Complete crop straw Pellet Plant For Biofuel Pellets

[Case 2] Biomass fuel 2 t/h straw pellet plant project

In the 21st century, straw is regarded as a green and renewable energy with a large scale of development and utilization. Crop straw contains a variety of effective components that can be used.

In addition to the vast majority of carbon, it also contains potassium, silicon, nitrogen, calcium, magnesium, phosphorus and other elements as well as cellulose, hemicellulose, lignin, protein, Amino acids and other organic components.

Research by the International Energy Agency shows that straw is a good clean and renewable energy source.

After the straw has been hot-pressed to a certain density and then burned, it can increase the combustion temperature and heat utilization rate, reduce the pollution of the air environment, and the burning speed is fast, saving time, making the straw a high-grade energy product and protecting the ecological environment.

The use of straw fuel in rural energy can provide high-quality fuel for life and production in urban and rural areas, which is an important measure to save fossil energy consumption and improve the ecological environment, and is of great significance to the sustainable development of the global economy.

• Nature of construction: newly built.
• Total investment: $220,000.
• Labor quota and work system: 10 employees, 16 hours a day, 300 days of annual production
• Project scale and product plan: The 2t/h straw pellet plant project covers an area of 7,000 square meters, including one office, two warehouses and one workshop.
  
  There is no canteen construction content in this biomass pellet line project. The designed production scale of this straw biomass pellet plant project is 15,000 tons of straw per year and 10,000 tons of straw pellets per year.

• Workshop: one, equipped with two biomass pellet machines, with an annual output of 10,000 tons of straw pellets.
• Office: one, for employees to rest and work.
• Warehouse: two, used to store products.

Name	Annual usage
Straw	15000 tons
Water	180 tons
Electricity	60000kW

Device name	QTY
Straw shredder	1
Straw pellet machine	2
Conveyor	1
Fan	1

1. Raw material straw: The biomass raw material is temporarily stored in the storage yard.
2. Crushing and screening: Due to the large size of crop straws, they cannot be directly used for molding processing. The main task of the crushing process is to crush the larger straws into short and fine granular raw materials with a straw crusher.
3. Biomass pellet machine molding: the raw material is extruded by a biomass pellet machine. The crushed material is fed into the biomass pellet machine. In the biomass straw pellet making machine, the crushed material is heated.
   
   And the heat source comes from the heat generated by the friction between the mold and the material and the heat generated by the friction between the materials due to the compression volume shrinkage.
   
   Under the action of a certain temperature and huge pressure, the lignin in the crushed material is melted into a “glue”, and the raw material is pressed and glued into a solid object, which is extruded from the ring die hole of the straw pellet mill and extruded into this product. Project product – solidified fuel.
   
   The cylindrical solidified fuel is continuously extruded from the corn stalk pellet machine, and cut into the required length by the cutting machine according to the market demand. The cut solidified fuel is conveyed to the packaging section, and the solidified fuel is naturally cooled during the transportation process.
4. Packaged finished product: The solidified fuel that is cooled during the transportation process is measured, packaged, and sealed in sequence before being stored in the warehouse.

(1) Water supply works

The water used in this 2t/h straw pellet plant project is mainly domestic water used by staff. The project has a total of 10 employees, and the domestic water consumption is calculated as 60L/d per person, and the water consumption is 180t/a.

The domestic sewage produced is calculated as 85% of the water consumption, so the domestic sewage production is 0.51t/d, 153t/a. A new well was built in the factory with a depth of 60 meters and a water output capacity of 20m³/h, which can meet the water demand of this project.

(2) Drainage works

There is no production wastewater discharge in this straw biomass pelletizing plant project. The wastewater of the project is mainly domestic sewage. The sewage discharge is calculated according to 85% of the water consumption. The sewage generated is 0.51t/d, 153t/a. Take it out and use it as farmyard manure.

(3) Heating

The office is heated by electric heating in winter, and the production workshop does not provide heating. There is no canteen construction in this project.

(4) Power supply

The power supply of this project is provided by the local power grid, which can meet the electricity demand of this 2t/h straw pellet plant project.

[Case 4] 3 t/h straw pellet plant project

• Project nature: newly built
• Project investment: a total investment of 180,000 US dollars
• Occupied area: The total area of the project is 666.7m² (about 1.0 mu), and the total construction area is 460m², 1 new workshop.
• Construction scale: After the project is completed, 9,000 tons of biomass fuel pellets will be processed.
• Labor quota and work system: The labor quota of this project is 3 people, and a shift system is implemented, with 10 hours of work per shift and 300 days of work in a year.
• The project covers an area of 666.67 m², and only builds one production workshop with a construction area of 460 m².

• Raw material: straw
• Consumption: 9010t/a
• Storage capacity: 5t/a
• Packing form: Bulk
• Storage location: workshop raw material area

• 1 set of crushing system: straw grinder, silo;
• 1 set of granulation system: straw pellet press, finished product warehouse;

The customer’s straw raw material moisture is less than 15%, and has been chopped and sliced, so there is no need to configure hay cutters, slicers and straw dryer.

The process flow we design for customers is as follows:

The purchased raw materials are transported to the factory area by a transport vehicle covered with a tarpaulin, and crushed by a straw pulverizer. The crushed straw powder enters the raw material warehouse through negative pressure suction for storage, and the raw material is transported to the straw pellet machine by a fully enclosed screw for extrusion.

Compression forming, the formed pellets are transported to the finished product silo through a fully enclosed conveyor belt for temporary storage, and after the pellets are naturally cooled, they are manually packed in tons of bags and wait for sale.

Water supply

The water for this 3 t/h straw pellet plant project is uniformly supplied by the water supply station where the project is located, and the water quantity and quality can meet the water demand of the project. The water used in this project is mainly domestic water and fog cannon water, with a total water consumption of 8.84m³/d.

1. Production water: This project is mainly used for dust suppression during raw material loading and unloading. This project uses a fog cannon machine for dust suppression. The water consumption of the fog cannon machine is 1.5m³/d, which is centrally supplied by the water supply system where the project is located.
2. Domestic water: This project has a labor quota of 3 people, all of whom are nearby residents. They do not have board and lodging in the factory area. RThe domestic water consumption of employees is 50L/ Calculated by people•d, domestic water consumption is 0.15m³/d.

Drainage

The rain and sewage diversion system is adopted for the drainage of the project, and the rainwater is collected separately and discharged outside. The daily spraying water of the fog cannon machine is taken away with evaporation, and no production wastewater is generated.

The amount of domestic wastewater generated is calculated based on 80% of the water consumption, so the amount of domestic wastewater generated is 0.12m³/d, mainly washing wastewater, and the amount of wastewater generated is small, which is directly used for dust suppression in the factory area.

Heating and cooling

This 3 t/h straw pellet plant project has no production heat. Electric heaters or air conditioners are used for heating in winter, and coal-fired boilers are not used; air conditioners are used for cooling in summer.

Power supply

The power consumption of this project is connected to the local power supply pipeline network, and the power and voltage can meet the power demand of this project.

Since the project site has strict environmental protection requirements, in order to further reduce the amount of fugitive dust, the main measures to be taken in this project are as follows:

• Minimize the generation of dust in production in terms of process design, and choose more advanced production equipment in this industry, which can reduce the phenomenon of dust running and emitting;
• Raw material transportation vehicles should adopt closed body as far as possible, and ensure that the materials are not spilled or leaked.
• In the process of sieving and granulating, try to use closed equipment;
• Minimize the drop of the material at the material outlet to reduce the escape of dust;
• The workshop and dry powder spare room shall be airtight.
• Clean and collect dust deposited on the ground or workbench regularly.
• Strengthen the collection and management of unorganized emissions from the 3 t/h straw pellet plant workshop, and install workshop dust purifiers in the workshop material loading process and dry material standby powder room to reduce workshop dust emissions. 

Biomass energy is an important part of energy resources. Its development and utilization can alleviate my country’s energy shortage, provide clean and high-quality energy, and can partially replace coal, oil and natural gas. As biomass energy, it has the advantages of no public harm, renewable and beneficial to environmental protection.

Many countries are very rich in biomass energy. The development of biomass solid fuels and the implementation of coal substitution can significantly reduce carbon dioxide and sulfur dioxide emissions and produce huge environmental benefits.

Especially in recent years, the government and the public have paid more and more attention to the impact of agricultural residues residues on environmental pollution, and put forward higher requirements for the resource utilization and harmless treatment of agricultural residues. 

Therefore, investing in the establishment of a straw pellet plant will be supported by the government.

Hazards of incineration of straw and other agricultural, rural and agricultural residues:

• Pollution of the air environment, endangering human health. When burning straw, the three pollution indexes of sulfur dioxide, nitrogen dioxide, and inhalable particulate matter in the atmosphere reached their peaks, among which the concentration of sulfur dioxide was twice as high as usual, and the concentration of nitrogen dioxide and inhalable particulate matter was three times higher than usual.
  
  Equivalent to the fifth level of daily average concentration. When the concentration of inhalable particles reaches a certain level, it will greatly irritate the mucous membranes of the eyes, nose and throat, and cause coughing, chest tightness, and tears in mild cases, and may cause bronchitis in severe cases.

• Cause a fire, threatening the safety of people’s life and property. Straw burning is very easy to ignite the surrounding combustibles, especially near the mountains and forests. Once a fire is triggered, the consequences will be disastrous.
• Cause traffic accidents, affecting road traffic and aviation safety. Since there is a large amount of farmland on both sides of most expressways, the smog formed by burning straw will cause air visibility to decrease, and the visible range will be reduced, which will easily lead to traffic accidents.
• Destroy the soil structure and cause the quality of farmland to decline. The burning of straw causes the ground temperature to rise sharply, which can directly burn and scald the beneficial microorganisms in the soil, affect the full absorption of soil nutrients by crops, directly affect the yield and quality of farmland crops, and affect agricultural income.

[Case 6] 5T/H straw pellet plant

This straw pellet plant project is a new project, and the customer rented an existing factory building for project production. The plant covers an area of 3.82 mu (2544m²), with a total construction area of 4500m².

According to the actual needs of customers, we have configured crushers, pulverizers, straw biomass pellet mills and other facilities for customers. After being put into operation, it can reach the production capacity of 12,000 tons of pellet fuels per year.

After biomass is compressed and molded, its volume is greatly reduced, which makes it easier to transport, store and use, and solves the key problem of large-scale utilization of biomass.

In view of this, the client is optimistic about the market prospect of crop pellet production, and uses the purchase of wood chips or wood scraps and agricultural and forestry waste from surrounding rural areas as the source of raw materials for this project to achieve comprehensive utilization of resources.

The 5t/h straw pellet plant project uses the purchase of agricultural and forestry waste straw, wood chips or wood scraps from surrounding rural areas as the source of raw materials for this project, and reduces the moisture in the raw materials through natural drying, without using fuel for drying.

• Construction nature: newly built
• Total investment: $350,000
• Product specification: 8mm in diameter, about 1.6-2.4cm in length
• Main raw materials: straw, flue-cured tobacco rods, sawdust or wood scraps, etc.
• Working system: 8 employees, 300 days a year, 8 hours a day, one of them is on duty every day, and the rest of the employees do not live in the factory.

The total area of the project is about 2544m², including 400m² living area, 1944m² processing workshop, 200m² molding workshop and warehouse. The factory building and cement hardened ground have been completed.

During the construction period of the project, decoration and equipment installation will be mainly carried out, and no other buildings will be built.

• Production workshop: The production workshop is 1944m², with a height of about 7m. It uses the built buildings in the leased factory area for decoration and renovation. It is mainly engaged in the production of biomass pellets. After the straw pellet plant project is completed, it can achieve an annual output of 12,000 tons of biomass pellets.
• Warehouse and granulation workshop: covers an area of about 200m². Relying on the built buildings in the project area for decoration and transformation, it is used for the molding of biomass pellets and the stacking of raw materials.
• Office area: The office covers an area of about 400m², using the existing rooms in the site as the office area. (Related solution: 2t/h biomass pellet manufacturing plant)

Biomass pellets are mainly wood chips or wood scraps, agricultural and forestry wastes (mainly straw, flue-cured tobacco rods, etc.), which are extruded into rod-shaped biomass pellet fuels through the pressure of a biomass pelletizer.

The site of this project is small, so it is not suitable for drying a large amount of raw materials. In view of this problem, we suggest that customers control the moisture content of the purchased raw materials to about 20% as much as possible, or rent another site for drying raw materials, and avoid drying in the factory area.

The production of the 5t/h straw pellet plant project does not add any auxiliary materials, and does not use waste wood containing paint. The main raw and auxiliary materials used in the operation process are detailed in the following table:

Name	Consumption
Scrap wood, offcuts, sawdust	6150.9t/a
Agricultural and forestry waste such as straw and flue-cured tobacco stalks	14352.1t/a
electricity	13000kw•h/a
Water	240t/a
Packaging material (bag)	0.7t/a

Since the sales target of the product is industrial and civil use, the production of the product will be processed into rods (different in thickness) according to different fuel equipment and scope of use.

According to the diameter of 8mm and the length of about 1.6-2.4cm, the process flow and related equipment are designed to be suitable for various boilers and kilns, with an annual output of 12,000 tons.

The process flow is briefly described as follows:

The customer collects agricultural and forestry wastes such as straw and flue-cured tobacco rods at fixed points. When the agricultural and forestry wastes are not enough, the leftovers, sawdust, and waste wood produced by the wood processing plant are purchased as raw materials for production. (Related solution: 1-1.5t/h biomass pellet production line)

They need to be dried, crushed, and crushed according to the moisture content and particle size of the purchased raw materials. After processing, it will be granulated for production.

1. Drying: The moisture content of the raw materials that can be directly used for crushing by the crusher is about 15%-20%. If the moisture content of the purchased raw materials cannot reach the standard of 15%-20%, the raw materials will be dried first.
   
   When its moisture content is reduced to between 15% and 20%, it will be crushed. Due to the small size of the project area, the construction unit designed to control the moisture content of the purchased raw materials at about 20%, try to avoid drying raw materials in the factory area, or rent another site for drying raw materials.
2. Chipping: Use a crusher to cut waste wood, straw, bellflower, etc., and large pieces that cannot be crushed directly into small pieces.
3. Crushing: Agricultural and forestry wastes are pulverized by a pulverizer to make the particle size less than 5mm. The biomass pulverizer is only equipped with a material inlet and a material outlet.
   
   After feeding, close the material inlet to reduce dust escape. After the dust generated by the pulverizer is treated by a cyclone dust collector and a bag filter, all the collected dust can be reused in the production line .
4. Granulation: The crushed materials of the project are made into granular biomass fuel through physical extrusion. The material transportation process is closed transportation, and the materials transported to the granulation workshop are fed to the straw pellet making equipment by a forklift.
   
   The whole process Do not use manual dumping of materials.The project is made into finished products through extrusion. The extrusion process is a physical process, without adding any adhesives, and without chemical reactions. Except for the connection of the feeding auger and the outlet, the equipment is sealed;
5. Conveying and cooling: The granulated biomass pellets are naturally cooled by conveying, so that their temperature can reach the conditions for packaging and storage, and finally conveyed to the finished product warehouse.
6. Packaging: The compressed hot pellets pass through the screening at the end of the conveyor belt, and the qualified biomass pellets fall into the finished product bin. The bottom of the finished product bin is a funnel-shaped discharge port, and the finished product can directly fall into the packaging bag.
   
   After the machine is packaged, it can be stockpiled and sold. After molding, the biomass pellets have been compressed and compacted, and basically no dust will be generated during the bagging process. Unqualified products are discharged and collected and returned to the granulation process.

Name	QTY
Slicer (crusher)	1
Straw shredder	1
Straw pellet machine	2
Bag filter	3
Cyclone dust collector	2
Loader	1
Forklift	1
Grabber	1
Bucket	1

The entrance and exit of the living area and the production factory area of the project are connected to the road on the south side, so the transportation is convenient. The plant covers an area of 3.82 acres (2544m²), with a total construction area of 4500m². The crushing and crushing workshop of the 5t/h straw pellet plant project is located on the west side of the living area and the southwest of the entire factory area.

In order to reduce the impact of noise on the sensitive points on the east side of the factory boundary during the project operation period, we designed to arrange the crusher and pulverizer on the northwest side of the crushing and crushing workshop, as far away from sensitive points as possible.

The warehouse, granulation and molding workshop are located on the northwest side of the crushing and crushing workshop. About 8m east of the factory boundary is a residential area. There is a living area between the production plant and the residential area. The cement hardened ground in the factory area separates rain and sewage.

While promoting the development of the local economy, the construction of the project can also achieve comprehensive utilization of resources, reduce the occurrence of random stacking and incineration by local farmers, and reduce the generation of air pollutants to a certain extent.

The 5t/h straw pellet plant project continues to use the completed factory buildings for project production, no open-air operations, waste gas and noise are reasonably designed and equipped with disposal facilities, the solid waste disposal rate in the factory area can reach 100%, and waste water is not discharged outside, which minimizes the impact of project production on the surrounding environment Impact.

Straw biomass pellets mainly use corn stalks, cotton stalks, wheat straws, tobacco stalks, etc.) as raw materials, and are extruded into rod-shaped biomass pellet fuels through the pressure of a biomass pellet press.

1. It’s renewable energy
   Straw is a green plant and a renewable energy source. Biomass fuel can reduce zero emission of CO, which is very beneficial to control climate warming.
2. It’s a low-pollution fuel
   The pellet fuel made of straw as the main component is low-pollution. The oxygen content of straw fuel is 3-4 times larger than that of coal, with less heavy hydrocarbons, good combustion effect, and the blackness of smoke is lower than Ringelman level 1.
3. The economy is reasonable and the scope of application is wide
   The cost of processing straw into pellet fuel is significantly lower than that of diesel and natural gas. The economic advantages of biomass pellet combustion boilers are very prominent.
   
   Substituting fuel oil, gas, and electric heating boilers can save users a lot of operating costs. Compared with coal, although the price is similar, its superior environmental protection performance and renewability are unmatched by coal-fired boilers.
4. High combustion efficiency, saving energy
   Due to the high volatile content of straw fuel, less ash, less moisture, flammability, mechanical, chemical, and smoke exhaust incomplete combustion heat loss is small, and the combustion efficiency is as high as 95%.
   
   Under the same conditions, the thermal efficiency is increased by more than 7% compared with the coal-fired furnace, and the energy saving is about 10%.