The 50 TPD Semi-Continuous HTC Reactor System

The 50 Ton per Day (TPD) Semi-Continuous Hydrothermal Carbonization (HTC) Reactor transforms wet organic waste into high-energy hydrochar briquettes. This system processes complex feedstocks—such as sewage sludge, municipal organics, and agricultural waste—without energy-intensive pre-drying.

Designed for scalability, the system features a closed-loop heat recovery process that lowers utility costs, speeds up the payback period, and offers a sustainable alternative to landfills and traditional incineration.

Key Technical Edge

Multi-Stage Thermal Efficiency

Traditional HTC systems suffer from high operational costs due to continuous external heating demands. This layout resolves that inefficiency with a three-vessel system:

• Reactor 1 (Pre-Heating & Pre-Pressurizing): Captures waste heat directly from the main reactor jacket via an integrated concentric heat exchanger. This saves up to 40% in initial thermal energy input.

• Reactor 2 (Actual HTC Reactor): Fully agitated with a heavy-duty helical blade to maximize heat transfer and ensure a uniform carbonization reaction.

• Reactor 3 (Cooling & Controlled De-Pressurization): Uses an advanced cooling coil array and high-pressure choke valves to drop temperature and pressure safely without flash-venting valuable process energy.

Zero-Cost Internal Fuel Loop

The system operates on its own output. By integrating a dedicated Hydrochar Briquette Burner directly into Reactor 2, a fraction of the manufactured briquettes serves as the plant's primary thermal fluid heat source. This eliminates dependency on natural gas, fuel oils, or external fossil fuels, shielding operations from volatile energy markets.

Industrial Durability

Built entirely from high-grade SS316 Stainless Steel, the system withstands the corrosive, high-pressure (15 to 30 bar), and high-temperature (180°C to 250°C) environments inherent to organic waste processing. The layout utilizes progressing cavity slurry pumps and robust valve skids to handle high-solids mixtures without clogging.

Market Applications

The system is built for deployment across several sectors:

• Municipal Wastewater Plants: Converts wet sewage sludge into sterile, odor-free fuel, entirely avoiding high landfill disposal fees.

• Agricultural Processing Facilities: Processes wet crop residues, manures, and agro-industrial waste stream mixtures simultaneously.

• Food & Beverage Manufacturers: Diverts spent grains, packaged food wastes, and organic pulps from landfills directly into high-BTU solid fuels.

This technology is developed at www.biocom.id.