Your Carbonisation Questions Answered

With over a decade of experience in biosolids and biomass carbonisation technology, the team at Pyrocal is well equipped to tackle the many questions that come from CEOs, water and wastewater professionals, operators, consultants, and environmental specialists.

Pyrocal’s technical manager Deric Dignon unpacks the answers to some of the most common questions that arise.

Q1: What are your carbonisation system’s labour requirements?

At less than 0.5 FTE, our systems have very low labour requirements. This is because they are fully automated and controlled by a PLC with built-in failsafe systems, protections, and interlocks.

Q2: What is the system’s capacity?

Our systems cover a capacity range from 200 kg/h to 650 kg/h with higher capacity requirements covered with multiple units.

Q3: Can the system be moved to another site?

Yes, our modular design allows relocation on your site with minimal infrastructure requirements. Compared to fixed plants with very high capacity, our technology is agile and easy to integrate into existing systems.

Q4: How long does installation and commissioning take?

Mechanical installation takes about three weeks, electrical installation another two weeks, and commissioning another two weeks. The total time from project kick off to commissioning is just under eight months.

Q5: What is the plant footprint?

At w 4m x l 15m x h 9m for our CCT12 system and w 14m x l 32m x h 9m for our CCT20 system, our equipment requires minimal space and can be customised to some extent. We recommend a standard layout configuration as customisation may create access challenges for equipment maintenance.

Q6: What feedstock characteristics are important?

The key characteristics are energy content, moisture content, and particle size. Other qualities like fixed carbon, volatile matter, and ash content also play an important role. Our continuous carbonisation systems are built to work best with feedstocks that have an energy content above 11 MJ/kg, a moisture content below 12%, and a particle size from 3 to 10 mm.

Q7: Why is particle size important?

Variations in particle size can affect the degree of carbonisation of each particle. If the particles are too large, they might not heat all the way through, which can lower carbonisation efficiency and affect the quality of the biochar. Smaller particles, on the other hand, carbonise too quickly and may be over treated.

Q8: What support and delivery options do you offer?

We take a flexible approach to getting your system up and running and our delivery models are designed to match your operational goals, budget, and risk profile. The options include:

• Equipment supply only for projects with design-and-build contractors
• Integrated systems with drying and carbonisation equipment supplied

Beyond delivery, we work closely with our clients to assess site readiness, feedstock variability, and operational constraints. Our support covers installation guidance, commissioning, operator training, and ongoing technical assistance so every system is delivered for success, not just installed.

Making carbonisation work in the real world

From system set up to feedstock considerations to ongoing technical support, Pyrocal’s approach is all about making carbonisation work in the real world.

Deric concludes, “Whether from biomass or biosolids, our continuous carbonisation systems are designed to run smoothly, integrate easily and produce high-quality biochar consistently.”

If you have more questions or want to find out how carbonisation could work on your site, Deric and the Pyrocal team are ready to help.