Detailed Project Report (DPR) on Biochar Production from Wood and Agro Waste (Capacity: 48 Tons/Day)

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.

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)