3R Zero Emission Carbon Bio-refinery Technology

The 3R Technology

Added value recycling and reuse of biomass waste streams for advanced and safe horticultural food crop nutrition and transport bio-fuel / bio-oil productions by integrated 3R pyrolysis, catalytic and biotechnological process.

In a world with finite resources there is no infinite development opportunity with sustainability, unless circular economy is not fully implemented. In this context there is no one fit for all processing technology or product solution, but still only the high end solutions are viable and sustainable. The 3R technology provides market competitive and advanced replication model with BAT/BREF (best available technology reference).

 

Traditionally, biomass waste is viewed as an unnecessary and uneconomical element. In the reality biomass waste and by-products are a misplace resource, existing at a wrong place at a wrong time. Recycling of biomass waste and animal by-products by the advanced 3R pyrolysis technology generates new resources and added value products. The objective of the 3R ZERO EMISSION PYROLYSIS PROCESS, NUTRIENT RECOVERY AND RESOURCE CONSERVATION technology is the added value upgrading and valorisation of animal by-products into safe and high value biochar, bio-oil, soil amendment and recovered phosphorus products (organic Phosphorous fertilizer) by integrated thermal and biotechnological recycling means.

The 3R zero emission carbon processing and nutrient recovery understands the language of the Mother Nature and takes lessons from Her. Whatever technical, environmental and/or climate challenge the 3R faces, it is considered that most probably one or more of the world's >30 million creatures and natural processes has not only already faced the same challenge during the past millions of years, but has also evolved effective strategies to solve it as well. The term waste is unknown in the Mother Nature as all and any materials must be processed, recycled and reused in a most efficient way, as simply no any creatures can afford to loose any available materials. Same as the 3R zero emission carbon processing means a total recycling and reuse of agricultural waste and food industrial byproduct materials, "the resources", for conversion into high added value recovered fertiliser products. In this evolutionary process, the stone age did not ended because there where no more stones, but rather because new - more efficient - options come up, that supported the rapidly developing market demands. As a result, the 3R zero emission carbon processing, phosphorus recovery and biochar products open new technical, economical, environmental and climate solution opportunities, specifically targeted for the temperate climatic zone countries applications in the EU, Australia, USA and Japan.

 

3R Phosphorus recovery process:

For larger scale please click on the pictures

 

 

3R zero emission technology application map:

For larger scale please click on the pictures

The INPUT FEED STREAMS are low value animal by-products; such as high Phosphorous content food grade (category 3) animal bone meal. The OUTPUT PRODUCTS are high quality and safe Animal Bone bioChar - ABC for wide range of agricultural (recovered organic Phosphorus fertilizer with min. 30% P2O5, biochar) and environmental (adsorbent) applications.

The specific pyrolysis process is based on a horizontally arranged, indirectly heated revolutionary designed rotary kiln, providing reductive thermal decomposition of any biomass up to 850 degree C in vacuum. The  zero emission and the highly efficient pyrolysis process add up to comprehensive recycling and the reuse of all material and gas feed streams. The output natural products are tested and validated for open ecological soil applications by the Soil and Plant Protection Authority. The 3R process provides high feed flexibility: it's efficient for carbon and resource conversion both for animal by-products and plant based biomass, suitable for temperate climatic zone  applications. Although its highly advanced and comprehensive performance, the 3R technology does not contain any exotic technical solutions and materials.  

The 3R biomass recycling offers economic viability, generates new resources, produces high market demanded natural products and low cost green energy. The 3R organic waste recycling also has a great potential for resource conservation, nutrient recovery and GHG emission reduction as well. The 3R pyrolysis process is a patented original solution and industrial design, its development is priority  supported by the EU since 2002.

The 3R competitive eco-innovative process and operational prototype at TRL8 level has been successfully demonstrated (3R Pyrolysis Center) between 2004 and 2015 and scale up to next level is prepared.

The 2016/2017 targeted economical throughput production capacity of the replication model is 6500 t/y (that equivalent with 4000 t/y output), which is further expandable to 20,800 t/y nominal capacity (that equivalent with 12,500 t/y output).

 

The 3R Pyrolysis Process Competitive Advantages and Characteristics

The 3R technology is an original solution. 

Many known pyrolysis options are different alternative modifications for incinerator or gasification options which modifications are generally experienced not to be functional in industrial scale. Since 1980’s several multinational companies set up traditional and modified thermal treatment programs with different gasification (partial oxidation) and reductive processing design, but many such modification are failed.  The 3R recognition has been the core concept, that advanced and efficient pyrolysis designs, incl all details, must be fully engineered for the reductive thermal processing conditions only and design elements/experiences cannot truly be overtaken from other types of (incineration and gasification) thermal processing units. The 3R Pyrolysis technology provides the following basic aspects:

  1. The 3R is not a modified traditional thermal treatment design. The 3R is a horizontally arranged indirectly heated rotary kiln with material core temperatures up to <850°C under negative pressure conditions. This original solution is purposely developed for highly efficient indirect heat transfer and maintenance of true reductive thermal processing conditions in vacuum.
  2. The true reductive thermal processing environment provides safer, better, faster, less costly and more environmental friendly than any known solutions and resulting high economical added value output products.
  3. The 3R is a new generation, proven, demonstrated at TRL8 level, comprehensive and original solution.
  4. The 3R design does not contain exotic technical solutions and materials.
  5. Low operational and maintenance costs.
  6. Advanced sealing technology ensures the totally closed and totally safe operation of the rotary kiln.
  7. The 3R auxiliary installations are also objective driven developed and designed for the pyrolysis - reductive thermal processing - conditions only.
  8. The 3R is a zero emission solution for primary designed applications, where all and any material streams are recycled and reused (e.g. converted into safe and valuable products), same as done by the nature in millions of years.
  9. High input feed flexibility (bone meal, meat & bone meal, processed animal protein, dry animal manure, agricultural plant waste) provides a broad range of  sustainable and high value output products (bone char, biochar, recovered Phosphorus and Nitrogen fertilizers, transport bio-oil green energy) with high market demanded performance.
  10. Continuous and automated throughput.
  11. The 3R is a high efficient energy conversion process.
  12. The 3R refine the crude pyrolysis oils with highly complex chemical structure into refined biofuel.
  13. Modular system.
  14. Meets all strict and comprehensive EU/AU/US environmental norms and standards beyond the year 2015.The 3R zero emission pyrolysis processing is an official and high priority EU Commission programme since 2002 with involvement of Science and Technology from 10 EU countries. The 3R competitive eco-innovative process and operational prototype at TRL8 level has been successfully demonstrated between 2004 and 2015 and scale up to next TRL9 level is prepared. The 2016/2017 targeted economical throughput production capacity of the replication model is 6500 t/y (that equivalent with 4000 t/y output), which is further expandable to 20,800 t/y nominal capacity (that equivalent with 12,500 t/y output). The 3R pyrolysis technology is fully permitted by EU MS Authorities under the strict EU regulations. Industrial scale pyrolysis plant installation and operation permit number: FES/01/0851-33/2015 (Issuing Authority Industrial Safety Inspection and ten other advising Authorities).
  15. Economy: rapid ROI (2-4 years) with high return on investment.

Summary of the main competitive advantages of our 3R technology over other pyrolysis options are the followings: 

  1. TECHNOLOGY: revolutionary engineering design original solution for high efficient indirect heat transfer.
  2. ENVIRONMENT: Zero emission processing performance.
  3. CIRCULAR ECONOMY: Phosphorus recovery from animal by-products.
  4. ENERGY: specific design for energy efficient reductive thermal processing.
  5. INVESTMENT: affordable in CAPEX price and OPEX cost.
  6. BUSINESS: economical & profitable conversion of low value organic waste streams by a robust 3R technology into safe, high added value and market demanded natural bio-products.

3R Mission and Strategy

One of the main challenges of the 21'st century is the increased need for sustainability and competitiveness of  agricultural and food production, while safeguarding consumer health, decreasing environmental impacts in agriculture, horticulture and forestry and taking account of climate change. For land based biological resources, special emphasis to be placed on low-input and organic food crop production systems and improved management of resources, with prime concern of optimal recycling and reuse of agro/ food industry waste streams.

The 3R mission is to provide an advanced, economical and environmentally safe ZERO EMISSION PYROLYSIS PROCESS, PHOSPHORUS RECOVERY and RESOURCE CONSERVATION technology solution, - with  a unique new perspectives for valorised reuse and added value recycling of biomass waste streams into such products like bone char, biochar, recovered Phosphorous and Nitrogen natural fertilizers, highly demanded for green energy, agricultural and carbon negative environmental applications.

The new generation 3R pyrolysis technology solution is a high added value valorization of the biomass waste with wide feed flexibility providing a board range of end-products with the co-production of refined carbons (biochar) and recovered organic Phosphorus fertiliser (Animal Bone bioChar), bio-fuels and recycled liquid Nitrogen fertilizers, all with enhanced overall economy and competitiveness.

The 3R technology is dedicated to provide a cost efficient carbon refining and nutrient recovery solution which is environmentally sustainable for a long term producing added value products  for agriculture,  green energy and environmental product industries, while implementing the waste prevention, environmental protection, resource preservation and sustainable economical growth support concepts.

The 3R Zero Emission Carbon Refinery mission meets basic global challenges by providing efficient solution for biomass waste management:

  1. You can't have infinite economical growth on a finite resource planet, the generated waste materials are need to be efficiently recycled and reused.  3R MISSION: providing high level skills in carbon cycles, nutrient recovery, soil fertilization, bio-energy and sustainable environmental solutions.
  2. Biomass Waste is just a resource in the wrong place, and we need to use each resource for its highest purpose. Every output as an input, every waste as a resource.  3R MISSION: recovering more value from waste for less overall costs, when all and any costs are included.
  3. Waste streams are resources and not unusable materials, subjects to right and advanced recycling technology are applied. 3R MISSION: advanced zero emission industrial pyrolysis processing technology is developed and applied.
  4. Energy is the ability to do work, and without it nothing happens.  3R MISSION: we are not planning for an economy with less energy consumption, therefore green energy from waste and by-product resource streams are having an increased importance.
  5. Sustainable economical growth can only progress together with sustainable environmental and climate protection. 3R MISSION: sustainable economical and ecological biomass waste recycling and reuse.

3R Zero Emission Pyrolysis and Nutrient Recovery Process Industrial Development History

The 3R-ZERO EMISSION PYROLYSIS PROCESS and NUTRIENT RECOVERY innovation started in the late 80's and the RTD programmes accelerated after 2002, when the European Union started to support the development programme (EU-FP5 Multi Fuel, EU-FP6 Protector, CIP-ECOINNOVATION, REFERTIL) on a priority large scale basis. For more information please visit our 3R PROJECT References.

The 3R pyrolysis and nutrient recovery technology is aiming to enhance the total reuse of waste biomass from agriculture and food industry, in order to economically reduce the use of mineral Nitrogen and Phosphorous fertilizers in safe food crop production, while minimiznig the negative impact of agriculture on the environment and on climate change.

After years of RTD, advanced engineering, validation and field demonstration works, the 3R  pyrolysis and nutrient recovery technology is ready to be commercially licensed and to implement full scale industrial and production systems from the economical 6500/year throughput capacity towards medium scale 20,800/year throughput capacity.

CURRENT STATUS: The status of the 3R industrial pyrolysis and nutrient recovery technology is post development, industrially proven, Authority permitted and field demonstrated. It clearly reached proven full scale industrial phase, with a comprehensive fully scale up engineered design.

2017: READY FOR COMMERCIALIZATION

For more information aout our related EU Projects please visit the 3R PROJECT References.

3R Management

Mr. Edward Someus (inventor, owner)

Swedish environmental engineer with core competence of organic waste added value recycling and valorization by pyrolysis, carbon processing and reuse applications. Born 1951; education: University of Lund in Sweden (1972 - 1978), graduated in 1978, M.Sc., Natural and Environmental Sciences.

Sectors of Personal Expertise: renewable energy/clean technology/environment/organic waste management/bio-energy. Combining high level of scientific knowledge with industrial engineering and field applications, specializing in the: research, technical development, engineering, permitting, industrial applications and implementation of the zero emission carbon refinery, low temperature carbonisation and pyrolysis technology, for recycling and reuse of carboniferous materials by integrated thermal/biotechnological means.

 

Edward Someus is a Swedish environmental engineer from the University of Lund, with +30 years core competence and specialization on biochar science and technology, industrial manufacturing, product formulations and agricultural field applications under market competitive conditions. Specific zero emission pyrolysis technology developed (“3R” Recycle-Reduce-Reuse technology) for carbon refinery processing and material/nutrient added-value recovery, most importantly Phosphorus, such as extraction of high P2O5 concentrated innovative ABC Animal Bone bioChar organic fertilizer from rendering industrial animal bone by-products.

The work field is covering area from the matured phase of applied research into full industrialization of carbon refinery systems to convert biochar science into legalized and economical industrial practice. The economical biochar processing capacities ranging usually from the small industrial 6500 t/y to medium industrial scale 20,800 t/y throughput capacities.

These biochar development works are based on the EU regulations and Member State legal permits for biochar processing, product safety, accredited analytics and applications for the interest and benefits of SME farmers. Since 2002 Edward Someus is biochar S&T coordinator and key technology designer for large scale EU research projects, involving ten EU countries, including FP7 REFERTIL project 2011-2015 for EU28 standardization and full law harmonization development of the biochar products.

Edward Someus is a member of the EIP-AGRI (run by the European Commission DG Agriculture and Rural Development) Nutrient Recycling Focus Group.

Edward Someus has been selected as a Member of the EU DG Grow-JRC STRUBIAS (struvite-biochar-ash) Expert Group, a sub-class of the Commission Working Group on fertilisers.

Publications

Projects

TERRA senior management team having capabilities and highly experienced to develop business opportunity in the agricultural raw material recovery sector.

AttachmentSize
Edward Someus EuroPass CV332.61 KB
Edward Someus CV387.45 KB

3R Pyrolysis - Nutrient Recovery - Biochar - Agro-Biotech Field Demo Center

“3R Pyrolysis” Center for Phosphorus recovery,  biomass valorization, renewable energy, and innovative agricultural biotechnology demo - training

Operational field: from advanced applied science to economical scale up and industrialization of pyrolysis, solid state fermentation, agrobiotech and synfuel technologies

 

 

The 3R pyrolysis center combines  science, industrial engineering and practice. TERRA HUMANA is the owner of the fully permitted industrial site in West Hungary, which is dedicated to innovative and advanced agricultural, environmental and industrial technology field demonstrations under different EU programmes. The specific works include pyrolysis technology (carbonization, torrefaction) and biomass added value utilization processes, with commercial objective driven production of bone charcoal, biochar and innovative natural Phosphorous / Nitrogen fertilizers.

The field demonstration of the advanced 3R design and innovative technology is bridge over practical science with clear industrial application orientation, engineered scale up design development and economical commercialization.

The 3R site installation and operations are Authority permitted, including official Authority permit for specific biochar production and application for open ecological soil environment use.

3R & Technology

TERRA HUMANA Company Info

Terra Humana Ltd. / COMPANY PROFILE (PDF) / 3R Mission

Terra Humana Ltd. is a technology intensive company playing a leading role in zero emission pyrolysis technology engineering, phosphorus recovery and biochar industrial production. TERRA senior management team having capabilities and highly experienced to develop business opportunity in the agricultural raw material recovery sector.

3R ZERO EMISSION PHOSPHORUS RECOVERY

  • Animal bone BioChar - recovered and high nutrient dense organic Phosphorus fertiliser
  • Bio-Oil renewable pure energy
  • Adsorbent products for water treatment

Owner, Key Technology Designer:  Edward Someus EuroPass (CV)

Carbon refinery, pyrolysis, Phosphorus recovery; bio-oil & synthetic fuel; biochar, Animal Bone BioChar & carbon biotech formulation; NPK plant nutrient recovery and recycling; carbonization processing of food grade animal biomass by-products (bone meal cat. 3, MBM & PAP cat. 3-2-1); and low moisture content manure from herbivorous animals and agro/forest plant biomass residuals

Contact information

Terra Humana Ltd.

(Edward Someus)

Skype:

edwardsomeus

E-mail:

biochar@3ragrocarbon.com
edward.someus@gmail.com

3R Newsletter

 

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