Carbon Zero Bio Char Production Technology

Hello,
Thanks for your inquiry.

We currently are offering pre-manufactured small to medium scale biochar kilns, as
well as customized engineering plans that can be used to manufacture larger
capacity biochar production facilities.
The pre-manufactured kilns come in 3 models, producing from about 100 kgs of
biochar per batch up to 750 kgs per batch if wood is used as the feedstock. The
lowest-priced model can process only split wood, whereas the other models can
process a much wider variety of feedstocks. Prices for these batch kilns range from
about 7500 Swiss francs to 75,000 Swiss francs, excluding shipping.
We charge 10,000 Swiss francs to develop a set of plans from one of the 3 models
shown below. This price would include customizations for either capacity or
feedstock. Engineering for accessory processes such as the utilization of excess
energy produced, the condensation of liquids or tars from the raw syngas stream,
etc would be charged extra. We also charge 10,000 Swiss francs to license the
manufacture of a unit from plans we provide. The license fee for the first unit
manufactured is waived if we are paid to customize plans for you.
In simple terms, we offer a very low cost path for clients to establish biochar
manufacturing facilities, but we do not assume liability for the manufacture or
commissioning of the unit.
Details of the pre-manufactured kilns and engineered biochar production facilities
follow:
Pre-manufactured Kilns
Batch Kiln 100-MK 1
Batch time around 8 hours

Moisture content up to 40%
Feedstock size logs, up to 30cm in
length and 10cm in diameter
Feedstock type Wood
Feedstock volume 1.5m3
Fuel source logs, up to 15cm in
Char yield up to 100kg per burn
Infrastructure used handheld leaf
blower (provided with the kiln)
Price: ~ 7500 Swiss francs
Simple and easy to use, this kiln has a cylindrical body 1.2 meters high and 1.5
meters in diameter. The kiln has an internal combustor (firebox) which hangs from
the lid and provides heat to convert the feedstock to biochar. It takes about 8 hours
for a batch to be processed, depending on the moisture content, type and size of
the feedstock.
The kiln is loaded from the top, and unloaded through a door at the bottom. A handdriven winch is used to remove the lid for loading. After a burn, the kiln is left
overnight to cool before unloading. A single batch can produce up to 100 kg of
biochar.
The kiln runs on a two stage cycle. First the feedstock is dried, then it is charred.
The design relies on air convection to distribute heat throughout the feedstock bed.
It is for this reason that feedstock is limited to split or small diameter wood. During
the drying stage small logs are burned in the firebox to provide heat. As
temperatures within the kiln rise to around 450 C, the feedstock releases syngas.
Once syngas is available, it is burned in the combustor to maintain suitable charring
temperatures.
The kiln is transportable on a small trailer. It is therefore likely that in most areas,
planning permission would not be needed. It does however produce some steam
and smoke, so it is advisable to locate it away from buildings and people. The kiln
does not need electricity to run. It uses a leaf blower included with the kiln to supply
air to the internal combustor.
Batch Kiln 100-MK 2
Batch time from 3 to 10 hours

Feedstock size wood shavings or
rice husk, up to 30cm length logs
Feedstock type most biomass
Feedstock volume 1.5m3
Fuel source logs, up to 15cm in
Char yield up to 100kg per burn
Infrastructure used 3 electric fans
and a generator (provided with the
kiln)
Price: ~ 25,500 Swiss francs
The MK 2 is a small-scale biochar kiln capable of processing a wide range of

different materials. Process temperatures can be controller to an accuracy of within
25 degrees C. These 2 factors combined make it an excellent choice for trials and
research. As with the MK 1, the cylindrical body is 1.2 meters high and 1.5 meters
in diameter, and it has an internal combustor (firebox) to provide the heat necessary
to convert the feedstock to biochar.
The MK 2 has been tested on a wide range of feedstocks including wood shavings,
woodchip, logs, rice husks, coffee husks, rush and wetland reed. The kiln can
process feedstocks up to 60% moisture content. The length of a given batch varies
significantly, depending on the moisture content, type and size of the feedstock
used.
The kiln is loaded from the top, and unloaded through a door at the bottom. An
electric winch is used to remove the lid for loading. After a burn, the kiln is left
overnight to cool before unloading. A single batch can produce up to 100 kg of

biochar.
The kiln runs on a two stage cycle. First the feedstock is dried, then it is charred.
The kiln acts as a steam drier during the first stage, using 3 electric fans to force
steam through the feedstock. One key factor as to whether a feedstock is suitable
for use in the kiln is the porosity of the feedstock bed. The fans must be able to
force the steam to flow through the material. During the drying stage small logs are
burned in the firebox to provide heat. As temperatures within the kiln rise to around
450 C, the feedstock releases syngas. Once syngas is available, it is burned in the
combustor to maintain suitable charring temperatures.
The kiln is transportable on a small trailer. It is therefore likely that in most areas,
planning permission would not be needed. It does however produce some steam
and smoke, so it is advisable to locate it away from buildings and people. The kiln
does need electricity to run, however it is supplied with a suitable generator in case
supply from the electricity grid is not available.
Batch Kiln 500-MK 1
Cycle time variable, up to 8 hours

Feedstock size from rice husk, wood shavings and wood chip up 30cm
length logs
Feedstock type most types of biomass
Feedstock volume two kiln bodies or retorts of 6 cubic meters each
Fuel source woodchip
Char yield up to 750 kg per cycle (per 6 m3 retort)
Infrastructure used 4 electric fans and a generator (provided with the kiln)
Price:~ 75,000 Swiss francs excluding shipping
The 500 series batch kiln is a commercial unit that produces up to 750 kg of biochar
per burn. The kiln is built in to a 20 ft container which allows it to be transported
anywhere a truck can reach.
The kiln consists of two kiln bodies (retorts) with a capacity of 6 cubic meters each,
and a central combustor or burner that provides heat to both. The kiln uses a two
stage process: the first stage dries the feedstock, while the second stage pyrolyzes
the feedstock into biochar. The retorts are processed in alternate cycles so that
excess heat from the active retort is used to dry the feedstock in the inactive retort
(and possibly initiate pyrolysis if 24/7 operation is desired). In this way, the kiln
reduces the external fuel requirements for the drying of feedstock, thus making the
processing of wet materials much more viable.
If there is a gap in the symmetry of the process in which syngas is not available to
produce needed heat, the central burner automatically reverts to burning woodchip.
The central burner also burns woodchip to perform a cold start of the kiln until there
is sufficient syngas being produced.
This kiln can process a wide range of feedstocks including wood shavings,
woodchip, logs, rice husks, coffee husks, rush and wetland reed, up to 60%
moisture content. The burn time can vary dependent on the moisture content, type
and size of the feedstock used. Process temperatures can be controlled to an
accuracy of within 25 degrees C.
Engineered Manufacturing Plans

The engineered manufacturing plans we provide are developed to your
specifications of feedstock, throughput and accessory processes requested. This
approach allows us the flexibility to develop a solution that will meet your unique
needs. We can also become more deeply involved if requested, providing
consulting, help to get the unit manufactured, or assistance in the commissioning
phase, but it should be understood that only a local engineer would be licensed to
commission the unit, and your local engineering firm will need to review and
perhaps modify the plans before you go ahead with manufacture to ensure the unit
will meet local regulations. We have 3 general designs that we are working with, as
shown below:
1) a horizontal bed continuous feed unit that would look something like this:
The above unit can be used for a variety of feedstocks, it has a pre-dryer,
incorporates the ability to closely control process parameters of temperature and
residence time, and can be flexibly configured to make use of the excess heat
produced, and condense tars from the raw syngas. Capacity can be adjusted by
increasing/decreasing the width and length of the unit, up to a maximum of about 4
tonnes of char produced per 24 hour day. Heat energy to dry and pyrolyse the
feedstock is provided by flaring a portion the syngas produced (except at startup,
where a separate gas source is needed). The unit requires a relatively small
amount of electricity to run the blowers, feed mechanisms and control electronics.
2) a verticalcontinuous feedsilo unit that would look something like this (note the
dimensions - it would be several stories tall):
This unit is designed for higher capacity production from wood chip only. As
dimensioned above, it would process about a tonne of wood chip per hour and
produce a tonne of biochar every 3 hours - 8 tonnes of biochar per 24 hour day.
The diameter and height can be increased to increase capacity, up to perhaps 16
tonnes a day.Process parameters of temperature and residence time can be
controlled.
3) a tilting batch kiln designed to process sticks and split wood:
Units 1 and 2 above are designed to be run 24/7, like a manufacturing plant,
whereas the batch kiln is designed to be run intermittently. The tilting mechanism
allows for easy loading and unloading. It is also possible to configure 3 units in a
round robin fashion so that the excess heat from one is used to start the pyrolysis
process in another. These units require no electricity, but there is more manual
labor involved in preparing the feedstock, loading and unloading the units.
Units 1 and 3 are the easiest designs to
implement. Unit 2, especially because of the
high capacity, higher capital investment and
likely need for custom-built infrastructure, is
more challenging to implement.
Let us know if you have further questions.
Nando Breiter
CarbonZero
Via Rompada 40
6987 Caslano
Switzerland
+41 (0)91 600 9601
+41 (0)76 303 4477 cell
skype: ariamedia

Carbon Zero Bio Char Production Technology

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Hello,

Thanks for your inquiry.

Batch time around 8 hours

Batch Kiln 100-MK 2

Batch time from 3 to 10 hours

The MK 2 is a small-scale biochar kiln capable of processing a wide range of

overnight to cool before unloading. A single batch can produce up to 100 kg of

Batch Kiln 500-MK 1

Cycle time variable, up to 8 hours

Engineered Manufacturing Plans

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