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The Role of Sieve in Biomass Pellets Production

Biomass pellets are a very characteristic product, which must be characterized with high burning quality. However, the unavoidable dust and fines mixed with biomass pellets will affect the burning effect. Therefore, a sieve is a good choice in biomass pellet plant, which can separate the dust and fines from the acceptable quality product.

Reasons for Fines Production

In the biomass pellet production, the part of raw material particles which are not stuck together is called fines. Inadequate pressure inside the pellet mill and insufficient binder are the main factors that result in higher percentage of fines. The harder the pellet is, the less fines it results in. If the pellets are not mechanically strong enough, they will easily shatter into fines in the process of delivering or packaging. It must be noticed that the final pellets with more fines can not meet the requirements of quality standards. Therefore, how to reduce the fines percentage should be the a key matter that the pellets producer should think over.

Sieving Process of Biomass Pellets

Sieves are used to separate the unqualified pellets or granules, and screen off the fines, which has a vital influence on the quality and capacity of biomass pellets. After cooling, the fuel pellets are fed into the industrial sieve, where the broken biomass pellets are separated from the complete ones. The separated fines can be recycled as raw materials for pelletizing, which can not only minimize the biomass losses, but increase the conversion rate of biomass to pellets. Grading according to different sizes of pellets can also be achieved through the sieve. However, if the pellet mill process the raw material in the correct operation way, the fines content can be reduced and this step can be skipped.

How to Increase the Biomass Pellet Capacity through the Sieve?

* The length and width of the screen determine the sieving efficiency and wood pellet mill capacity respectively. In order to increase the capacity, we can feed the screen in its full width, thus increasing the capacity of pellet mill and making full use of the screen.

* Increase the number of sieve tray holes. The more holes, the more materials pass through the screen, which is conductive to improving sieving effect and increasing wood pellet mill capacity.

* If possible, it is better to adopt wet screening. It can not only increase the capacity, but lessen the escape of dust, which is good for the environmental protection.

* Adjust the angle of the wood pellet mill. Proper angle is helpful to decrease the thickness of materials, achieving thin layer sieving.

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Making Sunflower Husk Pellet in Ukraine

Biomass pellets are becoming more and more popular throughout the whole world, which are often produced from wood residues or agricultural crop wastes. Therefore, pelletizing can be considered as way to make use of biomass residues that would otherwise remain unused.

Advantages of Making Sunflower Husk Pellet in Ukraine

* In Ukraine, sunflower is the chief oilseed crop. Because of the combination of high price, relatively low cost of production and traditionally high demand, sunflower has become one of the most consistently profitable crops. However, for the sunflower seed oil manufacturers or sunflower seed processors, how to deal with the useless sunflower husks has become an annoying problem. Turning sunflower husks into pellets is precisely the sensible strategy.

* It’s rather explainable that sunflower husk pellets get more and more popular both in Ukraine and all over the world. Such pellets are cheaper than wood ones, moreover they could be used (even more effectively) instead of gas and coal, which pollute the environment and get more and more expensive. After pelletizing, the density is improved largely, the ash content and moisture content are lower. And the sunflower husk pellets do not include dust and spores from plants. Therefore, sunflower husk pellets can burn longer, cleaner and more efficient than sunflower husk. In addition to their compact package, sunflower husks pellets can be stored and delivered through long distance without additional troubles and costs. All these factors indicate that the sunflower husk pellets are a kind of renewable, clean and eco-friendly fuel energy.

Sunflower Husk Pellets Production in Ukraine

Total pellet production in Ukraine is estimated to have reached 240 thousand tons per year. 50% of this amount are pellets and briquettes from sunflower husk and straw.

In the sunflower husk pellets market, a growth rate of 27% in the number of pellet traders and of 50% in pellet producers has been observed in the first half of 2011 compared to 2010. Sunflower husk feedstock is naturally cheaper during the oil-extracting period. In 2010 until the first half of 2011 there were 102 sunflower husk pellets traders and 32 producers operating in the market. Among the regions, the largest number of traders came from Zaporizhia, Kyiv, Kherson and Donetsk regions.

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Making Bagasse Pellets in Vietnam

Vietnam, with the tropical monsoon climate and subtropical monsoon climate, is very suitable for the growth of sugarcane. The sugarcane grows fast and can be planted in the whole Vietnam. After harvest, the crop produces sugar juice and bagasse. With the help of wood pellet mill, bagasse, the fibrous dry matter can be recycled into biomass pellets for energy production.

Traditionally, bagasse is used as fuel for the boilers and kilns, a fiber for paper production, agricultural mulch and raw material for chemicals production. Even so, bagasse is still regarded as a burden instead of blessing due to the accumulation of million-ton bagasse each year. Therefore, strategically solve the problem of bagasse transportation and storage is required.

Advantages of Making Bagasse Pellets

Turning the bagasse into pellets not only enhance the value of agricultural production process, but also contribute to environment protection. In the combustion process of bagasse pellets, emissions of sulfur dioxide and nitrogen oxides are lower than conventional fossil fuels due to the low levels of sulfur and nitrogen contained in the bagasse. Besides, the process is dust-free, reducing dust explosion potential and minimizing particle emission.

As sugarcane is a seasonal crop, after the harvest, the supply of bagasse would reach to peak shortly. After pelletizing, the volume is decreased and bulk density is increased greatly. So more BTU contains in per volume unit. Pelletizing can not only solve the problem of storage and transportation economically, but improve the burning efficiency of bagasse efficiently. Besides, the bagasse pellets can be the feed ingredient.

How to Make Bagasse into Pellet Fuel

Vietnam is one of the biggest sugarcane producers, every year large amount of bagasse are accumulated. In Vietnam, the common machine for bagasse pellets in industrial production is the ring die wood pellet mill, which is much more suitable for large-scale production. The moisture content of bagasse is typically 40-50%, so a dryer is necessary. The complete bagasse pellet production process includes crushing, drying, pelletizing, cooling and packaging.

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Differences Between Wood Burning Stoves and Pellet Stoves

Wood burning stoves and pellet stoves are alternative heating sources to fossil fuels that use a renewable energy source. There are three points in general differences, that’s fuel used, the amount of working required operation and how the heat produced. The wood burning stoves can keep hot for a long time and are a burn hazard with operator, especially with the children. But the pellet stoves don’t get too hot to touch, so the burn hazard is not possible.

* Fuel Used. The pellet stoves make the pellets as burn materials, which are made of compact sawdust, wood chips and paper waste and so on. But also the biomass fuels also are the materials like shelled corn, soybeans, cherry pits or sunflowers. Besides, the pellets can be delivered or bought in sacks and stored in a basement. However, the wood burning stoves can burn the hardwood like oak, walnut and hickory which must be split to suitable length and dry before burning. Meanwhile, the hardwoods are not easy to store and occupy the space.

* Consideration. Wood burning stoves need a lot more work to do. Such as cutting, splitting, hauling and stacking. You must physically start the fire and remove the ash daily. Wood burners are messy, adding time for cleaning and dusting. However, the pellet stoves are usually self-igniting with the temperature controlled by a thermostat knob on the front of the stove. Empty the ash bin every few days and fill the hopper with pellets as needed.

* Features. Wood burning stoves must have a chimney, and produce radiant heat. However, the pellet stoves use the conventional fuel, a auger powered by the electric motor moves the pellets into the stove.

* Environmental Concerns. Wood burning stoves are less efficient, which means more of the heat goes up the chimney, especially older stoves. Older models produce as much as 40 grams of smoke per hour. Newer EPA certified models produce no more than 7.5 grams of smoke per hour. Use a carbon monoxide detector when burning wood. Pellet emissions are so minimal that they are not regulated by the EPA.

* Potential. Wood burning stoves are less expensive and work well. But when you are in a remote location or power loss after a storm, because wood burners radiate heat, it is possible to cook on a wood burning stove. Pellet stoves, while more expensive and needing electrical power to operate, are safer for the family, burn cleaner, make less of a mess and are less work to use.

Our wood pellet mills include ring die wood pellet mill and flat die wood pellet mill for different requires. The wood pellets processed by our machines will satisfy your pellet stoves specifications for wood pellets to achieve a cost-effective choice.

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Ring Die-Vital Part of Ring Die Wood Pellet Mill

Ring die is the vital component of wood pellet machine. Its working performance and service life affect the electricity consumption, output and pellet quality directly. According to the incomplete statistics, the cost of wear and tear of ring dies usually counts for 25% of the plant's total maintenance expenses. So choosing the right ring die is the key to save the cost and profit-making.

Choice of Ring Die for Wood Pellet Mill 1. Choose the ring die according to the raw material and the output you need. Different raw materials require different die holes, porosity and compression ratio, and the ring die is much more suitable for large scale production. 2. Consider the materials that being used for manufacturing ring die. Generally, the ring die is made of carbon structural steel, alloy structural steel and stainless steel through forging, lathing, drilling, heat treatment, etc. Every process is so important that affects the service life of ring die, output and the pellet quality. For the raw material with high corrosivity, stainless steel ring die is a nice choice. 3. Roughness of die hole also affects the ring die quality. Excessive high roughness affects the shaping of wood pellets, even causes the blockage. If the die holes is drilled by multi-station gun drill, they will be more smooth to discharge the final pellets. 4. The clearance between roller and ring die has an important impact on the effective use of ring die. It is requisite to adjust the clearance between the die and roller to an appropriate range, which is essential to the final pellet products. Generally, the clearance between 0.1mm to 0.3mm is better, and for the new die and new rollers, the clearance should be larger. 5. Choose proper compression ratio of ring die. Generally speaking, the small ratio of hole depth and diameter can increase the output, reduce the power consumption, reduce the wear of ring die, while lower the hardness of the pellet and increase the percentage of powered pellets. If not, the density and pellet quality will be improved, while the production costs will be increased.

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Cooling Process in Wood Pellet Production

Necessity of Wood Pellet Cooling Process

After the pelletizing process, the temperature of wood pellets is between 60-80 degrees and the moisture content is close to 15%. At this moment, packing these pellets right away is not recommendable. The hot, soft and plastic pellets are easy to generate steam.

Besides, the moist pellets are easy to break into powder without cooling. So a pellet cooler must be used to reduce their surface temperature and the moisture content, which prevents the pellets from condensation and mildew, makes the wood pellets easy to transport and store, meanwhile helps screen good and pure pellets.

The Effect of Wood Pellet Cooling

Cooling procedure improves pellet durability and reduces dust accumulation during the transportation and storage of the end products. Counter flow cooler is a cooling type that common used in wood pellet industry currently, which works on the principle of counter current heating exchanging. Besides, almost all coolers have the function of separating the fines or dust from the rest of acceptable quality product. The separated dust and fines are recycled in the pellet mill so as to minimize the biomass losses and increase the conversion rate of biomass to pellets. Cooling can improve the pellet quality, reduce cracks in the pellet surface and reduce the amount of fines.

To achieve the required cooling effect, pressure and volumetric flow rate of air, length of column along with the residence time will play a crucial role. It includes intake air lock, cooling chamber, grid gate, blower, and pipeline and cyclone assembly.

Why Choose the Counter Flow Cooler?

Counter flow cooler is not the only type of cooler that we can choose to cool the pellets. But why we choose the counter flow cooler? 

1. Counter flow cooler is high efficiency. After cooling, the temperature of cooled pellets would be lower than the room temperature 3 to 5 centigrade and the moisture will be removed by 3.5%.

2. Counter flow cooler discharges automatically. The unique sliding-valve discharging unit also ensures it running stably and discharge smooth.

3. The rotating material sprinkle device ensures material be cooled equably and drastically; the countercurrent cooling method avoids direct blowing of cool air on the hot pellets, which prevents surface cracking of the pellets, maintaining high pellet quality.

4. The series counter flow coolers can match with secondary volute separator for combination use. And can be used to cool down all kinds of pellets.

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The Working Principle of Flash Pipe Dryer

1.The wet materials are put into the hopper. Then the fuel boiler generates hot air which mixes with wet materials and then is sucked into the pipes by the exhausted blower quickly. 2.The hot air is going through the curving pipes, thus wet materials can get fully dried during the drying process. 3.After the wet materials get dried, they are expelled out by the exhausted blower.

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How Does Sawdust Drum Dryer Work

1. Put the sawdust into rotary drum dryer with transfer system, flied by raising plate device which are uniform distribution in the drum cylinder. 2.The sawdust are evenly distributed in rotary drum dryer cylinder, then fully contact with the hot air, speed up the drying heat and mass transfer. 3. During the drying process, under the effect of plate and hot treatment in rotary drum dryer, the materials are dried evenly and efficiently. 4. The dried sawdust comes out from the end of rotary drum dryer and for wood pellet pressing.

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Disc wood chipper structure and working principle

Disc wood chipper is composed of machine chasis, disc knife, feeding hopper, engine, encloser and electric controlling device. It works in this way: wood materials are drawn from hopper at 10-15° leaning of the edge and chipped as soon as they encounter chipping blades. Disc blades set uniformly on disc plate; during chipping, cutting blades spin at high speed and chipping chamber creates airflow by which wood chips are blow out of the discharge hole.

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Wood Crushing Machine Working Principle

Wood crushing process combines blades cutting & high speed air flow impacting and collision together; at the same time, it finishes fine sawdust sorting and further processing. Crushing chamber adopts multistage crushing circuit and finely processing principle, ensuring huge impact, high production efficiency and good crushing ability. Rotors create high speed air flow and rotate along with blade cutting; wood materials speed up and repeatedly impact the chamber and among themselves. Therefore, the robust crushing chamber construction and reasonable structure make wood crusher a reliable wood processing device.

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Requirements on Wood Pellet Raw Materials

The workable raw materials can be of any type agricultural wastes, forestry wastes, lumber residues and crop straws, etc. The diameter of input materials should be 2mm-6mm; the moisture content should be around 12%-20%.

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Small Capacity Electric Sawdust Pellet Press Working Principle

Flat die wood pellet machine is operated through gear driving the spindle and die. Designed in vertical type, raw materials fall down from the hopper into pelletizing chamber smoothly just because of gravity. In pelletizing chamber, wood materials are compressed into pellets between rollers and die through die holes. A sharp cutter would immediately cut the exposed pellets into regular length. The relatively low rotary speed can ensure pellets’ integrity.

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How Does Ring Die Wood Pellet Mill Work

Ring die wood pellet press mainly consists of overload protection device, external discharging mechanism and pressurization oil pump lubrication system. The variable frequency and speed-changing motor is equipped for even feeding. The raw materials are delivered into wood pellet machine through a conveyor and then enter into a rotating ring die by a feeder, finally pulverized material will be pressed into ring die through two rotating press rollers. The resulting pressure compresses the material and extrudes it through the holes in the die. Then the pellet will be out directly.

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Wood pellet packing machine

Automatic wood packing machine is advanced designed and manufactured bagging machine with PLC controlling technology adopted and accurate measure instrument equipped, thus it has high weighing precision, bagging speed and stable performance. The quantative bagging machine is broadly used in easy flow wood pellets, feed pellets and some powder materials with no corrosivity. Automatic wood weighing and packing machine plays the indispensible role in improving wood pelletizing efficiency.

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Counter Flow Pellet Cooler

Counter flow cooler is the basic tool in cooling pellet fuel for convenient package, transport or storage. It has large cooling capacity from 3 ton to 20 ton per hour and is specially fit for industrial biomass pellet production line. The reasonable structure and counter-flow principle guarantees that wood pellets are cooled evenly and sufficiently.

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Wood Hammer Mill

Wood hammer mill is the most widely applied grinding machine in wood processing industry, and its extensive recognition and popularity lies in the scientific structure. Our wood hammer mill is innovatively designed in the space between hammers and rotors, which makes sure hammers are perfectly protected from metal and other hard residue entry. For grinding wood materials, wood hammer mill tends to welcome to crush soft and small materials such as tree branches, straws, herb, crop stalks, etc. whose diameter is less than 50mm. It has great crushing efficiency and can ensure the end materials diameter of 3mm-5mm. 

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Drum wood chipper machine

Drum wood chipper features a large, motor-powered drum located at the center of the machine. It is a dedicated device producing quality wood chips for energy generation and wood pulp industry. That’s why it is popular in places where wood chips used as the starting material for further production like wood pellet plant, particleboard mill, fiberboard factory, biomass power plant, etc. The chipping materials are of great variety such as wood, stalk or straw, etc. Our wood drum chipper is extremely robust and scientifically designed which can transfer wood materials into uniform and high quality chips.