Build a Large Capacity Wood Pellet Factory, 5k tons/month Up

A large capacity wood pellet factory has a greater risk than a small capacity wood pellet factory. At the factory the production target becomes an important benchmark in addition to the quality of the wood pellets, of course. The consequence is the use of reliable production machines so that the production target can be achieved. Whereas in small capacity wood pellet factories, usually with small production, with short working hours the quality of the production machines is not as good as for such large capacities, so the investment for purchasing machines is also cheaper. Ability to work continuously with long working hours, minimum downtime, as well as stable output and product quality. These high-performance production machines usually have high “flying hour” so they can be relied on. Although the price of the tool is more expensive, it is still an option because the goal is achieved, namely the quality and quantity of wood pellet products according to the plan.

In general, a manufacturer of production equipment or machinery and especially wood pellets does not make from A-Z or all of its equipment (complete line). In general, they are specialists in only one or several equipments, especially the pelletiser / pelleter because it is the heart of the wood pellet production. While other equipments is made by other companies. When the production equipment or machine manufacturer offers a complete line unit for the production of wood pellets, they mean that they have added a number of supporting equipments from several of their network vendors. So is it possible if you want to make your own wood pellet factory according to your own wishes or do customization so that the equipment from a number of vendors is assembled by yourself so that the wood pellet production line is complete? Of course you can, but it requires a number of special skills or is like making your own car with equipments or components from many vendors. For example, assembling a number of these machines and even though they are from well-known engine manufacturers, they may not provide optimal performance because do not know their characteristics including the compatibility.

Although basically to get the best level of performance with a high level of efficiency but looking for the best combination not an easy thing. The price factor is also another variable to get the best combination. Experienced machine providers or sellers can provide according to the buyer's wishes, especially with a limited budget but want excellent performance. The higher “the flying hour” or the experience of the machine provider, the better in providing the offer because they already know the characteristics of each of the equipment. Installation, commissioning, training to after sales service are the next considerations. In the large wood pellet industry, customization of equipment from various vendors making production equipment to the safety aspect is a common thing. Moreover, the selection of the equipment is also based on the experience of wood pellet factories that are already operating. Customization is indeed something unique that is much influenced by previous experiences.

Previous experience with a certain equipment manufacturers is an important experience to determine the performance or characteristics of an equipment. Of course, it is very difficult to know all the characteristics of the equipment available on the market because there are so many manufacturers of equipment providers, the location of the equipment providers and the ability to handle a wood pellet project. In addition to technical factors, human relations factors also play a role in this, especially the success stories of previous projects. Upgrading equipment is usually become an entry point for collaboration with other vendors, especially since the previous vendor did not have this capability, for example, to increase the efficiency and flexibility of raw material belt dryer used to replace rotary dryer due to better drying capabilities, or certain hammer mill that also have certain capabilities and so on. And especially if you already have long experience with them before.

Wood Pellet For Green…Green World!

The growth of human consciousness as a result of environmental degradation in the form of climate change and global warming fostered efforts to reduce the magnitude of the environmental damage. Sources cause damage to the environment due to human greed through economic activity to exploit nature excessively. Humans should be the manager of this nature wisely instead of vice versa due to short-term interests and lust. The growing awareness of the need to be maintained and are arranged so that led to concrete efforts. Without clear rules and binding activity of all human beings on earth, the impossible nature of the improvement will be done well.

We are witnessing today a variety of companies that the state wants to be recognized as a company or a country most concerned in environmental issues and  no exception, Indonesia . That way they compete with its Go Green program such as CO2 Reduction and the like. With such recognition generally they wanted a special place among consumers or their partners so that the products or programs they will also readily accepted  these  circles. These activities also generate new economic activity that is the Green Economy. How big is the Green Economy or Green Business this? The answer of course depends on how big the mitigation of climate change and the environment in corporate entities or countries concerned to the global scope.

Wood pellets are a popular solution for mitigation of environmental and climate change issues. Wood pellets from wood biomass is carbon-neutral fuels and renewable energy sources with the requirements of wood biomass as a source of raw material of wood pellets to be undertaken on an ongoing basis and do not damage the environment. Continuous availability of raw materials is one of the key factors of business success of the production of wood pellets, so because of the current limitations of wood pellets is not only but also from agricultural wastes or biomass plantations could be called pellets or agri-wastepellet. Energy planatations with SRC (short rotation  species) is one way to produce wood biomass as a source of raw material of wood pellets faster and be sustainable. Indonesia is huge potential for energy planatation and will be better when integrated with other sectors.

Global Market Competition of Wood Pellet

Massive wood pellet demand mainly from South Korea as the primary market has encouraged the growth of wood pellets wood pellet industry in Southeast Asia. Indonesia, Malaysia, Thailand and Vietnam are the countries that responded positively to the demand of wood pellets from the South Korea. The growth of industrial wood pellets in each country is different speed depending on the readiness of the industry, the availability of raw materials and ease various other business support facilities. Although Indonesia is slow to respond to the demand of wood pellets, but in fact Indonesia has a tremendous opportunity to lead this industry due to the potential availability of abundant raw materials from waste-wood waste and cultivated by making a energy plantation.

The extraordinary potential in Indonesia is ogled by Korea to increase the volume of exports of wood pellet to Korea, which means that the growth of industrial wood pellets should be accelerated. The greater the demand and lack of supply pushed the price of wood pellets is expensive, so the more the industry grows to gain momentum at this time, when the demand is very large, while its minimal supply. Timber industry wastes which initially becomes a problem when it began to be seen as a potential raw material for industrial raw material in wood pellets.

Wood pellet market will be even better if the global awareness of the use of renewable energy, particularly biomass is getting better and sustainably cultivated globally or countries compete to lower the temperature of the earth. For the wood pellet market in Asia, besides Korea now Japan also have started to squirm. Availability of woody biomass for the production of wood pellets and when raw materials cultivated through energy plantation take a longer time, has made the pellets from biomass such as pellets from palm empty fruit bunches (EFB Pellet) have also been received, the insistence current needs. If awareness of the environment and climate change has been conceived and implemented in the environmental regulations or the global energy industry or business trends in particular wood pellets and biomass to energy in general will grow and survive long enough.

Cost to Benefit Ratio at the Wood / Biomass Pellet Plant

Wood or biomass pellets plant have a vital role in the production of wood or biomass pellets. Target production with standard quality and stable can only be achieved if the wood or biomass pellet plant working optimally. The use of high quality machines is one means that the production process is running optimally. Some criteria to assist the selection of machines for wood or biomass pellet mill, among others:

1. It has been proven and tested, in terms of quality and quantity.
2. Ease of operation and maintenance.
3. Ease of start-up until a stable production.
4. Durable and stubborn, so rare in problem and effective for production in the long term.
5. Meet the rule "3 x 3" that these machines have been used in 3 different places with operating time of more than 3 years.
6. Reliable after-sales services such as ease of obtaining spare parts and auxiliary materials other processes as well as a quick solution if at any time there is a problem in plant operations. Even had there was also a wood or biomass pellets plant were connected to the Internet and can report a variety of problems that occur in the plant so quickly that it can take action quickly as well.
7. Good in Safety Aspects  and minimum environmental pollution impacts

Indeed obtain provider machines of wood or biomass pellets plant that meet the above requirements is not easy especially in Indonesia, in particular, wood or biomass pellets industry is new thing. The prospective producers of wood or biomass pellets should be quite keen attention to this, especially just only lured cheap price, without further thought to the long-term orientation.

There is no guarantee also that something expensive certainly give better results, as well as for machines of wood or biomass pellet plant is. Without regard to the number of the above criteria may be your only losses due to incur huge costs for the purchase of the machines, but the results are not as expected.

Machineries for wood pellets plant that meet the above criteria are usually quite expensive, but the cost-to-benefit ratio is good so that in general will give a good profit as well. Optimization is how to get the machinery of wood or biomass pellets that meet the above criteria with affordable price. This could be one of them to import a vital machines only on wood or biomass pellet plant and the rest made domestically.

Environmental Aspects of Wood Pellet Plant

When the process of wood pellets production do not pay attention to the environmental aspects, there will be a negative impact on the environment. Just like the usual plants always have an impact on operations for environment as well as wood pellet plant. The environmental impact was mainly noise pollution and air pollution. Engine or motor of the various units of production in the wood pellets plant is the main cause of the noise pollution. Vibration due to the large variety of equipment operational wood pellet plant also has implications for building damage around the location of the wood pellets plant. To minimize to overcome the problems then use of silencers or the selection of the motor which does not cause disturbing noise and vibration dampening mounting becomes important.

While the problems of air pollution, it is mainly caused by the exhaust gases from the combustion furnace for heating dryers, dust and VOCs (Volatile Organic Compund) of the dryer, dust and cooler from pelletiser. The dust pollution can be more severe if we process of grass type pellet.  A number of equipments have been developed to overcome this, as stated in the tables below:

 

Noise elimination and air pollution needs to be done to the acceptable norms. Considerations such as ease of operation, maintenance and the cost are some important things so that these devices can be applied and reached a level that is safe for the environment. Selection of plant location is quite far from the people settlement are also alternatives to reduce the cost of using the equipments for the elimination of pollutants.

Why Choose SRC Energy Plantations Than Palm Oil Plantations?

A number of the people plantations who produce fresh fruit bunches (FFB) was not able to be accommodated by the palm oil mill (POM), meaning that the ratio of the number of the POMs are not comparable with the number of palm oil plantations. Indonesia is the largest of palm oil producer (CPO=Crude Palm Oil) in the world with an area of oil palm plantations reach 10 million hectares by 2013. Palm oil productivity reached 27 tons / ha / year of FFB with a yield of CPO about 3.7 tons / ha / year, with the start of harvest after 4-year-old and productive period of about 25 years. With the average price of TBS IDR 1800/kg for every hectare would produce about IDR 48 million / year, a promising revenue from the plantation business course. But because all the FFB can not be processed due to the absence of plant it will not necessarily provide the desired benefit.

 

Energy plantation with SRC is an alternative for those who want to develop the plantation business investment is not so great. Plants such as calliandra and gliricidae very easy to grow, easy care, quick harvest, continue to be productive for about 25 years and fertilize the soil. Increasing the value added can be done with eg intercropping with crops. Unused land and marginal land could be pursued to the energy plantaion with thse plants. With the productivity of wood biomass around 20 tons / ha / year, with a price, let’s say, IDR 400/kg it will get a IDR 8 million / year for each hectare, it is far below of the economic aspect of palm oil plantation, but by the age of 1 year can be harvested, seeds and maintenance costs also very cheap, then it could be a consideration.

 The price of modern palm oil mill average price of IDR 4 M for every tonne of FFB / hour. With POM 45 tons FFB / hour capacity  it takes an investment IDR 180 M, a large amount of investment. As for the price of wood pellet mill capacity of 3 tons / hour range from IDR 5 M to become more affordable. Economic analysis of palm oil mill and wood pellet mill is almost the same, with the average ROI (Return on Investment) of 3.5 years.

Origins of the Wood Pellet

History of the manufacture of wood pellets begin from the energy crisis of oil in the 1970s. Wood pellet making technology itself is adopted from animal feed/fish pellet technology  that had already been applied.  Along with the development of various technological modernization in line with the characteristics of raw materials, product specifications or market demands according to international standards, production efficiency and capacity of the plant to meet market needs. Efforts to create alternative energy from renewable sources  with several quality improvements of raw material into the solution at that time. After the oil crisis of the 1970s ended the production of wood pellets decreased. But when the problem of global warming, climate change and efforts to increase the added value of woody biomass and the rapid depletion of fossil fuels began in the 1990s finally wood pellets again received great attention.

Woody biomass in particular is said to be a source of alternative energy that can be renewed only if the production is done in a sustainable manner. Forest plantations or energy crops is an attempt to sustainable production of biomass sources in addition to the utilization of wood wastes from various industrial timber that must also be traced if from legal sources. Sawdust in particular is the best raw material for the production of wood pellets, but because of its availability is usually not a big plus if collected from a number of sawmill waste for example, and so much demand that should be observed when actually be used for the production of wood pellets. 

The wood logs are part of a plant or tree are best to produce pellets. If the premium quality woodpellets (pellets Class A1) produced,  the debarking process must also be done to minimize its ash content. While part of trees or other plants that have a higher ash content so it can not be used for the production of premium quality wood pellets. Wood pellets have the best quality lowest ash content and high calorific value and are generally only used for the home heating in some European countries, the U.S. and Canada. While wood pellets with a lower quality than that its use in industry. 

Log wood for premium wood pellet feedstock after debarking

In contrast to European countries and the U.S. are generally using wood pellets for domestic consumption as heating, in Asia generally digunakansebagai wood pellet fuel or power generation industries. The differences in consumption patterns due to climatic conditions, among others, as a result of its geographical location and the awareness of the environmental impact.  Various advantages of wood pellets for industrial and domestic applications and a wide range of driving factors on environmental issues, climate change, global warming and the economy makes it increasingly massive demand for the commodity.