Introduction
Reducing the carbon footprint is becoming a priority for many companies worldwide. Implementing innovative technologies, such as hydrothermal carbonisation (HTC), offers practical solutions for both industry and the environment. HTC converts biomass, including organic waste, sewage sludge, or agricultural waste, into biochar, which is CO₂-neutral, has a high energy value, and offers a wide range of applications.
Our company’s cooperation with INNOTEC enables the implementation of an advanced HTC system that combines process efficiency with deployment flexibility. As a result, we offer comprehensive biomass processing solutions characterised by process speed (5–6 minutes) and adaptability to various types of feedstock.
Key Applications of HTC Technology
Effective Waste Management
All types of organic waste, regardless of their moisture content, can be processed in our HTC system. This process ensures:
- Complete sanitisation of waste by eliminating pathogens, pesticides, antibiotics, and microplastics.
- Biochar production with a calorific value of up to 23 MJ, which can be used as solid fuel or raw material for syngas production.
Effluent as a By-product
The effluent generated during the HTC process is a mineral-rich liquid that can be used as:
- Mineral fertiliser supporting sustainable agriculture.
- Substrate in biogas plants, increasing energy production efficiency.
Advantages Compared to Competitors’ Innovations
- Process flexibility: Our solution allows the process to be stopped and restarted at any time, which distinguishes HTC from biological fermentation processes.
- Compact installation: Our installations require little space, are simple to build, and easy to operate.
- Integration with the iPLAS system: We ensure full control over every stage of the HTC process thanks to an advanced monitoring and reporting system.
How HTC Technologies Can Help Companies
Technologies based on hydrothermal carbonisation (HTC) offer a wide range of applications that can significantly contribute to improving operational efficiency and sustainability in enterprises. Below are the key ways in which HTC processes can support businesses:
- Energy production: Biochar, as a high-energy fuel, can be used to generate heat, cooling, or electricity.
- Support for agriculture: Biochar as a soil additive improves soil structure and water retention capacity.
- Sustainability: Our technology supports the circular economy by reducing waste and promoting renewable energy sources.
Implementations and Deployments
Thanks to our cooperation with INNOTEC, we implement HTC installations tailored to the needs of various industries, from agriculture to the chemical industry. Our solutions contribute to increasing operational efficiency, reducing the carbon footprint, and generating new revenue streams from by-products.
Please feel free to contact us to learn more about the possibilities of HTC technology in your company!
Examples of HTC Implementation in Other Companies Worldwide
1. TerraNova Energy GmbH – Sewage Sludge Processing
The German company TerraNova Energy has developed the TerraNova®ultra process, which enables the efficient conversion of sewage sludge and biowaste into biochar through hydrothermal carbonisation (HTC). This technology mimics the natural process of coal formation, significantly accelerating it. At temperatures of around 180–200°C and pressures of 20–35 bar, biomass is converted into hydrochar (biochar) within a few hours.
- CO₂ emissions reduction: Converting sewage sludge into biochar reduces the amount of waste sent to landfills, which limits methane and carbon dioxide emissions.
- Renewable fuel production: The resulting biochar is characterised by a high calorific value and can replace fossil fuels in power plants or cement factories, contributing to the reduction of greenhouse gas emissions.
- Soil quality improvement: Biochar can be used as a soil conditioner, increasing its fertility and water retention capacity, as well as sequestering carbon, which promotes long-term CO₂ storage in terrestrial ecosystems.
- Recovery of valuable components: The technology enables the recovery of phosphorus and nitrogen from sewage sludge, which can be used as fertilisers, supporting sustainable agriculture and reducing dependence on artificial fertilisers.
In Poland, the Solina municipality, in cooperation with TerraNova Energy and its Polish partner Schwander Polska, plans to build a TerraNova®ultra installation at the wastewater treatment plant in Berezka. This will be the first installation of its kind in Europe, processing 3,000 tonnes of bio-waste annually into 400–500 tonnes of hydrochar. The project aims to produce renewable fuel and fertiliser from bio-waste, contributing to environmental protection and economic benefits for residents.
2. AVA-CO2 – Pioneer on an Industrial Scale
The Swiss company AVA-CO2 was a pioneer in the industrial implementation of hydrothermal carbonisation (HTC) technology. In 2010, it launched the world’s first industrial HTC demonstration plant in Karlsruhe, and in 2012, it began trial operation of the full-scale HTC-1 plant.
HTC technology enables the conversion of biomass, such as organic waste or food scraps, into biochar. The process involves heating biomass in an aqueous suspension to a temperature of 180–250°C under increased pressure, which leads to the formation of solid biochar, known as hydrochar. The resulting biochar can be used as a fuel or soil additive, supporting carbon sequestration and improving soil properties.
In 2011, AVA-CO2 established a subsidiary, AVA Biochem, focusing on the production of 5-hydroxymethylfurfural (5-HMF) from biomass using a modified HTC process. In 2014, AVA Biochem launched the world’s first industrial plant for the production of 5-HMF in Muttenz, offering a sustainable material for the chemical, food, and pharmaceutical industries.
The HTC technology developed by AVA-CO2 and its subsidiaries has contributed to the efficient processing of organic waste into biochar and the production of valuable chemical compounds, such as 5-HMF, supporting sustainable development and the circular economy.
- Benefits:
- Utilisation of organic waste.
- Reduction of CO₂ emissions.
- Increasing soil biodiversity through the use of biochar.
3. Carborem – Innovations in Continuous Processes
The Italian company Carborem srl has developed an industrial hydrothermal carbonisation (HTC) plant called Carborem C700, operating in continuous mode. This system converts sewage sludge, agro-industrial waste, and digestate from the organic fraction of municipal waste into biochar (hydrochar). The HTC process in the C700 reactor takes place at a temperature of approximately 190°C for 1 hour, leading to efficient dehydration of the sludge and concentration of phosphorus in the solid product.
In 2019, the country’s first HTC plant built by Carborem was launched in Mezzocorona (Trentino, Italy). This facility processes digestate from an existing anaerobic digestion plant, fed with sludge from local wineries and dairies. The resulting hydrochar is stabilised and processed into compost, which is then used in agriculture, fitting into the circular economy model.
- Benefits:
- Continuous processing increases efficiency.
- Reduction of greenhouse gas emissions.
- Ability to adapt the technology to various types of biomass.
4. Schwander Polska – Polish Solutions to Global Challenges
Schwander Polska has implemented hydrothermal carbonisation (HTC) technology for processing municipal and industrial waste, such as sewage sludge and biowaste. The HTC process converts these materials into hydrochar (biochar), which can be used as an alternative energy source with a calorific value of approximately 25 MJ/kg and as a soil improver.
In March 2024, Schwander Polska launched the first HTC installation of this scale in Poland, with a capacity of approximately 2,000 tonnes of organic sludge per year. This installation is capable of processing various organic waste fractions, including sewage sludge, biowaste and digestate, allowing for the optimisation of treatment processes.
According to an expert opinion by Mikrobiotech, the HTC biochar produced by Schwander Polska meets the requirements for use as a fertiliser product and exhibits the characteristics of a relatively valuable solid biofuel. The leachate generated during the dewatering process of HTC biochar also meets the requirements for use as a fertiliser product or soil improver.
HTC technology enables efficient organic waste management, reducing the amount of waste sent to landfills and contributing to environmental protection. Additionally, integrating HTC technology into the wastewater treatment process helps meet the requirements of the new Urban Wastewater Treatment Directive of the European Parliament and of the Council, which introduces energy neutrality targets for municipal wastewater treatment plants.
Schwander Polska plans further implementations of HTC technology in various regions of the country, including the Solina municipality, where a hydrothermal carbonisation plant is being designed to process sewage sludge and biowaste.
- Benefits:
- Local production of sustainable solutions.
- Reduction of waste volume.
- Support for the circular economy.
5. Central Mining Institute – Research Projects in Poland
The Central Mining Institute – National Research Institute (GIG-PIB) is implementing the HYDROCARB project, which aims to develop hydrothermal carbonisation (HTC) technology for municipal sewage sludge. The HTC process, carried out at temperatures of 180–250°C under appropriate pressure, enables the conversion of sludge into high-value carbon materials, such as graphites, porous carbons, nanotubes or carbon fibres. These materials are used, among others, as electrodes in supercapacitors and in selective adsorption processes.
The HYDROCARB project is being carried out in cooperation with Chinese institutions: Xi’an Jiaotong University and Huazhong University of Science and Technology. The project is funded by the National Centre for Research and Development as part of the 3rd call for joint research projects under Polish-Chinese cooperation. The project implementation period is 1 September 2024 – 31 August 2027.
The activities of GIG-PIB within the HYDROCARB project align with the principles of the circular economy, offering innovative waste treatment methods and reducing greenhouse gas emissions, while supporting the development of modern carbon materials.
- Benefits:
- Innovative use of municipal waste.
- Technology development towards reducing CO₂ emissions.
- Applicability in many industrial sectors.
Summary
Examples of companies such as TerraNova Energy, AVA-CO2 or Schwander Polska show that the implementation of HTC technology brings tangible environmental and economic benefits. Reducing greenhouse gas emissions, converting waste into usable products and supporting the circular economy are among the most significant effects of applying this technology.
At a time when sustainable development is a key element of business strategies, HTC is becoming a tool that is not only necessary but also profitable.
If your company wants to join the ranks of innovation and sustainability leaders, HTC technology could be the answer to modern challenges related to CO₂ emissions.
