Genesis Industries Technology

Pyrolysis Unit:

Features of these units:

  • Clean and simple continuous feed operation
  • Energy-negative operation
  • 2-Stage Reactor chamber to separate heavy condensable gaseous compounds from syngas
  • Waste gases are used to dry feed stock increasing overall efficiency and reducing CO2 emissions
  • Variable speed drive
  • Variable operating temperatures
  • Rugged design for durability
  • Very few wearing parts
  • Low cost replacement parts.
  • Designed to handle a variety of feedstock from cereal straw to feedlot and timber-based wastes.

Pyrolysis Unit Capacity: Model CR-2:

The feedstock capacity of this unit assuming moisture content of 20-25%, is 200kg/hr. Biochar output, 50kg/hr. Energy output is approximately 100-200 KWH in the form of syngas depending on the feedstock. This then can be converted to electrical energy via a small steam turbine or engine-generator at additional cost. NB: Energy outputs are extremely variable due to the great variation in characteristics and properties of organic material. Trial runs need to be conducted on each biomass to get an accurate energy output rating. This unit can be increased or decreased in capacity by 25% to suit the end user’s needs.

Pyrolysis Unit Capacity: Model CR-3:

This unit is still in the design phase and will not be available until mid-2012. Feedstock capacity of this unit assuming moisture content of 20-25% is 1000kg/hr. Biochar output, 250kg/hr. energy output, 400kw in the form of syngas.

Pyrolysis System:

  • Available for nominal 160kg/hr biomass input (assuming: average biomass moisture of 10-12%)
  • Primary function of this unit is to produce BIOCHAR; a soil amendment.
  • Pyrolysis gases (Syngas) maintain temperatures and high flow rates through the unit.
  • Depending on biomass moisture content/energy values, excess Syngas is produced.
  • Excess pyrolysis gases can be used to power a micro-turbine or furnace/boiler.
  • Unit designed to process a variety of feedstocks.
  • Modular design for future expandability.
  • Minimal electrical demand.
  • Two x 2.2kw Bonfiglioli Variable speed motor/gearbox drive system.
  • Thermal ceramic coatings used over mild-steel construction.
  • Multizone process
  • Proven Continuous Flow Transport Process
  • Precision temperature and pressure control
  • Nitrogen purge system
  • Low pressure system, < 1bar.
  • Heat demands balanced in steady state operations
  • Requires outside energy source for startup; natural gas or propane models available.
  • System Controls:
  • Automated temperature control.
  • Simple operation to allow operator engagement.
  • Operator safety features.
  • Automatic Shutdown, including various fail-safe methods.

Site Requirements:

  • Maximum Footprint: 40 ft x 20ft x 15 ft high
  • Electrical Service: 100 Amp max
  • Water line
  • Gas supply

Performance Data:

Each feedstock will be different. The different yields of products are due to varying chemical and structural composition between different feedstocks. To determine actual output for a particular biomass, initial performance testing of each particular feedstock is recommended to establish a range of performance and co-product yields.

Throughput is determined by feedstock density, particle size, moisture content, chemical composition, microporous structure, etc. Our data has been derived from processing various biomass feedstocks. The majority of analysis has centered on waste poultry litter, Almond shell & husk, and Grape Mark (residues remaining from wine grape crushing).