DCI™ is a thermochemical recycling and separation technology designed to process mixed waste and biomass into syngas and a clean, carbon-rich solid residue.
The DCI process is based on gasification, a proven thermochemical concept that has been used for over 100 years, for example in coke production. It combines pyrolysis and high-temperature cracking in a single, continuous step within a smart, continuous-flow reactor.
Both solid reactions and gas cracking take place in one open vertical shaft built from refractory materials. Heat is transferred to the feedstock through radiation from the reactor walls, creating a stable and controlled temperature profile. Near the bottom of the shaft, temperatures reach approximately 1,000 °C. The slow vertical movement of the material ensures sufficient residence time, allowing pyrolysis and cracking reactions to fully complete while minimizing mechanical abrasion.
No external air or oxygen is admitted into the solids shaft. As a result, hydrocarbons are completely converted into gas and solid carbon, producing a clean solid residue that retains most of the original minerals and metals. Agglomeration of solids is minimal, as slag-melting temperatures are avoided.
The produced gas is further heated to ensure the decomposition of complex hydrocarbons such as PAHs, dioxins, and PFAS. The ensuing components are removed at this time, leaving a high-quality syngas comprised of CO and H2. From the hot zone of the reactor shaft, the gas is directed into surrounding gas channels.
All process steps: conversion, separation, and gas cracking take place within the same reactor. The reactors’ design ensures a stable, efficient, and fully integrated system.
To convey the maturity of our innovation we refer to the Technology Readiness Level system, which has steps 1 to 9.
TRL 1 and 2 were covered by our literature study and patent.
TRL 3 was covered during laboratory testing.
TRL 4 & 5 were reached in our pilot called Lab Scale Reactor for DCI™ with a capacity of 4 kg/h
TRL 6 will be reached in our DCI™ with an expected capacity of 6 kg/h.
TRL 7 & 8 will be reached in a demonstration plant which will have an expected capacity of 50-100 kg/h and is part of a 24/7 operating facility.
TRL 9 will be reached in a demonstration plant which will have an expected capacity of 1000 kg/h and is part of a 24/7 operating facility.
2022 - Q3
Our IP became established worldwide after our first patent was issued on July 14th 2022. Following this milestone, we reached Technology Readiness Levels (TRL) 1 and 2.
2022 - Q4
We demonstrated proof of principle that gasification is possible in refractory materials, reached TRL 3, and distributed a detailed report to our sponsors.
2023 – Q1
We commissioned the LSR 80 and began operations with the dedicated DCI furnace. We reached TRL 4 and distributed a report to our sponsors.
2023 – Q2
We began small sample testing in the DCI furnace with the start of micro container tests to repeat the the P.O.P in the LSR 80.
2023 – Q3
We conducted the first oxygen injections in the DCI furnace, reached TRL 5, and distributed a report to our sponsors.
2024 – Q1
The first scale step which increased the shaft diameter from 80 mm to 100 mm to enhance flow volume. Additionally, the initial trials with a new gas cleaning system were started.
2024 – Q2
The commissioning of the LSR 100 brings several advancements, including newly retrievable activated carbon which adds product value from the DCI. Additionally, the first run of a printed circuit board has been initiated to begin complex waste separation. Other developments include the initial processing of waste wood class A and B, and the start of automating the output of the solid products from the DCI.
