Detailed Project Report on BIOCHAR PRODUCTION (CAPACITY: 48 TON/DAY)

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.

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ENGINEERS INDIA RESEARCH INSTITUTE
4/54, Roop Nagar, Delhi-110007 (India)
Phone: [phone]
E-mail: [email protected]
Website: www.eiriindia.org




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.

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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

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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

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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

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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

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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

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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

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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

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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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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%