Pellet boilers pyrolysis master. Industrial pellet boilers - Pyrolysis Master, FACI, Roteks. Video review of the design with a lower combustion chamber

Today in economical Europe, solid fuel boilers (pellet and pyrolysis) are one of the most popular types of heating. A solid fuel boiler does not require electricity, gas or liquid fuel; ordinary dry wood or coal is enough for it. In this way, it is not much different from a conventional stove, but it is much more economical, more efficient and safer.
Solid fuel boilers are perhaps the most independent and self-sufficient heating method country houses, because solid fuel boilers are in no way connected with engineering communication systems: neither with electricity, nor with gas pipelines, and especially with centralized systems heating. Consequently, solid fuel boilers are absolutely indispensable in remote, remote settlements.
Despite the fact that such boilers are very similar in essence to a conventional oven, they are usually equipped with modern systems automation, equipped with all the necessary sensors responsible for equipment safety, temperature and other important parameters.

One of the important classifications by which solid fuel boilers are divided is depending on the material of the heat exchanger. There are cast iron and steel boilers, operating on solid fuel.
Cast iron solid fuel boilers are considered more durable. Their peculiarity is that they heat up for a long time, but at the same time cool down slowly, but they must be used extremely carefully, because cast iron is a rather fragile material and can crack from a sharp temperature change. Fortunately, currently modern technologies made it possible to improve cast iron boilers and reduce their fragility.
Steel solid fuel boilers are more resistant to the “vagaries” of temperature, but have another drawback - weakness to corrosion, which is usually caused by condensation. Cast iron boilers do not suffer from this problem. It is this minus that makes solid fuel boilers with a steel heat exchanger less durable, but cheaper. In any case, the service life of solid fuel boilers with a steel heat exchanger depends on the quality of the steel and its thickness.
Boilers made from sheet steel are less susceptible to destruction from sudden changes in temperature, since steel is a ductile material. The walls of such a boiler are thinner than the walls of a cast iron one, and in order to avoid getting burned, the outer part of the body is insulated from the inner part with modern non-flammable materials. So if you live in a country house permanently, then it is best to purchase a solid fuel boiler made of cast iron. And if you live in the city, and you only visit your house and heat it only during your presence, then it makes sense to install a steel boiler. A steel solid fuel boiler can also be used as an auxiliary boiler if gas or electricity shortages often occur in your area. If desired, some boiler elements can be replaced or new ones can be added in order to switch to the new kind fuel (gas or liquid fuel). True, one nuance needs to be taken into account here - the efficiency of such a converted boiler will be slightly lower than that of a boiler specially designed to work with gas.

Pellet boilers

Is complex engineering device, heating the coolant by burning derivatives of wood or coal fuel: briquettes or granules (pellets).

Operating solid fuel boilers in automatic mode allows you not only to reduce operating costs by shifting most of the worries about servicing and monitoring the operation of equipment to automation, but also, using a solid fuel boiler with automatic loading, to achieve the level of comfort of using gas boilers. Such solid fuel boilers (automatic) are still rare on the Russian market, but given the promising opportunities, we can assume a great future for them.
Pellets are made from wood waste, which is crushed and pressed into small cylindrical pellets. Their size ranges from 6 to 14 mm in diameter and no more than 70 mm in length. To produce this type of fuel, no chemical components are used, and therefore pellets are an environmentally friendly material and at the same time have a high calorific value. The use of pellets makes it possible to reduce the presence of humans in the operation of the boiler by automating the process of feeding pellets into the boiler. When transported in a car and stored in a private home, they take up little space. Pellet heating equipment is produced abroad and in Russia. Domestic models, as a rule, are cheaper than imported ones, and foreign ones have more service functions.

Construction of a pellet boiler

Pellet boilers are a steel structure, components which includes the housing, burner, firebox, heat exchanger, fuel hopper and chimney. After burning the fuel, hot gas is formed; when it leaves the furnace, it flows around the heat exchanger and transfers almost all of its heat to it. The “smart” design of pellet boilers is the key to amazingly high efficiency (at least 85%). The power of the devices varies from 15 kW to several megawatts. The heat exchanger is made of various materials, such as cast iron or steel.

How do pellet boilers work?

Servicing the boiler is easy. It is enough to load fuel into the bunker. Pellets are fed into the firebox from a special hopper by an automatic conveyor. The capacity of the standard bunker provides the boiler with fuel for about 7 days, then the storage is refilled. If desired, this process can be fully automated. The fuel is ignited automatically. This process involves an electric heating element and a fan that pumps air into the firebox. When the fuel burns steadily, the ignition system is turned off.

Types of pellet boilers

1. Equipment intended only for the use of pellets;
2. Conditionally combi boilers- usually operate on bio-pellets, but can accept briquettes or firewood as a “spare” fuel for a short time;
3. Universal boilers - can operate on any solid fuel. It is enough to dismantle the pellet burner, and the device is ready to be loaded with traditional solid fuel.

Advantages of heating with pellets

• Biogranules are almost completely recycled. Moreover, a negligible amount of combustion products is removed automatically, no more than 1 – 2 times a month;
• Supply of granules and the entire work process (heat generation and hot water) fully automated;
• The cost of pellets is lower than other solid fuels. Biogranules are always available for free sale. Buying a “refill” for pellet equipment is not a problem;
• Ideal for heating a private home, cottage, where it is not possible to heat with gas.

Pyrolysis or gas generator boilers

Pyrolysis boilers are capable of burning wood gas generated during the combustion of firewood, thereby significantly increasing their productivity and efficiency. The fuel in them burns almost completely, leaving almost no ash. In them, the wood is first completely dried at high temperature and a small amount of oxygen, turning into charcoal and the volatile part - pyrolysis gas, which is then burned with high efficiency in the firebox. As the gas burns, it interacts with active carbon and, as a result, the smoke leaving the boiler contains much less harmful impurities.
Compared with classical method combustion, pyrolysis boilers use the unique ability of solid fuel to transform into a gaseous state at high temperatures and in the absence of air. Pyrolysis boilers have a slightly higher price than their classic counterparts with the same power, but their high efficiency and ease of maintenance justify the cost of the purchased boiler in a very short time.

Pyrolysis boiler - design and principle of operation

A pyrolysis boiler works like this: fuel (wood) is placed in the upper chamber, it is ignited, the chamber door is closed and the boiler fan is turned on. As soon as the temperature inside the upper chamber rises above 250 °C, the wood begins to char, releasing generator gas that enters the lower chamber through the nozzle. Here, secondary air is added to the gases obtained as a result of pyrolysis by pressurization and they burn, returning some of the heat to the lower level of the fuel fill. Secondary air is an air flow that flows around the fuel in the upper chamber on the sides or enters through special slots in the door of the lower chamber of the pyrolysis boiler. Heat is taken from the pyrolysis boiler and transferred to the coolant (water or air) through the contact of the coolant pipeline with the bottom of the lower chamber of the boiler. From one full load of the fuel (upper) chamber, the pyrolysis boiler produces heat from 6 to 12 hours, depending on the quality of the fuel and heat needs.

Fuel for pyrolysis boiler

In practice, solid fuel pyrolysis boilers can operate effectively on any type of solid fuel, be it wood, peat, brown and black coal. Of course, the duration of complete combustion for each type of fuel is different and it looks like this:

• soft wood - combustion time no more than 5 hours;
• hard wood - combustion time about 6 hours;
• brown coal burns in about 8 hours;
• black coal burns for up to 10 hours.

Pyrolysis boilers are most effective when working on dry wood. It is dry firewood 45-65 cm long, the humidity of which does not exceed 20%, that not only provides maximum power to the boiler, but also extends its service life. Those who have the opportunity to buy dry firewood or at least dry it if the humidity is too high can safely buy pyrolysis heating boilers without doubting the efficiency of their operation. If you are not confident in this possibility, then you can choose a modern high-tech heating boiler, the firebox of which combines 80% of highly efficient pyrolysis fuel combustion and 20% of traditional one. Modern combined boilers provide high-quality combustion of not only firewood, but also wood waste, peat, coal or any mixture of them with a humidity of up to 50%.

Advantages of pyrolysis boilers:

• high efficiency achieved by two stages of fuel combustion, as a result, complete combustion fuel and high efficiency - up to 90%;
• work from one bookmark for quite a long time, up to 12 hours (for conventional wood-burning boilers, about 3-4 hours, but for top-burning boilers this figure is longer - from 30 hours with wood, to 6-7 days with coal).
• opportunity automatic regulation parameters, the combustion process allows automation, is easily adjusted and controlled;
• It is necessary to clean the ash pan and gas ducts less often;
• integrates into almost any heating system without requiring any major changes;
• laying unsplit logs is allowed;
• environmental friendliness achieved by combustion more harmful substances in the lower chamber, so that they are not released into the atmosphere;
• Very high speed heating the coolant, water or air, to a comfortable temperature of 60°C.

Disadvantages of pyrolysis boilers:

• the need for electricity required to operate the fan (smoke exhauster);
• high cost compared to conventional heating boilers;
• the need for low fuel moisture, firewood should have a moisture content of no higher than 20%;
• they require a high load in operation; when it drops below 50%, combustion stability is disrupted and tar accumulates in the smoke channel;
• All models of pyrolysis heating devices are single-circuit units that do not heat water for domestic needs.

And yet, high environmental friendliness, efficiency and economy, achieved through complete combustion of fuel and minimal heat loss, fully compensate for the shortcomings of pyrolysis gas generator boilers, and the circle of their admirers is steadily expanding.

Specialists of the company "Thermogorod" Moscow will help you choose, buy, and install a heating boiler, will find an acceptable solution at a price. Ask any questions you are interested in, a telephone consultation is absolutely free, or use the form "Feedback"
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Boilers of the LONGLIFE series are available in capacities of 18-250 kW. Designed for burning all types of solid fuel with a fraction suitable for manual filling of the firebox.

The firebox is equipped with water-filled grates and two doors for easy loading of fuel and cleaning of the ash residue of combustion products.

The boiler heat exchanger has the maximum heat exchange area in its class due to the surfaces that form a 5-way movement of gases in the firebox on the way to the chimney pipe.

Due to the developed heat exchanger surfaces, the boiler has a large coolant capacity, which allows it to act as a storage buffer and prevent boiling of the coolant when circulation is disrupted.

The process of fuel combustion in the boiler is controlled by the controller through forced submission air using a modulated fan. The controller algorithms decide on the need for the current intensity of fuel oxidation based on the coolant temperature, reading this indicator through a probe in the heat exchanger.

Automation is manufactured in Europe. Almost all European brands of solid fuel boilers order serial production of controllers from the same enterprise.

On the domestic market a large number of companies engaged in the production of industrial boilers. Industrial-type units operating on pellets are especially popular today. In this article we will talk about three Russian manufacturers that produce similar equipment: Pyrolysis Master, Faci, Roteks.

• Pyrolysis Master
• Roteks

Characteristics of industrial pellet boilers

Let's present the characteristics of industrial pellet boilers Pyrolysis Master PELLET PRO 100-1000 and PELLET 100-320, FACI 105-850 and ROTEKS 100-300 in the table.

Parameters/Model Pyrolysis Master PELLET PRO 100-1000 Pyrolysis Master PELLET 100-320 FACI 105-850 Roteks 100-300

GENERAL INFORMATION
Country of Origin	Russia Moscow	Russia Moscow	Russia, Chelyabinsk	Russia, Chelyabinsk
power, kWt	100-1000	100-320	105-850	100-300
For what objects is it intended?	Any industrial systems heating		Low-rise heating objects with operating pressure in the heating system up to 0.2 MPa	Low-rise heating objects with operating pressure in the heating system up to 0.3 MPa
KEY DESIGN FEATURES
Working pressure in the boiler jacket	0.6 MPa	0.2 MPa	0.2 MPa	0.3 MPa
Coolant temperature	Up to 115 gr.C.	Up to 95 gr.C.	Up to 95 gr.C.	Up to 95 gr.C.
Compliance with GOST-307.35-200	Full compliance	-	-	-
Burner type		Horizontal tray type retort	Vertical retort	Vertical retort
Availability of ash chamber	+	+	-	-
Heat exchanger type	Fire tube 3-way	Plate 5-way	Fire tube 2-way	Fire tube 3-way
Availability of turbulators	Included	-	Add. option for money	-
Feeding system		2-screw with fire break	2-screw with fire break	2-screw with fire break
Screw properties		Thick-barreled with a short arm and a thick spiral, mounted on two bearings each	Thin-barreled with a long arm and a thin spiral, mounted on two bearings each	Thick-barreled with a medium-length arm and a thick spiral, the lower auger is mounted on one bearing
Convenient service of screws and transport channels		Cleaning screw channels through service hatches without removing the screw feed		Cleaning of the screw channels is possible after disassembling the feed
Protection of the gearbox and auger from deformation when jammed	+	+	+	+
Convenience of servicing the burner and screw channels		Removable burner, maximum comfort for service	Not collapsible, no service possible	Difficult to disassemble, service possible
Heat exchanger balancing	Balanced, the coolant tends to equalize temperatures throughout the entire volume in the jacket	Absent	Absent	Absent
Automatic pellet burner cleaning Low quality and high ash content		Add. option for money (movable grate, operation is controlled by boiler controller algorithms)		There is no design possibility of automating burner cleaning
Automatic cleaning of the burner from residual smoldering products when the boiler goes into pause or stop, to prevent smoldering from being thrown into the lower auger of the feed system		The burner is completely cleaned according to the specified controller algorithms, when the burner is equipped with auto-cleaning		There is no constructive possibility of implementing the task
Pellet combustion portions		Full-fledged, due to the tray architecture of the burner working fluid		Not full-fledged, due to the large reservoir of the burner working fluid
Automation of ash removal	Add. option for money	Add. option for money	Add. option for money	-
Automation of heat exchanger cleaning	Full-fledged technology using a pneumatic block with a shock pressure of 0.6 MPa, controlled by several controller algorithms (during operation, after entering a pause, after entering a stop.)		Mechanical surface grinding technology	There is no constructive possibility
KEY FEATURES OF AUTOMATION
Autoignition	Standard	Standard	Add. option for money	Standard for the LUX series
Weather-compensated control		In the basic configuration (the controller is equipped with functionality and an outside air sensor)	Absent	Absent
Working on a weekly schedule		In the basic configuration (the controller is equipped with functionality for programming operating modes by hour of day for each day of the week)	Absent	Absent
DHW circuit control	Standard	Standard	Absent	Absent
Additional management heating system circuits		In the basic configuration +2 circuits, expansion up to 7 additional circuits is possible. module	Absent	Absent
Three way valve control	Standard	Standard	Absent	Absent
Control via room thermostat		Basic support room regulator	Absent	Absent
Providing boil protection	Standard	Standard	Standard	Standard
Control of the combustion process using an oxygen sensor LAMBDA PROBE		Option (when connecting a lambda probe)	Absent	Absent
Remote control via the Internet		On a computer (demo) and on a smartphone (ios or android)	Absent	Absent
Remote control via SMS	Add. option	Add. option	Absent	Add. option
Controller User Interface		Touch screen, no analog buttons		Analog keypad with basic screen
Controller interface language		Russian + all European languages	English	Russian

Pyrolysis Master

The Pyrolyz Master company can be characterized by two keywords - high technology and efficiency. This is due to the fact that the manufacturer independently develops the design of the equipment and actively cooperates with European companies, producing boiler equipment under a licensed production scheme.

Industrial pellet boilers Pyrolysis Master is presented in the PELLET PRO 100-1000 kW and PELLET 100-320 kW series. This efficient equipment, characterized by high performance. Heats the room in the shortest possible time and retains heat for a long time.

Heating devices of the PELLET PRO series 100-1000 kW are manufactured in accordance with the requirements of GOST-30735-2001. The working pressure in the boiler jacket is 6 Atm. The coolant supply temperature is up to 115°C.

In the event of a temporary power outage, it is possible to heat the boiler with wood or fuel briquettes.

Boilers can be operated using most types of solid fuel in the form of pellet fraction. The technical and economic indicators of the boiler declared by the manufacturer are achieved when using fuel with specific heat combustion of at least 16.4 MJ/kg. When using fuel with a different calorie content, or a moisture content of more than 20%, the technical and technical-economic indicators of the boiler operation may differ either up or down.

The boiler is equipped with automatic equipment to maintain set temperature coolant at the outlet and an automatic ignition system.

A weather-dependent regulation system has been implemented, it is possible to control using a built-in programmable thermostat and the ability to monitor and control the heating process remotely using additional modules.

The basic volume of the pellet bunker is from 1000 liters and can be increased at the request of the buyer.

Additionally, the boiler design allows the installation of automatic ash removal, automatic pneumatic cleaning of the heat exchanger, and controllers for remote control boiler using a smartphone or computer via the Internet and via SMS messages, as well as automation controllers for the hydraulics of the heating system.

Character traits boilers have a twin-screw feed and a tray burner. All electrical components and automation are made according to high quality European standards.

Let's look at the main technical characteristics of both series.

Units of the PELLET PRO 100-1000 kW series are capable of effectively heating a room from 1000 to 10000 m².

Pellet boiler Pyrolysis Master PELLET PRO

Equipment and functionality:

• heat exchanger of the boiler combustion chamber for industrial facilities with a working pressure of 0.6 MPa and a supply temperature of up to 115°C;
• practical tray-type retort burner with automatic cleaning for pellets with different ash contents;
• equipment operation is fully automated;
• there is weather-dependent regulation and a weekly schedule for the operation of the heating device;
• burner made of cast iron, with a twin-screw fuel supply system and a ceramic auto-ignition heater;
• turbulators;
• pellet hopper 1-2 m³ (volume can be any to order);
• control heating circuits and three-way valves;
• boiler power differential control (PID), which ensures the smoothest and most economical operation in all heat consumption ranges;
• there are tools designed to service the combustion chamber;
• auto-cleaning of the burner (an additional option for pellets with high ash content - sunflower husks, bark, peat, slab);
• SMS control of the heating device (additional option);
• boiler control via PC, smartphone (additional option).

PELLET series boilers 100-320 kW are designed to supply heat to rooms with an area of ​​1000-32000 m².

Industrial pellet boiler Pyrolysis Master PELLET

The functionality and characteristics of pellet boilers are as follows:

• heat exchanger for the most economical consumption of pellets;
• high productivity - efficiency reaches 90% or more;
• the retort burner is unpretentious to the quality of pellets, the boiler can be fired even with the cheapest pellets;
• high-quality European-made electronics guarantee the uninterrupted stable operation of the boiler;
• the burner is made of cast iron, has a twin-screw fuel supply system and ceramic auto-ignition;
• boiler automation with sensors;
• hopper for pellets (can have any volume upon request);
• auto-cleaning of the burner (additional option for pellets with high ash content: peat, bark, sunflower husk);
• ash removal system (additional option);
• SMS boiler control (additional option);
• boiler control via computer, smartphone (additional option).

FACI

Pellet boilers produced by this manufacturer belong to the category of economical equipment, because... Pellets of any quality can be used as fuel (wood, buckwheat, peanut, almond, pine nut shells, coal, firewood, etc.).

Pellet boiler FACI

FACI boilers are environmentally friendly clean look heating systems, they can be installed both in closed and open systems heating. You do not have to constantly monitor the operation of the equipment; they are very easy to clean.

Included heating devices includes a large hopper for loading fuel, and on the front side of the boiler there are doors for cleaning. All Faci boilers, in particular industrial ones, are safe to maintain and operate. This is due to their design and built-in automation. The units also have overheating protection.

All boilers have a twin-screw fuel supply system, which means that the flame will not get from the boiler into the bunker. If we compare traditional solid fuel units with FACI, the latter produce the most economical heat.

Their productivity is high, efficiency reaches 92%, which indicates that the fuel is burned to the end.

Another important advantage is that pellet boilers produced by FACI are environmentally friendly pure source thermal energy. The design of the devices is such that the fuel burns completely, and in terms of flue gases and emissions into the atmosphere, the units correspond to class A, the best in Europe.

Industrial-type boilers include heating devices with a power from 105 to 911 kW. Designed for heating and providing hot water in rooms with an area of ​​1050 to 10000 m². They are made from high quality durable steel. Due to the fact that the design includes a three-row heat exchanger, it is ensured high efficiency and saving energy. The heat exchanger is made of flue seamless steel pipes, which are immersed in water, they are located in the upper part of the combustion chamber, equipped with a downward screw. This indicates that the system is naturally protected from backfire. The devices can operate on any type of crushed fuel.

Technical characteristics and functionality:

• automatic fuel supply mode (main) - pellets, crushed biomass;
• manual fuel supply mode (backup) - firewood, briquettes;
• three-row heat exchanger;
• twin-screw automatic fuel supply system (the risk of fuel fire in the bunker is reduced to zero);
• the burner is made of cast iron;
• fuel bunker ensuring continuous operation of the device;
• volumetric combustion bowl;
• digital control panel;
• the air is pre-mixed, which increases efficiency;
• automatic system ash removal (additional option);
• auto-ignition of the boiler (additional option);
• automatic heat exchanger cleaning system.

Roteks

Roteks pellet boilers are produced by ChZSK, a Russian manufacturer of pellet boilers for heating, modular boiler rooms, units and components for boiler equipment. The equipment is considered effective and is in wide demand among domestic users.

Rotex pellet boiler

As distinctive features This equipment can be distinguished by the presence of a retort burner, which is absolutely unpretentious to the quality of pellets, a three-pass heat exchanger - vertical, which allows you to keep the surface of the heat exchanger clean.

In this regard, Rotex pellet boilers are characterized by high performance, efficiency reaches 93%. If necessary, in specialized stores you can always find spare parts that are much cheaper than imported ones.

Industrial pellet boilers Roteks are presented in a series from 100 to 300 kW in the LUX and ECONOMY configurations.

The technical characteristics of heating devices of both series with the same power do not differ in any way.

Boilers classified as “LUX” and “ECONOMY” operate on solid granulated fuel, comply with the requirements of GOST 20548-87 and GOST 30735-2001, and are fully automated. The advantage of the LUX series is the availability of a remote on/off option, as well as SMS notifications about the operation of the boiler.

We can conclude that it is not for nothing that all three manufacturers occupy leading positions in the market, because produce high-quality equipment. When choosing industrial pellet boilers, you need to carefully analyze all the options and, based on your personal requirements, choose the most best option. If you choose a boiler from the three proposed options, then based on practicality and efficiency, the Pyrolysis Master equipment looks the most attractive. But the final choice is yours.

teplofan.ru

How do industrial pellet steam boilers work?

Some types of industry: oil refining, woodworking furniture, etc. need a lot of steam. Industrial pellet steam boilers are ideal for this purpose. Heat generators generate a sufficient amount of thermal energy to warm up work areas and provide the necessary volume of steam and hot water.

Scope of application of pellet steam boilers

The industrial pellet boiler is mainly used in industry to produce steam. The most popular equipment is for the following types of activities:

• Petroleum refining industry - petroleum products are heated with steam to improve fluidity and facilitate pipeline transportation.
• Wood processing industry - using steam to create optimal conditions especially for drying valuable species wood The percentage of defects allowed when drying boards and timber is reduced.
• Furniture industry - in the manufacture of certain types of boards (fibreboard, etc.) used in the production of furniture, steam is required.

An industrial pellet steam boiler is universal and can operate on any wood waste, and even wood dust, which makes its operation especially beneficial in the woodworking and furniture industries.

Design and principle of operation of a steam pellet boiler

Industrial steam boilers high power on fuel pellets, are a synthesis of two types heating equipment. The process of heating steam and the liquid coolant medium is carried out in the same way as in other steam units, but for combustion, pellets are used as the main type of fuel. This is reflected in technical characteristics ah pellet industrial boilers: performance, time battery life etc. In simple language, the structure of steam units, without complex technical details, can be explained as follows:

• The fuel is burned at a temperature of 1800°C.
• The heated flue gases are fed into the convective shaft, where they are pre-cooled to 800°C, and after passing special system chimney pipes, up to 100°C.
• There are two water containers inside the case. The first serves to supply coolant to the heating system, the second to produce steam.

High-power industrial solid fuel pellet boilers usually have a water-tube design. The design of such systems is more complex, but provides increased production of steam and thermal power for heating systems.

How pellets are burned

The technology for burning pellets in industrial steam boilers is practically no different from that used in household units, with the exception of the increased volume of fuel required to maintain the operation of the system. Supply and combustion occurs as follows:

1. The pellets are fed to the burner.
2. Using electric ignition, the pellets are set on fire.
3. To increase combustion intensity and temperature, air is forced onto the burner. Thanks to oxygen, the fire torch has the necessary structure to maintain a stable temperature in the firebox.

Pellet burners for steam boilers are connected to automation that fully controls the combustion process. The system is controlled from the control panel or using a remote controller.

An important feature of steam units is the combustion of fuel at extremely high temperatures. To avoid overheating, it is necessary to distribute evenly air currents and heat inside the firebox. For this purpose, a specially designed grate is used.

The grate allows you to use other types of fuel (sawdust, wood chips and wood dust) during operation. To prevent metal warping, water cooling of the grate is provided.

Continuous Pellet Feed System

Pellet feeding into an industrial boiler is carried out using a mechanical screw or pneumatic transmission. Fuel pellets are poured into a separate room connected by a transport line to the unit. By means of an auger or pneumatic device (worm gear), pellets are taken into the room and sent to the burner. The fuel supply is controlled automatically. Depending on the heating, the rate of delivery of granules increases or decreases. Even pellet industrial boiler houses, using this device, can operate autonomously throughout the heating season. To maintain operation, it is necessary to refuel the fuel hopper from time to time, as well as clean the chimney and firebox walls from carbon deposits.

Possibility of using wood chips, sawdust, briquettes

Although pellets remain the main type of fuel in steam units, other types of wood fuel can also be used:

• Briquettes.
• Woodchips.
• Wood processing waste.

Of course, the boiler will not operate solely on wood dust. But if necessary, you can add it in a ratio of 30% of the total fuel volume. To achieve maximum heat transfer, sawdust and wood chips should not contain more than 20-25% moisture.

Which pellets are best for steam boilers

The quality of pellets affects the performance and service life of the boiler. The use of gray fuel pellets with a higher percentage of ash content leads to the following:

• Pellet consumption - it would seem that purchasing cheaper fuel pellets helps you save money due to less money needed to purchase them. In fact, inexpensive pellets have a lower calorific value, which significantly reduces heat transfer and, accordingly, leads to increased fuel consumption.
• Equipment failure - gray pellets, when burned, leave a larger amount of ash that settles directly under the burner or at the exit of the screw transmission. Accumulated carbon deposits lead to failure of bearings, jamming of the screw transmission and its burnout.

The weak point of industrial pellet boilers for steam production is the susceptibility of the screw transmission system to wear due to the use of low-quality pellets. Based on the fact that white fuel pellets have the best calorific value, they do not affect the performance of the system so much; it is best to use them during operation.

Pellet consumption during combustion steam boiler per month can be easily calculated based on the heated area of ​​the room. Approximate costs for each m² will be about 6.5 kg. Additional Information indicated in technical documentation units.

Main manufacturers of pellet boilers for industry

The choice of a pellet steam boiler should be based not only on technical characteristics and performance. The manufacturer of the equipment is also important. All proposed equipment can be divided into two categories: those that are made abroad and on the territory of the Russian Federation:

• Foreign pellet boilers for heating industrial premises - there are several manufacturing companies: FAKO, LIBERATOR POWER, etc. Recently, modular boiler rooms manufactured in China have become widespread. The products of the manufacturer Heguo are in demand.
• Domestic manufacturers of steam boiler systems using pellets are less well represented. Most manufacturers focus on domestic use of systems. Among a dozen domestic factories, one can highlight the SLON company, which produces simple but reliable steam boilers.

In most cases, the purchase of a high-power steam plant is made to order, after providing the technical characteristics of the building and detailed description necessary additional functions that the purchased equipment must support.

Advantages of steam pellet equipment

Steam boilers operating on wood pellets, significantly reduce heating and steam costs. Installation is carried out in any room suitable for this purpose. If necessary, you can purchase a block-modular boiler room. The advantages of steam pellet equipment are:

• Versatility - in addition to the main fuel - pellets, boilers work effectively on almost any solid fuel: wood chips, sawdust, wood dust. The use of heating systems of this type in the furniture and woodworking industries is especially beneficial, since during the production process a large amount of waste remains, which can only be used for heating rooms and generating steam.
• Economical - due to the special design of the boiler, which uses the heat generated by the fuel during combustion and the energy of the exhaust gases. The consumption of granules is reduced by approximately a third, while the heat transfer remains at the same level.
• Easy operation of an industrial pellet boiler. Once connected, the heating and steam generation system operates autonomously. The owners of the module are required to monitor the level of pellets in the storage, as well as clean the combustion chamber, burner, grate and auger from accumulated soot. Some models have a self-cleaning system. In such boilers, maintenance is required no more than once every 2-3 weeks.
• Functionality – Steam boilers are specialized equipment mainly used to produce heat and steam simultaneously. Some models are additionally equipped with a steam generator, which allows you to obtain highly heated dry steam.

For industrial purposes, this type of equipment is the best choice, as it can significantly reduce maintenance costs.

Disadvantages of industrial pellet boilers

Reviews that have appeared on the operation of steam heat generators operating on pellets help to identify several main disadvantages inherent in each model of equipment:

• Water supply – for the boiler to operate, it is necessary to supply water at a strictly defined temperature that has been purified. Installation of a primary water treatment system will be required.
• Restrictions during operation. If steam is not needed during the production process, it is better to refuse to purchase this type of equipment. Alternatively, you can create an additional heating system that runs on steam.

The disadvantages of steam boilers are mainly related to their design features and areas of application. For furniture and oil refining production, food production, steam heat generators are the optimal solution to the issue of heating and steam production.

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Pellet industrial boiler for heating industrial premises

It is logical to assume that the choice of a pellet boiler for a private home and for industrial premises large area - these are two opposite sides. In this article we will look at the main points of selection and specifics of functioning of a pellet boiler for an industrial premises. Also, you will have to take into account future labor and financial costs for boiler room equipment and operation of the Lavoro pellet unit.

Why is a pellet boiler so good in production?

This is an excellent saving on gas, which in our time will be too expensive to fully heat a large room.

Durability and high strength of the unit. Industrial pellet boilers are generally characterized by high wear resistance, since efficiency and versatility are important to the owner.

The pellet unit is very unpretentious and omnivorous: it can handle any organic fuel in the pellet and briquette format, including even sunflower husks.

Why pellet boilers are rapidly gaining popularity among owners industrial enterprises?

As we mentioned above, the first and main reason is the high cost. natural gas, which is successfully compensated by the cheapness and availability of wood fuel.

Also, Lavoro Eco pellet mechanisms in production have truly enormous power, reliability and efficiency!

An autonomous pellet boiler system, to which an automatic fuel supply is also connected, is the best engineering solution for heating a large room. In essence, it is a complex and well-thought-out set of mechanisms and devices that spares the owner’s hands and allows significant savings, providing maximum power and high percent Efficiency

Another advantage of purchasing a Lavoro pellet boiler is the availability of wood fuel. For example, if you are going to buy heating system for your woodworking plant, then you will not have big problems with the solution to this issue. In addition, you will save a lot of money. Almost all enterprises of this type (also pulp and paper) use waste from their own production as fuel. Why not a convenient and profitable option?

Installing one or more pellet units in production solves two problems at once: providing heat and hot water supply.

How to choose good quality pellets for heating production premises?

There should not be too much dust in the packaging of pellets.

The granules should not have swollen parts or strong cracks.

Pellets should not be gray in color. This shows that they are lying around. Normal color for pellets ranges from yellow to brown.

Can you determine the quality of granules even by smell? It should be pleasant, woody, slightly sweet. There should not be any chemical odors in them.

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Industrial pellet boilers

Home » Industrial pellet boilers

OFFER

for the supply of boiler equipment based on a KPU brand pellet boiler running on biofuel (wood or peat pellets) or wood chips, relative humidity up to 18%.

Currently, NKZ Pro-Energy LLC offers a serial range of pellet boilers with capacities: 100, 200, 300, 500, 750, 1000 and 1500 kW. They are intended for heating and hot water supply of individual houses, cottages and small farms with a total volume of premises up to 51,800 m3. In automatic mode, they are used as fuel as fuel pellets, and wood waste (sawdust, wood chips) relative humidity up to 18%. The basic kit includes a boiler, a hopper, and a separate remote control automatic control(not built-in).

1.Description of the delivery contents.

The KPU brand pellet boiler has a design combining a firebox and a heat exchanger and consists of the following main components:

1.1. The combustion chamber of the boiler is located inside a cylindrical heat exchanger. In the lower part of the firebox there is a burner with a pushing grate, into which fuel is supplied by a screw conveyor. During operation, the grate bars move back and forth, pushing fuel. Fuel is supplied to the screw conveyor from the bunker. The burner is equipped with a pipe for connecting an emergency fire extinguishing system, which supplies water to the auger when its temperature exceeds a preset value. The firebox is equipped with a combustion door through which the burner is serviced. The combustion door has an observation window to monitor the combustion process. The under-grid space is subject to periodic cleaning. The frequency of cleaning depends on the type of fuel and is determined during operation. The blower provides air supply to the burner. Adjustment of the amount of air is provided from the control panel during commissioning and depends on the type of fuel and required power boiler The heat exchanger with smoke tubes is located vertically around the combustion chamber. The coolant (water) is pumped into the heat exchanger from below, the flue gases, falling, wash internal walls pipes where heat exchange occurs. At the outlet of the heat exchanger, a safety group is installed in its upper part, which includes a safety valve, a pressure gauge and a ball valve. Safety valve serves to release excess steam (water) from the boiler when the pressure in it increases above the design value. The pressure gauge is used to control the pressure in the heat exchanger. The ball valve is designed to bleed the steam-air mixture from the heat exchanger. The heat exchanger is equipped with a cleaning hatch located on top, which provides access to the heat exchange surfaces of the smoke pipes when carrying out work to clean the heat exchanger from deposits (the recommended service area above the boiler is 1.5 meters). The heat exchanger has thermal insulation, which reduces thermal energy losses in environment. A cleaning hatch is used to remove ash from under the heat exchanger.

1.2. The flue gas purification system, complete with a smoke exhauster, is designed for dry purification of gases released during certain technological processes, including combustion tree species fuel and peat. The cyclone consists of a housing with a guide screw, a storage hopper on a frame structure with gas ducts and a smoke exhauster. At the bottom of the cyclone there is a receiving container for collecting ash deposits, into which solid waste particles fall due to centrifugal forces. Each cyclone is supplied for a boiler of a certain power.

1.3. To automatically supply fuel to the combustion unit, an operational hopper with a screw conveyor is used. The operational bunker is a cone-shaped metal container with a loading volume of 0.6-2.2 m3. The bunker has a hatch for Maintenance and a technological hole for supplying fuel to the screw conveyor, which is closed with a gate when the boiler is operating in manual mode. To regulate the amount of fuel supplied in order to avoid overloading the bunker, volume sensors are used, with the help of which the operation of the entire fuel supply system is controlled from the control panel of the automatic system. To drive the screw conveyor, gearmotors made in Italy are used, which have a good service factor and do not require frequent maintenance. The dosage of the amount of fuel is automatically adjusted using a frequency converter from the control panel of the boiler complex. The mechanical fuel supply device is equipped with a humidification system, as well as fire protection system.

1.4. The automatic control system of the automatic control system based on the MITSUBISHI programmable controller and frequency converters allows for automatic ignition of the boiler, regulation of the combustion process and fuel supply in automatic mode. Measurement and regulation takes place according to three main parameters: the temperature of the forward and return coolant supply, the temperature of the exhaust gases. Emergency temperatures are monitored, control commands are issued, light and sound alarms are provided emergency situations, possibility of data archiving. Upon additional request, it is possible to supply a heat meter.

The delivery set includes all necessary sensors.

1.5. It is used to remove flue gases to higher layers of the atmosphere. chimney height 7.3 - 16 meters. The pipe consists of a thick-walled support section and intermediate sections, which are connected to each other through angle profile flanges. There is a cleaning hatch and a condensate drain at the base of the pipe. The pipe is secured using three braces, depending on the location. When located near a residential sector, the height of the pipe can be increased to 21 meters.

To heat a private house without a centralized gas supply, they mainly use accessible and inexpensive solid fuel. However, traditional types heating devices, operating on this type of fuel, have a rather low efficiency and are labor-intensive to operate. Boilers that appeared not so long ago long burning, using the pyrolysis method, are more efficient, economical in fuel consumption and easy to maintain.

Criterias of choice

Pyrolysis boilers for home heating are designed to operate on different types fuels: wood, coal, peat, sawdust, pallets. Highest performance due to complete combustion fuel in the pyrolysis mode have wood-burning devices. Therefore, if it is possible to inexpensively and in sufficient quantity to prepare firewood for the entire heating season, then you can buy and install just such a boiler at home.

Otherwise, it's better to buy universal device, capable of working on any solid fuel. Structurally, they are designed in such a way that they can burn up to 80% of fuel resources in pyrolysis mode, and the remaining 20% ​​in the mode of a simple solid fuel unit.

You should also pay attention to:

unit power. When calculating this indicator, the area of ​​the building that will be heated by a long-burning pyrolysis boiler and the level of protection of its rooms from heat loss are taken into account;

volume of the combustion chamber. A boiler with a small combustion chamber will require more frequent fuel supply, so it cannot be left without maintenance for a long time, especially in severe frosts;

quality of the internal coating of the chambers. Chambers with walls lined with ceramic concrete are more protected from burnout, maintain integrity at the maximum heating level and provide proper combustion fuel;

the combustion duration with a full fuel load must be at least 10 hours;

level of automation for device safety. A long-burning pyrolysis boiler must be not only productive, but also safe, so when purchasing, you need to check whether it is equipped with an alarm and an automatic shutdown system;

presence of an additional circuit. A heating device with one circuit can only be used to heat a room. If you plan to use the boiler to organize hot water supply, then you need to immediately buy a device with a dual-circuit design;

price. You should not save on buying a boiler, as cheap models may not have enough technical capabilities for optimal heating of the room. It is better to purchase a boiler of proven brands that have already been tested in harsh Russian winters and have earned good feedback owners.

Model overview

The modern market offers a lot different models long-burning pyrolysis boilers, differing in a number of technical characteristics, dimensions and price..

Pyrolysis Master LONGLIFE 18-250 kW

High efficiency, automatic control of the boiler operation and circulation allow this device to effectively perform its functions on one load for 8 - 72 hours (depending on the type of fuel used). The boiler is equipped with a digital controller, an air supply fan, and a 5-pass heat exchanger with a large volume of coolant, ensuring its high performance. The combustion chamber is equipped with water-filled grates and two doors for loading fuel and removing ash residue. The device works equally effectively when manually loading any type of solid fuel into the combustion chamber: coal, briquettes, firewood, sod peat.

Maximum heating area - 18 - 2500 m²;

power - 18 - 250 kW;

• Price range depending on power: - 980 - 7300 conventional units.

Buderus Logano S171

The German pyrolysis boiler of this series has an increased volume of the loading section and an improved heat exchanger design and is adapted to work in both natural and forced ventilation coolant. Its body is made of high-alloy steel 5 mm thick; fireclay bricks with a longer service life are used for lining the firebox; two ash pan doors, one located on top and the other on the front panel, provide ease of cleaning. Uninterrupted operation unit and the protection function is performed by a powerful automatic control system.

Maximum heating area - 500 m²;

power - 50 kW;

• Dimensions - 699x1257x1083 mm;

  The average price is 3600 conventional units.

Bastion M-KST

Universal pyrolysis boilers Russian production with a power from 12 to 30 kW, differing from imported analogues in a lower price and compact size, capable of heating an area from 100 to 300 m² (depending on power). Volatile devices that do not require frequent removal of ash waste. The combustion chamber is made of low-alloy steel grade 09G2S; it can simultaneously accommodate firewood, coal, and wood waste from 40 to 120 dm³. They can work without refueling for 4 - 12 hours (depending on the moisture content of the fuel, the type of wood, the organization of the chimney, etc.). Efficiency factor - no less than 85%. The price varies in the range of 670 - 1200 dollars.

Trajan T

Single-circuit devices operating on wood, fuel or peat briquettes. They can maintain a comfortable room temperature with one load of fuel for at least 8 hours. In T series models, the draft is adjusted automatically; with additional equipment with a heating element with a power of up to 3 kW, the coolant temperature will be maintained after the wood burns out for several hours.

Models of the Trayan T series boiler	power, kWt	Heated area, m²	Dimensions (WxHxD), mm		Price, dollar

Our company has been professionally engaged in heating systems for private homes, cottages and commercial properties for many years, using long-burning wood-coal and pellet boilers as heat sources.

In recent years, we have seen an active growth in demand and popularization of the so-called “pyrolysis machines”. Such equipment, like all solid fuel heating devices, has a water circuit for the coolant.

In Moscow and the Moscow Region, the demand for installations of this class is growing every year despite the crisis, and there are good reasons for this. The main reason for choosing such heating devices for a private home is the efficiency and comfort of operation.

As for the economic benefits, it is centered around reducing the cost of firewood, briquettes, or coal. Using any of the listed types of fuel, this group of heating devices allows you to reduce the cost of purchasing fuel by at least 30%. This indicator helps to pay for your purchase in just a few seasons of operation, which is not possible to achieve when using classic designs that burn pellets, wood or coal.

Comfort of operation lies in the duration of combustion, frequency of loading and cleaning. Thanks to the reduced consumption of fuel raw materials, the operating time of the “pyrolysis machine” on one stack increases by 2-3 times, in comparison with cheap popular designs, and reaches 6 hours. In boilers with top combustion and 12 hours in gas generators with bottom combustion. The method of fuel combustion contributes to the low formation of dry residue (ash), which must be periodically cleaned from the firebox and ash box. This fact also has a beneficial effect on the comfort of using the heating device - owners of such heating installations have to clean out ash much less frequently.

The samples with the lower combustion chamber of pyrolysis gases have the longest operating time from one stack of firewood. The design of such installations implies the presence of a boost fan or smoke exhauster and nozzle. Of course, gas generators of this type are energy dependent. You can also emphasize the high cost of such installations. Models of this design cost at least 2 times more than heat generators with an upper combustion chamber for pyrolysis gases.

Products of this design are represented in our catalog by several brands, most of which are European and only two of which come from Ukraine. As for European brands, we can mention the Czech WATTEK and Atmos, the German Buderus, and the Bulgarian SunSystem. According to Ukrainian brands, these are products of the popular MotorSich brand and BTS gas generators.

Regarding Czech brands, we would like to highlight Wattek as more technologically advanced and advanced equipment. German Buderus is the only brand from Germany that is represented on our market. We have no installation experience with the Bulgarian brand, but the quality of the products is high level. According to brands from Ukraine, these are two different products. Each with its own advantages, however in the domestic sector, we are inclined to the BTS brand due to the available fireproof materials used in the gas generation chamber and nozzle.

Design of gas generators with a lower combustion chamber:

Video review of the design with a lower combustion chamber:

Now let's talk about the most common gas generators in Russia with an upper combustion chamber of pyrolysis gases. These heat generators are of Russian origin, produced at several factories, most of which are located in the Kostroma Region. One manufacturer is located in the Moscow region.

Russian pyrolyzers also use the principle of “dry distillation” of solid fuel, which allows them to correspond to the class of pyrolysis combustion heating devices. But the operation of these installations is based on natural traction. Russian equipment belongs to top-combustion gas generators, since the combustion zone of the resulting gases is located above the pyrolysis area (fuel decomposition into gas and ash). The resulting gaseous fuel enters with the help of natural draft into the fuel loading chamber standing above it, where it mixes with heated secondary air and ignites, burning more deeply than with direct combustion from wood.

Equipment of this group is much cheaper, which is why it has become very popular in our Country.

Popular brands include Burzhuy-K, Trayan, and Lavoro in the household segment. Industrial installations this design is very popular in trademark"Pyrolysis Master".

If we talk about our opinion, we give preference to products for household use in the Trayan brand, due to its progressive design, long service life and the most attractive price among all compared brands.

Trayan brand equipment truly has the best design characteristics, making the furnace service life and efficiency the best in the segment.

The most popular and promoted products in the household segment today are gas generators of the Burzhuy-K brand.

Top combustion chamber design:

To summarize, we would like to talk a little about the numbers and what to choose. Russian heating devices burn for 6-8 hours on one tab. European and Ukrainian - up to 12 hours. Despite the fact that gas generators with a lower chamber are much more expensive, this design works more efficiently and is less demanding on the chimney and heating system.

For those who do not want to experience difficulties during operation, it is better not to save...