Crusader Engineering: offering continuous technological improvement
and development
Standard industrial sized biochar kilns.
A very small hobbyist’s kiln that is ready to “fire up”. The lower chamber is the burner box or fuel; the upper chamber is the pyrolysis chamber where the magic happens.
Timber treatment plant.
Industrial pyrolysis combustion chamber. All images: Crusader Engineering
Since its inception in 1984, Auckland-based Crusader Engineering has evolved into an innovative design, mechanical and process engineering company exporting a range of excellent products worldwide. Timber & Forestry enews invited Howard Snoad, Director, to outline the company’s biochar and timber treatment capabilities.
BIOCHAR PROCESS KILNS
Mr Snoad says Crusader Engineering “offers a proven, highly effective and simple way to help with the very complex issue of climate change – within our chosen field of timber processing and forestry.
“Our systems produce the incredible biochar – a charcoal-like substance created by the pyrolysis of biomass, which includes wood, bark, sawdust, etc. Biochar effectively locks in solid carbon and helps to rejuvenate precious agricultural lands, and reduce landfill volumes and disposal costs (including CCA-treated timbers) – plus it has a myriad of other great qualities.
“In combination with our expert technical Māori partners, we are highly experienced pyrolysis engineers at the forefront of research and development for an environmentally sustainable biochar future.
“We have successfully designed and built multiple robust, reliable and practical pyrolysis biochar kilns of all sizes for New Zealand industry – some powered by waste wood instead of fossil fuels. They include large industrial pyrolysis systems for urban wastes approved by local authorities; viable, large-scale modularised and transportable systems; or small hobbyist kilns.
“Our kilns are especially effective in areas dealing with a significant excess of biomass – such as forestry slash, timber processing sites and landfills.
“Timber processors often use their waste wood materials to power boilers for heat or power. However, we can incorporate the waste heat energy from the wood-fired pyrolysis kiln into the boiler process.”
Mr Snoad is keen to emphasise that biochar is more valuable than just being used as boiler fuel. “Potentially it can become a revenue stream, while helping with climate change and positive public relations.”
Further, he notes that Pari Rikihana, a previous customer, has successfully teamed with Crusader. “Pari has been designing and running various pyrolysis systems for the last 20 years, so is very experienced with practical processes and general know-how in assisting our customers. He has worked with a number of prestigious entities including Massey University, Solid Energy and Rayonier, just to name a few – as well as different councils around New Zealand.
“His work includes a proprietary plug flow reactor, primarily developed to process CCA-treated timber in our pyrolysis combustion chambers to meet New Zealand’s arsenic emission standards – and to reduce CCA biochar/wood volumes, lock carbon in the ground, and reduce disposal costs at landfills.
“The reactor took Pari and his team many years and a significant monetary investment to develop – and included important assistance from Brett Oldfield, the owner of Combustion Control Limited here in Auckland.”
TIMBER TREATMENT
Mr Snoad adds that Crusader Engineering is also an independent manufacturer of timber treatment plants (TTPs). “We not only work with timber processors – but also, historically, with reputable international chemical preservative suppliers, keeping us at the forefront of plant design, and health and safety.
“Our world-class process control and management reporting software gives our clients the advantages of complete software (and hardware) autonomy and flexibility.
“We offer a custom service, supplying compliant plants that meet customers’ existing and future requirements. They range from large automated and sophisticated ‘turnkey’ systems to small, manual self-contained plants for the smaller or remotely situated operator.”
He adds that Crusader Engineering supplies quality, robust equipment, using superior componentry from reputable suppliers. “Our TTPs have proven to be excellent value for money, which is why we’ve had a good number of repeat business customers.
“We supply both aqueous and solvent (LOSP) based preservative TTPs, and have enjoyed exporting some 12 projects to Australia – and six more into Southeast Asia, Fiji, the USA and the United Kingdom over the years.”
Crusader Engineering has also undertaken numerous upgrades and additions to existing plant and software systems, and continues to offer ongoing and comprehensive customer support.
Mr Snoad says the firm has also developed a radio frequency (RF) technology for its LOSP solvent removal and recovery system from timber with very low moisture contents.
“Furthermore, with RF we can also dry biomass down to similarly very low moisture contents to sterilise materials. An example of this is the proven ability to kill Legionnaires’ disease in potting mix.
“Our philosophy remains one of continuous improvement and development, correctly believing that our future lies in offering the best and most up-to-date technology available.”
