PRODUCTION LINES FOR PELLETS

Pellets are modern ecological fuel, which in its production uses biomass renewable sources. Advantages are high calorific value and the possibility of heating the boiler automatically without manual reloading. This type of fuel is very easy to handle, transport and store. The heating comfort is therefore close to the heating comfort when using gas.


WOODEN PELLETS

Waste from wood production is used for their production – sawdust, clean shavings and wood chips without bark

AGROPELLETS

The initial raw material is mostly straw, which would otherwise find no meaningful application. Agro pellets may not only be used for heating, but also for hygienic litter and can then be used in a biogas plants.


PRODUCTION LINES FOR BRIQUETTES

Briquettes can replace classical pieces of wood in heating. Wood waste with a bark can be used in their production. Big advantage is using the so-called “night briquettes” with longer burning time.


COMBI PELLET / BRIQUETTE LINE

Thanks to a modular solution, pellets and briquettes can be produced simultaneously on a single CON-PELET®

Our main goal is to find economically, technically and logistically optimal solution for our customer.
For that purpose we designed a compact line CON-PELET® 1000 COMPACT with the capacity of 1 ton per hour. When a higher capacity is requested we use the CON-PELET® TWIN where the capacity is doubled. From these two basic assemblies we than create an individual solution according to a specific wish of our customer. The design is mainly affected by the type, size and conditions of the feedstock and the finished product requirements.

Great attention was also paid to the reliability of the line. Although the line runs fully automatically, it is built modularly, allowing among other things, to optimize its performance asccording to the existing sales of pellets.

When designing the line we put the greatest emphasis on its economy. The line is simple, reliable and only 2-3 people are needed for its operation, depending on the method of packaging. The line CON-PELET® 1000 COMPACT consumes less than 100 kWh of electricity per 1 ton, which is a crucial parameter for the economical operation of the line and its profitability. The competition grows with the increasing popularity and consumption of pellets and the price is being pushed down towards the production costs. Therefore the level of production costs is important for the return on investment.

The line is composed of separate sections, allowing its operation even in the necessary maintenance procedures and replacements of worn parts in one of the sections. For cases of such a necessary downtime, you can for example sort and dry the input raw material for this period of time in advance. The main section is the pelletising section which consists of two separate presses with the capacity of 500 kg/h each and matrices with extended service life. Therefore, when changing the matrices, the line does not have to be switched off and can continue to operate at reduced capacity.

The bennefits of our technology CON-PELET®

  • The line is designed modularly and in case of any failure in one of the modules, the other parts of the line can operate independently
  • Low energy consumption (below 100 kWh/1t of pellets)
  • Low personnel costs (2-3) trained workers
  • 2 parallel pressing units with extended service life
  • Section for gross material sorting, which eliminates the possibility of unwanted and abrasive materials like gravel, sand, metals or larger particles of the processed material causing any production problems. This protects the rest of the line from demage and prolongs the service life.

The output of CON-PELET® 1000 COMPACT

We are able to provide a technology with the daily output of 8 tons of pellets (one-shift production) up to 48 tons of pellets when choosing the CON-PELET® TWIN and operating in three-shifts.

Energy

Total electric power input of the line is 196 kW

Dimension of the line

Layout of the line including sorting section:

  • Width x length 12 x 27 m

Recommended dimensions of the hall:

  • Width x length 15 x 60 m (space for the line and storage of operational materials and finished products)
  • Height of the hall siding at least 5 m and height of the gable wall in the ridge at least 7 m

Recommended flooring:

  • Concrete, thickness at least 50 cm, maximum inequality 1 cm/1 m

The line equipment

  • Input conveyor, chain conveyor with a reservoir 1800x600x500 mm
  • Vibrating screen wit the output of 8-12 spcm per hour
  • Screw output conveyor
  • Input hopper
  • Feeding conveyor to the crusher
  • Crusher
  • Air transportation ventilator
  • Dust filtration
  • Intermediate container
  • Feeding conveyor to the press 2 pcs
  • Press 500 2 pcs
  • Vapor and dust extractor 2 pcs
  • Cleaning vibrátory conveyor 500 2 pcs
  • Cooling conveyor 500 2 pcs
  • Big bag holder 2 pcs
  • Electrical installation switchboard
  • Control panel
  • Pipelines and cables
  • Mixing plant electrical installation switchboard
  • Switchboard
  • • Hopper with w screw conveyor with a capacity of 2-3 m
  • • Hote air boiler with a 600 kW burner
  • • Drying drum with dividers and blades
  • • Hopper with a screw conveyors
  • • Separator of solid particles
  • Packing pellets is solved individually according to customer´s requirements.
  • Packing in big bags – basic and the simplest solution
  • Packing in PE bags of desired weight (5-15 kg)

There is a rough sorting to ensure the removal of large pieces of wood and any undesirable additives and contaminants. The sorting is performed by removable sieve with an optional mesh size, typically 15-30mm. Only material suitable for the processing falls through the sieve. The remaining “dirt” remains on the belt. Sorted material is in the input storage of the cylinder drying machine fed by using the automatic regulation by a screen conveyor.
The capacity of the storage is conceived to hold 1,7 ton (8-12 m3) of raw material with the natural humidity, which corresponds to the consumption of raw materials needed for one hour of production

Accessories for the dryer consist of a dosing conveyor and a hopper. Dosing conveyor provides transport of material from the hopper to the drying drum. The sorted out material of volume up to 2 m3 is collected in the hopper.

The movement of the material and hot combustion gases are during drying in cyclone ensured by a fan. The main cyclone is welded from a steel plate and its upper part is of a cylindrical shape. The lower part has a frustoconical shape. The conical part is ended by a flange for turnstile. The turnstile consists of a cast-iron casing and a rotor with blades.
The advantage of our solution is that the material can either flow into the storage and continue in the process or can be transfered to a separate container or an open area with another conveyor in order to create a reserve for possible future use. Material for the reserve can be dried regularly but also in the case of a shutdown of any part of the line in order to prevent economically inefficient operation of the line.

It contains all the electrical equipment of the entire line – circuit breakers, main switches, etc.. The control panel for the line, which is not shown in the diagram above, will be constructed at a convenient location according to a space available.

The material is from the crusher transported through another filter into the storage container. Below the container there is a homogenizer, which is equipped with a sprinkling system in order to regulate the optimum moisture of the feedstock material before processing. There are discharge conveyors leading from the homogenizer, which dispense the optimally processed material into the pellet press.

It is designed for different cooling intensity. Filling into big bags requires less cooling than direct filling into bags. In terms of energy consumption, it is more effective to fill the pellets in the big bags first and then into bags after they are cooled down.

Bagging plant, where the pellets are packed into 10-25 kg bags can be connected to the line or can operate separately. In such a case it is advantageus that the bagging plant does not have to be a part of the pellet line and can be transfered to another section of production plant as needed.

Part of the cylinder drying machine is a hot air bolier with a 600 kW burner with which the sufficient drying temperature is ensured, based on the desired moisture on the output. For efficient operation, it is recommended to turn the boiler on approximately 1 hour prior to first drying.

Part of the cylinder drying machine is a hot air bolier with a 600kW burner. The material intended for drying is regulated and sucked with a fan together with the flue gas into the inner drum shell. At the end of the shell is the flue gas stream and the partially dried mass turned in space between the middle and inner drum shell, it is turned again and after passing between the middle shell and the outer shell, the dried material including the flue gas is sucked out into the cyclon. During this process, the drum rotates around its axis, so that the material is constantly being shaken up through the blades and due to the flow of the hot flue gases and progresses through the dryer.

It serves as a storage of dried raw material and is then transfered into the grinder. In case of downtime of the sorting section or the dryer it is possible to dispense the material from the reserve directly into the storage bin.

It ensures a constant granulometry of the output material. It is a hammer mill, which due to adjustable grinding size unifies the input friction prior to homogenization and compression to the desired size.

It processes the material without chemical additives. It is the final output of the pellet line. The press consists of a removable matrix and pressing elements. The advantage of two pellet preses is both the eventual gradual aquisition but mainly the possibility of operation of at least one press in case of a planned shutdown. Another advantage is the possibility of having one press for pellet production and one for briquette production. A different way of packing is needed for the briquette press.

The filling into big bags has numerous advantages. The line automatically throws the pellets into big bags and no personnel is needed, as it is in the case of bagging plant. The big bag has to be exchanged with an empty one once every two hours. With an effective use of human resources it is a powerful tool which allows a good utilization of production time of the personell operating the line

Contact Contechin

Ask for indicative price quotation for a specific technology.

CONTECHIN s.r.o.

Adress: Úzká 162, 790 81 Česká Ves
ID: 01814745 Tax ID: CZ01814745