NuCoal Process


Integro has developed a cost-effective solution capable of commercial scale. The basic steps in the production of NuCoal are as follows:

1. Raw Material - The Integro NuCoal Process begins with sourcing raw biomass, primarily wood waste, such as tree tops, limbs and thinnings created from saw timber and pulpwood harvesting. Our proprietary systems also allow us to produce NuCoal from agricultural waste, purpose grown crops, and municipal waste.

2. Size & Screen - The material is pre-processed to achieve consistency in size. The biomass is reduced if necessary and screened for foreign objects.

3. Pre-Drying - The material is moved through a process that reduces moisture to a specific level. 

4. Torrefaction - The biomass enters the torrefaction reactor where the remaining moisture is converted into steam as it is heated. This steam becomes the medium used to keep the torrefaction environment inert. The torrefaction process also causes a portion of the dry mass of the feedstock to be converted into an energy-rich gas stream that will be used as fuel to create the heat required for the torrefaction process. Because our process is self-sustaining, our manufacturing carbon footprint is extremely low.

5. Sizing for Densification - Torrefied biomass leaves the reactor and moves through a grinding system that prepares it for densification. At this point, the torrefied biomass is easily reduced to a powder-like consistency.

6. Densification - The torrefied material is densified using modified wood products densification machinery in a novel process. Integro’s proprietary approach to this step is key to the creation of NuCoal.

7. Transportation - The finished product is now ready for shipping. NuCoal is loaded into rail cars (or trucks or barges) for direct delivery to its customers or to local ports for use abroad.