Plant Operation

Our Biomass-to-Energy plant is located in Kaharlyk (Ukraine). The current stage of the project is electricity network connection. The plant is opened for pyrolysis process presentation now.

Plant Specifications:
·  Input materials – biomass (sunflower seed husk)
·         Input capacity – 1.5 t/hour
·         Moisture of input raw – no more than 10%
·         Fraction of the input particles – about 5x20 mm
·         Output products:

– electric power – 3.2 MW/hour (0.2 MW/hour is used to feed the pyrolysis system, rest 3 MW/hour is for sale).
- briquettes for barbecue – 0,35 t/hour (pressed solid residue of the pyrolysis process).

Continuous Pyrolysis Reactor

Prior to load the prepared raw materials (after sorting, drying and crushing) into the continuous pyrolysis reactor it should be heated up to 700 oС. The prepared raw is moving into the reactor only when the temperature inside the reactor is appropriate. The process of thermal destruction of prepared raw occurs inside the active part of the reactor without oxygen access (the air-lock mechanism designed by our engineers ensures the technological stability of the process).
The gas condensate mixture is generated as a result of the thermal destruction process. The prepared raw is transforming into the solid carbonized residue (pyrocarbon) after moving through the active part of the reactor. The solid pyrocarbon is directed to the unloading mechanism. Than it is stabilized and pressed into fuel briquettes or directed to feed the steam boiler for electricity production.

The output pyrolysis gas goes to the system for condensing and purification. This system ensures the gas separation from condensate (liquid fuel), and further pyrolysis gas purification. The purified pyrolysis gas is directed to the steam boiler to produce electricity. The pyrolysis reactor may operate using liquid pyrolysis fuel or pyrolysis gas produced.

Control and Monitor System

The pyrolysis facility is equipped with the temperature and pressure sensors to monitor the parameters of the pyrolysis process. The automatic system is used to control the burner devices.

The scroll drives of the reactor module is equipped with frequency converters to manage the rotary speed. The automatic system monitors all the emergency situations, and informs the operator by means of LED-indecators.
The security system activates automatically in case the specified parameters are exceeded. All control and monitor devices are installed into control cabinet. Grounding device and emergency stop button are also implemented into the control cabinet.

Power generating module

The steam boiler is included into the Plant structure. The boiler capacity 25 t of steam per hour. The boilers’ burners are able to operate on three types of fuel:
- solid high carbon product,
- pyrogas,
- liquid fuel.

The steam to feed the steam engine is generated inside the boiler as a result of the high-efficient combustion of all output fuel products.

The steam from the boilers moves via the steam pipeline directly to the steam engines, which transform the steam energy into rotation. Then, the steam moves to condensing system, where water (condensate) is collected. The condensate is directed to deaerator, where the gases are separated from the water. The water is transported from the deaerator back into the boilers. The container for water storage included into the layout to prevent the stop of steam boiler operation. The operation scheme of steam boiler and steam engine is closed.
The steam engine is installed into the same frame with the alternator and connected via coupling sleeve.
The steam engine requires the steam having specification as follows:
- Steam pressure – 8-10 Bar,
- Steam temperature – 175-185 oC.

Types of Recyclable Biomass appropriate for this technological solution:
·         garden and street biodegradable waste;
·         wood processing residues (trunks of trees, branches, bark, wood chips);
·         organic agricultural waste (animal waste, harvest and plants residues);
·         food waste;

·         textile waste;
·         paper and organic packs;
·         by-products from biogas production.