Process & Operations

Process

Process: ROI has designed the ENVIROSAVER™ and CARBONATOR™ carbonizing system to strike a balance between high-volume conversion of wood and vegetative debris, reduced greenhouse gas emissions and the ability to produce a high-quality end-product, biochar.

Both high or low moisture debris can be fed, and no grinding or chipping is required or suggested. However, in cases where the material is already processed, the ROI ENVIROSAVER™ 400 model can combust ground material, as it has a feed hopper which will meter in the product below the top above chamber air curtain and a live floor in the pyrolysis chamber to advance the material during the carbonizing process.

The system’s primary carbonizing chamber is designed to sustain consistent temperatures exceeding 2,500°F (1,370°C) throughout operation. The systems rugged thermal-ceramic walls, designed specifically for this environment, sequester heat energy through the carbonizing process. This sequestering of energy is then released and re-distributed throughout the entire carbonizing chamber, equalizing temperatures, rapidly evaporating the water and other small molecules of the debris being introduced.

A high velocity curtain of air across the entire top of the primary carbonizing chamber seals the chamber from the atmosphere. The release of smoke particulates made of tiny combustible solids that would normally be present ignite beneath the above chamber curtain instead of being emitted to the atmosphere. Combustion efficiency is additionally enhanced by under-chamber air, providing sufficient oxygen throughout the entire primary combustion chamber.

As new debris are continually added in to the primary carbonizing chamber, previous loads begin to carbonize or char as debris temperatures increase by way of pyrolysis. Through several patented techniques the char is passed down through the grate to the char-pan. Further combustion is prevented through cooling, oxygen starvation and quenching processes to produce the highest value end product. Discharge augers continually discharge the near ambient biochar at easily adjustable rates.

By sequestering the carbon in the wood through pyrolysis, the release of Carbon Dioxide (CO2) into the atmosphere is drastically reduced over other processes that require complete combustion and conversion throughput is increased. Additional benefits of the ROI system: ROI’s Carbonizers will operate without having to be shut down, again, significantly increasing throughput over inferior and outdated designed incineration devices called air curtain burners or air curtain destructors that lack ROI’s carbon negative process, control features, mobility while operating, recycling capabilities, and overall performance.

ROI’s design allows for operator flexibility in manufacturing a desired end product by simply swapping out the quick interchangeable grate(s) in the bottom of the primary carbonizing chamber.

 

Operations

Operations: Once the clean wood and vegetative debris are loaded inside the primary carbonizing chamber or Fine Debris Hopper, the ENVIROSAVER™ or CARBONATOR™ is ready to be ignited for continual carbonizing.

Taking approximately 7-10 minutes for the debris in the carbonizing chamber to become completely engulfed, the above chamber and under-air is turned on and increased in increments to full velocity, utilizing the operator interface control panel.

The desired rate of loading debris for maximum performance is to load the carbonizing chamber continually for the remainder of operations. Keeping all debris beneath the over chamber air is required for the debris to carbonize most efficiently. Depending on the model ENVIROSAVER™ or CARBONATOR™, along with options chosen, end-product handling may differ based on the customer’s desires.

Shutting down the ENVIROSAVER™ or CARBONATOR™ is based on overall material mass. The shut-down process requires the operator to halt loading approximately 30-45 minutes before departing the site. Debris in the primary carbonizing chamber fall beneath the grates into the char-pan. Once all char has been extracted and quenched, surrounding areas must be checked to ensure site and equipment safety.