical reactions. Biochar pyrolysis reactor can choose high temperature and corrosion resistant materials such as SS304, SS316L, and SS310S. This ensures the service life of the furnace body under long-term high temperature operation. This also reduces the frequency of maintenance and replacement of equipment.
Smooth Pipeline Operation
The insulation of the combustible gas pipeline prevents condensable organic volatiles from clogging the pipeline. In addition, the purge device can regularly remove the biochar accumulated in the pipeline, which does not avoid the increase of airflow resistance in the pipeline. In addition, it can also prevent the powder from sticking to condensable organic volatiles and blocking the pipeline.
Financial Return Analysis for Biochar Pyrolysis Machine
When evaluating investment of pyrolysis machine for biochar, ROI (return on investment) analysis is a key tool to measure is pyrolysis project profitable. The following ROI analysis table will help you more clearly understand the payback period, cost-effectiveness and potential profits of equipment investment. Thus, this will help you make more informed decisions.
| Return on Investment of BST-50 Wood Chips Carbonization Project in The Middle East Regin | |||||||
|---|---|---|---|---|---|---|---|
| Project Name | 5TPH Wood Chips Carbonization | ||||||
| Introduction | According to the market data of Middle east region, the estimated ROI report, the various expenses are as follows: | ||||||
| Fixed Investment Cost | Item | Details | Unit | Unit price/USD | Quantity | Amount/USD | Remark |
| Equipment | BST-50 | Set | 250000 | 1 | 250000 | ||
| Transportation | From China to Destination Port | Set | 90000 | 1 | 90000 | ||
| From Port to Site | Set | 5800 | 1 | 5800 | |||
| Customs tax | 0.15 | Set | 37500 | 1 | 37500 | ||
| Installation | Beston technician's salary | Day | 350 | 50 | 17500 | ||
| Round -trip airtickets | Ea | 2420 | 2 | 4840 | |||
| Visa | Ea | 350 | 1 | 350 | |||
| Local welder | Day | 65 | 100 | 6500 | Two welders are needed | ||
| Local plumber | Day | 65 | 20 | 1300 | |||
| Local labor | Day | 16.8 | 50 | 840 | |||
| Crane forklift etc. | Day | 80 | 30 | 2400 | |||
| Materials | Installation materials ready | Set | 3500 | 1 | 3500 | Foundation, pipe, etc. | |
| License | / | Ea | 2000 | 1 | 2000 | Environmental, firefighting, etc. | |
| Workshop | 500 | ㎡ | 160 | 500 | 80000 | ||
| Total amount | 502530 | ||||||
| Operating Cost | Raw materials | Wood chips | Ton | 100 | 120 | 12000 | |
| Water | / | m³ | 1.76 | 3 | 5.28 | ||
| Electricity | / | KWH | 0.11 | 2922 | 321.42 | ||
| Fuel | Natural gas | Liter | 7.25 | 270 | 1957.5 | ||
| Labor | / | People | 16.8 | 4 | 67.2 | ||
| Maintenance | / | Day | 85 | 1 | 85 | ||
| Depreciation | 8 years | Day | 209.3 | 1 | 209.3 | ||
| Tax | 0.05 | 0 | |||||
| Total amount | 14645.7 | ||||||
| End Products Price | Biochar | 0.3 | Ton | 680 | 36 | 24480 | 30% of input |
| Wood vinegar | 0.08 | Ton | 1280 | 9.6 | 12288 | 8% of input | |
| Tar oil | 0.02 | Ton | 450 | 2.4 | 1080 | 2% of input | |
| Total amount | 37848 | ||||||
| Daily Income | 23202.3 | ||||||
| Monthly Income | Working day | Day | 25 | 580057.5 | |||
| Yearly Income | Working day | Day | 300 | 6960690 | |||
Beston Biochar Pyrolysis Solutions: Success Cases Worldwide
Beston biochar pyrolysis machine has been successfully used around the world. We have gained high recognition from global customers. Beston Group provides professional integrated services such as plan formulation, equipment manufacturing, equipment installation, and operation team training. We are able to provide tailor-made solutions for every project. Below are some success stories from different countries and regions, showing how our equipment has brought significant benefits to customers around the world.
Join Us in Advancing Sustainable Biochar Pyrolysis Solutions
Beston Group is committed to providing customers with efficient and sustainable equipment. Through continuous innovation and optimization, we help customers around the world achieve a win-win situation in revenue and environmental benefits. If you are interested in our products and solutions, we look forward to exploring more green and environmentally friendly business opportunities with you. Beston Group looks forward to working with you to promote a sustainable future. Welcome to follow our LinkedIn page for more industry trends, technology updates and success cases.