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Large-Scale Industrial CarboREN Plant Concept
The following diagram introduces the concept for a large-scale industrial SunCoal® CarboREN® plant and explains the individual process steps.
1. Receiving and Storage
Before being treated, delivered green waste is stored either in open or closed containers, depending on composition. The storage in the CarbonREN plant is designed for automatic loading on nights or weekends.
Before being treated, delivered green waste is stored either in open or closed containers, depending on composition. The storage in the CarbonREN plant is designed for automatic loading on nights or weekends.
2. Controlled Crushing and Filtering
The biomass is crushed and reduced to a grain size of 60 mm. A filter removes larger pieces and re-deposits them for crushing. The reduced biomass is then delivered either directly, or after the washing phase described below, to the hydrothermal carbonization. Depending on the contamination level of the biomass, a magnetic separator can also be used in re-filtering.
The biomass is crushed and reduced to a grain size of 60 mm. A filter removes larger pieces and re-deposits them for crushing. The reduced biomass is then delivered either directly, or after the washing phase described below, to the hydrothermal carbonization. Depending on the contamination level of the biomass, a magnetic separator can also be used in re-filtering.
3. Washing (optional)
A separate washing phase is only needed in the case of heavily contaminated biomass (for example, from the compost garbage bin). During this phase, the reduced biomass is separated from impurities such as sand, stones and a small portion of fine organic material. These can be re-used in a later phase. The resulting reduced and washed biomass is then stored for hydrothermal carbonization.
A separate washing phase is only needed in the case of heavily contaminated biomass (for example, from the compost garbage bin). During this phase, the reduced biomass is separated from impurities such as sand, stones and a small portion of fine organic material. These can be re-used in a later phase. The resulting reduced and washed biomass is then stored for hydrothermal carbonization.
4. Hydrothermal Carbonization (HTC)
The HTC-Cooker is the core technology of the CarboREN plant. During this phase the resulting biomass is „cooked“ according to the principles of hydrothermal carbonization. In just a few hours, temperatures of 200°C and pressure of 20 bars completely breaks down the coarse structure of the biomass and separates out a part of the primary water and oxygen as water. Modern regulation and operation technologies allow for consistent conditions and quality of treatment. The resulting HTC-slurry is thoroughly hygienically treated in preparation for the next phase.
The HTC-Cooker is the core technology of the CarboREN plant. During this phase the resulting biomass is „cooked“ according to the principles of hydrothermal carbonization. In just a few hours, temperatures of 200°C and pressure of 20 bars completely breaks down the coarse structure of the biomass and separates out a part of the primary water and oxygen as water. Modern regulation and operation technologies allow for consistent conditions and quality of treatment. The resulting HTC-slurry is thoroughly hygienically treated in preparation for the next phase.
5. Mechanical Dehydration
During mechanical dehydration a press reduces the water content of the HTC-slurry. The dehydrated HTC-cake is then ready for the thermal drying phase (described below). The separated water is reused in the process.
During mechanical dehydration a press reduces the water content of the HTC-slurry. The dehydrated HTC-cake is then ready for the thermal drying phase (described below). The separated water is reused in the process.
6. Thermal Drying
The HTC-cake is dried into SunCoal, with water content less than 10%. The design of the drying facility can be created based on client location stipulations. For example, the CarboREN process can use surplus heat from existing plants or existing local or district heating. The customer specified product composition also has an effect on the optimal placement of the thermal drying. Wastewater produced by the CarbonREN process can either be directed to a treatment plant or biologically treated in the CarbonREN plant itself.
The HTC-cake is dried into SunCoal, with water content less than 10%. The design of the drying facility can be created based on client location stipulations. For example, the CarboREN process can use surplus heat from existing plants or existing local or district heating. The customer specified product composition also has an effect on the optimal placement of the thermal drying. Wastewater produced by the CarbonREN process can either be directed to a treatment plant or biologically treated in the CarbonREN plant itself.
Processing and Treatment
Dried SunCoal is processed into SunCoal powder or SunCoal pellets, according to customer specification and further use. The SunCoal powder can be converted to syngas in a gasifier and further treated to produce, for example, BtL-fuels.
Dried SunCoal is processed into SunCoal powder or SunCoal pellets, according to customer specification and further use. The SunCoal powder can be converted to syngas in a gasifier and further treated to produce, for example, BtL-fuels.
Transport
The processed SunCoal pellets can be transported overseas in an environmentally friendly manner by bulk freight ships. Countries that support the use of renewable energies can then use the pellets for co-firing purposes, for example. BtL-fuels can also be transported overseas in an environmentally friendly manner with tank-ships to be used in other countries as a renewable energy resource, in order to, for example, fulfill biofuel blending quotas.
The processed SunCoal pellets can be transported overseas in an environmentally friendly manner by bulk freight ships. Countries that support the use of renewable energies can then use the pellets for co-firing purposes, for example. BtL-fuels can also be transported overseas in an environmentally friendly manner with tank-ships to be used in other countries as a renewable energy resource, in order to, for example, fulfill biofuel blending quotas.
