Transport system for the bread oven powered by pellets
In this section we would like to present an interesting installation that demonstrates the versatility,reliability andefficiency of Aspiroenergy, our pneumatic pellet conveying system.
Coop Genossenschaft
The installation was commissioned by Coop Genossenschaft, a leading Swiss retail and wholesale company. Their headquarters in Castione has a bakery that bakes bread for sale on a daily basis.
The plant, which operates day and night throughout the week, is powered by pellet burners positioned on three 3.6 MW furnaces. Before our intervention, the fuel was stored in an external silo that conveyed the pellets to the burners through a flexible auger system.
The customer contacted us because they were looking for an alternative pellet conveying system: the transport exclusively relied on auger systems was prone to frequent blockages and excessively ground the pellets, creating sawdust and wood chips that were too small for proper and efficient combustion.
At the same time, he wanted to expand its facility by activating a fourth furnace to increase production.
We approached the request to provide the client with a definitive solution through the integration of Aspiroenergy: its features, combined with our experience in custom design, have proved to be perfect for responding to both civil and industrial requests, such as the following.
Customized design of an industrial pellet transport system
Layout being designed
After a remote talk with the customer to determine an estimate of costs and several possible solutions, we conducted a free on-site inspection at the concerned production area.
Given the plant's huge pellet consumption and the complexity of the installation, a special tailor-made design was created, capable of handling large workloads and, above all, able to adapt to the conformation of the existing plant.
We proposed to the customer to eliminate the flexible auger system in favor of a pneumatic pellet conveying system , such as Aspiroenergy, to transport the pellets from the service tank to the different burners. Our solution develops as follows:
1. Implementation of an extraction sump at the base of the silo. A robust 7-meter rigid steel auger is connected to it to convey the pellets to an intermediate tank inside the building. The auger is activated when the sensor located inside the tank detects a lack of pellets.
External view with extraction pit at the base of the silos and long steel screw conveyor
2. Four independent pellet suction lines, operated by our Aspiroenergy conveyor system, depart from the inner tank. The pellets travel pneumatically inside the pipe until they fill the eight reservoirs located above the furnaces (two reservoirs for each furnace).
Auger unloading on intermediate tank and start of the 4 pellet suction lines with Aspiroenergy
3. Finally, at the bottom of these reservoirs are placed horizontal augers that extract the pellets and by gravity deliver them to the burners.
Pellet distribution line to the burners with Aspiroenergy
Aspiroenergy pellet transport system for a 4.8 MW production cycle
The customer has expanded the capacity of its plant: as a result of the new project implementation, it has increased from 3 to 4 furnaces with a power gain of 1.2 MW.
Therefore, the production cycle served by the Aspiroenergy system is now powered by 48 pellet burners developing a total capacity of 4,8 MW, with the potential to handle up to 970kg/h (maximum pellet consumption).
Replacing the flexible auger system with the new Aspiroenergy system has brought great benefits to the customer:
- The system is reliable and fully automated
- Pneumatic transport does not suffer from blockages because the pellet does not get stuck on the auger
- The continuity of service is guaranteed for the benefit of productivity
- The pellets are not ground by the augers and arrive intact to the burners, ensuring more effective combustion
- Pellet-passage pipes follow the environment's perimeter conformation, avoiding unnecessary clutter and leaving room for operators
- The drastic decrease in residues and wood dust dispersed into the environment ensures a healthier and cleaner workspace
Tailor-made products used to supply the production cycle with pellets
- 1 long tailor-made auger of 7 meters for extracting the pellets from the silos
- 4 Aspiroenergy transport lines with oversized turbine
- 1 hanging service tank
- 4 fall systems with splitter to convey the pellets on the 8 tanks per tower
- Aspiroenergy automatic filter cleaning kit to ensure constant suction power over time
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