Biomass Pellet Processing Line In Kyrgyzstan

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overview

This is a 1.3t/h biomass pellet processing line in Kyrgyzstan project.

Kyrgyzstan is a Central Asian country dominated by agriculture, with more than 40% of the country’s total population employed in agriculture. Every year, a large amount of crop waste is generated during the planting and harvesting process, such as corn stalks, wheat stalks, rice husks, vegetable stalks, peanut shells, and sawdust generated during wood processing. These wastes are often burned or discarded on the spot, leading to increasingly serious problems of air pollution, soil degradation and resource waste.

In order to achieve the resource-based and efficient utilization of agricultural and forestry wastes and promote the optimization of energy structure, the Kyrgyz government has actively promoted the renewable energy development strategy in recent years and encouraged enterprises to carry out clean energy and environmental governance projects. Against this background, a local agricultural comprehensive enterprise invested in the construction of a 1.3 t/h biomass pellet production line.

After the biomass pellet plant project is completed, it can comprehensively utilize 15,232.945 tons of crop waste each year, and produce 2,000 tons of molded biomass pellet fuel and 3,000 tons of biomass charcoal annually, which will not only solve the problem of waste treatment, but also help the development of the regional clean energy industry.

The total investment of the biomass pellet processing line in Kyrgyzstan project is 89,000 US dollars, which is mainly used for equipment purchase, installation engineering fees and environmental protection management. The project investment is all self-raised by the customer.

The project has a labor quota of 7 people, and the workers work 6 hours per shift, two shifts, and the annual working time is 300 days.

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Construction content and project composition

The biomass pellet processing line in Kyrgyzstan project uses idle factory buildings to build a comprehensive utilization project of biomass waste resources. The project covers an area of about 3,000m2 and has 17 sets of equipment.

The biomass pellet production line project composition includes main engineering, auxiliary engineering, storage and transportation engineering, public engineering, environmental protection engineering, etc. The composition of the project is shown in the table below.

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Product plan

The biomass pellet processing line in Kyrgyzstan project mainly uses waste resources such as biomass (sawdust, peanut shells, rice husks, straw, cottonwood, vegetable stalks, etc.) as raw materials to produce biomass briquette fuel and biomass charcoal.

After the project is fully completed and put into production, it will comprehensively utilize 15,233.945 tons of fresh crop waste annually to produce 2,000 tons of briquette fuel and 3,000 tons of biomass charcoal. The specific plan is shown in the table below.

Note: The production process of biochar in this project generates a certain amount of accessories, mainly wood gas, wood tar, and wood vinegar. Among them, wood gas (containing a small amount of VOCs) is used as energy to be recycled in the high-temperature drying process, wood tar is entrusted to a qualified unit for disposal as hazardous waste, and wood vinegar is a by-product that is barreled and taken away.

Product and accessory physical and chemical properties description:

（1）Molded fuel

Molded fuel is a rod-shaped fuel generated by crushing, low-temperature drying, molding and other processes using waste resources such as sawdust, peanut shells, rice husks, straw, cottonwood, and vegetable stalks as raw materials.

（2）Biochar

Biomass charcoal is a solid product produced by high-temperature drying and pyrolysis of waste resources such as sawdust, peanut shells, rice husks, straw, cottonwood, and vegetable stalks under anoxic conditions. This environmental impact assessment mainly refers to the biochar produced by further processing of molded fuel in a high-temperature drying furnace.

Its main component is carbon element, with very low ash content and a calorific value of about 27.21~33.49 MJ/kg. In addition, there are hydrogen, oxygen, nitrogen and other small amounts of elements. Biochar is a hydrophobic substance, with an ash content of less than 6%, a sulfur content of about 0.07%, pores accounting for more than 7% of the volume of the charcoal, a specific gravity of generally 1.3~1.4, and a calorific value that depends on the high-temperature drying conditions, generally around 8000 kcal/kg. Biochar has a large number of micropores or excessive pores, which gives it a high specific surface area, and after the tar substances in the pores are removed, it will have good adsorption properties.

Biochar is used for:

• 1) fuel;
• 2) carburizing agent;
• 3) desiccant, medical, etc.

（3）Wood vinegar and wood tar

Wood vinegar is the hot flue gas generated when the biomass raw material is dried at high temperature, which condenses into an acidic liquid when it is cooled. The wood vinegar of this project is distilled wood vinegar, and the product specifications are shown in Table 3-2. The main component is acetic acid.

According to the “Catalogue of Hazardous Chemicals” (2017), acetic acid is not a hazardous chemical, so wood vinegar is not a hazardous chemical.

Wood vinegar is used for:

• 1) Wood vinegar can be used to improve soil and can also be used as a soil disinfectant;
• 2) Deodorization and odor elimination;
• 3) Food fumigation to make food taste more delicious;
• 4) Plant growth regulator;
• 5) Food preservation;
• 6) Beverage additive;
• 7) Feed additive;
• 8) Sterilization and itching relief.

The main component of wood tar is wood creosote, with a density of about 1080kg/m3, a boiling point between 203~220℃, and a flash point between 84~86℃.

Wood tar is used for: 1) Sterilization; 2) Disinfection; 3) Deodorization; 4) It can be used as a tranquilizer.

（4）Wood gas

The main components of wood gas are CO, CH4, H2, N2, etc. The density of wood gas is 0.916kg/m3.

Wood gas is used for: stove fuel, used to replace gasoline, diesel and other fuels, with high calorific value, clean and other advantages.

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Composition of main equipment and raw and auxiliary materials

(1) Main equipment for biomass pellet processing line in Kyrgyzstan

The biomass pellet processing line in Kyrgyzstan project purchased about 17 pieces (sets) of main equipment, see the table below.

(2) Raw and auxiliary materials and energy consumption

The raw and auxiliary materials and energy consumption required for this biomass pellet processing line in Kyrgyzstan project are shown in the table below.

Note: Density of liquefied gas is 2.35kg/m3

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Brief description of biomass pellet process flow

This biomass pellet processing line in Kyrgyzstan project purchases waste resources from local farmers (mainly peanut shells, rice husks, straw, cottonwood, vegetable stalks and other wastes) and waste resources from wood processing plants (mainly sawdust and other wastes) and uses advanced production processes and equipment to process and utilize biomass.

The core process of this biomass pellet processing line in Kyrgyzstan project is: using low-temperature dryers, rod making machines, high-temperature dryers and other equipment to process biomass waste resources, mainly producing molded fuel and biochar, wood vinegar as a by-product, barreled for takeaway, wood tar as hazardous waste entrusted to qualified units for disposal, and wood gas (containing a small amount of VOCs) collected and burned for low-nitrogen heating. The advantages of the process are as follows: The utilization of waste can realize the industrial production of biochar.

① Crushing:

Straw, cottonwood, vegetable stalks and other raw materials that need to be crushed (water content is 35%) can be directly transported to the crusher for crushing after being transported to the project plant by car or other means; if the incoming material volume is large, the raw materials can be temporarily stored in the raw material temporary storage area.

The crushed materials are directly sent to the feed conveying screw machine for feeding. A gas collection hood is set above the crusher discharge port to collect crushing dust.

② Loading:

Manually load the crushed materials or materials that do not need to be crushed, such as peanut shells, rice husks, and sawdust (peanut shells, rice husks, sawdust and other materials that do not need to be crushed are transported to the project area by car, and the car hood is covered with tarpaulins to prevent dust). A gas collection hood is set above the feeding inlet to collect the feeding dust, and the feeding process is a closed spiral advancement to the low-temperature drying furnace.

③ Low-temperature drying:

Since the moisture content of the material is 35%, and the subsequent process requires the moisture content of the material to be no more than 10%, the project is equipped with an electric heating low-temperature dryer to dry the materials that meet the size requirements.

After verification, the low-temperature dryer of the biomass pellet making plant project is powered by electric heating, and the drying temperature is 60°C. The dried materials are directly transported to the screw machine silo through the discharge conveyor screw for temporary storage. A pipeline is set inside the electric heating low-temperature dryer to collect the low-temperature drying dust in a negative pressure closed pipeline.

④ Molding:

The materials in the silo are directly transported to the rod making machine through a closed conveyor belt for molding. The rod making machine squeezes the product into a molded fuel (moisture content 10%), part of which is directly sold out, and part is further processed into biomass charcoal for sale. A gas collection hood is set above the discharge port of the rod making machine to collect the molding dust.

⑤ High-temperature drying:

The molded fuel is transported to the high-temperature drying furnace through a closed conveyor belt for high-temperature drying. The high-temperature drying temperature is divided into three stages.

• The first stage is 60 to 150℃, generally about 0.4 to 1.2 hours, which can basically dry the moisture in the material;
• The second stage is 200 to 350℃, generally about 2 to 4 hours, and hot flue gas begins to be generated in this stage;
• The third stage is 350 to 450℃, generally about 2 to 4 hours, and a large amount of hot flue gas begins to be continuously generated in this stage.

The material production ratio of the high-temperature drying process of this project is roughly: biomass charcoal 33.3%, solid waste 1.66%, hot flue gas 65.04% (hot flue gas includes wood gas (containing a small amount of VOCs) 20%, wood vinegar 33.3%, wood tar 1.3%, water vapor 10%, and smoke 0.44%). In the initial stage of the high-temperature drying furnace, bottled liquefied gas is used as fuel for indirect heating.

After the high-temperature drying process produces enough wood gas, wood gas is used for indirect heating. The materials in the high-temperature drying furnace will produce hot flue gas after high-temperature drying treatment.

The non-condensable gas (wood gas and smoke) after condensation and separation of this part of the hot flue gas is led to each high-temperature drying furnace through pipelines and then subjected to low-nitrogen combustion for heating. The combustion exhaust gas is then discharged after common high-voltage electrostatic dust removal.

⑥ Cooling and separation:

The hot flue gas generated by the high-temperature drying process is collected by the flue gas collection system and then cooled by water before entering the liquid storage tank for separation, separating the wood tar, wood vinegar and wood gas in the flue gas. Among them, wood tar and wood vinegar are collected in the equipment liquid storage tank.

Wood tar and wood vinegar are layered in the liquid storage tank, with the lower layer being wood tar and the upper layer being wood vinegar. After static and complete separation, the wood vinegar and wood tar are barreled (the maximum capacity of each barrel is 400kg/barrel). Wood vinegar is stored in barrels as a by-product in the finished product temporary storage area and finally sold.

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Plane layout

The biomass pellet processing line in Kyrgyzstan project uses the existing factory building for production.

The south side of the production workshop of the project is divided into finished product storage area, cooling and separation area, general solid waste storage area-high temperature drying area-molding area, crushing area, low temperature drying area-hazardous waste storage area from south to north, and the northwest corner of the workshop is the raw material storage area.

The overall layout of the process flow is compact and reasonable. Combined with the actual situation of the production facilities, it tries to make the flow of people and logistics go their own way, and comprehensively considers factors such as the short material transportation route and the convenient transportation of raw materials and finished products.

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Public works

(1) Water supply and drainage engineering

1) Water supply

① Domestic water

The biomass pellet processing line in Kyrgyzstan project has a labor quota of 7 people. The project does not have a canteen or dormitory. The living water consumption of employees is calculated at 50L/person.d. Therefore, the project’s living water consumption is 105m3/a, and the municipal water supply is used.

② Production water

The circulating water volume of the hot flue gas condensing equipment of this project is about 2.8m3/h, and the replenishment volume is calculated as 1% of the circulating water volume. Therefore, the replenishment volume of the project condensing circulating water is 1000m3/a, and the municipal water supply is used.

③ Ground spraying water

The workshop spraying volume of this biomass pellet processing line in Kyrgyzstan project is 0.5m3/a, and the annual spraying is 300 days, so the ground spraying water volume is 150m3/a.

2) Drainage

Domestic water: The domestic sewage generation rate of this project is calculated as 80%, so the domestic sewage generation volume is 84m3/a, relying on the built septic tank and supporting sewage pipe network;

Production water: The water used in the condensing equipment is recycled, and the loss is regularly replenished, and it is not discharged.

Ground spraying water: Evaporation loss, not discharged.

(3) Power supply

The power consumption of this project is 45,000 kWh/a, which is supplied by the municipal power supply. The project relies on the existing distribution room of the surrounding power generation company, and the project will not be newly built.

(4) Heating

The low-temperature drying and high-temperature drying processes of this biomass pellet processing line in Kyrgyzstan project require heating energy supply.

The low-temperature drying process has a drying temperature of about 60°C and uses electricity as energy for drying; the high-temperature drying process uses low-nitrogen combustion of liquefied gas or low-nitrogen combustion of wood gas (containing a small amount of VOCs) generated by the high-temperature drying process for heating.

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Why the Client Started This biomass pellet processing line in Kyrgyzstan Project

Agricultural waste treatment pressure is high, and environmental protection requirements are increasing.

The client is a large agricultural planting and processing enterprise, which accumulates a large amount of waste such as straw, rice husks, vegetable stalks, and peanut shells every year. The previous treatment methods were mainly open-air stacking and burning, which not only polluted the environment, but also did not comply with national environmental protection policies. It is urgent to establish a sustainable treatment and resource path.

Build a green circular economy system and increase corporate added value

The biomass pellet mill plant project converts low-value waste into high-value-added clean fuels and biochar, which can greatly improve the overall resource utilization efficiency of the enterprise and create a closed-loop green agricultural industry chain from “planting-processing-energy recovery”.

Meet the local clean fuel market demand

Kyrgyzstan has cold winters and a long heating period, but fossil fuels are expensive and unstable in supply. Molded biomass pellets, as an alternative fuel, can supply the clean heat source needs of local residents, schools, hospitals, industrial boilers, etc., and have great market potential.

Promote corporate green transformation and obtain policy and financing support

The biomass pellet processing line in Kyrgyzstan project is in line with the national and international sustainable development direction, and is easy to obtain government green project subsidies, international development fund loans and carbon emission reduction support, reducing corporate financing pressure.

Biomass charcoal brings new profit points

The by-product biochar of this project can be used for soil improvement, livestock and poultry deodorization, industrial desulfurization, and even exported for activated carbon raw materials. It has good economic and environmental benefits and is a new breakthrough for enterprises to expand their product lines.

If you are interested in this biomass pellet processing line in Kyrgyzstan project, feel free to contact us for free customized process design solutions, production line equipment lists and quotations, production line layout diagrams and other information.