Thermolysis

Thermolysis is a thermochemical process that results in the decomposition of biomass through heat (about 500°C). Two co-products derive from thermolysis:

• a solid carbon compound (biochar)
• thermolysis gases, composed of condensable (tars, oils, etc.) and non-condensable gaseous components (mainly dihydrogen – H_2, carbon monoxide – CO, and carbon dioxide – CO₂ )

The reaction is allothermic (external source of energy) and is performed in anaerobic conditions (absence of oxygen), which differentiate thermolysis from pyrolysis. A small part of the gas produced is used to supply the required energy to power the process: external energy sources such as electricity from the grid are not required.

Haffner Energy’s thermolysis process is a breakthrough technology protected by 15 patent families or more than 80 international patents. It is the result of over 30 years of experience converting biomass to energy, including 15 years of R&D.

Thermolysis is then combined with a reforming step that cracks molecules at very high temperatures (around 1000°C). The long-chain molecules of thermolysis gases are split into short molecules (mostly dihydrogen – H₂, carbon monoxide – CO, carbon dioxide – CO₂, methane – CH₄). This stage is key for the destruction of tars, oils, and long carbon molecules produced at the thermolysis stage. 

The thermolysis step combined with the reforming step produce a very energetic (around 15 MJ/kg) syngas (synthesis gas), rich in hydrogen, called Hypergas®. Both steps are built in a modular unit called the Hypergas® Module.

Gasification through Gasiliner® 

For large projects where access to local and competitive biomass can become the limiting factor, gasifying the biochar in order to significantly increase Hypergas® production per unit of biomass can be of paramount importance. 

Haffner Energy’s gasification process consists in gasifying the biochar, which means converting the solid carbon into hydrogen and carbon monoxide. This conversion is carried out at high temperatures (around 1000°C) with the addition of steam. Steam reacts with the carbon through the reaction C + H₂O → H₂ + CO. 

Biochar, due to its considerable specific surface area, allows almost total conversion of coal, with ideal reaction kinetics. This translates into very high yields while reducing the ash to the inorganic fraction only. 

Haffner Energy’s Gasiliner® differs from other known gasification technologies by being unaffected by low–temperature melting ashes, allowing the process to be biomass–agnostic. 

Hypergas®

Hypergas® is the renewable hydrogen-rich syngas produced by Haffner Energy’s technology. Its high concentration in hydrogen (> 45% vol), which confers it a high heating value, and its low-impurities content sets it apart from standards syngases.

The quantity of Hypergas® produced depends on the Hypergas® Module range (from 10MW to 50MW). This Hypergas® Module is common to all our solutions. It is divided into:

• a thermolysis sub-unit
• a reforming sub-unit
• a purification sub-unit
• auxiliary equipment with instrumentation and regulation equipment

Once produced, Hypergas® can be then processed in different ways to:

• be used for industrial applications as a substitute to natural gas
• produce renewable hydrogen
• produce Sustainable Aviation Fuel (SAF)
• produce renewable methanol

Biomass

Haffner Energy has over 30 years of experience converting biomass to energy.

Haffner Energy’s process is notable for being biomass-agnostic. Biomass is an abundant commodity; it is also subject to strong seasonal and interannual variations, as well as to major availability differences depending on the region. Being biomass–agnostic considerably strengthens long-term security of feedstock supply, and significantly reduces costs. It also improves the chances of generating excellent societal acceptance of new projects, which is typically a challenge when using restrictive biomasses. Biomass and organic waste without recovery create value when used as feedstock for bioenergy, particularly for farmers. It is also an excellent way to stimulate the circular economy. 

Our approach aims at creating value from biomass residues with no use competing uses (in compliance with RED III and with Annex IX of RED II), mainly from agriculture and organic wastes and residues such as:

• Cereal straws, silo waste 
• Bagasse, beet pulp, olive pomace 
• Short rotation coppice
• Vine residues and shoots 
• Corn cobs  
• Green Waste 
• Biomass from regenerative crops on marginal lands (XanoGrass™, Miscanthus, Bamboo..)  
• Biomass fraction of industrial waste not fit for use in the food or feed chain 
• Algae (brown and green algae, sargassum….) 
• Biomass fraction of wastes and residues from forestry and forest-based industries (bark, branches, pre-commercial thinning, leaves, needles, treetops, saw dust, cutter shavings) 
• Manure 
• Sewage sludge, paper mill sludge, digestates from biodigesters, etc.
• Organic Municipal Solid Waste (MSW) biomass fraction of mixed municipal waste 
• Other non-food cellulosic material 

The use of sustainable or biomass residues as a feedstock for energy production offers decisive benefits. It is an abundant and affordable resource that can be found in many places across the globe. The ubiquity of biomass thus allows the relocation of the entire energy production value chain, from the collection of feedstock to the final user, enhancing the energy and environmental transitions of territories as well as their energy sovereignty.

A biomass-to-energy expert, Haffner Energy has a clear and proven track record of ensuring that only sustainable biomass with no competing uses can be procured for our process. Our team boasts an extensive knowledge of the EU sustainability criteria related to the production of biogases, as mentioned in the article 29 of the EU Renewable Energy Directive. Biomass sustainability is also a concern in the USA, as mentioned in the 2016 Billion-Ton Report published by the US Office of Energy Efficiency & Renewable Energy. 

Our Biomatch service was created with the purpose of supporting our customers in the sourcing of sustainable biomass for their projects. Haffner Energy is committed to making sure the agricultural feedstock is not competing with food uses, and not obtained from land with high-carbon stock or peatland. The same principle applies for forestry biomass, which should respect the hierarchy of use and be collected according to established sustainable forest management practices.

Biochar

Biochar is the solid co-product of biomass thermolysis. It is a carbon-rich material containing the biogenic carbon absorbed by plants from the atmosphere via photosynthesis. The co-production of biochar through thermolysis is optional.

Carbon sink 

Biochar made from lignocellulosic biomass through Haffner Energy’s process is a powerful carbon sink: one ton of biochar can sequester about 3 tons of CO₂eq. After compensating all emissions of production (manufacturing, transport and operating) it amounts to around 2 tons of CO₂eq per ton of biochar. 

Such sequestration can entitle producers to receive Carbon Removal Certificates (CORC) that are tradable on the voluntary carbon market. 

Biochar has been identified by the IPCC as one of the most impactful solutions for combating climate change, with a potential to remove between 0.3 Gt and 6.6 Gt of CO₂ per year (IPCC AR6, WGIII), due to its long-term carbon sequestration properties while offering multiple co-benefits