MULTI‑ECO — modular industrial carbonization complex

Reliability and industrial durability — the design was created by long-term basis of semi-continuous batch type pyrolysis units operation under industrial production conditions.

Logistic flexibility of the Production complex — the trolleys and mobile platforms organize sequential movement between loading, drying, carbonization, cooling and unloading areas.

Consistent lump charcoal quality — optimized heat distribution and controlled carbonization provide uniform processing of the feedstock, supporting high product yield, mechanical integrity, and stable fixed-carbon (Cfix) values.

Environmental safety — pyrolysis gases are subjected to high-temperature thermal oxidation before discharge, ensuring effective neutralization of combustible and harmful gaseous compounds while recovering their energy for the process.

Energy efficiency — the energy contained in pyrolysis gases is reused to sustain carbonization and provide heat for feedstock drying, minimizing external fuel consumption and improving the overall thermal efficiency of the system.

table semi-continuous production — the multi-chamber configuration allows individual pyrolysis chambers to operate in staggered cycles, providing a steady production flow while maintaining stable thermal conditions and efficient utilization of process heat.

1. Dry pyrolysis unit: a process without the formation of liquid pyrolysis products;
2. Indirect feedstock heating and carbonization control: prevents contact between the heat-transfer medium and the feedstock, which is critical for process control, and uses technology to prevent excessive gas release;
3. Feedstock drying: excess heat from the carbonization process is used to remove moisture efficiently; drying the feedstock to < 15% is a mandatory stage for achieving high capacity and high mechanical strength of the final product;
4. Cycle balance: the drying time is effectively equal to the pyrolysis duration, which is taken into account in the system configuration;
5. Environmental safety: the primary thermal oxidizer and hot cyclone (T > 1200°C) ensure complete gas neutralization, ash treatment and the absence of harmful emissions.
6. Finished-product parameters: nominal fixed-carbon content (Cfix): 75–90%, provided that the feedstock ash content does not exceed 1.5%.

Multi-chamber design

The unit consists of several carbonization chambers operating in parallel. Each chamber accommodates two feedstock trolleys, increasing the heat-transfer area and ensuring efficient use of the working volume. Sequential loading and unloading of individual chambers enables stable operation of the complex and an even output of finished product, without losing excess thermal energy, which is used to meet the process’s own energy needs.

Vortex firebox and pyrolysis-gas neutralization

The unit is equipped with a vortex firebox with an automatic start-up gas burner; an automatic burner operating on wood pellets or chips may also be installed. Pyrolysis vapour-gases from the pyrolysis chambers are collected in a common gas collector and directed to the vortex firebox, where they are neutralized while producing a high-temperature heat-transfer medium—the energy potential required to sustain the process, including feedstock drying. Residual gaseous compounds leaving the pyrolysis chambers are additionally neutralized at high temperatures before discharge into the atmosphere, making the process environmentally safe and energy-efficient.

Modern thermal insulation

The carbonization chambers are manufactured using modern high-temperature thermal-insulation materials. Reducing the thermal inertia of the structure accelerates the unit’s transition to operating conditions, reduces heat losses and increases the overall energy efficiency of the process.

Logistics and mechanization

The multi-chamber layout enables the sequential movement of trolleys between the loading, drying, carbonization, cooling and finished-charcoal unloading areas. Well-designed internal logistics reduce manual operations, shorten chamber servicing time and ensure continuous operation of the production section.

Automated control system

The automated control system (ACS) monitors the temperature parameters of the pyrolysis chambers with due regard to the process thermal regimes, controls the vortex firebox and manages pyrolysis-gas neutralization. Automation reduces the effect of the human factor on cycle duration, capacity and charcoal quality. The ACS stores process parameters and enables remote control and monitoring via the Internet. This allows the plant manager and GREENPOWER specialists to monitor equipment operation, analyze the history of production cycles and adjust process settings.