From Pelleting Plants
With more than 25 years of experience, Costruzioni Nazzareno has become a leader throughout Europe in the design and construction of “turnkey” systems for processing industrial waste. A plant or system is a group of machines joined together for the production cycle. This cycle differs in every plant, as the characteristics of the product to be processed (type of wood, particle size, moisture content, initial state, etc.) are always different. The system may be divided up into sections that may be automated according to customer requirements or requests; in other words we can supply a fully automated plant or automate just single sections.
Over the years its wood pellet production systems have become the flagship product and the brand has become a global household name in the sector. In 1999 the company built its first complete pellet production systems and over the past few years has specialized in this field, building up extensive experience by producing more than 40 systems worldwide.
The Costruzioni Nazzareno production process
Throughout the production process, Costruzioni Nazzareno strives to provide only the very best in customer care, attentive to its customers’ needs from the very beginning. All systems are produced following the stages below:
- Initial contact with the customer to gather information and data to carry out the preliminary study;
- The system is designed and the offer drawn up;
- The offer is discussed, the technical solutions chosen are explained and their management within the space available illustrated;
- Once the order has been placed, the project is developed by the Technical Department and the customer is given all the technical documentation needed to produce the system: complete design, drawings and dimensions of any building work, drawings and dimensions of compressed air, plumbing and electrical systems;
- All documentation requested by the customer to apply for grants or other applications to relevant bodies is made available;
- The machines are manufactured;
- The system is installed;
- Start-up, commissioning, final control and production tests are performed;
- The customer’s technicians are given extensive training in all aspects of the running of the system;
- After-sales service is provided throughout the working life of system.
Pelleting plant layout sample
FEEDING: crushing, sorting and selection
The particle size of the material used is one of the fundamental parameters when choosing the feeding system of the line. You can in fact choose two types of machines to feed the material:
- Crushing or chipping machine with belts or chains when pieces of wood or brushwood are present in the material.
- Selector and/or sorting machines when the material consists of wood chips, shavings or sawdust (sorting threshold with raw materials over 25x25x5mm) with feeding by means of a hydraulic extraction hopper or worm screw.
Specific mechanical or pneumatic conveying systems carry on the production flow to the subsequent stages.
Another very important parameter for the production of pellets is the humidity of the material. The maximum processing humidity possible for a pellet-making machine is estimated at around 12-13% UR. If the material to be processed is over this parameter, the line requires a dryer or a dehydrating unit that is able to dry the product.
Such a machine needs a generator to produce hot air, or more in general, heat that can carry out the drying process; there are many ways to create heat, such as using sawdust, chips, natural gas or methane or other systems or fuels on request.
Between the biomass boiler and the dryer it is possible to install a cogenerator which produces combined electricity and heat in the form of hot water.
PREPARING THE PRODUCT
The dried product subsequently undergoes de-dusting, selecting and refining, where it is taken to the maximum particle size of 6-7 mm required for the production of an even/homogeneous product. From here it will be conveyed to storage and to the subsequent final transformation.
PRODUCING THE PELLETS
The material prepared is transformed into pellets by a pelletmaking press. The pellet production line ends with the cooling (air/product) and dedusting of the pellets. The line also includes an auxiliary, general dust suctioning system with filters that treat the air to be discharged into the atmosphere and to recover the dust which will go back to the production line. Once they have been cooled and cleaned the pellets pass through a weighing system before being packaged into specific customized sacks or big bags. This bagging system can be managed manually or automatically, like the subsequent stage of placing the sacks/bags onto pallets.