Wood energy conference
Oct. 8th 2004 Cork Ireland
BIOMASS PELLETING Industrial production of wood pellets Why? What? How? How much? By: Peter H.D. Lange Sales manager CPM/Europe
Wood energy conference
Oct. 8th 2004 Cork Ireland
Who is CPM California Pellet Mill Roskamp/Champion since 1883 TYPE OF BUSINESS: EQUIPMENT FOR PELLETING AND PARTICLE SIZE REDUCTION MAIN OFFICE BASED IN: USA ANNUAL TURNOVER Over €70Mi l l i on TOTAL NUMBER OF EMPLOYEES: over 300
Wood energy conference
Oct. 8th 2004 Cork Ireland
CPM worldwide • • • • • •
MANUFACTURING SITES MERRIMACK / USA CRAWFORDSVILLE / USA WATERLOO / USA AMSTERDAM / EUROPE WEXFORD / EUROPE SINGAPORE / ASIA
TRADE REPRESENTATIVES • OVER 50 OFFICES COVERING AMERICA, EUROPE, ASIA, AFRICA AND AUSTRALIA
Wood energy conference
Oct. 8th 2004 Cork Ireland
Why biomass pelleting? Pellets are: Dust free: reducing dust explosion potential minimizing particle emission Uniform: more efficient control of combustion
Wood energy conference
Oct. 8th 2004 Cork Ireland
Why biomass pelleting? Pellets are: Free flowing: facilitating material handling and rate of flow control Increased bulk density: more BTU’ s per volume unit economies storage and transportation
Wood energy conference
Oct. 8th 2004 Cork Ireland
Why biomass pelleting? Fuel for Burning •ø 6 / 8 mm: household stoves •ø 8 / 18 mm: Industrial •Energy level: 5 kWh/kg •Compared to Oil: 1 ltr oil = 2 kg Wood pellets
Wood energy conference
Oct. 8th 2004 Cork Ireland
Biomass applications •Wood •sewage sludge •RDF •Coal •Sunflower hulls •Bagasse •Peat •Meat and bone meal •Others
Wood energy conference
Oct. 8th 2004 Cork Ireland
Raw material sources Saw dust • Chips / dust from sawmills • Size usually 2 x 2 x 15 mm • Moisture content usually 50-60%
Wood energy conference
Oct. 8th 2004 Cork Ireland
Raw material sources Shavings Fines from; • Cutting / Sanding / Machining dried planks • Moisture content usually 6 –12%
Wood energy conference
Oct. 8th 2004 Cork Ireland
Shavings from furniture industry Hard wood can be used as well as soft wood, like: •Beech •Oak •Pine •Sprous
Wood energy conference
Oct. 8th 2004 Cork Ireland
Logs are cut in the sawmill Logs are sawed into planks
Wood energy conference
Oct. 8th 2004 Cork Ireland
Raw material sources Waste woods Used pallets • Window frames / doors from destruction of buildings • Moisture content usually 8 –12%
Wood energy conference
Oct. 8th 2004 Cork Ireland
Oversize product is shredded Product is passing hand picking line
Wood energy conference
Oct. 8th 2004 Cork Ireland
Chips are ground Chips in..
Champion hammer mill with 75 kW producing approx 4 t/h …saw dust out
Wood energy conference
Oct. 8th 2004 Cork Ireland
Saw dust is dried and pelleted Drum type dryer as well as belt dryers
Saw dust is pelleted
Wood energy conference
Oct. 8th 2004 Cork Ireland
Pellets can be marked Pellets are encoded to indicate pellet producer and production batch, assuring quality standards.
Wood energy conference
Oct. 8th 2004 Cork Ireland
… bagged and packed …
Wood energy conference
Oct. 8th 2004 Cork Ireland
Final destination of the pellets
Wood energy conference
Oct. 8th 2004 Cork Ireland
The challenge Fr om wast e…
….to fuel
Wood energy conference
Oct. 8th 2004 Cork Ireland
The CPM technology
A Pelletmill compresses mealy or powdery materials through a ring die into A-class granules.
Wood energy conference
Oct. 8th 2004 Cork Ireland
Pelleting process CPM FLOW DIAGRAM PELLETING INSTALLATION AIR ASSIST HAMMER MILL
1.60
COOLER ASPIRATION
6.40
BELT MAGNET
SAWDUST CONVEYOR
RAW MATERIAL INPUT
WATER AND STEAM ADDITION 2.10
1.40 6.20
MIXER
3.10 RIPENING MIXER
1.50 DOSING SCREW
1.10
HAMMERMILL 1.20 1.30
PELLETS CONVEYOR
6.30
FINES FINES AIR AIR ASSIST ASSIST HAMMER HAMMER MILL MILL
6.10
4.10 FEEDER MIXER
COUNTERFLOW COOLER
5.10 PELLET MILL 7.10
SCREW CONVEYOR
SIEVE
SAWDUST BACK TO PROCESS
FILE: FLOWDIAGRAM 1A DATE: 19-JULY-2002
PELLETS CONVEYOR FINISHED PRODUCT
PRODUCT COOLER ASPIRATION AND HAMMER MILL ASSIST WATER ADDITION
Wood energy conference
Oct. 8th 2004 Cork Ireland
Grinding Contact Point
"Flow Director"
Primary Destruction Zone Full Hammer Tip Speed Zone
Acceleration Zone
"Regrind Chamber"
Champion hammermills: •Robust heavy duty grinders •Wear cost extremely low •Around €0,05 per ton depending on sand content
Wood energy conference
Oct. 8th 2004 Cork Ireland
Ripening / Conditioning [1]
415
[2]
Wood energy conference
Oct. 8th 2004 Cork Ireland
Ripening / Conditioning RIPENING AND MIXING BIN AS KEY ELEMENT Advantage: •Homogenizes the raw material •Gives the possibility to add more water if needed •Reduces energy consumption up to 10% •Higher capacity 415
Wood energy conference
Oct. 8th 2004 Cork Ireland
Raw material is pelleted
Wood energy conference
Oct. 8th 2004 Cork Ireland
The CPM pellet mills Model 7900 pellet mills • 7930-4 with 250 or 315 kW • Capacity 4 –5 t/h
Wood energy conference
Oct. 8th 2004 Cork Ireland
Dies and rollers •Wear cost for pelleting approx. €1 per ton, depending of type of wood and sand content
•Dies designed to withstand pelleting forces
•Special roller design for wood applications
Wood energy conference
Oct. 8th 2004 Cork Ireland
Cooling and sifting •Cooling the pellets to facilitate storage
•Low / no maintenance •Low energy consumption
Wood energy conference
Oct. 8th 2004 Cork Ireland
Energy consumption Transport
Grinding
Pelleting
Cooling
5 kWh/t
15 kWh/t
60 kWh/t 2,5 kWh/t
Various
Total
2,5 kWh/t +/- 85 kWh/t
Wood energy conference
Oct. 8th 2004 Cork Ireland
I t ’ sall about cost per ton!! RELATION INVESTMENT TO PRODUCTION CAPACITY
Optimum size for a production line • Investment per ton per hour • Operating cost per ton • Labour cost • Technical limitations • Practical limitations
pelleting
€2, 500, 000
€2, 000, 000
conditioning RELATION INVESTMENT TO PRODUCTION CAPACITY
€1, 500, 000
cooling
€1, 000, 000
sifting
€500, 000
controlls and electrical installation
€0 1
5
15
PRODUCTION SIZE IN T/H
30
transport, bins, installation and engineering
INVESTMENT PER TON PRODUCTION CAPACITY IN EURO
T O T AL IN VEST M EN T IN EU R O
grinding
€500, 000 €450, 000 €400, 000 €350, 000 €300, 000 euro/ton
€250, 000
tph
€200, 000 €150, 000 €100, 000 €50, 000 €0 1
5
15
PRODUCTION SIZE IN T/H
30
Wood energy conference
Oct. 8th 2004 Cork Ireland
Operating cost per ton Operating cost per ton. Electrical, consumables and Maintenance; Around €7,- to €9,- per ton.
operating cost per ton 40 30 eu ro
operator
20 10
consumables & maintenance
0
energy (electrical) 1
5
15
ton per hour
30
Operator cost depending on capacity and country! A 20 euro/hour operator can make 1 t/h or 15 t/h 20/1 = 20 ,- euro/ton 20/15 = 1,33 euro/ton
Wood energy conference
Oct. 8th 2004 Cork Ireland
Team up with the specialists Team up with CPM • Knowledge • Experience • Global network • Low operating cost • Reliable equipment • 24 x 7 x 52
Wood energy conference
Oct. 8th 2004 Cork Ireland
THANK YOU FOR YOUR ATTENTION
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