Energy Recovery Facility from all kind of biomas

The technological line of Thermolysis Energy Recovery Module from all kinds of biomass in an innovative solution based on patent No. 204294.

During valorization occurs biomass enrichment, reduction of moisture (M), reduction of sulfur element (S), reduction of chlorine element (Cl) and reduction of weight. Bound carbon element (C>70%) significantly increases and ash content (A) slightly increases.

Name: biochar FLUID SA brand is a trademark of renewable fuel classified under the symbol CN 4403 90 00.

FLUID SA from Sędziszów built “turnkey” complete Energy Recovery Facility from all types of biomass with a moisture content max. 50% and average calorific value – 10 MJ/kg. The technological process enables poliproduction in a continuous cycle, 24 hours per day; 7 days a week.

The efficiency of the world’s first Energy Recovery Facility in Sędziszów is equal to carbonizing about 24 Mg/h of biomass with an average moisture content 45%, which allows to produce:

  • Max 2 Mg/h of biochar FLUID brand with a calorific value not less than 24 MJ/kg,
  • Max 0.4 MW of green electricity,
  • Max 0.2 MW of cold and,
  • Max 0.8 MW of heat.


Technological process

Operational movement always begins with warming-up of the reactor. The reactor is heated up by an exhaust generator. The oil burner heats the exhaust generator, which heats the flowing air, made by a fan. Hot air and exhaust from the oil burner flow into the interior tangentially to its inner ceramic casing. After reaching about 650˚C inside the reactor, the oil burner shuts down and at the same time the biomass is fed to the retorts. Minced (max 50mm grain) plant biomass, with a moisture content below 45% (max 50% allowed) with an average calorific value of 10MJ/kg, moves, by the scraper feeder, to the hopper dryers i.e. the tray rope. When moving to the hopper dryers, the biomass is dried in the rotary drier to a moisture content below 25%. The reactor’s internal hopper keeps the heated, dried biomass in the atmosphere of air deficiency. From the internal hopper, the biomass moves to the retorts. Hot and dried biomass moves forward and it is subjected to an intensive process of further heating without oxygen, followed by partial degassing of light hydrocarbons. These gases, through the opening in the retorts escape into the interior of the reactor and are burnt in the hot air, which due to the tangential inlet to the reactor, moves swirling around the inner wall of the reactor, heating itself. The combustion of hydrocarbons escaping from the retorts creates proper authotermal conditions of the process without the need for further heating with on oil burner. The process of thermolysis in retorts and the absence of oxygen cause carbonization of biomass. The process is conducted in an automatic control system, in time and temperature selected so as to obtain partial gasification and to increase the calorific content of the product to approximately 25MJ/kg. A product with the trade name biochar FLUID brand is created. It is renewable fuel, ecologically clean and with high energy density. This fuel is unloaded from the lower retorts to a sealed container from where it is taken by a water-cooled screw feeder. The purpose of this tray is to cool biochar to a temperature below 40°C and move it to the installation of storage bins called “Big Bag”. In order to extinguish the produced biocarbon completely, compressed CO2 is fed to the installation and additionally biochar is sprinkled with water. A lot of thermal energy is accumulated in hot exhaust gases from the autothermal process, which, through a system of heat exchangers, is used for the production of “green” electricity, whereas from the cooling of the condensate is used for the production of renewable heat, which is sold to the city’s thermal system or for the production of cold for air conditioning or biomass drying.



Costs of production and profitability from Energy Recovery Facility

Technological scheme of the Energy Recovery Facility