Biochar & Sustainable Processing Lines

Kerone's systems can process a wide range of feedstocks including agricultural residues (rice husk, straw, bagasse), wood chips, sawdust, sewage sludge, food waste, and municipal solid waste.

Biochar production typically occurs at pyrolysis temperatures between 350°C and 700°C, with specific temperatures selected based on feedstock type and desired biochar properties.

Yes, Kerone's systems include syngas recirculation for process heat generation, and can also be configured with gas engines or turbines for co-generation of electricity.

Kerone designs its biochar production systems to meet the quality criteria of the European Biochar Certificate (EBC) and International Biochar Initiative (IBI) standards.

Biochar is a stable form of carbon that resists decomposition for hundreds to thousands of years when applied to soil, effectively locking atmospheric CO2 out of the carbon cycle.

Yes, verified biochar carbon removal credits can be registered and sold through established carbon markets. Kerone provides documentation support for carbon credit applications.

Kerone offers systems ranging from small farm-scale units processing 100 kg/day to large commercial facilities processing several tonnes per hour.

Kerone integrates syngas afterburners, thermal oxidizers, cyclones, and wet scrubbers to ensure emissions from the pyrolysis process meet applicable environmental regulations.

Industrial biochar production involves the thermochemical decomposition of organic biomass such as wood chips, agricultural residues, or sewage sludge at temperatures between 350°C and 700°C in an oxygen-limited environment. Kerone's biochar production systems use continuous rotary kilns or fixed-bed reactors with precise temperature and residence time control to maximize biochar yield and quality. The syngas by-product can be recycled as fuel, making the process energy-neutral or even energy-positive. Biochar quality is characterized by surface area, porosity, pH, carbon content, and ash composition.

Efficient waste-to-biochar conversion requires feedstock pre-treatment (sizing, drying to <15% moisture), optimal reactor temperature selection (500–600°C for high-quality biochar), and effective syngas management. Kerone's waste-to-biochar systems are pre-engineered to handle diverse feedstocks, with integrated drying pre-treatment, controlled-atmosphere reactors, and syngas combustion chambers for heat recovery. Feedstock moisture content is the single most critical factor; wet feedstocks dramatically reduce efficiency. Kerone's lab-scale pilot trials allow optimization before full-scale investment.

Agricultural waste including rice husks, sugarcane bagasse, wheat straw, corn cobs, and coconut shells is an abundant and cost-effective feedstock for biochar production. Kerone's agricultural waste biochar systems are sized for farm-scale to industrial-scale operations, with robust feeding systems designed for variable particle sizes. Biochar from agricultural waste typically has high silica content (especially rice husk biochar) and is widely used for soil amendment, water filtration, and as a carbon sequestration material. Kerone also provides turnkey systems with biomass pre-processing and biochar cooling and packaging.

The best waste-to-energy conversion technology depends on the waste type, moisture content, scale, and desired output (heat, electricity, fuel, or biochar). For dry organic waste and biomass, pyrolysis and gasification are highly efficient and produce valuable by-products. For mixed municipal solid waste, combustion with energy recovery (CHP) is most established. For wet organic waste, anaerobic digestion (biogas) may be preferred. Kerone specializes in pyrolysis-based waste-to-energy systems, offering complete solutions from waste pre-treatment and drying through reactor design to gas cleaning and energy utilization.

Biochar has a wide range of applications spanning agriculture and industry. In agriculture, it is used as a soil amendment to improve water retention, enhance microbial activity, increase crop yields, and sequester carbon. In industry, biochar is used as an activated carbon precursor, a filter media for water and gas treatment, a rubber and polymer additive, a construction material additive, and an electrode material for energy storage. Kerone's biochar production systems are designed to produce application-specific biochar qualities, with customized activation and sizing steps available for high-value applications.

Kerone's biochar and sustainable processing systems are designed to directly support corporate ESG (Environmental, Social, and Governance) commitments and sustainability reporting frameworks such as GRI, CDP, and Science Based Targets initiative (SBTi). On the environmental side, biochar production sequesters carbon in a stable solid form for hundreds to thousands of years, each tonne of biochar produced represents approximately 2.5–3 tonnes of CO₂ equivalent permanently removed from the carbon cycle, a verifiable, auditable carbon removal credit. Kerone's systems also divert organic waste from landfills, reduce methane emissions from decomposing biomass, and generate clean energy from syngas, all of which contribute to measurable Scope 1 and Scope 3 emission reductions. The systems are engineered to operate with near-zero stack emissions through integrated afterburners, condensate management, and particulate filtration. Kerone provides detailed mass and energy balance documentation and process data logging to support third-party verification and ESG audit requirements, making it straightforward for customers to include biochar operations in sustainability disclosures and annual reports.

Kerone's pyrolysis-based biochar production systems generate three valuable co-products alongside biochar, each of which can be monetized or utilized to improve overall system economics. Syngas (pyrolysis gas), primarily composed of CO, H₂, CH₄, and CO₂, is recovered and combusted in an integrated burner to supply the thermal energy needed by the reactor itself. In well-optimised systems this makes the process thermally self-sufficient, eliminating or significantly reducing external fuel costs. Pyrolysis oil (bio-oil), condensed from the vapor fraction, can be used as a substitute for heavy fuel oil in industrial boilers or further refined into bio-based chemicals and fuels. Process heat recovered from the system's hot exhaust gases can be directed to pre-dry incoming wet feedstock or supply heat to adjacent processes such as space heating or hot water generation. Kerone's engineering team designs the energy integration between all three co-product streams during system engineering, ensuring maximum resource utilization and the lowest possible operating cost per tonne of biochar produced.