seminar on the commercialization of sustainable...

Carlo Figà Talamanca – 18th of April 2013 | Hotel Equatorial Bangi, Malaysia

BIOCHAR CONCEPTS AND GREEN TECHNOLOGIES SEMINAR ON THE COMMERCIALIZATION OF SUSTAINABLE BIOCHAR

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CONTENT OF THE SEMINAR


8.00 Am Registration

9.00 am Biochar Concepts and Green Technologies

10.30 am Tea break

11.00 am Social, Economic and Environmental Impacts of Biochar

1.00 pm Lunch

2.00 pm Biochar Market Access Opportunities and Commercialization Experiences

3.30 pm Tea break

4.00 pm Possible Collaborations Feasible to Malaysian Biomass SMEs

5.00 pm End of day 1 programme

Background in Industrial Engineering

Project Manager and consultant of Innova S.p.A. – ITALY Technology Transfer EU R&D projects ICT and Renewable Energy

CEO of Innova Consulting Group (US branch of Innova S.p.A.) - USA Technology Transfer Development project in Latin America (development through TT) ICT, Biotech and Aerospace

Freelance Consultant for EUEI PDF, GERES, Italian Trade Commission, TUV - Cambodia Sustainable development Renewable energies & Energy Efficiency Business development

CEO and owner of Sustainable Green Fuel Enterprise (SGFE) - Cambodia

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A FEW WORDS ABOUT MYSELF...


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WHY ARE WE HERE?


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WHO IS FAMILIAR WITH THE CONCEPT OF:

BIOCHAR?

CLIMATE CHANGE/GLOBAL WARMING/GRENHOUSE EFFECT?

CARBON FINANCE?

RENEWABLE ENERGIES?

AGRICULTURAL PRACTICES?

SUSTAINABLE DEVELOPMENT (development project)?

OTHER?


ALL OF THESE TOPICS ARE RELATED!

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CLIMATE CHANGE

Climate change is a term that refers to major changes in temperature, rainfall, snow, or wind patterns lasting for decades or longer. Both human-made and natural factors contribute to climate change:


Human causes include burning fossil fuels, cutting down forests and developing land for farms, cities, and roads. These activities all release greenhouse gases into the atmosphere.

Natural causes include changes in the Earth’s orbit, the sun’s intensity, the circulation of the ocean and the atmosphere, and volcanic activity.

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FACTS AND FIGUERES ABOUT GLABAL WARMING


Global surface temperatures have risen by 1.3 degrees Fahrenheit (ºF) or 0,72 degrees Celsius (ºC) over the last 100 years.

Worldwide, the last decade has been the warmest on record.

The rate of warming across the globe over the last 50 years is almost double the rate of warming over the last 100 years..

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THE GREENHOUSE EFFECT


While carbon dioxide is the most widely recognized GHG, the Kyoto Protocol addresses six greenhouse gases:

carbon dioxide (CO2)

methane (CH4)

nitrous oxide (N2O)

hydrofluorocarbons (HFCs)

perfluorocarbons (PFCs)

sulphur hexafluoride (SF6)

“Many” countries (for example the countries listed in Annex 1 of the Kyoto protocol) started taking measures to reduce GHG emissions. However effort needs to be done on a global scale... GHG don’t remain only above your country, but are global!

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WHAT CAN WE DO AGAINST CLIMATE CHANGE?


Combating climate change has to build on innovation, new technologies and exchange!

Global action based on continuous innovation and rapid diffusion of climate change technologies (CCTs)

Conditions that allow all countries, to adopt, adapt, innovate and produce CCTs on their own.

The transfer of CCTs is regulated in a treaty commitment under the United Nation Framework Convention on Climate Change (UNFCCC) and its Kyoto Protocol, however actual transfers on a non-commercial basis are rare.

TT

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WHAT IS BIOCHAR?


Definition: “Biochar is a solid material obtained from the carbonization of biomass.”

(Explanation/translation: Biochar is a name for charcoal.)

Continuation of definition: “Biochar may be added to soils with the intention to improve soil functions and to reduce emissions from biomass that would otherwise naturally degrade to greenhouse gases. Biochar also has appreciable carbon sequestration value. These properties are measurable and verifiable in a characterization scheme, or in a carbon emission offset protocol.”

Definition taken from www.biochar-international.org:

(Integration of explanation/translation: Biochar is a name for charcoal when it is used for particular purposes, especially as a soil amendment.)

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THE “BIOCHAR CONCEPT” (1/2)


Biochar as a soil amendment: • A practice that converts agricultural

waste into a soil enhancer.

• The process creates a fine-grained, highly porous charcoal that helps soils retain nutrients and water.

• Biochar also improves water quality and quantity by increasing soil retention of nutrients and agrochemicals for plant and crop utilization.

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THE “BIOCHAR CONCEPT” (2/2)


Biochar as a tool to combat Climate Change:

• The carbon in biochar resists

degradation and can hold carbon in soils for hundreds to thousands of years. When the biochar is buried in the ground as a soil enhancer, the system can become "carbon negative“, by sequestering carbon in stable soil carbon pools.

• SUSTAINABLE biochar practices can produce oil and gas byproducts that can be used as fuel, providing clean, renewable energy A technology estimated to be able to store up to 2.2 gigatons of carbon annually by 2050.

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DOUBTS ABOUT BIOCHAR


Biochar is still a relatively new concept and there are still controversial issues...

• Comparison with the disputed results of biofuels

• Doubts about ability to act as soil amendment

• Suspects about biochar increasing loss of organic carbon from humus

• Biochar may not be a stable carbon pool

• Biochar effects on soil fertility not always positive

• Potential for Oxygen depletion

• Economic non-viability of concept and related technologies

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A LITTLE BIT OF “BIOCHAR HISTORY”


Origin of Biochar - Terra Preta

Terra preta is a type of very dark, fertile soil found in the Amazon Basin, estimated to be made about 2500 years ago by adding a mixture of charcoal, bone, and manure to the otherwise relatively infertile Amazonian soil. • Human and animal excrements • Kitchen refuse, such as animal bones

and tortoise shells • Ash residue from incomplete

combustion • Biomass of terrestrial plants • Biomass of aquatic plants Efforts to recreate these soils are being undertaken by private companies. Academic research efforts continue.

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BIOCHAR PRODUCTION TECHNOLOGIES (1/4)


BIOCHAR PRODUCTION = CHARCOAL PRODUCTION

Charcoal production is an ancient process and there are different methodologies and technologies to produce charcoal/biochar: • home made systems vs. industrial systems • focus on:

• Charcoal production (yield and quality) • focus on heat • focus on energy production

At the base of all charcoal production systems is the thermal process of PYROLYSIS!

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Pyrolysis and gasification vs. incineration:

• Pyrolysis and gasification, like incineration, are options for recovering value from biomass (waste) by thermal treatment.

• Pyrolysis and gasification technologies form part of a group of processes and techniques, collectively known as advanced or novel thermal treatment. In reality, the basic technology concepts are not novel, but recently, several “new” techniques have been developed.

• Pyrolysis and gasification turn biomass (waste) into energy rich fuels by heating the biomass under controlled conditions.

• Whereas incineration fully converts the input biomass (waste) into energy and ash, pyrolysis and gasification deliberately limit the conversion so that combustion does not take place directly . Instead, the convert the biomass (waste) into valuable intermediates that can be further processed.


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PYROLYSIS Thermal degradation of biomass in the absence of air/oxygen to produce char, pyrolysis oils and syngas


GASIFICATION breakdown of hydrocarbons into a syngas by carefully controlling the amount of oxygen present.

BIOMASS FUEL

decomposition

CHAR

Tar, H2, CH4

H2, CO, CO2

PYROLYSIS GASIFICATION

O2, H2O ash, char

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Pyrolysis vs. Gasification


PYROLYSIS • Maximum yield of biochar/charcoal • Possibility to collect pyrolysis oils • Possibility to collect syngas • Minimum yield of energy

GASIFICATION • Maximum yield of energy (heat and or

electricity generation) • Minimum (no) yield of everything else

There are controlled processes in between, where there is only a partial gasification

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CHARCOAL INDUSTRY IN MALAYSIA

EXAMPLES OF BIOCHAR PRODUCTION CHARCOAL PRODUCTION (1/14)

Malaysian charcoal manufacturing industry is thriving, thanks to demand from keen Japanese consumers, who are buying more than half the country's total production. In 2009 the small industry made sales of about 3 million Malaysian Ringgit (808,300 U.S dollars) a month. In the Northern Malaysian state of Perak, there are 336 charcoal making kilns, which provide a valuable source of employment for locals. Factories are mostly centered in the small town of Kuala Sepetang, turning mangrove trees into charcoal at high temperatures inside dome-shaped kilns for up to one month. The industry represents an important source of local income, however experts are concerned that over-logging and illegal logging activities could cause irreversible damage to the environment.

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CHARCOAL PRODUCTION IN PERAK


The logs are positioned in vertical position inside the kiln, then the kiln is closed, apart of a small hole in the front where it gets ignited (ignition fire).

The first stage of the process is the drying phase were the humidity level inside the logs decreases through evaporation for about 8 to 10 days.

After about 10 days the kiln is completely shut off and the pyrolysis starts . This phase takes about 12 to 14 days.

Then the cooling process starts, this takes another 8 days.

http://www.pbase.com/alexfoong/charcoal_worker



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CHARCOAL PRODUCTION IN CAMBODIA


Traditional kiln technology is archaic, weakly efficient and polluting

Low efficiency : 6.5 kg of wood to produce 1kg of charcoal

Long process : average duration of 3 weeks

Low quality : no control on the process

Low calorific value YIELD OF 15%

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THE YOSHIMURA KILN – Japanese Technology


Made of bricks and metal

Allows a precise control of the carbonization process.

Allows the collection of wood vinegar

Produces 1 kg of charcoal from 4.5 kg of wood compared to the 6.5 kg needed by Cambodian kilns

YIELD OF 22%

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8

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4

5

3

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DESIGN AND COMPONENTS OF THE YOSHIMURA KILN


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1. PVC pipe

2. Ceramic head collector

3. Metal cover

4. Metal internal chimney

5. Metal grate

6. Body of the kiln

7. Exhaust chimney

8. External furnace


YSH KILN CHARCOAL PRODUCTION AND WOOD-VINEGAR COLLECTION CYCLE (1/3)


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Yoshimura kilns are based on the principle of carbonization by partial combustion.

Characteristics: an external heating system, a central heat distribution, four outlet chimneys and a condensation system (wood-vinegar).

The heat needed for the carbonization is first produced by the combustion of wood in the external furnace, to dry the load and ignite the transformation.

Hot smoke (800 °C max) goes across the wood load from the top to the bottom of the kiln. Thus, smoke and gases generated during carbonization are collected through a metal grate and evacuated by the four outlet chimneys (cleaner healthier process).




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The upper end of each chimney is topped by a ceramic bell (head collector). Each bell assures the evacuation of the pyrolysis gases in PVC pipes. The pipes are cooled by

air in natural convection and act as condensers.

The liquid obtained (wood vinegar, or pyroligneous acid)

flows by simple gravity down the PVC pipes. It is collected

at the head collector and then stored in drums.

A cycle of carbonization is composed of different steps: loading, carbonization (drying, pyrolysis, wood vinegar collection, refining), cooling and unloading. One cycle lasts from 7 to 10 days and requires 2 operators (12 hour shifts) operating however 2 kilns at once.




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The loading and unloading operations can be reduced to actually half a day each.

By pre-drying the wood at the open air for 40-60 days, the carbonization cycle is reduced of 2 additional days

Overall, a full YSH kiln cycle can be run in 7 days!

YSH KILN CYCLE TIMING

Days 1 2 3 4 5 6 7 8 9 10

Process steps

Loading

Carbonization

Cooling Unloading Drying

Pyrolysis

Refining Wood vinegar collection

Post collection


CHARCOAL CHARACTERISTICS FROM YSH KILNS


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By controlling the process, wood is well carbonized. The charcoal has a higher rate of carbon resulting in a higher calorific value

Lower quantity to do the same cooking task

Less smoke and no sparks when burning

15% more efficient charcoal

Traditional Improved

Calorific value [MJ/kg] 26 30


WOOD VINEGAR PRODUCED/COLLECTED WITH YSH KILNS


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Raw wood vinegar is stored from 3 to 6 months in drums (200L capacity, resistant to acid). During this period, the raw wood vinegar performs a decantation and separates into 3 phases:

Phase 1: oil at the top

Phase 2: usable wood vinegar in the middle

Phase 3: tar at the bottom

Characteristics:

pH = 3

Acid content = 3%


Wood vinegar has a great variety of uses and advantages:


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Food processing:

Conservation of food (smoking)

Seasoning and taste

Agriculture:

Antivirus and antibacterial for soil diseases

Antivirus and antibacterial for plant and trees diseases

Insect repellent and insect killer for plants and trees

Fertilizer

Other:

Coagulation of rubber latex


Other charcoal production kilns (1/2):


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Drum kiln

Iwate kiln


Other charcoal production kilns (2/2):


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Retort kilns


Outcome of charcoal production:


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Prick (grass) char

Sugar cane waste char Coconut char

CHARCOAL and...

Char residues = Biochar


Scientific basis of fire and the TLUD technology

EXAMPLES OF BIOCHAR PRODUCTION “COOK STOVES” – THE TLUD TECHNOLOGY (1/2)

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Heat causes pyrolysis (chemical decompo-sitions into combustible gases) and carbonization (charcoal creation).

Charcoal can be “char-gasified” into gases.

The created gases can combust; solids do not!

These processes can occur at different rates and in different places in different fires.

Control and separation of these processes are the keys to different types of combustion.


TLUD is “Top Lit Up Draft”

EXAMPLES OF BIOCHAR PRODUCTION “COOK STOVES” – THE TLUD TECHNOLOGY (2/2)

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Ignition at the top of a column of chunky dry biomass

Createion of a down-ward migrating pyrolytic zone (or front) that is starved of oxygen

Creation of charcoal plus pyrolytic gases (“smoke”)

Gases move upward to where fresh secondary air enters, resulting in clean combustion of the gases for heat for cooking.

Output: heat and biochar!

Gas

Secondary Air

Charcoal

Pyrolysis

Ungasified Wood

Primary Air

Blower

BEF WoodGas CampStoveExample with FA: FA = Forced Air or Fan Assisted


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Variations of TLUD gasifier cookstoves.

[ Top row is with fans. ]


EXAMPLES OF BIOCHAR PRODUCTION CHARRING OF OIL PALM WOOD WITH TLUD (1/2)

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EXAMPLES OF BIOCHAR PRODUCTION CHARRING OF OIL PALM WOOD WITH TLUD (2/2)

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Gasification concept:

EXAMPLES OF BIOCHAR PRODUCTION ENERGY PRODUCTION THROUGH GASIFICATION (1/9)

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Gasification is a process that converts organic (or fossil based carbonaceous) materials into carbon monoxide (CO), hydrogen (H2) and carbon dioxide (CO2).

This is achieved by reacting the material at high temperatures (>700 °C), without combustion, with a controlled amount of oxygen and/or steam.

The resulting gas mixture is called syngas (from synthesis gas or synthetic gas) or producer gas and is itself a fuel.

The power derived from gasification and combustion of the resultant gas is considered to be a source of renewable energy if the gasified compounds are obtained from biomass.

Fixed-bed updraft gasifier.



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The simplest of the air-blown gasifiers.

Air enters at the bottom of the furnace, rises through the grates on which the biomass char is resting at a temperature of around 1100 C.

The air first meets the char, then the gases produced by this combustion and move into the char where there is little air present and are reduced to CO and H2 by the excess carbon.

As the gases continue to rise, they make contact with the wet, incoming biomass and dry it.

Very simple, but has the principal problem that a wide range of chemicals, oils and tars produced by pyrolysis and become constituents of the gas stream, and these could condense anywhere where the temperature is low. For this reason the gas from this gasifier must be used close to the gasifier exit (in a "close-coupled" mode);.



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Designed to deal with the main problem of the emerging gas carrying tars and oils.

The air is introduced above the grate so that combustion takes place in a constricted section of the cylinder and a char bed forms below these air inlets.

Gases are drawn off at the bottom of the gasifier, pass through the char bed resting on the grate and are reduced by the excess carbon, exiting at high temperature. Any chemicals which are produced in the pyrolysis zone above the combustion area pass through the high temperatures of the combustion and reduction zones, where they will be "cracked" to form simpler gases or char.

The tars and oils are reduced to less than 10% of the value in updraft gasifiers.



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Systems developed for large scale gasification.

These beds contain either inert material (e.g. sand) or some reactive material such as limestone or catalysts.

The air or oxygen enters below the bed rising through it in such a way as to keep the material in suspension. acting like a fluid.

Small particles of the biomass are fed continuously into the bed using a screw feeder.

Rapid mixing of the solids within the "fluid", providing good heat transfer throughout the bed, so that all the processes (drying, pyrolysis, combustion and reduction) take place about the same temperature (around 900 C).

The gas velocities are high and a significant portion of the solids is entrained above the bed. These solids can be recirculated to the bed using a cyclone separator.



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GASIFIERS OUTPUT! Rice husk CHAR from gasifier in Siem Reap Province (CAMBODIA)



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GASIFIERS OUTPUT! Rice husk CHAR from gasifier in Siem Reap Province (CAMBODIA)


BIOCHAR PRODUCTION - CONCLUSIONS

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Gasification and pyrolysis production systems can be developed as mobile or stationary units.

Pyrolysis and gasification units operated by larger industries can process up to 4,000 kg/hour.

Small scale gasification and pyrolysis systems can process 50 kg/hr to 1,000 kg/hr.

Micro scale drum kilns (200 l feedstock chamber) can produce 8 to 12 kg of biochar in 1- 4 hours;

Charcoal-making stoves show promise of bringing low-cost biochar to rural areas.

Gasification output: Char & Ash Quantity strictly dependent on the gasifier type

and fuel used output in weight between 5%-20% of input (up to

30% for rice husk) ash content of output ~ 70%. for gasifiers ash content of output ~5%-15% for charcoal making

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THANK YOU FOR YOUR ATTENTION

Carlo Figà Talamanca – CEO

E:[email protected]

M: +855 (0)97 8159256

SGFE office & factory: Phlove Lom, Phoum Russey, Sangkat Stueng Meanchey, Khan Meanchey, Phnom Penh, CAMBODIA

www.sgfe-cambodia.com

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