Short Description
Within the GreenCarbonLab, the GCL pyro 90k enables the upscaling from laboratory testing to demonstration at the pilot scale. GCL pyro 90k is a pilot pyrolysis unit in which knowledge gained at the laboratory-scale is implemented and validated, with the aim of producing large quantities of biochar (up to 10 tonnes) with specific properties.
Key Technical data:
• Pyrolysis unit: dual auger
• Feedstock input: 30 - 90 kg/h
• Biochar output: ~20 kg/h
• Heat supply: Internal combustion of pyrolysis gas
• Temperature range: 300 - 800 °C
• Residence Time: 7 - 75 minutes
• Test duration: continuous operation 24/7
Contact Person
Manuel Schwabl
Research Services
• Testing the pyrolysis of selected feedstocks at the pilot scale
• Evaluation of process upscaling after optimisation of process parameters at the GCL pyro 2k
• Pilot and demonstration production of biochar with specific target properties. The produced biochar can afterwards tested for application in different fields (as soil amendment, additive in construction materials, … )
The GCL pyro 90k has a continuous biochar output of around 20 kg/hour and a daily biochar production of approximately 500 kg. Over several days of operation, test batches up to 10 tonnes of biochar can be provided. The pyrolysis unit is designed to process feedstocks having max. 20% of moisture and a particle size below 25 mm. Example of feedstocks used for testing are walnut shells, woodchips, wood pellets.
Methods & Expertise for Research Infrastructure
The GCL pyro 90k unit, manufactured by REW Regenis, consists of the following components:
• Biomass input system
• Pyrolysis reactor
• Pyrolysis gas burner
• Flue gas scrubber
• Biochar output system
Feedstocks are stored in a 6 m3mixing hopper and delivered to the reactor by a variable speed dosing screw and an input conveyor. The feedstock input can be set between 30 and 90 kg/h.
The core components (including the pyrolysis reactor, gas burner, and flue gas treatment system) are installed in a 40-foot high-cube container. The reactor itself is a 6-meter-long, double-walled, twin-screw allothermal unit. Biomass is fed into one end of the reactor, while biochar is discharged from the opposite end, with pyrolysis gases extracted concurrently.
Once it has left the reactor, the biochar is cooled to ambient temperature by air and transferred to storage vessels. The pyrolysis gases are cleaned by a cyclone before entering a specially designed gas burner for use with pyrolysis gases. Here the gas is mixed with preheated air and combusted with low emissions. A lambda sensor continuously monitors the excess air ratio, dynamically adjusting the air flow to ensure optimal combustion conditions.
The reactor is indirectly heated in a countercurrent configuration using flue gases. Immediately downstream of the combustion chamber, the hot flue gases are diluted with cold air in order to achieve the target pyrolysis temperature, which is adjustable between 300 °C and 800 °C. The flue gases then flow through the outer shell of the reactor’s double wall. Two additional air injection points enable the temperature profile along the reactor length to be fine-tuned. Afterwards the flue gases are directed to a quench scrubber unit where they are cooled and cleaned with water.
The pyrolysis system is designed for continuous, automated operation over several days, with manual intervention required only for the periodic emptying of the biochar collection hopper.