Large-scale semi-continuous carbonization: MULTI-ECO

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MULTI-ECO is a family of GREENPOWER engineering solutions for the industrial carbonization of wood and other biomass. The system is designed for flexible integration into different site and logistics conditions: from sites with crane-based logistics to capital stationary complexes. Thanks to indirect retort heating, CFD optimization of the chambers and a reliable pyrolysis gas neutralization system, MULTI-ECO ensures stable production of premium-grade large-lump charcoal for metallurgy, BBQ and other industrial applications.

Basic technological platform

Dry Pyrolysis: a process without the formation of liquid pyrolysis products;
Indirect heating during carbonization: prevents contact between the heat carrier and the feedstock, which is critical for process control;
Drying agent for feedstock drying: use of excess process heat for efficient moisture removal from the feedstock; drying to <15% is a mandatory stage for achieving high charcoal strength and quality;
Cycle balance: the drying time is 1.5-2 times longer than the pyrolysis duration, and this is already taken into account in each system configuration;
Environmental safety: the primary thermal oxidizer and the hot cyclone (T > 1200°C) ensure complete neutralization of gases, ash decontamination, and the absence of harmful emissions.

Main elements of the MULTI-ECO complex

1. Primary thermal oxidizer – ensures complete neutralization of harmful substances;

Primary thermal oxidizer — T and Secondary thermal oxidizer — S

2. Gas collector and system of primary and spent heat-carrier channels – for controlling vapor-gas flows and thermal processes;

3. Separate pyrolysis chambers and trolleys or retorts, removable or stationary – the configuration is selected according to the customer’s infrastructure;

Pyrolysis chambers with stationary retorts

Removable retort

4. Drying chambers with replaceable baskets – configured depending on the selected pyrolysis chamber configuration;

5. Chimney or induced-draft fan – draft generation and emissions control;

6. Product discharge and stabilization system – forced cooling and preparation for packaging/logistics;

7. ACS / I&C — automation of the processes of loading, neutralization of pyrolysis gases, temperature control, and monitoring of product quality parameters.

V1. MULTI-ECO [Modular / Trolleys]

Modular solution with trolleys and mesh baskets. The system is designed to be supplied as ready for operation as possible for fast commissioning.

Capacity: 96-144 t/month.
Advantages: fast installation, easy scaling, readiness for operation in difficult locations.

V1. MULTI-ECO [Modular / Trolleys]

V2. MULTI-ECO [Removable Retorts]

Complex with removable retorts and crane-based logistics. It enables high production volumes with flexible production cycle management.

Capacity: from 150 to 300 t/month.
Advantages: high loading density; optimal for facilities with developed crane infrastructure.

V2. MULTI‑ECO [Removable Retorts]

V3. MULTI‑ECO [Stationary Retorts]

Industrial complex based on large-volume stationary retorts for capital projects with maximum integration into the site infrastructure.

Capacity: from 200 to 400 t/month.
Advantages: maximum service life, stable thermal regimes and process automation.

V3. MULTI‑ECO [Stationary Retorts]

Brief description of the production process

Feedstock preparation – wood is cut into large pieces/fractions and loaded into the drying chambers;
Feedstock preparation and drying – excess process heat is used for drying, and high drying efficiency is achieved through direct contact between the drying agent and the feedstock;
Loading into retorts – prepared and dried feedstock is loaded into removable or stationary retorts;
Indirect heating of the pyrolysis zone — heat is transferred through the retort walls, eliminating contact between the feedstock and neutralization products. This is critical for preserving the shape and mechanical strength of the pieces;
Pyrolysis gas neutralization — pyrolysis gases discharged from the pyrolysis chambers are directed to the Primary Thermal Oxidizer / Secondary Thermal Oxidizer. Complete neutralization ensures environmental safety and provides an additional heat source for drying and maintaining the process ;
Discharge and stabilization – finished charcoal is discharged to the designated location, where it is cooled and, if necessary, stabilized.

ACS and process control

MULTI-ECO is equipped with an automatic control system (ACS) that ensures safe and stable operation: loading level sensors, thermocouples and parameter measuring devices, automatic actuators for controlling air and heat-carrier supply, pyrolysis gas neutralization control logic and protective scenarios in case of deviations. Integration with cloud monitoring and remote service is possible.

Product quality and guarantees

Target fixed carbon content (Cfix) – designed to achieve and maintain Cfix >= 82%, depending on the required specification;
Quality stability is ensured by CFD optimization of the chambers and thermal regime control;
Design solutions minimize feedstock overconsumption and unexpected product losses during transport and stabilization.

Pyrolysis unit parameters *

Parameter	MULTI-ECO – Removable Retorts	MULTI-ECO – Stationary Retorts
Charcoal capacity, indicative, t/month	150-300	200-400
Target Cfix, controlled	>= 82%	>= 82%
Recommended infrastructure	Crane/forklift availability	Capital site, forklift with rotator
Modularity	Medium	Low – stationary structure
Environmental performance	Complete neutralization of harmful substances	Complete neutralization of harmful substances

*Indicative only; for configuration selection, please request an individual assessment.

Feedstock

A wide range of raw materials can be processed by environmentally safe pyrolysis (more information about the pyrolysis process):

firewood and energy wood;
woodworking and logging waste, non-standard wood, including roots, branches and similar materials;
various fuel briquettes such as Pini-Kay, Ruff, Nestro and Nielsen.