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ESAF TradeCo

Innovative Solutions

Biomass Carbonisation Technology

Carbonisation to Diesel

Advanced wood pyrolysis with Fischer-Tropsch synthesis converting biomass waste into premium renewable diesel, activated carbon, and standalone energy systems.

45-60% Diesel Yield
95% Energy Autonomous
$800-2000/ton Activated Carbon
Wood Carbonisation to Diesel Process Flow

Complete biomass carbonisation process from wood chips to renewable diesel and activated carbon

The Carbonisation Process

Six integrated stages transform wood biomass into high-value diesel fuel, biochar, and energy

01

Biomass Preparation

Wood feedstock is dried, chipped, and sized for optimal pyrolysis

  • Moisture reduction to <15%
  • Chip size: 10-50mm
  • Feedstock density optimization
  • Contaminant removal
02

Pyrolysis Reactor

PATENTED INNOVATION

Thermal decomposition in oxygen-starved environment at 400-600°C

  • Temperature: 400-600°C
  • Residence time: 30-120 min
  • Pressure: Near atmospheric
  • Zero oxygen environment
03

Syngas Recovery

Volatile gases captured, cleaned, and separated for Fischer-Tropsch synthesis

  • CO + H₂ enrichment
  • Tar removal & cleaning
  • Gas composition optimization
  • H₂:CO ratio adjustment (2:1)
04

Fischer-Tropsch Synthesis

PATENTED INNOVATION

Catalytic conversion of syngas into liquid diesel fuel

  • Temperature: 200-350°C
  • Iron/Cobalt catalysts
  • C₁₀-C₂₀ hydrocarbon chains
  • Diesel yield: 45-60%
05

Energy Recovery

Excess syngas powers steam turbines for process energy autonomy

  • Steam turbine integration
  • 85-95% energy self-sufficiency
  • Grid export capability
  • Heat recovery optimization
06

Biochar Processing

PATENTED INNOVATION

Solid carbon residue upgraded to activated carbon or soil amendment

  • Biochar yield: 25-35%
  • Activation for high-value carbon
  • Soil carbon sequestration
  • Water filtration applications

Optimal Dual-Line Configuration

Maximum efficiency achieved through integrated production and energy lines

Line 1: Diesel Production

Maximum Fischer-Tropsch Output

  • Optimized Syngas Conversion

    100% syngas directed to Fischer-Tropsch catalysts

  • Premium Diesel Output

    45-60% conversion rate with C₁₀-C₂₀ hydrocarbons

  • Biochar Co-Product

    25-35% solid carbon for activated carbon upgrade

Line 2: Energy & Fuel

System Autonomy & Power

  • Process Heat Supply

    Syngas combustion fuels Line 1 reactor operations

  • Steam Turbine Generation

    Excess energy powers facility (85-95% self-sufficient)

  • Biochar Processing

    Dedicated activation line for premium carbon products

Integrated System Benefits

140%

Revenue vs. Single Line

95%

Energy Independent

3x

Faster ROI

Economic Advantages

Multiple revenue streams and operational cost savings deliver superior returns

Premium Diesel

$0.80-1.20/L

Production cost vs. $1.50-2.00/L market price

60-150% profit margin

Activated Carbon

$800-2000/ton

From $50-100/ton raw biochar

1500-2000% value increase

Energy Savings

$200-400k/yr

For 50 TPD facility energy costs

85-95% energy autonomous

Carbon Credits

$50-150k/yr

2.1 tons CO₂ reduction per ton wood

Additional revenue stream

Total Revenue Potential (50 TPD Facility)

Diesel Sales (45% yield)$2.5-4.0M/yr
Activated Carbon (30% biochar)$1.2-3.0M/yr
Energy Savings/Export$200-400k/yr
Carbon Credits$50-150k/yr
Total Annual Revenue$4.0-7.5M/yr
CAPEX Recovery Period2.5-4 years

Based on $12-18M total CAPEX (including dual-line setup)

Technical Specifications

Industry-leading performance metrics and operational parameters

Diesel Yield

45-60%

Per ton of dry wood

Biochar Yield

25-35%

High-carbon solid residue

Energy Self-Sufficiency

85-95%

Via syngas combustion

Process Temperature

400-600°C

Pyrolysis reactor

Capacity Range

10-100 TPD

Tons per day wood input

CO₂ Reduction

2.1 tons

Per ton of wood processed

ROI Period

2.5-4 years

Full system payback

Activated Carbon Value

$800-2000/ton

Premium biochar processing

Product Portfolio

Four high-value outputs from a single integrated process

Renewable Diesel

45-60% by weight

Drop-in fuel compatible with existing diesel engines and infrastructure

Applications:

Transportation fuel
Industrial applications
Power generation
Marine diesel

Biochar

25-35% by weight

High-carbon solid with soil amendment and carbon sequestration properties

Applications:

Agricultural amendment
Carbon credit generation
Water filtration
Activated carbon feedstock

Activated Carbon

From biochar upgrade

Premium adsorbent material with 500-1500 m²/g surface area

Applications:

Water purification
Air filtration
Industrial processes
Pharmaceutical grade

Process Energy

85-95% self-sufficient

Excess syngas combustion for steam turbine electricity generation

Applications:

On-site power
Grid export
Thermal energy
Process heat

Environmental Impact

Carbon-negative technology addressing multiple sustainability challenges

Waste Biomass Utilization

2.5 billion tons

Global wood waste annually converted to value

CO₂ Reduction

2.1 tons

Per ton of wood processed vs. fossil diesel

Carbon Sequestration

500+ years

Biochar locks carbon in soil permanently

Circular Economy Integration

Zero Waste Process: 100% of wood biomass converted to valuable products

Energy Closed-Loop: Self-sustaining operations with minimal grid dependence

Carbon Negative: More CO₂ removed than emitted through biochar sequestration

Multi-Sector Impact: Benefits transportation, agriculture, and industrial sectors

Ready to Transform Biomass into Value?

Explore how our carbonisation technology can deliver sustainable diesel, premium activated carbon, and energy independence for your operations.