British Biochar News. Issue 3. January In this Issue: Biochar Producing Technology: Earth Systems MPP20 PYREG

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1 Issue 3 January 2016 British Biochar News In this Issue: Welcome to the winter edition of the BBF Newsletter, Biochar Exeter retort, which are perfect for many gardening and horti- hope that all readers find the articles interesting and informa- Biochar Producing Technology: Earth Systems News. We hope that all members had a happy Christmas and continue pushing through the short, cold and wet days of January and are looking forward to the year ahead. This issue will focus on biochar cultural needs. This issue will look at the Earth Systems Mobile Pyrolysis plant which is a batch pyrolysis unit that processes large quantities of waste biomass and turns it into large amounts of valuable tive and that they may help deploy and develop the biochar industry in the UK. Lastly, we would like to highlight that the British Biochar Foundation s directory is still live and available through our MPP20 PYREG producing technology on an international scale with articles from two companies one based in Australia and another in Germany. The technologies talked about biochar. We also look at technology developed by PYREG based in Germany. Their unit can effectively pyrolyse a variety of biomass to help remove waste and website. So get your businesses listed as soon as possible. The team at BBF British Biochar Foundation Directory are also on a larger scale than we looked at in the first issue of this newsletter in August. Previously we looked at technologies including the Kon-Tiki kiln, the Carbon Catcher unit and the produce energy for commercial needs. We would like to thank Earth Systems and PYREG for taking the time and effort to write articles for our newsletter. We Deploy and develop the biochar industry in the UK 1

2 Earth Systems CharMaker MPP20 Biochar Production Tales from Hong Kong The CharMaker MPP20 is a mobile batch pyrolysis unit designed to efficiently and cleanly pyrolyse a large amount of biomass feedstock and convert it into valuable biochar. Earth Systems Earth Systems believes biochar holds a lot of potential being a fantastic soil additive but also helping combat greenhouse gas emissions providing a local solution to a global problem. Earth Systems is an international environmental and social consultancy firm founded in Australia but with offices across the world from Bristol (UK) to China and Senegal. We have worked on numerous carbon and energy projects providing pyrolysis expertise and biochar production technology to help solve an array of different problems. This article presents our recent experience with biochar production in Hong Kong and also looks at the technology we have developed to help solve some of the issues surrounding the use of biochar. Kadoorie Farm and Botanic Garden (KFBG) Hong Kong is a highly populated territory with many mountainous areas that have been deforested over many centuries of human settlement. The soils in these montane areas are highly fragile and the slopes are battered by winds and rain, causing large scale erosion and frequent landslides to occur. The natural vegetation fails to recover in these soils leading to a cycle where more erosion occurs, native vegetation decreases, causing more soil erosion etc. The Hong Kong Government has previously solved the issue with a range of heavy engineering projects which although effective at preventing landslides are unsustainable and detrimental to the natural environment. At KFBG they are trying to clear land of non-native species and unproductive plantations and revert back to native vegetation but the poor soils and exposed slopes represented a severe problem. Another problem faced by KFBG is that their land clearance work and day-to-day care of the gardens was causing a large amount of waste biomass to build up. Such biomass can be expensive to dispose of especially in large quantities and The degraded mountain soils surrounding KFBG and lack of native vegetation. Biochar produced from the CharMaker MPP20 this is all the more difficult in a highly populated region such as Hong Kong. These were a tough set of problems to solve and this is where biochar comes into the story. Biochar Biochar represented a fantastic solution to the Botanic Garden s problems. It would effectively dispose of the waste biomass turning it into valuable biochar. The biochar could be added to the soil, improving its structure as well as its water and nutrient holding capacities. It would subsequently help prevent soil erosion and when inoculated, enhance plant growth and facilitate forest restoration. However, although biochar seemed like a good solution, there were a number of obstacles that had to be overcome. Firstly, biochar production equipment often needs the feedstock to be finely processed and extensively dried. This was not an option for the Botanic Garden which did not have the scale of processing equipment to do this. If the biochar was to be purchased then it would be a very large expense especially for the quantities needed for large scale habitat regeneration and this is assuming that this much biochar could be purchased at all. And lastly, there were questions about the sustainability of the 2

3 [The CharMaker has] been trialled on over 50 different feedstocks Right: Earth Systems Environmental Engineer Rob Laird (right) shaking hands with Dr Gunter Fischer, Head of Flora Conservation at KFBG. The main pyrolysis plant and drier unit are both visible. Left: The pyrolysis unit loaded with wood ready to start the pyrolysis process. The CharMaker not only produces large amounts of valuable biochar from waste materials but also creates useful liquids, gases and even energy generation. biochar produced from other sources. Perhaps a better solution could be conceived. CharMaker MPP20 The KFBG staff had not given up on biochar and they came to visit Australia where Earth Systems were operating their CharMaker MPP20. The CharMaker MPP20 is a mobile batch pyrolysis unit designed to efficiently and cleanly pyrolyse a large amount of biomass feedstock and convert it into valuable biochar. The design is based on a shipping container layout and CHARMAKER MPP20 Key Facts as a consequence is easily transported despite the large amounts of biomass it can handle. In fact one MPP20 in Australia has now travelled over 20,000km and is still in almost continuous operation. It has also been trialled on over 50 different biomass feedstocks from African Mahogany to railway sleepers and straw bale. KFBG were impressed with the CharMaker design and in particular the large quantity of biomass taken per run, the extensive variety of feedstock that could be used and the lack of processing of the material required perfect for the biomass obtained from land clearance and gardening by the botanic garden. The CharMaker is also a smoke minimised design and this meant the char could be produced cleanly and efficiently. A CharMaker was soon purchased and delivered as a fully operational unit to Hong Kong. Earth Systems staff travelled to the site and helped train KFBG staff in the machine s use and soon large quantities of biochar were being produced. The process is a batch process and the amount of time taken for a run depends heavily on the feedstock and moisture content but a typical run may take between 5 and 10 hours. When complete the biochar is removed and quickly quenched in water. It is then crushed and top quality biochar is produced. Easy to Use Can handle a variety of feedstocks Numerous add-ons including heat and bioliquid extraction No chipping required Can produce as much as 1200kg dry basis per run. Highly mobile Long Term assistance from Earth Systems staff. Remote monitoring and control installed. Smoke minimised design The CharMaker also came with a number of innovative add-ons to help make the process more sustainable. A drier unit was installed which utilises the heat produced from the pyrolysis process to dry out other wet biomass, ready for its use in the main pyrolysis plant. The machine also had a built-in bio -liquid extraction system to obtain pyrolysis liquids from the gases produced in the process. These liquids are very complex and split into a number of fractions. Some fractions are high in oil content and can be utilised as a sustainable fuel source. An aqueous phase also occurs and is often termed wood vinegar. 3

4 This wood vinegar has potential for use as a germination enhancer and as a plant-derived pesticide. KFBG are actively pursuing the use of these liquids as well as investigating the use of heat generation from the system to generate power. Thus the CharMaker not only produces large amounts of valuable biochar from waste materials but also creates useful liquids, gases and even heat energy generation. The unit is now being run by the Botanic Garden s staff and biochar is being produced for application on the hillsides and in the gardens. Earth Systems staff are able to provide assistance if needed as the pyrolysis unit is connected to the internet and can be monitored and even controlled by Earth Systems from its international offices. In Hong Kong, the biochar is now being used as part of the forest restoration work, helping improve the structure of the soil, enhance its nutrient and water holding capacity as well as helping prevent soil erosion. Over time the forests will start to grow on the hillside, biodiversity will start to increase, and soil erosion and landslides will become a thing of the past. Biochar Dr Gunter Fischer and his demonstration plots of forest regeneration work utilising the biochar. Contact Information The unit is perfect for anyone with large amounts of waste biomass including botanic gardens, farmers, nurseries and forestry organisations. Earth Systems Bristol Office: enviro@earthsystemseurope.com Phone: +44 (0) Earth Systems Melbourne Office: enviro@earthsystems.com.au Phone: will hopefully allow all of this but whilst it does this, it remains for thousands of years, fixed in the soil, mitigating greenhouse gas emissions and watching the city and gardens develop. There is a lot to be excited about. British Biochar Foundation Directory The BBF Directory is a FREE service provided by members to advertise biochar related products, services and biochar producing technologies The BBF Directory is a FREE service provided by the BBF to all members to advertise biochar products, services and biochar producing technologies. The free listing can be up to 5000 characters with up to four images and a hyperlink to a website. The listing comes with a contact form so other users and browsers can contact you regarding your listing. The content is entirely up to you but will be checked-over by BBF and changes might be requested prior to listing. Please note that hyperlinks and addresses are not permitted in the listing itself and will be removed before publication Users have to register to use the Directory separately from the Forum site. The Directory can also be used for advertising the availability of biochar or feedstock for producing biochar or for advertising a request to obtain feedstock or a particular type of biochar. If you have any questions, please contact Simon Shackley on: simon@ britishbiocharfoundation.org To find the directory please visit: directory 4

5 PYREG Producing high quality biochar with PYREG Technology PYREG GmbH is an innovative solution provider in the field of environmental technology Producing biochar often starts with the need to solve a disposal problem. A good example of this criterion is Fetzer Rohstoffe & Recycling GmbH, a German recycling company, which entered the world of biochar two years ago. The Fetzer Company is situated in the south of Germany and recycles PET bottles (PET = polyethylene terephthalate). The collected empties are sorted, shredded, washed with hot water and sold again as secondary raw material to PET bottle manufacturers or other users such as plastic film producers. In addition the results of this process produce a waste made up of the detached labels as paper fibre sludge, which also had to be disposed of. Christoph Zimmermann, CEO of Fetzer Rohstoffe & Recycling GmbH, explained, three years ago, we had to solve two problems. On the one hand the disposal of paper fibre sludge didn t correspond with our recycling thoughts. On the other hand we have a large energy demand for our warm water cleaning process. We wanted to optimize that and therefore checked several recycling technologies. One of them was PY- REG". PYREG GmbH is an innovative solution provider in the field of environmental technology. It manufactures equipment for the production of biochar and via its subsidiary company, PYREG trades in the renewable thermal energy business and the material recycling of different biomasses as well as the marketing of the products it produces. Using the PYREG module, quality biochar is produced from organic residues, however, another innovative technique offered by the PY- REG module is the thermal treatment of sludge from a municipal wastewater treatment plant (WwTP) to recover its phosphorus content as an enriched plant available fertiliser. In both cases excess thermal energy is generated for further use. Mr Zimmermann speaking again, that was exactly what we needed: recycling the paper fibre sludge in a new product like biochar and generating usable excess energy for our PET-recycling-process in an eco-friendly way. The PYREG biochar production technique is based on dry carbonisation, which has the ability to carbonise different natural biomasses in a thermal way. What remains is a sanitised mineral and carbon-containing dry residue, which can be used, for example, directly for soil amendment or as additive in the livestock husbandry. The process starts with the transportation of biomass along a twin screw conveyor inside the reactor, via a rotary wheel sluice outside the reactor. At temperatures of approx. 650 C the biomass is completely carbonised. The technique means the input material is not incinerated, but partially burned by a staged combustion by means of a limited air supply entering the reactor. The carbon-rich product leaves the reactor via a second rotary wheel sluice. The other product, syngas, passes into the main combustion chamber and is burned by a FLOX -burner (flameless oxidation burner) to avoid thermal NO x at about PYREG P500 Module 5

6 In 2013 the Fetzer Company integrated successfully a PYREG module in their material flow management to produce high quality biochar according to the strict requirements of the EBC Currently there are more than 10 PYREG modules in operation in Germany, Switzerland and Austria 1,250 C. This thermal energy, in the form of exhaust gases, is used to heat up the central section of the reactor (the twin screw conveyor). Finally, the spare thermal energy (up to 150 kw) after leaving the annular space of the reactor, passes through a heat exchanger decoupling the usable excess energy. The spare thermal energy can be used for drying purposes - or other industrial processes, district heating for houses or steam production are some examples. The standard throughput per module is roughly 1,200 tonnes DS (dry solids) per year. The production of biochar from natural biomasses with high lignin content is approximately 350 tonnes DS per year. The compact modular design fits into a 3m x 2.8m x 9m container and can be scaled up by using several modules. Compared to some applications of pyrolysis and carbonisation the PYREG system is not used to generate a syngas or synthetic oil that can be exported and utilized elsewhere. The PYREG technology is therefore technically classified to be in the transition region between gasification and a combustion plant. Schematic diagram of the PYREG Process In 2013 the Fetzer Company integrated successfully a PYREG module in their material flow management to produce high quality biochar according to the strict requirements of the EBC (European Biochar Certificate). This certification is possible, because the staged combustion, on which the PYREG process is based, allows a selective temperature control at intermediate temperatures, which is essential for a continuous high quality of the carbonised material. Our certified biochar is in demand throughout Europe. Due to the increasing demand, we have already ordered a second PYREG module, which will be brought on line in middle of 2016, said Zimmermann. Once the reactor reaches the selected treatment temperature, the module is thermally self- sustaining and is designed to operate typically for 7,500 hours per year. Currently there are more than 10 PYREG modules in operation in Germany, Switzerland and Austria. As of mid-december 2015, the combined hours of operation exceeds 50,000 hours. More than 15 plants are due to follow in In the case of a biomass in the form of municipal sewage sludge Pyreg GmbH commissioned its first plant to recover phosphorus for the Linz-Unkel WwTP (situated close to Bonn, in Germany) in September In future around 18,000 m³ (700 tonnes DS) of sewage sludge will be treated with the new sewage sludge technology onsite at Linz-Unkel. After thermal handling there remains approx. 400 tonnes per year of a phosphorus fertiliser, which can be delivered to fertiliser industry without further preparation. (Continued on the next page) PYREG Module located at the Linz-Unkel Minicipal Wastewater Treatment Plant 6

7 This pioneering utilisation concept enables midsize wastewater treatment plants:- Independence regarding sewage sludge disposal, Long-term calculability of costs Safe disposal due to guaranteed ash utilization Reducing lorry transports by up to 90% Flexible capacity expansion due to modular design Eco-friendly, Energyefficient & low-labour plant operation For more information: PYREG UK: Phone +44 (0) Mail: PYREG GmbH: Phone: +49 (6747) , Mail: Web: Fetzer Rohstoffe & Recycling GmbH: Phone: +49 (7161) , Mail: Web: With Thanks to: Thomas White Simon Shackley Mike Weaver Adrian Morphett Nigel Murphy John Sanderson Contact Us: Any Questions please contact the BBF by or phone at: Phone: If you would like to contribute to further newsletters please do not hesitate to get in contact. All images in the PYREG and Earth Systems articles are owned by PYREG and Earth Systems respectively and should not be reproduced without permission. Any other images can only be reproduced with permission from the BBF. 7