Hydrothermal Carbonization (HTC) is a thermochemical process that converts wet organic biomass into a carbon-rich solid material known as hydrochar. Unlike conventional drying-based thermal processes, HTC operates under pressurized hot water conditions typically between 180°C and 260°C eliminating the need for pre-drying. This makes it a highly practical and energy-efficient solution for processing high-moisture feedstocks such as sewage sludge, food waste, agricultural residues, and municipal organic waste. Kerone’s HTC systems are designed for continuous and batch operations, built to handle diverse biomass inputs while delivering consistent, high-quality hydrochar output suitable for energy generation, soil amendment, and carbon sequestration applications.
Why Choose Kerone Hydrothermal Carbonization Systems
Kerone brings decades of thermal processing engineering into every HTC system it designs. What differentiates Kerone is not just the technology — it is the deep application knowledge that ensures each system is matched to the specific feedstock, throughput requirements, and end-product goals of the client. Kerone’s HTC reactors are built with corrosion-resistant materials, precision pressure and temperature control systems, and integrated process monitoring that reduces operator intervention. The result is a system that delivers reliable hydrochar quality, lower operational costs, and a processing line that scales from pilot to full industrial capacity without redesign.
Types and Features of Hydrothermal Carbonization Systems
Kerone offers both batch-type and continuous-flow HTC reactors, with configurations ranging from laboratory-scale pilot units to multi-tonne per day industrial systems. Batch reactors are well-suited for smaller operations or variable feedstocks, while continuous-flow designs are optimized for high-volume processing with consistent output. Each system includes feed pre-treatment modules, high-pressure reaction vessels, automated depressurization controls, hydrochar separation and dewatering units, and process water management systems. Heat recovery from the exothermic reaction is integrated to improve overall energy efficiency.
Key Features
Operates at 180–260°C with saturated steam pressure, no pre-drying of feedstock required
Continuous and batch configurations available for varying production scales
Integrated heat recovery system reduces external energy consumption
Corrosion-resistant reactor vessels built for long operational life
Automated PLC-based process control with real-time temperature and pressure monitoring
Modular design enables easy capacity expansion and plant integration
Handles diverse feedstocks including sludge, food waste, and lignocellulosic biomass
Produces hydrochar with consistent carbon content, calorific value, and particle characteristics
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Applications of Hydrothermal Carbonization Systems
Kerone’s Hydrothermal Carbonization Systems are extensively used across waste management, energy, and agriculture industries. Typical applications include:
Processing sewage sludge from municipal wastewater treatment plants into stable hydrochar
Converting food processing waste and organic residues into solid biofuel
Treating agricultural residues such as rice husks, bagasse, and manure for carbon recovery
Producing soil amendment materials for agricultural land restoration programs
Generating hydrochar as a feedstock for activated carbon production
Supporting industrial carbon sequestration and circular economy waste reduction goals
As industries across the world face tighter environmental regulations and growing pressure to reduce organic waste sent to landfills, Hydrothermal Carbonization has emerged as one of the most practical and scalable thermal conversion technologies available today. Kerone’s HTC systems deliver the engineering precision, material quality, and operational reliability needed to make that transition viable at industrial scale. Whether you are processing sludge, food waste, or agricultural biomass, a Kerone HTC system provides a proven pathway from waste to value.
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Frequently Asked Questions (FAQ)
HTC is a thermochemical process that uses hot water under pressure to convert wet organic biomass into hydrochar, a carbon-rich solid with properties similar to lignite coal, without requiring pre-drying of the feedstock.
HTC systems can process a wide range of high-moisture organic materials including sewage sludge, food waste, agricultural residues, manure, green waste, and certain industrial organic by-products.
Hydrochar is the primary solid product of HTC. It has a high carbon content, moderate calorific value, and can be used as a solid biofuel, soil amendment, activated carbon precursor, or in carbon sequestration applications.
Kerone's HTC reactors operate in the range of 180°C to 260°C under autogenous saturated steam pressure, typically between 10 and 45 bar, depending on the feedstock and process requirements.
Unlike pyrolysis, which requires dry feedstock and inert gas conditions, HTC uses water as the reaction medium, allowing wet biomass to be processed directly. This significantly reduces pre-treatment energy and cost.
Yes. Kerone provides laboratory and pilot-scale HTC systems for process validation, feedstock testing, and product quality assessment before scaling to full industrial capacity.
HTC is a slightly exothermic process. Kerone's systems incorporate heat recovery from the reaction to pre-heat incoming feedstock, improving overall thermal efficiency and reducing external energy input.
Yes. The process water from HTC contains dissolved organics and nutrients. Kerone's systems include process water management options such as anaerobic digestion integration or nutrient recovery for agricultural use.
Kerone designs HTC systems with throughput capacities ranging from small batch units processing a few hundred kilograms per batch to continuous systems handling several tonnes of wet biomass per hour.
Yes. HTC is one of the most effective technologies for sewage sludge treatment. It reduces sludge volume, destroys pathogens, and converts it into a stable, carbon-rich material that is easier to handle and dispose of or utilize.
Kerone designs its pressure vessels and process systems in accordance with applicable industrial pressure vessel standards and safety codes, including compliance with CE, ASME, or local regulatory requirements depending on project location.
Typical HTC residence times range from 1 to 12 hours depending on feedstock type, target hydrochar quality, and operating temperature. Continuous systems are designed to optimize this for maximum throughput.
Yes. Kerone conducts feedstock characterization and process trials to tailor reactor design, operating conditions, and product quality targets for each client's specific input material.
Routine maintenance includes inspection of pressure vessel seals, heat exchanger cleaning, instrumentation calibration, and periodic checks on the feed and discharge systems. Kerone provides maintenance schedules and training.
Yes. HTC significantly reduces organic waste going to landfill, lowers greenhouse gas emissions compared to conventional disposal, and produces carbon-stable materials. Kerone's systems are designed to meet environmental emission and discharge standards.
Kerone’s custom-designed heating and processing solutions are built to meet the demands of your growing operations. Whether you’re upgrading equipment, expanding production, or need a tailor-made solution
Peru
Chile
Argentina
Mexico
Colombia
Brazil
USA
Canada
United Kingdom
France
Germany
Spain
Italy
Netherlands
Sweden
Switzerland
Poland
Portugal
Ireland
Czechia
Romania
Hungary
Austria
Greece
Kazakhstan
Uzbekistan
Turkmenistan
Algeria
Egypt
Nigeria
Kenya
South Africa
Saudi Arabia
UAE
Israel
Russia
India
China
Japan
South Korea
Thailand
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Malaysia
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