General Char Information

Content What is Char? Environmental Choice Program Combustion Testing Applications Char Handling

What is Char?

Char is a significant co-product of the pyrolysis process having properties similar to coke. At 23–32 GJ per tonne, pyrolysis Char has a higher heating value than many grades of coal. Like BioOil and BioOil Plus, it is also a “green” fuel that is CO2 neutral.

Char is produced and shipped as a fine powder. The Char density is about 250 kg/m3 for all feedstocks except whitewood, which is significantly higher. Char is collected in 2 cyclones arranged in series. The density of secondary Char was found to be about 30% higher than primary Char. This is not reflected in the Char density listed below since the secondary system produced is only about 1.5-2% of the total Char collection.

Physical characteristics of Char vary with type of feed and the fineness of feed. Typically the Char particle size distribution can be 100% < 2mm, 95% < 1mm and 60% < 0.5mm.

In mixing BioOil with Char, the BioOil can pick up 5 - 10 % Char by weight and still be fluid enough for transportation. At 30 % the Char will sufficiently "dry up" the liquid.

Char properties and how they compare with conventional solid fuels

Table 1: Ultimate analysis of different coal (% by wt) – wood based Char

Coal	Carbon	Hydrogen	Sulphur	Nitrogen	Ash	Btu/lb
Pennsylvania	65.8	4.6	2.3	1.4	19.8	11,818
Ohio	64.2	5	1.8	1.3	16	11,478
West Virginia	72.1	4.8	1	1.4	11.7	12,643
Kentucky	70.9	5.1	2.3	1.5	9.8	12,637
Illinois	73.7	5.1	2.3	1.6	7.9	13,192
Biomass
Douglas Fir	52.3	6.3	0	0.1	0.8	9,069
Hickory	47.67	6.49	0	0	0.73	8,690
Maple	50.64	6.02	0	0.25	1.35	8,599
Ponderosa Pine	49.25	5.99	0.03	0.06	0.29	8,625
Peat	54.81	5.38	.11	.89	3.00	9,478
Poplar	51.64	6.26	0	0	0.65	8,939
Dynamotive Char	75-78	3-4	-	<0.3	5-12	12,000-13,000

Table 2: Composition of Char for white wood residues

Parameter	Typical Range
Moisture Content (% wt.)	<2
Volatile Content (% wt.)	16-23
Heating Value (btu/lb)	12,000-13,000
Heating Value (GJ/tonne)	28-30
Particle Size (mm)	<1
Flash Point (oF)	400

Table 3: Analysis of the ash in Char (Typical ash content: ~ 7%)

Metals in Char as % of Ash Content	mg/L in Digest	% in Ash	ppm in Ash
Ag Silver	<0.02
Al Aluminium	23	0.43	4,284
As Arsenic	<.02
B Boron	.15	0.003	28
Ba Barium	1.5	0.03	279
Be Beryllium	<0.01
Bi Bismuth	<0.05
Ca Calcium	144	2.68	26,821
Cd Cadium	<0.02
Co Cobalt	0.02	0.0004	4
Cr Chromium	0.79	0.01	147
Cu Copper	0.14	0.03	26
Fe Iron	44	0.82	8,195
K Potassium	13	0.24	2,421
Li Lithium	.01		0
Mg Magnesium	28	0.52	5,215
Mn Manganese	6.2	0.12	1,155
Mo Molybdenum	<0.02
Na Sodium	5.9	0.11	1099
Ni Nickel	0.07	0.001	13
P Phosphorus	6.7	0.12	1,248
Pb Lead	<0.02
S Sulfur	3.8	0.07	708
Sb Antimony	<0.02
Se Selenium	<0.02
Si Silicon	11	0.20	2,409
Silicates (Acid Insoluble Material)		85.0	850,000
Sn Tin	<0.05
Sr Strontium	0.56	0.01	104
Ti Titanium	1.2	0.02	224
Tl Thallium	<0.05
V Vanadium	0.07	0.001	13
Zn Zinc	0.50	0.01	93

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Environmental Choice Program

This certificate indicates that Dynamotive’s Char meets the stringent criteria of Canada’s Environmental Choice Program as a solid biofuel.

General Requirements

To be authorized to carry the EcoLogo™, the solid biofuel must satisfy the following:

• meet or exceed all applicable governmental and industrial safety and performance standards; and
• be manufactured and transported in such a manner that all steps of the process, including the disposal of waste products arising therefrom, will meet the requirements of all applicable governmental acts, by laws and regulations including, for facilities located in Canada, the Fisheries Act and the Canadian Environmental Protection Act (CEPA).

Product Specific Requirements

To be authorized to carry the EcoLogo™, the solid biofuel:

• must be manufactured from wood-wastes and agricultural wastes and / or clean construction and demolition wastes;

To be authorized to carry the EcoLogo™, the char must meet the following::

• to ensure a consistent hardness and energy content, bulk density must exceed 250 kg/m3 when tested using a method consistent with ASTM E-873-82 Standard Test Method for Bulk Density of Densified Particulate Biomass Fuels;
• to be burned easily and minimize particulate emissions, inorganic ash content must not exceed 10%, when tested using a method consistent with ASTM D-1102 Standard Test Method for Ash in Wood;
• to avoid equipment rusting rusting, sodium content must not exceed 300 ppm of watersoluble sodium, when tested using a method consistent with ASTM E-776 Standard Test Method for Forms of Chlorine in Refuse-Derived Fuel.

Combustion Testing – Onix Solid Burner, Montpellier OH

Char Combustion Test - Onix

The test began by burning wood and heating up the combustion chamber to 1700°F (927°C). The burning test duration lasted 3 hours for the wood and 1 ½ hours for the Char on the first day, following a repeat run on the second day. With both runs the feed supply to the combustion chamber worked smoothly and without problems. The steam exhaust leaving the combustion chamber in both tests appeared crystal clear, smoke free, and without spark.

It was observed that the flow of solid Char entered the combustion chamber in a cyclonical manner. The bottom of the chamber showed some ash accumulation.

The exhaust emission results showed NOx and CO as low, 75 and 2 PPM respectively.

The Char used for this test had a high content of ash (22.8 %) and moisture (27%), therefore the heating value was very low (7608 btu/lb). (Note that the HHV of above average Char is approximately 13100 btu/lb.)

Table 4: Data of Char burning test in Onix solid burner

Date: Nov. 9, 2006

Emission concentration
Oxygen %	11.7	11
CO ppm	2	2
CO2 %	9	9.7
NO ppm	73	75
NO2 ppm	0	0
NOx ppm	73	75
CO ppm @ (O2 = 15%)	2	1
NO ppm @ (O2 = 15%)	47	45
NO2 ppm @ (O2 = 15%)	0	0
NOx ppm @ (O2 = 15%)	47	45
Emission rate (kg/hr)
CO (kg/hr)	0.0018	0.0018
NO (kg/hr)	0.0716	0.0736
NO2 (kg/hr)	0	0
NOx (kg/hr)	0.0716	0.0736
Emission rate (kg/GJ)
CO (kg/GJ)	0.0012	0.0012
NO (kg/GJ)	0.0480	0.0493
NO2 (kg/GJ)	0	0
NOx (kg/GJ)	0.0480	0.0493

Note: Exhaust gases leaving the stack looks crystal clear with no smoke and spar

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Char Applications – Current and Potential

Early stage applications of Char are focused on direct substitution or augmentation of fossil fuels to produce process heat and power in the applications and markets described below.

BioOil production at pyrolysis plant

Char can be used as a substitute for other industrial fuels to produce the heat required for drying the feedstock and/or to supply heat to the pyrolysis reactor.

Sawmills

The majority of sawmills have lumber drying kilns that are used to dry green lumber prior to shipment to customers. Lumber kilns are either fuelled by natural gas or wood residue; the latter can be substituted with Char.

Power Generation

Another power generation option is to burn Char in a power boiler producing additional steam for heat and/or electricity generation. The value of Char in these applications depends on the commodity price of the displaced fuel.

Briquette Manufacturing/pelletizing Char can be used as a feedstock for manufacturing Charcoal briquettes/pellets. Royal Oak tested Dynamotive Char and found the briquettes performed well.

Cement

Cement plants typically burn coal or natural gas to provide heat for their limekilns. Minimizing transportation costs gives the best financial return for Char in this application, while also producing substantial carbon benefits. This is especially the case where current energy use is highly carbon intensive.

Thermal Power Generation

Co-firing of biomass with coal is becoming an increasingly common strategy for reducing emissions in coal-fired utilities. As the Char is CO2 neutral and contains virtually no sulphur, emissions are reduced in proportion to the amount of coal displaced in the power boiler. Minimizing transportation costs will again deliver a high financial return for Char in this application while also giving the potential for dramatic reductions in emissions.

Ammonium bicarbonate (NH4HCO3) fertilizer

Simply burying Charcoal in the soil is beneficial. Adding up to 10% Charcoal increases fertility in most soils, and if nitrogen is added to the Charcoal it produces an even more effective fertilizer. The Eprida ECOSS process came with the discovery that if ammonia (NH3), carbon dioxide (CO2) gas and water (H2O), are combined in the presence of Charcoal they will form a solid, ammonium bicarbonate (NH4HCO3) in the pores of the Charcoal.

As an example, an application of rice husk Charcoal can lead to crop yield increases of 10 - 40% due to the following:

1. The rice husk Charcoal increases the soil pH,
2. The aeration in the crop root zone is improved.
3. The water-holding capacity of the soil is improved.
4. There is an increase in the level of exchangeable K and Mg.

Mid to Long term opportunities

In addition to the applications described above, Char may be an appropriate feedstock for higher value applications that will require further development. These include the following: >

Activated Carbon

Nonporous bio-Char can be converted to highly porous activated Char by simple steam treatment at elevated temperature (>500°C) to produce high surface area (> 1000m2/g) activated carbon.

Activated carbon is used in a wide variety of purification and filtration systems such as municipal and industrial water treatment systems. At the moment, Dynamotive has successfully completed research tests on pyrolysis Char at the University of Saskatchewan, Canada.

Table 5: Analysis of surface area and porosity of activated and non-activated (virgin) Char samples

Sample ID	Surface Area, m2/g		Pore Volume, cc/g		Average Pore	Char
	Total	Micropore	Total	Micropore	Diameter, Ǻ	Yield, Wt %
Virgin Char	1.6	1.6	0.001	0.001	-	-
AC800, 1.5h,150,2:1	805	390	0.65	0.18	24.12	31.45
AC800 Ch***,1h,R1	1400	926	0.69	0.43	14.55	64

Char Pellets

Char can be used as a raw material to manufacture fuel pellets for use in Europe in domestic and industrial heating markets. This market is currently supplied by wood pellet products manufactured in Canada, the US and the EU. Fuel pellets made from Char would have a higher energy density than wood pellets.

Synthesis Gas Production/Gasification

Conventional liquid transportation fuels like diesel or gasoline are carbon based. But biomass is the only source of renewable carbon. While hydrogen is touted as the transportation fuel for the long term, it will require a whole new distribution infrastructure and new engines, e.g. fuel cells. Such changes will require decades to implement. It would be far cheaper in the short run to simply replace conventional fuels with equivalent fuels made from biomass derived carbon.

There is, at present, essentially only one known viable way to convert whole biomass to hydrocarbon fuels, namely by gasification and followed by Fischer-Tropsch conversion to liquids – the so-called BTL (biomass-to-liquids) process. Alternative biomass based fuels like ethanol or biodiesel, use only a fraction of the total plant biomass.

Economically practical plants for fuel synthesis will have to be of very large scale (several thousand tons per day of raw biomass required). This implies large costs associated with the transportation of large quantities of biomass; an intrinsically dilute resource. Dynamotive views BioOil as a key intermediate in the conversion of biomass to hydrogen or syngas since the volume reduction associated with the conversion of biomass to BioOil, BioOil Plus, and Char leads to enormous reduction in transportation and storage costs.

BioOil, BioOil Plus, and Char may be a suitable feedstock for the production of medium to high BTU synthesis gas via steam gasification. Successful lab-scale experiments have been performed at the University of Saskatchewan in cooperation with NRCan and CANMET labs. Additional successful gasification tests on BioOil/Char slurry (with 30% of Char content) have been performed by Dynamotive, Future Energy and FZK (research institute based in Germany) in September 2005.

Steel/Metallurgical

Char may be an appropriate substitute for high value anthracite coal, which is typically used in metallurgical applications such as iron production. A definition of the critical physical properties of metallurgical coal must be developed/obtained and the Char refined or conditioned to meet the requirements of the industry. Further investigation of this application is required.

Carbon Black

Carbon black is a purified form of carbon with many applications including ink jet printer inks and tire manufacturing. To compete in this market will require further processing/conditioning of pyrolysis Char.

Green House Gas credits

Replacing fossil fuel use with Char will also generate Green House Gas emissions reduction credits. These credits could then be traded through domestic trading systems or through the established international mechanisms set out under the Kyoto Protocol. The quantity and value of these credits will depend on what type of fossil fuel BioOil is displacing and where the credits are traded.

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Char Handling

Storage and transport temperature

Char is a flammable solid and TDG class 4.2 dangerous goods. Char contains 18 - 30 % by weight of organic volatile compounds.

Char is produced within seconds in the reactor and rapidly removed by cyclones, then, finally, cooled to about 40°C. It is not thermally stable: freshly produced pyrolytic Char and freshly produced pyrophoric Char can auto ignite spontaneously into a smoldering fire when exposed to air and/or oxygen.

This self-heating is related to two processes, water adsorption of the dried Char and chemisorption of oxygen. Both processes are exothermic reactions. When exposed to the atmosphere, dry Char will rapidly adsorb water vapour and oxygen, heat up and ignite if not cooled. Oxygen physically adsorbs onto the surface of the Char and chemically reacts with organic molecules within the Char. This reaction can release about 120 MJ per kg-mole of oxygen. Because oxidation rates will approximately double with each 10°C rise in temperature, the heat, if not dissipated, will promote a self-accelerating oxidation process and cause the Char temperature to rise progressively until the Char spontaneously ignites.

This creates a potential hazard wherever Char is stored or transported. The heat from the adsorption of water onto the dry Char can release about 20MJ per kg-mole of water. This "heat of wetting" raises the temperature of the Char causing an increase in the carbon oxidation.

To stabilize stored Char:

1. Char can be fully wetted
2. Char can be deactivated in a complex process in a gas stream in which temperature and oxygen content are - carefully controlled
3. Char deactivates over time

Shipment of Char

At the moment, Dynamotive is exploring different alternatives to overcome shipping difficulties regarding Char’s auto ignition properties.

Char Material Safety Data Sheet

HAZARDOUS INGREDIENTS:

Ingredients	CAS Registry Number	Concentration (%-weight/weight)
Carbon	7440-44-0	from 60 to 75 %

PREPARATION INFORMATION:

Prepared by:

Corporate Headquarters

Angus Corporate Centre
1700 West 75th Avenue
Suite 230
Vancouver BC V6P 6G2
Canada

T: (604) 267-6000

T: 1-877-863-2268

F: (604) 267-6005

info@dynamotive.com

Dynamotive USA, Inc.		First Resources Corporation		Dynamotive Latinoamericana
1650 Tysons Boulevard Suite 1550 McLean, VA 22102 U.S.A.		6520 Salish Drive Vancouver, BC V6N 2C7 Canada		Av. Quintana 585, 6º piso (C1129ABB) Buenos Aires Argentina
T: (703) 336-8450		T: (604) 267-6040		T: (54 11) 4802 2220
F: (703) 336-8462		F: (604) 267-6005		F: (54 11) 4802 1211

 

PRODUCT IDENTIFICATION:

Manufacturer:

Emergency Phone Numbers:

Corporate Headquarters Angus Corporate Centre 1700 West 75th Avenue Suite 230 Vancouver BC V6P 6G2 Canada T: (604) 267-6000 T: 1-877-863-2268 F: (604) 267-6005 info@dynamotive.com Dynamotive USA, Inc.   First Resources Corporation   Dynamotive Latinoamericana 1650 Tysons Boulevard Suite 1550 McLean, VA 22102 U.S.A.    6520 Salish Drive Vancouver, BC V6N 2C7 Canada     Av. Quintana 585, 6º piso (C1129ABB) Buenos Aires Argentina T: (703) 336-8450   T: (604) 267-6040   T: (54 11) 4802 2220 F: (703) 336-8462   F: (604) 267-6005   F: (54 11) 4802 1211

Dynamotive (604) 267-6000 CANUTEC (24 hours) (613) 996-6666

Product name:	Pyrolytic Char
Chemical family:	Carbon
Chemical name:	Carbon
Formula:	C
Synonyms:	Wood Charcoal
UN number:	UN1361
TDG Shipping Name:	Carbon, vegetable origin
TDG Classification:	Class 4.2, Packing group II

PHYSICAL DATA:

Physical State:	Granular or fine powder
Color:	Black
Odour:	Charred odour
Volatile Content (% wt.):	18 - 30
Ash Content (% wt.):	1 - 25
Carbon Content (% wt.):	60 - 75
pH:	Not available
Solubility in Water:	Insoluble
Bulk Density:	250 - 350 kg/M3
Vapor Pressure:	Not available
Vapor Density:	Not available

FIRE AND EXPLOSION HAZARD:

WHMIS Classification:	Class B, Division 4, Flammable solids
Unusual Fire / Explosion Hazards:	Char dust 0.055 kg/M3 is the minimum explosion concentration. Freshly produced pyrolytic Char may be subject to auto ignition and spontaneous heating, when exposed to air and/or oxygen.
Flash Point:	Not applicable.
Auto-ignition Temperature:	200 °C for fresh Char; 400 °C for aged Char.
Extinguishing Media:	Water spray or foam.
Note:	Do not use large solid sprays of water or foam as this can stir up dust clouds and cause flash fires.
Hazardous Combustion Product:	Carbon monoxide.

REACTIVITY DATA:

Stability:	Stable under ordinary conditions of use and storage.
Hazardous Polymerization:	Will not occur.
Incompatibilities:	Oxidizers
Instability Conditions:	Excessive temperatures
Hazardous Decomposition Products:	Carbon Monoxide and Carbon Dioxide

TOXICOLOGICAL PROPERTIES:

Route(s) of Entry:	Eye Contact; Skin Contact; Inhalation; Ingestion
Effects of Acute Exposure:	Coughing or mild breathing difficulties may result.
Inhalation:	May irritate mucous membranes and the respiratory tract.
Skin Contact:	May cause irritation.
Eye Contact:	May cause irritation.
Ingestion:	Not established.
Effects of Chronic Exposure:	Not established.
LC50:	Not available
LD50:	440 mg/kg (intravenous mouse)
Exposure limits:	Not established
Irritancy:	No information available
Sensitizing capability:	No information available
Carcinogenicity:	No information available
Reproductive toxicity:	No information available
Teratogenicity:	No information available
Mutagenicity:	No information available

PREVENTIVE MEASURES:

Personal Protective Equipment:
Eye Protection:	Safety glasses or goggles.
Skin Protection:	Latex or PVC gloves and apron or coveralls.
Respiratory Protection:	If dusting is a problem, a NIOSH/MSHA approved dust respirator must be worn.
Engineering Controls:	Use local ventilation if dusting is a problem. Eye wash stations must be available.
Storage Requirements:	Store at ambient temperature. Store away from oxidants in closed and properly labeled sacks or containers
Handling Procedures:	Avoid breathing dust. Avoid getting in eyes or on skin. Wash thoroughly after handling. Store in a cool, dry place away from direct sunlight, sources of ignition, and incompatible materials. Reseal containers immediately after use. Store away from food and beverages.
Spill or Leak Procedures:	Use recommended protective clothing and equipment. Clean spills in a manner that does not disperse dust into the air. Spill area can be washed with water. Collect wash water for approved disposal. Keep from entering water or ground water.
Disposal:	Waste disposal should be in accordance with existing federal, state/provincial and local environmental regulations.

FIRST AID MEASURES:

Skin:	In case of contact, wash skin with soap and water. Wash clothing before reuse. Seek medical attention if irritation occurs.
Eyes:	In case of contact, immediately flush eyes with lukewarm running water for at least 15 minutes, holding the eyelids open. Seek medical attention.
Inhalation:	If inhaled, remove victim to fresh air. If breathing has stopped, trained personnel should begin artificial respiration. If breathing is difficult, give oxygen. Seek medical attention.
Ingestion:	If swallowed, seek medical attention immediately.

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