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    Biochar Production (Capacity: 48 Tons/Day)

    Biochar Production (Capacity: 48 Tons/Day)
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    Biochar Production (Capacity: 48 Tons/Day)
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      BIOCHAR PRODUCTION (CAPACITY: 48 TON/DAY)

      [EIRI/EDPR/4748] J.C.: 2968XL

      Biochar is a carbon-rich material that is made from biomass through a thermochemical conversion process known as pyrolysis.

      When it comes to building a circular economy, every kind of waste is either eliminated or recycled into new valuable materials. But waste comes in all shapes and sizes—there’s no single “magic bullet” for addressing every different kind. That’s why scientists and policymakers call for a diversity of tools and solutions for achieving sustainable economies and societies. To understand biochar, it’s worth appreciating a specific form of waste—organic waste—and the problems it poses from a sustainability perspective.

      The most common types of organic waste that we encounter in our day-to-day lives are food waste, yard trimmings and clippings, and—hold your nose—sewage. While these are each different in terms of material composition and life cycle (how they are made and disposed of), they tend to present similar challenges (and, as we’ll see, opportunities).

      Loosely understood, any material that is immediately derived from plants and animals is organic. Another common term for this is biomass. Sometimes the term “biodegradable” is used to describe biomass as waste because it can be broken down into organic molecules by microscopic living things like bacteria, fungi, and microbes.

      Most everything, from an old cookie to a car axle, eventually breaks down under the right conditions and with enough time. But organic materials break down much faster than inorganic ones do. Because of the fast pace with which organic matter decomposes, it presents unique challenges when it comes to mitigating its environmental impacts as waste.

      When biomass degrades in a landfill or a treatment center, the potent greenhouse gases (GHGs) carbon dioxide and methane are released, among others. Methane is twenty times more potent than carbon dioxide as a greenhouse gas, though carbon dioxide remains in the atmosphere for much longer.


      COST ESTIMATION

      Plant Capacity            48 MT/Day

      Land & Building    Rented

      Plant & Machinery                    Rs. 5.10 Cr

      Working Capital for 2 Months    Rs. 2.65 Cr

      Total Capital Investment          Rs. 8.31 Cr

      Rate of Return                          19%

      Break Even Point                      71%


      CONTENTS

      INTRODUCTION

      THE VALUE OF ORGANIC WASTE

      BIOCHAR

      BIOCHAR AS CARBON CAPTURE

      SUSTAINABLE ENERGY THROUGH PYROLYSIS

      INTEGRATION WITH EXISTING VALORIZATION TECHNOLOGIES

      RAW MATERIALS

      TABLE: LIGNOCELLULOSIC COMPOSITION (WT%) OF CERTAIN BIOMASS RESOURCES

      PROPERTIES OF BIOCHAR

      EFFECT OF FEEDSTOCK PROPERTIES

      EFFECT OF TEMPERATURE AND HEATING RATE

      CHARACTERISTICS OF BIOCHAR FROM DIFFERENT FEEDSTOCK

      USES AND APPLICATION

      TABLE: ELEMENTAL ANALYSIS OF BIOCHAR PRODUCED FROM SOME   TYPICAL BIOMASS

      ENVIRONMENTAL APPLICATIONS OF BIOCHAR

      BIOCHAR AS ADSORBENT

      BIOCHAR AS CATALYST

      TABLE: REMOVAL OF ORGANIC POLLUTANTS BY BIOCHAR DERIVED FROM DIFFERENT FEEDSTOCKS AND PYROLYSIS TEMPERATURES

      BIOCHAR AS ANIMAL FEED

      SOME OF THE IMPORTANT APPLICATION OF BIOCHAR HAS BEEN LISTED BELOW. THESE ARE:

      AS A TOOL FOR WASTE MANAGEMENT

      AS A SOIL CONDITIONER TREATMENT OF WASTE WATER

      BUILDING SECTOR

      COSMETIC INDUSTRIES

      METALLURGY

      FOOD INDUSTRY

      TECHNOLOGIES IN BIOCHAR PRODUCTION

      SUSTAINABLE ALTERNATIVES TO INCINERATION

      COMMON FEEDSTOCKS AND PRODUCTS

      PRODUCTION PROCESSES FOR BIOCHAR

      THERMOCHEMICAL CONVERSION PROCESSES

      PYROLYSIS PROCESS

      CONCEPTUAL PYROLYSIS PROCESS

      TABLE: OPERATING CONDITIONS OF VARIOUS PYROLYSIS PROCESSES AND THEIR PRODUCT FRACTIONS (BIO-OIL, BIOCHAR, AND GAS)

      TORREFACTION PROCESS

      SLOW PYROLYSIS PROCESS

      INTERMEDIATE PYROLYSIS PROCESS

      FAST PYROLYSIS PROCESS

      FLASH PYROLYSIS PROCESS

      HYDROTHERMAL CARBONIZATION PROCESS

      MICROWAVE ASSISTED PYROLYSIS PROCESS

      PROCESS FLOW DIAGRAM

      OPERATIONAL PROCESS FOR BIOCHAR PRODUCTION

      TABLE: CHARACTERIZATION OF CASTOR, COTTON & PIGEON PEA STALK

      TABLE: COLOR PHASE CORRELATION WITH TEMPERATURE RANGE FOR DIFFERENT RESIDUE LOAD AND REACTION TIME DURING THERMO-CHEMICAL CONVERSION PROCESS

      PROCESS: THERMO-CHEMICAL CONVERSION OF RESIDUE TO BIOCHAR

      FIG.: SCHEMATIC PRESENTATION OF THE OPERATIONAL PROCESS FOR BIOCHAR PRODUCTION

      DETAILS OF PYROLYSER AND GASIFICATION

      PYROLYSIS

      SLOW PYROLYSIS

      FAST PYROLYSIS

      GASIFICATION

      FATE OF INITIAL FEEDSTOCK MASS BETWEEN PRODUCTS OF PYROLYSIS PROCESSES

      CARBONIZATION

      SUMMARY OF PYROLYSIS PROCESSES

      QUALITY CONTROL OF BIOCHAR

      TABLE: MERITS AND DEMERITS OF VARIOUS PYROLYSIS PROCESSES

      ANALYTICAL METHODS FOR BIOCHAR ANALYSIS

      COLLECTION, PROCESSING AND ANALYSIS OF BIOCHAR

      PROXIMATE ANALYSIS

      TABLE: VARIOUS ANALYTICAL METHODS FOR BIOCHAR ANALYSIS

      RECOVERY OF TOTAL CARBON AND NITROGEN

      TOTAL C RECOVERY

      TOTAL N RECOVERY

      PROPERTIES OF BIOCHAR

      TABLE: GENERAL PROPERTIES OF BIOCHAR PRODUCED AT THE END STAGE OF BIOCARBONIZATION

      BIOCHAR FROM CROP RESIDUES

      A. BIOCHAR YIELD

      B. PROXIMATE ANALYSIS OF BIOCHAR

      TABLE: YIELD AND PROXIMATE ANALYSIS OF BIOCHAR FROM DIFFERENT CROP RESIDUES

      BULK DENSITY AND TOTAL POROSITY

      GLOBAL MARKET OVERVIEW OF BIOCHAR

      KEY BIOCHAR COMPANIES:

      BIOCHAR MARKET ANALYSIS

      TECHNOLOGY INSIGHTS

      APPLICATION INSIGHTS

      REGIONAL INSIGHTS

      KEY COMPANIES & MARKET SHARE INSIGHTS

      KEY BIOCHAR COMPANIES:

      PRINCIPLES OF PLANT LAYOUT

      STORAGE LAYOUT:

      EQUIPMENT LAYOUT:

      SAFETY:

      PLANT EXPANSION:

      FLOOR SPACE:

      UTILITIES SERVICING:

      BUILDING:

      MATERIAL-HANDLING EQUIPMENT:

      RAILROADS AND ROADS:

      MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:

      PLANT LOCATION FACTORS

      PRIMARY FACTORS

      1. RAW-MATERIAL SUPPLY:

      2. MARKETS:

      3. POWER AND FUEL SUPPLY:

      4. WATER SUPPLY:

      5. CLIMATE:

      SPECIFIC FACTORS

      6. TRANSPORTATION:

      A. AVAILABILITY OF VARIOUS SERVICES AND PROJECTED RATES

      7. WASTE DISPOSAL:

      8. LABOR:

      9. REGULATORY LAWS:

      10. TAXES:

      11. SITE CHARACTERISTICS:

      12. COMMUNITY FACTORS:

      13. VULNERABILITY TO WARTIME ATTACK:

      14. FLOOD AND FIRE CONTROL:

      EXPLANATION OF TERMS USED IN THE PROJECT REPORT

      1. DEPRECIATION:

      2. FIXED ASSETS:

      3. WORKING CAPITAL:

      4. BREAK-EVEN POINT:

      5. OTHER FIXED EXPENSES:

      6. MARGIN MONEY:

      7. TOTAL LOAD:

      8. LAND AREA/MAN POWER RATIO:

      PROJECT IMPLEMENTATION SCHEDULES

      INTRODUCTION

      PROJECT HANDLING

      PROJECT SCHEDULING

      PROJECT CONSTRUCTION SCHEDULE

      TIME SCHEDULE

      ADDRESSES OF PLANT AND MACHINERY SUPPLIERS

      ADDRESSES OF PLANT AND MACHINERY SUPPLIERS (GLOBAL)

      SUPPLIERS OF RAW MATERIALS


      APPENDIX – A:

      01. PLANT ECONOMICS

      02. LAND & BUILDING

      03. PLANT AND MACHINERY

      04. OTHER FIXED ASSESTS

      05. FIXED CAPITAL

      06. RAW MATERIAL

      07. SALARY AND WAGES

      08. UTILITIES AND OVERHEADS

      09. TOTAL WORKING CAPITAL

      10. TOTAL CAPITAL INVESTMENT

      11. COST OF PRODUCTION

      12. TURN OVER/ANNUM

      13. BREAK EVEN POINT

      14. RESOURCES FOR FINANCE

      15. INSTALMENT PAYABLE IN 5 YEARS

      16. DEPRECIATION CHART FOR 5 YEARS

      17. PROFIT ANALYSIS FOR 5 YEARS

      18. PROJECTED BALANCE SHEET FOR (5 YEARS)

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