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BiomassFuel production from woody biomass

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The Task aT hand

Biomass is destined to play a decisive role in the transition from fossil fuels to renewable energies. Ambitious EU objectives for the year 2020 confirm this: From 2020 onwards, 20% of primary energy consumption is to be obtained from renewable energy sources, with biomass making up more than a third. The focus is naturally on usage for the generation of heat and electricity, but also increasingly for the generation of alternative fuels. However, the mobilisation of the necessary biomass is becoming a major challenge.In keeping with our slogan, "Technology for a better environment", we are keen to work on the solution to this challenge and therefore include biomass as one of the development focuses within the company.

Our expertise lies is the treatment of woody biomass for energy recovery – in particular the shredding and subsequent conversion into usable fuel. In addition to pellets from sawmill by-products and wood chippings there are other material streams which are suitable for the generation of fuel both in terms of economics and sustainability. Using the right technology, fuel mature enough for the marketplace can be generated from root stocks, drift wood, green waste (from gardening and landscaping) and untreated waste wood – all materials which also bring disposal revenues. This way, companies previously operating in the disposal business can transform themselves into energy suppliers. Our role is to develop the most cost-effective machinery and concepts for this dynamic market.

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Root stocks

Woodland residues

Timber, energy wood

Green waste

Yard pruning

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experTise

Waste wood untreated

Driftwood

Pallets

Green waste, wood trunks or root stocks – Komptech has the right fuel solution for any raw material:

Production of fuel from woody biomass and green wasteWe strongly believe in the case for high torque, slow speed shredders, flexible star screens and, where required, high-performance turners for the efficient production of renewable fuel.

Preparation of woodland residuesThe Forest is the name we give to a variant of the CRAMBO wood shredder tailored perfectly to this job. Features include semi-trailer, loading crane and fine fraction separation.

Production of wood chippingsKomptech is introducing a new generation of mobile chippers under the CHIPPO name with a product range that fulfils every need.

Komptech GmbhKomptech is a leading international technology supplier of machinery and systems for the mechanical and biological treatment of solid waste and for the treatment of biomass as a renewable energy source.Komptech’s product portfolio includes more than 30 different machine types, enabling the company to be active in the fields of competence treatment of solid waste and treatment of biomass.Komptech products cover the major processing steps of modern waste treatment and biomass processing, namely shredding technology, screening and separation technology and composting technology.Modular construction offering different performance categories simplifies combinations for complete systems.Always the focus: innovative technology and solutions that provide a maximum of benefit for the customers.

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Fuel production from woody biomass

InputVirtually any material falling into the category “woody biomass” can be considered as a source material. The process is particularly effective with root stocks, loose and bundled woodland residue, felled trees and woody green waste - all of which are generally available at no cost or for which disposal revenues are achievable. Storing unshredded, or after coarse pre-shredding, helps to reduce material moisture.

ShreddingApplication of the CRAMBO equipped with the bio-cutting unit results in even shredding. The material does not exit the shredding area until the particle size matches the hole size of the screen basket used, meaning the quantity of shredded material within the desired particle size is maximised. There is no additional generation of fine fractions and overlengths are reduced to a minimum. With the use of screen baskets with mesh size from 150 to 180 mm a perfect ratio of throughput and degree of shredding is achieved.

process Flow

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woody biomass:root stocksgreen wastewaste wood untreatedetc.

shredding screening

useable fuel fraction

oversized fraction

medium fraction

fines

• applicable for almost any kind of woody biomass

• flexible process design due to universally applicable machinery

• wide product range for every performance requirement

• production of renewable energy from waste

undersized fraction

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CRAMBO Wood shredderThe CRAMBO dual-shaft shredder shreds all types of wood and green waste to a fixed particle size. Slow-running rotors with shredding tools minimise fine particle and noise/dust emissions, and resist contaminants. The particle size generated is adjustable simply by exchanging screen baskets. A hydraulic drive with load-dependent speed control ensures maximum

of material moisture level and unique flexibility when it comes to changing screening sizes are distinguishing features of the MULTISTAR star screens. The spectrum of mobile technology ranges from the simple EASYSTAR screen deck to the compact MULTISTAR M3 and L3 three fraction and M2, L2 two-fraction screens, mobile star screens, right up to the high performance XL and XXL screen.

utilization of the motor performance. The performance range is from 242 to 429 kW, sufficient for a throughput up to 100 tonnes/hr. The hook lift platform, trailer chassis and steel tracks with hydraulic drive options provide excellent mobility.

MULTISTAR star screensSeparation into three fractions in one operation, effective action irrespective

ScreeningKomptech star screen technology is the best route to a defined fuel product. A fine fraction, a medium fraction and a coarse fraction are produced in one screen operation. The medium fraction generally represents the usable fuel sample.The rotating stars knock any adhesions off the material being processed as it passes through the screen segment. For woodland residue and root stocks in particular, this guarantees a high quality of usable fraction since soil, sand and stones are separated off as fine fraction. The coarse fraction is made up of overlengths which are shredded again.

ProductThe particle size of the produced bio-fuel is according to the G100 (acc. ÖNORM M7133) wood chip standard and applicable in biomass heating and power plants with appropriate feeding systems and grate firing without any problems.

key componenTs

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Fuel production from green waste

In order to generate a usable fuel fraction from fresh green waste with leaf or grass fractions, the biological decomposition process used is in the form of windrow composting.Coarse pre-shredding using the CRAMBO produces a high air pore volume in the body of the windrow. A TOPTURN triangular windrow turner turns the windrows, maintaining an intensive rotting process. The green fraction is mainly decomposed and the rest accumulates as fine fraction. The biological decomposition at temperatures up to 70°C, together with the discharge of water vapour during the turning process, results in a drying of the material. The process is halted after about ten days and the material is screened off.Fine fractions and overlengths are separated off in one process using star screening and a fraction with a precisely defined particle size is generated. The fine fractions are composted further and used as fertilisers and soil conditioners. In comparison to pure composting, cost-effectiveness increases by virtue of higher revenues for the fuel product, lower operational costs as a result of less material manipulation and increased system throughput due to shorter processing times.

process

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green waste(with grass, leaves)

shredding screening useable fuel fraction

oversized fraction

medium fraction

composting

intensive rottingwith turning

fine fraction

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Shredder CRAMBOAn intelligent system comprising screen baskets and cutter with interchangeable teeth ensures efficient shredding for any job, guaranteeing highest levels of throughput.

Windrow turner TOPTURN XThe TOPTURN X-series offers turning technology at the highest level: Wheel

The particle size is variable and is set from the rotation speed of the star screens. Plastics are separated by wind sifting, metals by magnets and stones by a roll separator. if required.This operation occurs either directly at the screen or if requirements for cleaning are higher, through combination with the HURRIKAN mobile windsifter.

or track drive, a large, hydraulically-driven turning drum and ease of use guarantee best working conditions.

Separation: MULTISTAR andHURRIKANContinuous cleaning by the patented Cleanstar cleaning system prevents both material wrap-around and adhesion of wet feedstock.

key componenTs

• simple process, easy to control

• production of compost and biomass fuel

• less material handling leads to lower operating costs

• additional revenues in a new business area

• increase of the whole plant throughput

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Preparation of woodland residues

Woodland residuesIn order to reach the ambitious goals of biomass utilisation, previously unused woodland residue has to become a component of our fuel mix in the future. Woodland residue is the collective name for treetops and branches that accumulates when harvesting timber and for root stocks that accumulate during uprooting. Including root stock, woodland residue makes up about to one third of the total mass of trees and is regarded as being on a par with wood chippings in regard to legislation and grants. A disadvantage of woodland residue is the high volume compared to its weight, and depending on material and production the existence of stones, sand and soil.

PreparationTransportation of unshredded material should be kept to a minimum and shredding must take place as close as possible to the clearing area. Because of the presence of contaminants only slow-speed shredders can be considered in the long-term. They also offer clear benefits in regard to product quality. So a self sustaining machine, as mobile as possible and equipped with the right shredding technology is required.

FacTs

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harvest of wood

transport with forwarder

transport with timber truckpreparation with CHIPPO 500

chipping area

processing area near to forest

preparation with CRAMBO Forest

Biomass CHP-plant

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Perfect equipmentUsing a modular system, the CRAMBO with bio-cutting unit is mounted on a semi-trailer chassis, a three-axle chassis, on steel tracks or onto a four-axle lorry, with slewing ring if required. Loading is via a mounted crane with grab.The CRAMBO Forest is mainly used in stockyard and processing areas located near forests and woods. Extend out the supports, fold out the conveyor belts and the machine is ready to use. The combination of the crane and swivelling chassis creates a high degree of flexibility when feeding and when discharging shredded material. Everything is under control from the crane – from the positioning of a root stock several tonnes in weight to all of the machine’s functions. Everything that fits into the large (2.8 x 2.0 m) shredding area - root stocks, tree trunks or branches - is shredded.Using the (optional) integrated fine particle separator, needles and soil fractions are separated off straight away on shredding. The biomass fuel is fed directly into a container via the discharge belt of the CRAMBO and transported to the next heating plant.

key componenTs

• high throughput at universal application

• resistant to contaminants due to slow speed

• quick-change system for screen basket and tools

• perfect equipment for the job: with crane,

fine particle separator and on wheel, tracks or lorry

crambo ForesT

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Production of wood chippings

Quality wood chippingsWood chippings have been used as a type of bio-fuel for some years. The high demand for biomass heating systems has given rise to technological advancements in firing technology, but at the same time has also increased the requirements made of fuel quality. The demand is for quality wood chippings that conform to the standard G30 or G50 (as per ÖNORM M7133), that have a precise cut and a low fine fraction.

chippo

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The CHIPPO seriesUnder the name CHIPPO starts at Komptech a new generation of mobile chippers for highest efficiency and product quality. After a successful start of the tractor- driven CHIPPO 510, the product range in the medium and high power field has been extended.A compact general-purpose talent, barely surpassable in terms of mobility, degree of working comfort and cost-effectiveness, goes by the name of CHIPPO 5010 C direct – here the drive power is delivered directly via a special drive by a 3-axle lorry (MAN). As the most powerful machine the new CHIPPO 7010 C represents a mobile, high-performance chipper that has a large movement of radius when mounted on a 4-axle lorry and that delivers the highest throughputs with a self-driven system rated at 700 HP – even with strong wood trunks. This requirement is also met perfectly by the CHIPPO 5010 C in the mid-performance range. Common to all of them are active feed system, material adjustment with two different drum speeds and selection of material discharge via blower or conveyor belt.

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key componenTs

• Active feed with pre-compression due to two horizontal and two vertical feed drums

• Two principles of chipping: High cutting rate for prunings, lower cutting rate with higher torque for wood trunks

• Perfect output quality due to large rotor (Ø 1050 mm) and adjustable blade advance (up to 25 mm)

• Integrated re-sharpening equipment for low maintenance effort

• Intelligent linkage of screen basket for opening/ closing during chipping

• Choice of discharge: - conveyor belt to save energy and preserve product quality - flexible and precise discharge via blower with variable rotation speed

• Solid design for highest stability and reliability

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Technology for a better environment

Komptech GmbHKühau 37A-8130 Frohnleiten[t] +43 3126 505 - 0[f] +43 3126 505 - 505[e] info@komptech.com

www.komptech.com

Komptech UK Ltd. Forge End, Lodge Farm,Kineton, Warwickshire, CV354 0JH[t] +44 1926 64 29 72[f] +44 1926 64 29 71[e] info.uk@komptech.com

We reserve the right to make technical changes due to ongoing development. E_0609