Typical failures and their troubleshooting

Failures of control and measuring instruments and automation (C&IA)
Mechanical failures and drive failures
Destruction of refractory lining and thermal channels
Critical emergency situations (ACS + Mechanics)
Important: This section is based on the technical regulations for typical faults of BIO-CARBON and covers software and hardware failures, mechanical breakdowns, and degradation of refractory structures.

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Economic Aspects
What is the cost of producing 1 ton of charcoal?

The production cost depends on many factors and is calculated individually for each project. The main cost components are:

  1. Feedstock (main cost item):
     • Cost depends on the region and type of raw material
    • To produce 1 ton of charcoal, 2.7–4 tons of dry feedstock are required (depending on Cfix)
  2. Electricity consumption (peak load):
    • BC-2: 8 kW/h
    • BC-3: 13.6 kW/h
  3. Personnel: 2 people per shift (operator + assistant)
  4. Maintenance: not more than 5% of the unit cost per year of operation
  5. Packaging and logistics


Advantages of BIO-CARBON:

• Zero fuel costs (after startup)

• Generation of excess heat that can be utilized

• Low energy consumption

• High level of automation = low personnel costs

What is the return on investment for BIO-CARBON?

The return on investment depends on:
• feedstock cost in the region
• market price of charcoal
• productivity of the selected model
• Cfix content in the finished product
• additional income (use of excess heat)

A typical payback period is 1 to 3 years, provided production and sales are properly organized.

Factors affecting profitability:
 ✓ availability of low-cost feedstock
✓ high market demand
✓ production of high-quality charcoal (Cfix 90–95%)
✓ use of excess heat for auxiliary processes
✓ packaging automation
✓ direct contracts with end consumers

To calculate the payback period for a specific project, it is recommended to contact GreenPower specialists, who will perform a technical and economic analysis taking all factors into account.

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