Heat olive oil in a large pot over medium-high heat. Add onion, carrots, and sausage, and saute until onion is translucent. Stir in garlic, and cook for 1-2 minutes longer.
Add tomatoes, chicken broth, oregano, basil, chili powder, and salt to the pot. Stir and bring to a simmer. Stir in barley, lentils, and half of kale. When kale has wilted a bit, add the remaining kale, stir to combine, and return to a simmer.
Reduce heat to medium-low, cover, and simmer for 45 minutes. Halfway through cooking time, stir and add up to 1 cup water if stew is thicker than you’d like.
Serve and add hot sauce to individual portions if desired. Great served with crusty bread on a cool night!