Research performed so far has benefited in development of the technology – method of manufacturing pellets from biomass and agricultural wastes, involving pre-fragmentation and cleaning of biomass, characterized in that biomass fragmented to a fraction of about 4-6 cm and agricultural waste fragmented to fraction of about 5 cm is fed to the vibropelletiser assembly, where the pre-forming roller pushes the biomass into the groves and partially into the forming slots of the main die, so that the biomass is pre-compacted and further fragmented. As a result of the rotation of the main dies, the pre-compacted biomass moves under the pressing roller equipped with punches, which rotates synchronously with the movement of the main die, so that the pressing roller punches are driven into the forming slots, wherein, simultaneously to the rotation, the pressing roller also vibrates with an impact energy of 2J to 40J and with frequency 900-3500 strokes per minute, which increases the temperature of the formed pellets to about 110-140°C and consequently evaporates the water and sinters the manufactured pellets.
The solution is now at the sixth technology readiness level (according to General Annex G of the Work Programme). It means that the system prototype was demonstrated and tested in a relevant end-to-end environment which represents a major step up in a technology’s demonstrated readiness. Milestones already achieved include first and second generation prototype positively tested.
One of the main technological challenges will be to design and develop a control system of the automatics system, which results from the fact that the previously used solutions in this area were poorly flexible and dedicated to one type of the batch material. In effect, the change of the batch material resulted in the need to trim the whole system. The solution planned under the project assumes a flexible method of matching the automatics system to the line operation specificity. This will be achieved by the proper installation of appropriate sensors, controllers and inverters. Under the project realization, it is assumed to use independent automatics systems for individual elements of the device coupled in one whole (the aim is to make possible a separate, individual operation of individual elements of the line). The control system has to ensure the operation of the whole system in two modes:
• manual operation mode, in which there is the possibility to individually switch on and off each receiver in two directions, with an option to control the speed of motors provided with frequency converters (inverters),
• automatic operation mode, where three modules are adjustable.
Another essential technological issue is associated with the creation of the demonstrators of the mobile line and the industrial line. The mobile line will be characterized by functions close to an industrial line, but at a specific level they will differ by the engineering details related, first of all, to the obtainment of the effect of mobility. The dimensions and the design of the mobile line should allow for its free positioning on a standard semi-trailer of the TIR-type lorry. This follows from the assumed ease of use and displacement of the line, that is one of the discriminating points of the project subject from the competition. It is assumed that the demonstrator of the mobile line will be made up of:
• feeding table;
• disintegrator;
• devices to separate impurities, stones, waste in the batch material;
• mixer;
• pelletizer;
• pellet coolers.
The operation of the whole system will be provided by a properly designed and made automatics system with a control cubicle.
The industrial demonstrator, due to its size, should operate under a roofing (hall or umbrella roof). The floor on which it will seated should ensure the proper resistance corresponding to the weight of the system. It will also be indispensable to provide all utilities, including exhaust hoods in the hall where the demonstrator will be located. The demonstrator of the industrial line will be made up of:
• feeding-cutting module;
• mixing module;
• preliminary granulation module;
• final granulation module;
• post-drying module;
• automatics and production process management modules;
• filtering system, using bag filters.
In the design of the demonstrators described it will be necessary to undertake work on the use of the impact of specific frequencies in the element of the production line which the pelletizer is. This is an innovative approach that has been filed with the international patent protection by ZUK and obtained the highest possible rating of the state-of-the-art technology, i.e. AAA. Owing to this solution, the energy consumption of the device operation will be significantly improved (reduction of the energy consumption calculated per ton of material). Additionally, the pellet thus formed has better physical properties, is more compact, easier in transportation, does not crumble or delaminate.
Implementation of the technology will greatly reduce problems associated with CO2 emission. The basis of our value proposition is the fact that use of biomass containing agricultural residues and waste in power and heating generation would reduce the CO2 emission by 95% per MWh (29 kg comparing to 713 kg CO2e/MWh from fossil fuels) . Thanks to our technology, market price of agricultural pellet is to be reduced up to 60%, leading to increase in demand for pellet fuels.
