SGC continuous rotary pyrolysis and torrefaction reactor

A patented, continuous, indirectly heated rotary kiln that combines torrefaction and pyrolysis in one integrated system. We design and manufacture it in Greater Noida, India.

One reactor, two modes

Run hotter and longer, the reactor makes biochar: stable carbon for removal credits, steel and soil. Run cooler, it torrefies biomass into bio-coal that replaces coal.

The drum is heated from outside through a double shell, so the biomass inside never meets flame or air. Gases released from the biomass are burned to heat the drum, which makes the process self-sustaining once it is running. Hot flue gas then dries the incoming feedstock.

SGC reactor shed at the Sanchore demonstration plant

Technical specifications

Reactor specifications

Parameter	Specification
Reactor type	Patented continuous rotary kiln that integrates torrefaction and pyrolysis
Throughput per line	0.4 TPH (400 kg/hr) DemonstratedLines of 0.8–1.0 TPH and 2.0 TPH in design
Operating temperature	250–500 °CAcross torrefaction and pyrolysis modes
Residence time	45–90 minutesAcross both modes
Pyrolysis conditions for certified biochar	400–450 °C, 60–90 minutes
Heating method	Indirect heating through a double-shell (jacketed) drum; oxygen-free reaction zone
Process energy	Self-sustaining: the reactor burns its own process gases as its heat source
Drying	Integrated dryer using hot flue gas; no separate pre-drying plant needed
Certified feedstock	Prosopis juliflora (invasive woody biomass) Isometric Class 1
Other design feedstocks	Bamboo, wood chips, sawdust, agricultural residues including paddy straw, RDF from municipal solid wasteNot covered by the Isometric certification
Products	Biochar (pyrolysis mode); bio-coal and torrefied biomass for pellets (torrefaction mode)
Biochar quality	Organic carbon ≥ 80.9%; H/C ratio ≤ 0.38
Controls	Sensors and programmable controllers, with PLC automation
Construction	Modular, compact design for road transport and staged capacity additions

How it works

From wet biomass to finished product

Feed and dry
Sized biomass enters continuously. Hot flue gas from the burner dries it on the way in.
Heat without air
The rotating drum is heated through its outer shell, so the biomass converts without burning.
Recover the gas
Gases released by the biomass are burned to heat the drum, so the process sustains itself.
Discharge
Biochar or bio-coal leaves the drum continuously, ready for cooling, sizing or pelleting.

Biochar discharged from an SGC reactor.

Design features

Integrated drying. Takes high-moisture feedstock directly.
Multi-stage rotary drum. Even heat exposure and controlled decomposition for consistent product.
Indirect heating. A double-shell structure keeps the reaction zone free of oxygen.
Self-sustaining operation. Recovers its own process gases as fuel.
Automated control. Sensors, transducers and programmable controllers for real-time adjustment.
Compact layout. Dryer and drum placed to cut footprint and insulation.
Modular build. Transported by road and expanded in stages, suited to plants near the feedstock.

Proven on Juliflora

Biochar made from Prosopis juliflora in an SGC reactor is certified Isometric Class 1, with organic carbon of 80.9% or higher and an H/C ratio of 0.38 or lower. The certification covers Juliflora feedstock only.

See the results →