LifeChar’s CarboChar process is a retort pyrolysis technology for the continuous conversion of plant biomass into biochar, by thermochemical reaction in the absence of oxygen at over 500°C. This technology features a high-performance fluid flow and heat exchange system, enabling higher energy yields to be achieved. The biochar production yield of this technology, depending on the type of raw material and conditions of use, is between 30 and 43%.

Depending on biochar production conditions, this process uses between 50 and 55% of the heat from pyrolysis gas combustion for its own consumption. The remaining thermal energy could be used to dry the plant materials entering the process. In this way, the biochar production unit could be self-sufficient in thermal energy. The maximum thermal power generated (depending on the biomass used) is 120 kWth for the CarboChar-1, 480 kWth for the CarboChar-2 and 1 MWth for the CarboChar-3.

The pyrolysis reactor can reach temperatures of up to 650°C, with precise control of the operating temperature. All pyrolysis gases (condensable and non-condensable) are burned to ensure continuous operation of the process. In this case, there are no additional modules for processing the pyrolysis oils produced by condensation of part of the gases. This significantly reduces the investment and maintenance costs associated with optimizing the number of modules making up the industrial plant.

Various types of raw materials, such as wood residues (chips, shavings and sawdust), agricultural by-products (wheat, rapeseed and maize straws, rice husks, etc.) and animal manure (poultry), have been successfully tested with the CarboChar industrial process.

The advantages of the CarboChar process are :

• Adaptation to the type and quantity of plant biomass to be processed.
• Continuous pyrolysis with zero greenhouse gas emissions.
• Reliable, autonomous technology that’s easy to control.
• High biochar production yield.
• Recycling of all pyrolysis gases produced.
• Low energy consumption: self-sufficiency in thermal energy.
• Low operating costs.
• Configurable pyrolysis temperature and biomass residence time.
• Parameterization of desired carbon content and required PCI.
• Stainless steel and refractory stainless steel installation.
• Best quality/price/performance ratio.
• Ecological concept.