Green Energy
Maximum Green Energy Capture
CarboFlow generates green energy with minimal losses which can be utilized in a range of formats.
Key Features
Our system combusts syngas inside the pyrolysis chamber to generate green energy with minimal losses, while controlled airflow ensures oxygen-free pyrolysis. Wrapped in water jackets, the chamber’s excess heat is also captured as hot water supplementing the flue gas to ensure maximum efficiency.
100% syngas utilisation
Pyrolysis and syngas combustion in same chamber to prevent losses.
Water jackets for heat recovery
Recovering heat lost from the machine in the form of hot water.
Flexible energy forms
The green energy can be utilized in any form depending on needs.
From by-product to on-site power
CarboFlow captures syngas, a valuable source of green energy released during pyrolysis, and immediately combusts it in the same chamber, avoiding the energy losses associated with venting or distant combustion. This energy not only self-sustains pyrolysis, but can be further harnessed in various formats to fulfil your on-site energy requirements.
CarboFlow is also equipped with integrated water jackets that wrap key hot zones and collect waste heat, producing hot water that can be piped to heating systems, pre-dryers, or onsite processes.
The result is an efficient energy capture system that can deliver green energy in the form of hot water, process heat or electricity on demand - reducing purchased fuel, cutting emissions, and lowering operating costs while simplifying site energy logistics.
Maximizing green energy generation viable through innovation
Syngas Combustion
The syngas produced from the feedstock undergoes controlled combustion in the upper chamber, generating extremely hot flue gases. For high-heating applications, this heat can be used directly coming out of CarboFlow's top hat, and diluted with air if temperature reduction is needed.
For normal heating applications, these hot flue gases can be passed through a heat exchanger, where the heat will be captured in the form of hot water. The hot water can drive an ORC to generate electricity.
The spent flue gases are finally passed through a cyclone or wet scrubber for cleaning before being released into the atmosphere.
Water Jacket Circulation
In spite of the strong insulation, some amount of heat from the pyrolysis and syngas combustion is prone to escape from the machine's body. Additionally, the constant high temperatures can damage the life of the machine in the long run. CarboFlow houses an innovative water jacket circuit that tackles both of these problems.
A circuit of water running through the top chamber of the machine absorbs the escaping heat and captures it in a cooling bank. This has a dual advantage - not only is the waste energy being captured, but the machine is prevented from overheating, thus expanding its lifespan.
Pyrolysis energy flows and applications
Plant Use
Self Sustaining
A portion of the syngas released from pyrolysis is combusted in the reactor to keep the process running at required temperatures.
This is a necessary energy requirement for running the pyrolysis plant continuously.
Drying
If the feedstock requires drying, it can be powered by the output of the heat exchanger, ensuring efficient use of energy and optimum performance of the pyrolysis process.
Parasitic Load
The CarboFlow system can be made
self-sufficient in terms of electricity requirements if an ORC is installed, or can be externally obtained. Typical parasitic load of a dual C-1000 plant is 40 kW.
Pyrolysis
The process of pyrolysis generates syngas, which when combusted releases a tremendous amount of energy.
Heat Exchanger
The combusted gases are passed through a heat exchanger, most often using water to transfer heat to where it is required.
ORC/Steam Turbine
The hot water can optionally be passed through an Organic Rankine Cycle (ORC) or a Steam Turbine Machine to generate electricity. Some residual heat is also available from this process.
External Use
High Heating Requirements
For industries with processes requiring high temperatures, such as furnaces or kilns, flue gases can be diverted delivering temperatures of up to 600C.
Regular Heating Requirements
Hot water of air can be delivered at temperatures of up to 95C, suitable for steam production, ambient heating or log drying.
Electricity generation
With sufficient heat available, the ORC can generate electricity for local use, or sale to the grid generating income for the plant.
Clean, efficient power that pays back
CarboFlow’s green energy system ensures that every unit of energy from pyrolysis is put to work. By using syngas in-chamber and recovering waste heat, you lower reliance on external fuel, reduce running costs, and secure a dependable source of site energy.
- Lower energy costs — Efficient energy capture cuts external fuel and electricity spend.
- Improved resilience — On-site power and heat keep operations running smoothly.
- Reduced OPEX & maintenance — Integrated combustion eliminates flaring and simplifies energy logistics.
- Stronger sustainability profile — Fewer emissions, greener operations, and potential incentives/green tariffs.
Clean, efficient power that pays back
CarboFlow’s green energy system ensures that every unit of energy from pyrolysis is put to work. By using syngas in-chamber and recovering waste heat, you lower reliance on external fuel, reduce running costs, and secure a dependable source of site energy.
- Lower energy costs — Efficient energy capture cuts external fuel and electricity spend.
- Improved resilience — On-site power and heat keep operations running smoothly.
- Reduced OPEX & maintenance — Integrated combustion eliminates flaring and simplifies energy logistics.
- Stronger sustainability profile — Fewer emissions, greener operations, and potential incentives/green tariffs.
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Check out CarboFlow's other features
Feedstock Drive
CarboFlow’s 20 auger drive system delivers uniform pyrolysis across diverse feedstocks, boosting efficiency, quality, and consistency.
Automation
Experience smarter pyrolysis with CarboFlow’s advanced automation. Our camera and sensor technology provide precise control, reduced waste, and optimised performance.
Support
We'll provide you with all the training and documentation you need to successfully operate your CarboFlow, and provide ongoing operator support.
Want to know more about our technology?
Our experts can discuss how it works and how it may match your needs.