Batch retort system

Source materials #wasteonly

Super material biocarbon

Super material carbon

Carbon C is the fourth most abundant element in the universe and is in position 14 in the periodic table of elements. It is the basic requirement for organic life. Probably carbon came to our planet only in the primeval cooling phase via meteorites and asteroids. Humans are made up of a good quarter of carbon. Fossil carbons such as petroleum, coal and natural gas are the remains of primeval biomasses compressed under pressure and heat.

Technical biocarbons are multi-talented, they

  • bind and store CO2
  • have surface areas from 100 to over 2,000 m2 per gram (SEM image on the right)
  • are real lightweights with an atomic mass of 12.011
  • bind water from 3 – 6 times their own volume
  • have adjustable surface properties and polarities
  • guide or prevent the flow of electrons
  • absorb and bind environmentally harmful substances
  • resist environmental influences and UV radiation
  • are heat resistant up to several hundred degrees Celsius
  • effect hardening, dimensional and pressure stability
  • create black as natural product color / replaces Carbon Black

Residual materials become raw materials and recyclables

The proprietary carbonation technology is characterized by input and output flexibility, process controllability, energy efficiency, and robustness. These are decisive criteria for low production costs, specific product properties, high qualities and quantities. In a “minus CO2 factory”, production can thus be adapted to material flows, special product requirements or changing markets within a few hours. The unique process also allows input containing impurities such as rocks, minerals, soils, metals and plastics to be carbonized or recarbonized (converted back to carbon).

Sawdust

Nothing remains

In timber construction, the whole tree can not be used for buildings. NET Materials® is changing that: sawmill residual wood is turned into biocarbon and then into CO2-storing semi-finished products for, for example, pipes, foils, profiles, insulation, concrete and plaster, and more.

Wood chips

The classic

Wood chips are available in large quantities worldwide and are an excellent feedstock for technical biocarbons.

Nut shells, etc.

The perfect ecosystem

Farmers supply us with biomass and we supply them with electricity, heat and agricultural NET materials independent of location, which in turn increase yields. In this way, organic farming becomes more efficient, effective and profitable – Which makes healthy food cheap for everyone.

Bamboo, Miscantus

CO2 suction machines

Bamboo grows up to one meter per day. On average, one hectare of bamboo stock absorbs about 17 tons of CO2 per year. The high carbon content makes it particularly hard and thus an excellent construction material and starting material for NET Materials®.

Screen overflow

From problem substance to enrichment for communities

In the laboratory, together with MVV Umwelt, we were able to prove that screen overflows can be carbonized. Screen overflows occur during the final screening of compost in waste management. They contain branches, plastics, metals, bones and other impurities.

Waste wood A1-A4

Old wood for new products

Class A1 and A2 waste wood often contains screws, nails, plastics and other impurities. Shredded, they are carbonized based on the 4th BImSchG V and refined into NET Materials®. With the 17th BImSchG the processing of polluted waste wood A3 and A4 is possible.

Rootstocks

A problem becomes a super fertilizer

Rootstocks that are costly and time-consuming to dispose of are simply shredded together with soil and stones and carbonized. The result is mineralized biocarbons and sanitized soil, i.e. excellent materials for agriculture and forestry.

Problem materials

Back to carbon

So-called recarbonization enables the transformation of problematic waste materials into valuable materials. Non-recyclable fiber composites, plastic-containing residues and paper sludges were successfully carbonized in the laboratory.

… and many more

Special features of the directly heated batch retort process

Pyrolytic carbonization processes, as continuous flow processes (rotary kilns, piles), generally depend on precisely prepared and small-sized input materials that can only be processed at a defined and high process temperature. This makes biocarbons expensive, limits their uses, and keeps volumes low. Interfering materials such as metals, plastics, stones lead to wear and malfunctions and must be sorted out beforehand in a time-consuming process. In addition, the biocoals are usually extinguished with water after the furnace against their self-ignition, which causes a water content of 20-40% and increases the sales weight. Therefore, these biochar are not offered in weight, but in volume.

In the minus CO2 factories of the carbonauten, different woody biomass residues and residual materials are carbonized. For this purpose, a directly heated batch retorting process was developed that flexibly processes different material streams to defined qualities and quantities of biocarbons, platform biochemicals and energy. The batch retort process is wear-free and fail-safe because, as a static slow pyrolysis process, it contains no moving parts. This means that materials with interfering substances such as nails, stones or synthetic fibers can also be carbonized. In addition, digital traceability of each batch is guaranteed. The process produces technical biocarbons with 0% water content so that high-quality carbonauten NET Materials® can be produced from them.

Features

  • Direct heating of biomass residues/waste
  • Modular and transportable
  • Can be used for a wide range of biomasses
  • Wear-free and robust (no moving parts)
  • High product quality
  • Precise temperature control between 400° – 700° Celcius
  • Continuous operation 24/7, at least 8,000 hours/year
  • Excellent energy balance (1 MWth waste heat/module)

Current developments on technology

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