This article focuses on the technical implementation of a biochar monitoring system. While the previous article discussed the biochar process and the MRV context, here the emphasis is on how such a system can be implemented in practice, using standard industrial components and proven integration approaches. For a broader overview of the biochar process and MRV requirements, see our previous article on biochar MRV monitoring.
Core device: 4G LTE universal I/O module
At the center of a typical biochar monitoring system is a 4G LTE universal I/O module, such as the TCG140-4.
The device acts as the local data collection and control point, handling sensor inputs, basic logic, and communication with remote systems over cellular networks. It operates independently on site and does not rely on fixed internet infrastructure, which makes it suitable for installations in remote locations.
The TCG140-4 also provides stand-alone alerting functionality, including email and SMS notifications, without relying on external software. Alerts can be triggered by sensor thresholds, missing data, device errors, or communication failures, ensuring that critical events are reported immediately.
Overall system architecture
The system architecture is intentionally simple. Field sensors and industrial devices are connected to the TCG140-4 using standard digital interfaces, most commonly Modbus RTU or 1-Wire. The module periodically reads data from connected devices, stores measurements locally, evaluates alarm conditions, and transmits selected data over cellular networks.
This modular approach avoids tight coupling between hardware and software and allows system integrators to select sensors based on technical and regulatory requirements rather than platform limitations.
Kiln temperature monitoring
Kiln temperature is one of the most critical parameters in the biochar process. Temperatures in the range of 500–700°C are typically measured using thermocouples with external metal probes. These probes are connected to an industrial temperature module with a Modbus RTU interface.
A module such as the TST320 allows thermocouple measurements to be read digitally by the TCG140-4. Using a digital interface improves reliability in industrial environments, reduces noise sensitivity, and simplifies long-term maintenance.
Methane (CH₄) monitoring
Methane monitoring is implemented using fixed industrial gas detectors installed near the pyrolysis and gas handling equipment. These sensors are designed for continuous operation and provide digital outputs suitable for integration into monitoring systems.
In this setup, methane sensors from European manufacturers such as MSR-Electronic (MSC + SC series) are commonly used. Sensor data is read by the TCG140-4 and evaluated locally. Abnormal values can trigger immediate SMS or email alerts, while all measurements are logged for later analysis and MRV reporting.
Weighbridge and material flow data
Material flow data is another key input for MRV. Biomass input and biochar output are measured using a weighbridge system. In this setup, the Laumas WTAB-BR weighbridge indicator provides weight data via Modbus RTU.
By integrating weighbridge data directly into the same monitoring system, material flows become part of the same data set as temperature and gas measurements. This improves traceability and reduces reliance on manual records and spreadsheets.
Monitoring software: local or cloud-based
On the software side, collected data can be forwarded either to third-party monitoring platforms or to a dedicated solution such as TC Monitor.
TC Monitor can be deployed as a local server installation or used as a cloud-based service, depending on project requirements.
The software provides dashboards, historical charts, and long-term data storage, supporting both daily operations and MRV reporting. While basic alerting is handled directly by the TCG140-4, the software layer enables centralized monitoring across multiple sites and users.
From measurements to MRV data
A biochar monitoring system is not only about collecting measurements. It is about creating a consistent and auditable data flow. When temperature, gas, weight, and system status data are collected automatically and stored in a structured way, MRV reporting becomes a natural extension of normal operation rather than a separate manual process.
This approach makes it possible to scale biochar monitoring systems across multiple sites while maintaining transparency, reliability, and data integrity.