Sampangan “Magic Box” Carbonization Technology

Sampangan technology, “The Magic Box”, has the ability to process biomass into valuable outputs
such as biochar and more, which we use in downstream circular implementations such as
regenerative agriculture, sustainable construction materials, and more.

Overall Technology Concept

The Carbonization technology uses thermal
radiation system with 3 main processes in 1
machine:
1. Main Carbonization Reaction
Chamber
Heat radiation. Combination of
pyrolysis and gasification processes
2. Carbon Quenching Chamber
Rapid cooling of carbon process
Fig 1 : The “Magic Box” Carbonization
Technology 3. Hydrolyzed Cyclone Reactor
Hydrolysis and condensation process
occurs.

The Science Behind the Technology

In general, biomass does not gasify as easily as coal, and it produces other hydrocarbon
compounds in the gas mixture exiting the gasifier; this is especially true when no oxygen is used.
Current common technologies to breakdown waste/biomass materials are pyrolysis and
gasification, these two are thermochemical processes. The key difference between pyrolysis and
gasification is that pyrolysis is done in the absence of air while gasification is done in the
presence of air (limited supply of oxygen). Each process has advantages and disadvantages.
Pyrolysis has a lower carbon conversion rate than gasification but it can process tar better than
gasification.

That is why Dr. Ishenny Carbonization Technology combines pyrolysis and gasification plus using
biocatalyst to process the waste/biomass. Combining pyrolysis and gasification results in a
better carbon conversion rate and in processing tar and other harmful materials for the
environment and human body. We also use biocatalyst to process that so we have lower the
energy needed. Furthermore, we use enzymatic hydrolyzed cyclone reactors to immediately react
with the flue gas produced from the reactor with water and biocatalyst and transform it into liquid
smoke and steam.
Specifications
- Input Capacity
Approximately 15 m3 per day, up to 10 tons per day (depending input material density)
- Components
- Hydro cyclone : 5 reactor tower hydrolyzed cyclone
- Capacity : 1 kL/day
- Compressor : 1 HP
- Water pump Head : 30 m2 unit
- Temperature max. : 1000 °F
- Pressure : 1 atm
- Stick mechanical : Carbon unloading
- Panel switch on/off: Remote control

- Machine Size Dimension

Carbonizer : 240 cm (L) X 121 cm (W) X 185 cm (H)
Reactor : 210 cm (L) X 100 cm (W) X 110 cm (H)

- Working area dimension

20 m x 20 m = 400 m2 (including loading area)

- Energy
a. For electronics and moving parts
The Magic Box energy source is from single-phase power electricity 220 V/7000
Watts.
b. For heat energy in the main chamber
Potential energy from the biomass/waste input. No external energy source required
(not diesel, not electricity, not biomass)

- Biocatalyst
Dr Ishenny Biocatalyst (trade secret)

- Machine Operations
24 hours, 3 shifts

- Operational Days (excluding maintenance and holidays)

288 days per year

- Product Output from Process

a. Activated Carbon / Biochar
b. Liquid Smoke
c. Liquid Carbon
d. Electricity (module in development)
Process Scheme
Process Flow Diagram of Sampangan Technology

Fig 2 : Process Flow

Fig 3 : Estimated conversion rate for 100% biomass input

Process Breakdown
Here are the Sampangan Technology process breakdowns.

Step 0: Kickstart the temperature from room temperature

We use organic biomass to kick start the main chamber temperature to 150 °C by burning the
biomass inside the main chamber for approximately 30 mins. Once it reaches 150 °C
temperature, the machine can continue operating continuously and create circular energy
creation from the waste/biomass input.

Step 1: Input
Spray Dr Ishenny biocatalyst (oil on an enzyme basis) to the waste/biomass input. Insert the
biomass into the main Reaction chamber. Insert a new batch every 30-60 mins (Fed-batch
method).

Step 2: Carbonization Process

The carbonization process starts when the materials enter the reactor by a fed-batch system with
an average process per batch is 30 minutes with feeding rhythm 20
min approximately and residency time 1-3 hours. The operating temperature and pressure in the
reactor range from 100 – 400 °C (will be stable at ± 200 °C later) and 1 atm. In continuous
operation, 24 hours/day, this reactor is capable of processing 15m3 or around 10 tonnes of
biomass. From this operation, the waste will turn to solid carbon with a yield range from 10-20%
and flue gas.

Step 3: Hydrolyzed Cyclone Reactor Process

The flue gas from The Magic Box Carbonization Reactor which contains SOX, NOX, COX, and vapor
will enter the hydrocyclone reactor to be reacted with water and biocatalyst to create liquid smoke
and steam. This process reacts the flue gas into liquid smoke and this can be proven by the
properties of liquid smoke which are: phenol, carbonyl, and acids compound. It also proved not
explosive, not flammable, not reactive, and not corrosive.
 Source : Sucofindo lab test for Sampangan liquid smoke
This proves that all flue gas components are reacted to become liquid smoke that ensures no
dangerous emission is released to the environment. On top of that, around The Magic Box we use
PM Index and CO2 sensor tools that show the PM Index is around 90-95 µg/m3 PM 2.5 and
115-125 µg/m3 PM 10; also the CO2 index is around 550-650 ppm. Environmental permits and
own measurements show low greenhouse gas emissions.

Step 4: Carbon Quenching Process

The solid carbon will then enter the cooling chamber to transform to biochar and liquid carbon.

Step 5: Output
After the input through all the process inside The Magic Box, it becomes:
1. Biochar / Activated Carbon (2-30% yields of organic biomass input)
2. Liquid Smoke (700 liters per day per machine)
3. Liquid Carbon (300 liters per day per machine)
Technology audit, registrations, certifications and lab tests

Source : Magic Box Certifications and Lab tests