The Carbonization Plant of the Future
20 years of experience. A world first in pyrolysis. 100% circular economy.
We don’t burn waste—we create black gold. With our industrial high-tech plant, we transform hard-to-recycle organic waste into premium biochar. The result: the foundation for the world’s most fertile soil (Terra Preta), massively reduced emissions, and active CO2 reduction.
Our Expertise
This facility is the result of over a decade of practical research and 40 years of vision. Together with our partners (the EU LIFE project and NGE), we have developed a pyrolysis technology that is unique in Europe. Not only is it extremely robust, but it also solves waste problems 100%.
Our 4-Step Process:
1. Intelligent Preparation: Whether wet biomass or compost screening residues—our system processes it all. In our intelligent walking-floor bunker, the material is completely dried to a 95% dry matter content in just 2 to 3 days.
2. High-Tech Pyrolysis (700°C): Fully automatic and brilliantly simple. The biomass travels through our custom-designed screw furnace under the exclusion of air. The clever part: The biochar never cools down inside the furnace. Pollutant gases have zero chance of attaching to the biochar and are completely and cleanly combusted at 900–1100°C.
3. Custom Refinement: Our EBC-AgroOrganic certified biochar can be milled to an extremely fine degree—from under 1 mm down to an incredible 10 micrometers. Perfect for specialized applications in agriculture, plastics, geopolymers, and more.
4. The Charging: Right after production, we spray our self-recovered nitrogen onto the biochar. This perfectly prepares it to be "charged" with microbiology later on. This process produces our highly effective soil activator.
- 3-Stage Heat Cascading: The plant produces 1 megawatt of surplus heat! We use it for the pyrolysis process, to dry sewage sludge (at 300°C), and utilize it a third time (at 70°C) via a heat exchanger for drying the fresh biomass and for building heating.
- On-site Nitrogen Production: We extract the ammonia from the exhaust air, wash it out in an acid scrubber, and thereby produce approx. 80 tons of pure nitrogen in the form of ammonium sulfate per year—our very own fertilizer for the biochar!
- Zero Waste (even with plastics): Even microplastic contamination in the screening residues is not a problem. They are completely gasified at 700°C and subsequently converted into clean energy at 900-1100°C.
The Raw Material
It all starts with organic residues that were previously often considered problematic: screening residues from composting, sawdust, paper fiber sludge, or agricultural residues like sunflower husks.
- The Innovation: Our plant is an "omnivore." Through a special multi-stage process (including magnetic separators and a water bath for stone separation), we process these materials so that they form the perfect basis for high-quality biochar.
Intelligent Drying & Preparation
Before the biomass enters the furnace, it must be dried with absolute precision.
- The Process: In our transfer bunker featuring a walking floor, the material is brought to a dry matter content of 95% within 2 to 3 days.
- The Efficiency Factor: We solely use the waste heat from our own pyrolysis process for this. A closed energy loop that wastes no external energy.
The Carbonization
The magic happens in our newly developed reactor (NGE technology): thermochemical conversion under the exclusion of air.
- The Technology: At temperatures of 700°C, the biomass is carbonized in controlled screw conveyor pathways.
- Purity Without Compromise: Since the biochar never cools down inside the furnace, pollutants from the gases cannot attach to it in the first place. The result is extremely pure, highly porous biochar in EBC Premium quality (PAH content <2.5mg/kg).
The Energy Marvel (Cascading)
While the biochar is being created, we use the released energy three times:
- Pyrolysis: The process maintains itself thermally.
- Sewage Sludge Drying: With 300°C hot exhaust gas, we dry sewage sludge as a service for a sewage sludge mono-incineration plant.
- Low-Temperature Heat: After drying, the exhaust air is condensed out, and the released energy is used to heat our buildings and dry the fresh biomass.
Nitrogen Recovery & Refinement
We wash the nitrogen (ammonia) out of the exhaust air from the sewage sludge drying process in an acid scrubber.
- Our Own Fertilizer: This is how we produce approx. 80 tons of pure nitrogen in the form of ammonium sulfate directly on-site every year.
- Activation: We spray this nitrogen solution directly onto the still-fresh biochar. This turns an "empty" biochar into a nitrogen-loaded biochar, which is essential for producing our soil activator.
High-Tech Milling
Not all biochar is created equal. Depending on the application, we mill the product in our facility:
- Coarse (up to 1 mm): Ideal for use in liquid manure and biogas plants.
- Ultrafine (up to 10 micrometers): So fine that it feels like cream. These specialty biochars go into industry—for plastics, geopolymers, or as color pigments.
Schwarzerde & Bodenaktivator
This is our masterpiece and the actual goal of 40 years of research. We don't just mix our premium biochar in; we create the so-called Biochar-Mineral Complex.
- The Action: The biochar is naturally equipped with valuable minerals and is "charged" by us directly after production with our in-house nitrogen.
- The Effect: It acts like a gigantic sponge. Nutrients and water are stored and no longer washed away. It provides the perfect habitat for soil microorganisms and permanently transforms depleted soils into the most fertile earth in the world—Terra Preta.
FeedChar & ManureChar
Together with our partner company CharLine, we produce biochar for direct application in animal husbandry. Here, too, the circle closes in a brilliant way:
- Animal Health: As Feedchar, it binds toxins in the animals' digestive tracts and promotes vitality.
- ManureChar: In the barn and in the manure pit, the biochar massively reduces odors and prevents the outgassing of harmful ammonia.
- The Climax: When farmers later spread the liquid manure on their fields, the biochar, soaked with nutrients, ends up in the soil and permanently builds up fertile soil there as well.
CO2 Sink Certificates
Our biochar does not rot. The carbon that the plants previously absorbed from the atmosphere is safely locked away in the soil for millennia through our pyrolysis process.
- The Impact: We actively remove greenhouse gases from the atmosphere, generating up to 2,000 tons of CO2 sink certificates annually. These certificates are not only an additional source of income to make our circular system economically viable, but they also offer an extremely transparent way to promote true climate neutrality.
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