CHARCOAL KILN

EKKO and EKKO+

DESCRIPTION OF THE KILN ELEMENTS

2021

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Contents

Introduction ........................................................................................................... 3

1. Brief description of the EKKO-2 ........................................................................ 4

2. Сombustion chamber .......................................................................................... 6

3. Afterburner ......................................................................................................... 7

4. Processing chamber ............................................................................................ 8

5. Reinforced rail and chamber rails for "EKKO +" ............................................... 8

6. Side and back walls of the chamber .................................................................... 9

7. Thermal channels of the chamber ....................................................................... 9

8. Kiln insulation .................................................................................................... 9

9. Control chamber ................................................................................................. 10

10. Chimney ........................................................................................................... 10

11. Control panel and control and measuring devices for “EKKO+” ...................... 10

12. Belimo actuators for chamber dampers and afterburner damper for "EKKO +" 11

13. Trolley .............................................................................................................. 12

14. Mobile platform ............................................................................................... 12

15. Stationary trestle ............................................................................................... 13

16. Portable trestle .................................................................................................. 13

17. Electric or mechanical winch ............................................................................ 13

18. Trolley tipper.................................................................................................... 13

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Introduction

This document describes equipment for the production of high-quality charcoal and thermal energy

from materials of plant origin. By reading it, you will become acquainted with the improvements we have

made in the design of the EKKO series charcoal kiln, and how they affect its reliability and efficiency. This

description can be useful both beginners and experienced charcoal burners, as well as for potential investors

in the bioenergy industry.

The main design & construction principles of GreenPower™ implemented in the equipment:

1. The carbonization furnace chamber is manufactured using modern insulating materials that can

withstand ultra-high temperatures (up to 1300 ° C), which eliminates the need for "ballast" refractory

bricks, concrete and sheet metal. This solution speeds up the process and increases plant efficiency.

2. The automated control system developed by us allows automation of the technological process, so

minimizing the influence of the human factor on the productivity of the charcoal kiln and the quality

of the finished charcoal. The introduction of the ability to save all data about production parameters

at all stages of charcoal production in Cloud storage via the Internet allows you to provide remote

ONLINE control of the work of maintenance personnel, and the entire technological process as a

whole.

3. The unique design, produced with experience acquired over 20 years, guarantees the reliability and

maintainability of the charcoal furnace and its elements. The charcoal kiln will reliably serve for

more than 5 years, and if necessary any part and element can be easily and quickly repaired or

replaced.

4. Logistics and mechanization. Competent and well-thought-out logistics of the charcoal production

complex makes it possible to eliminate costs that may exceed the cost of the equipment itself: the

purchase of expensive forklifts and the installation of hoists, crane beams, and building of hard

surfaces for production which is necessary when using forklift. This compares favourably with most

other manufacturers, who usually do not indicate these costs at the stage of purchasing charcoal kilns.

Below you can find the description of the charcoal kiln elements which have been improved.

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1. Brief description of the EKKO-2

The EKKO-2 charcoal kiln consists of: 2 drying / pyrolysis chambers (5A/5B) connected through the

control chamber (6) with the afterburner (2) with chimney (4) and the furnace (1); automatic operation is

provided by the control panel (13). The delivery set may also include logistics elements for the charcoal

production site: mobile platforms and an electric winch for moving the trolleys, stationary trestles for loading

the raw materials into the trolleys and cooling and unloading of the obtained charcoal. The chambers can be

operated in two modes –“DRYING” and “PYROLYSIS”. Full combustion of pyrolysis products in the

furnace of the kiln and then residual thermal oxidation in the afterburner of its ensure the environmental

safety of the operational process. All the control units are mechanized. A permanent record of the main

operating parameters is maintained, which makes it possible to analyze the operation of the kiln.

Main elements of the kiln

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Control panel

Logistics elements

1. Сombustion chamber

2. Afterburner

3. Connecting flue with gate

4. Flue

5. Drying / pyrolysis chambers A & B

6. Operating chamber

7. Dampers of chambers A and B

8. Gas collectors of chambers A / B

9. Gate valves of pyrolysis gas for chambers A

/ B (butterfly valves)

10. Gate valves of steam for chambers A / B

11. The heat channels for chambers A / B

12. Trolley rails

13. Trolley in chamber

14. Control panel

15. Trolley

16. Mobile platform

17. Stationary overpass.

18. The cross over platform

19. Rails for the mobile platform

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2. Сombustion chamber

The basis of the modern furnace design was decided in early 2017. In 2017-2019 the furnace was being

tested. As a result any identified design flaws have been eliminated. Only then was the furnace approved for

mass production.

Main advantages of the “EKKO+” furnace design :

• Extra safety margin. We replaced the main insulation material - ceramic fiber, with a similar one,

but with a higher temperature resistance up to 1340°C. In the “Standard model” it is 1230°C.

Standard advantages of the furnace of the kiln:

• Low thermal inertia provides a “quick start” – it takes only 30-40 minutes for the furnace to get

ready for the operating mode, which significantly reduces fuel consumption and the time required

to start the process. For comparison, previously it took about 24 hours to “enter operating mode”.

This factor reduces the time for commissioning works: our commissioning staff can devote more

time to staff training and organizing work on the production site. “Quick stop” makes it possible

to carry out service and other necessary works within 3-4 hours of stopping the kiln, (in the previous

model it took 48 hours).

• Low heat losses. High efficiency ensures that all the available heat is used for the process execution,

i.e. there is substantial fuel saving for the process. For example, earlier, when using raw materials

for pyrolysis with a humidity of 60%, about 500 kg of wood was required before the start of gas

emission; in a new design - less than 100 kg.

• Low weight. The weight of the furnace is less than 1,5 tons. For comparison, the brick furnace

weight was more than 7 tons.

• Suitability for long-term transportation, loading-unloading operations. Low weight and no brick

lining ensure no damage to the furnace lining during transport.

• Maintainability. The furnace is made of special panels that are joined together, which makes it easy

to replace a failed unit. The delivery set includes materials using which it is possible to quickly

repair the lining of the furnace.

“Fire-grate of EKKO+”

The “EKKO+” carbonization furnace model includes an additional refractory brick (+1500 kg) at the

rear of the combustion chamber, this option has two advantages at once:

Protection of ceramic fiber from mechanical impact: ash, excessive shrinkage of ceramic fiber, due to

exposure to high temperatures> 1340 ° C, can occur in case of gross violation of the operating

conditions of the furnace by personnel;

Refractory brick is a heat accumulator that compensates for the excess and lack of heat energy during

the carbonization process

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Scheme of additional refractory bricks for the combustion chamber

3. Afterburner

The afterburner provides the combustion of unburned pyrolysis products in the сombustion chamber

of the “EKKO” charcoal kiln. In fact, it performs the function of a second сombustion chamber, which ensures

complete combustion of pyrolysis products and the environmental friendliness.

For EKKO carbonization furnace GreenPower™ provide 2 different types of afterburner: STANDART

and EXTRA types.

The “Extra” type afterburner is larger and is used for very dry and hard raw materials, it’s very

important for pollution control and long service life of chimney.

EXTRA afterburner

Thermal channels

From extra ceramic

wool 1340°C

additional

refractory brick

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4. Processing chamber

There are two chambers with loading hatches in the kiln. The trolleys with raw materials are loaded

into the chamber and there all the main processes take place – drying/pyrolysis/calcination.

The main elements of heat channels (heat supply and waste heat removal) are constructed from heat-

resistant steel, with a maximum permissible operating temperature > 850 ̊С. The combustion temperature of

pyrolysis gas can exceed 1300 ̊С, therefore, if operating conditions are violated and the kiln is allowed to

operate at temperatures above critical, the metal overheats and loses its physical properties (burns out).

5. Reinforced rail and chamber rails for "EKKO +"

The under-rail beams of “EKKO” furnaces are located in the lower part of the process chambers. A

trolley with raw materials moves along them for loading, and then moved into the chamber during the

carbonization process. This unit of the furnace is one of the very important elements of the “EKKO” furnaces,

since the docking of the trolley with the gas collector of the chamber, which must be as tight as possible,

depends on its geometry.

Under the influence of high temperatures, which may arise due to the leakage of the trolley in the

"pyrolysis" mode, failure of the elements of the ACS system or due to negligence of workers, deformations of

the rails and under-rail beams may occur. This may allow partial undocking of the trolley. In this case there

may be depressurization of the trolley and the occurrence of combustion of pyrolysis gas directly in the

chamber, which in turn leads to more serious damage. Therefore, our design involves reinforcement.

Reinforced under-rail beams consist of an I-beam (18 cm), and rails from a channel (6.5 cm). This design

ensures reliable operation, even if personnel violate the basic requirements for operating the oven.

Reinforced under-rail for "EKKO +"

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6. Side and back walls of the chamber

The back wall of the process chamber in the EKKO + furnace is also covered with refractory material,

which prevents damage from contact with high temperatures and an environment aggressive to metal.

Chamber back wall design on the left "EKKO +" and on the right "EKKO"

7. Thermal channels of the chamber

Designed to supply heat to the pyrolysis drying chamber from the combustion device, and remove

waste heat to the afterburner and chimney.

Damage to the thermal channels of the chamber can occur due to improper operation of the furnace. It

is very important to follow the rules of the operating instructions and maintain the furnace correctly.

If, during inspection or operation, damage to the heat channel in the chamber in its front section (at the point

of joining with the channel from the firebox), burnout / hole / crack is found, then it is necessary to stop the

furnace, take a photo and send it for analysis to GreenPower for recommendations for further action. In the

event of such damage, there is a loss of heat from the supply heat channel directly to the exit from the chamber

with a rotary damper (waste heat), which can be seen by the presence of a change in the color of the metal of

the rear wall of the chamber. That is, the heating agent bypasses the body of the chamber and, passing along

the rear wall, leaves the chamber. This causes incorrect readings of the T4 / T5 thermocouple (in fact, at the

entrance to the chamber, the temperatures significantly exceed the permissible 800 ℃) and cause metal

burning and failure of the chamber dampers.

8. Kiln insulation

The afterburner, the walls of the chambers and the furnace are made of multi-layer high-temperature

resistant ceramic wool materials that have insulating properties and minimal heat inertia. Reducing heat loss

from the furnace allows us to:

• Reduce the operational cycle duration

• Reduce consumption of supplementary fuel

• Increase service life of the kiln

• Improve charcoal quality

• Increase the kiln productivity

Shows

corrosion of

metal due to

temperature

Heat-resistant

metal coated with

refractory material

Thermal channels

of the chamber

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9. Control chamber

This is a specially designated place in the kiln design between the drying/pyrolysis chambers and the

furnace, where the main technological components of the kiln are installed:

Furnace-chamber connections are equipped with valves and determine the chamber mode –

"DRYING" or "PYROLYSIS".

The furnace valves have two locations: one provides the supply of the heat carrier to the chamber, to

ensure the “PYROLYSIS” mode, the other - to discharge the worked-out heat carrier from the chamber to the

chimney for the “DRYING” mode. They are driven by electric actuators automatically, or by the operator.

Gas collector. This device ensures the discharge of products released during the processes from the

chambers. The gas collector is connected to the steam and gas pipes with valves.

Pyrolysis gas pipes are provided for removal of pyrolysis products from the chamber into the furnace.

They are insulated and go through the hot zone, which eliminates the formation of condensate.

10. Chimney

It is one of the most important devices of the kiln as it has a high influence on the progress of the

process. The main difference from other models of charcoal kilns is “one chimney”, which ensures equally

high and stable draft regardless of the mode in which the kiln operates. The design of the chimney provides

for forced cooling of the pipe, which prevents the metal from failing due to exposure to high temperatures.

11. Control panel and control and measuring devices for “EKKO+”

The kiln is equipped with a reliable system of control and measuring devices, the use of which

eliminates the effects of moisture. The maximum mechanization of the kiln maintenance and automation of

the process control are provided, eliminating the human factor and allowing maximum management of the

maintenance personnel.

1. The Touch Screen. Now the kiln is controlled using the modern screen, which provides the User with

ample options.

2. Mechanical buttons on the control panel. There are main over-ride buttons for manual control of the

kiln and its stop.

3. Internal storage and recording to Flash Card. The new control panel provides for recording to the

internal storage, or to the Flash Card, which can subsequently be removed and used on a PC.

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4. Remote and local control. Using this, the control of the kiln can be either directly at the kiln or remotely

using a stationary PC. Thus it is also possible to control a complex of the kilns.

5. Automatic control or manual control. Production process control can occur both in “Manual” and in

“Auto” modes, this function is very important for reaching the maximum production indicators.

Control panel with the Touch Screen ‘10

12. Belimo actuators for chamber dampers and afterburner damper for "EKKO +"

Swiss-made actuators for chamber dampers are reliable, time-proven and are available for sale and

service in almost any country in the world. These dampers provide emergency closing in the event of

an emergency power outage, a «fail-safe» system. In addition, these types of dampers have built-in

sensors for the position of the damper, this provides a more accurate adjustment of the dampers of the

thermal channels of the chamber and the damper of the afterburner. This enhances process efficiency.

Damper Actuator LF24-SR US for chamber dampers

Touch Screen ‘10

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Configurable Damper Actuator AHX24-MFT-300 for afterburner damper

13. Trolley

Processes of loading, drying and pyrolysis of raw material and afterwards cooling, stabilization and

unloading of the charcoal take place in the trolleys. They are equipped with baskets for raw materials

(optionally), loading hatches and channels for the output of the drying / pyrolysis products.

There are two types of the trolleys:

• Top loading, used for mechanized loading of raw materials and unloading of the charcoal

• Front loading, used for manual loading of raw materials and unloading of the charcoal

14. Mobile platform

This is designed for moving the trolleys around the working site and is used for loading/unloading of

the trolleys into/out of the chambers, and for the installation of the trolleys onto the stationary trestles.

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15. Stationary trestle

This provides a place on the working site for the trolleys, during loading of raw materials and

unloading, cooling and stabilization of the charcoal.

16. Portable trestle

This is a short removable trestle that is necessary for moving the trolleys between the chambers and

logistics elements, and for transferring the trolleys into the chamber.

17. Electric or mechanical winch

Provided for the mechanized moving of the trolleys with raw materials or charcoal around all the

logistics elements and for loading/unloading of the trolleys into/out of the chambers.

18. Trolley tipper

This is a unit for the mechanized unloading of the charcoal from the trolleys. It is used only with the

trolleys with top hatch.