18-20T/H Rice Husk Straw Pellet Plant in United States

Project Origin

Biomass is the solar energy fixed on the earth by photosynthesis of plants. The biomass produced by photosynthesis is about 170 billion tons per year, and its energy is about 10 times the annual consumption of the world's main fuels.

However, the current utilization as energy is less than 1% of its total amount. In order to complete the carbon cycle in nature, most of these unused biomass will release energy and carbon by natural decomposition and return to nature.

On the other hand, due to the excessive consumption of fossil fuels, these limited resources are consumed too quickly and too early, releasing a large amount of excess energy and carbon, breaking the energy and carbon balance in nature, and aggravating the deterioration of the environment and global climate.

Through biomass energy conversion technology, biomass energy can be efficiently utilized to produce various clean fuels, replace coal, oil and natural gas and other fuels, and produce electricity, thereby reducing dependence on mineral energy, protecting national energy resources, and reducing the pollution caused by energy consumption to the environment.

In this context, the client of the rice husk straw pellet plant in United States project, a traditional American energy company, invested 700,000 US dollars to build new buildings and purchase new equipment to build a biomass pellet production and processing project using corn stalks, corn cobs and rice husks as raw materials.

There is an idle house in the factory area, which will be used as a staff dormitory after the project is put into production. After the project is completed, it will produce 30,000 tons of biomass pellet fuel annually.

Construction content and scale

The customer uses the existing vacant land to build this large rice husk straw pellet plant in United States project. The total area of the project is about 7500m2 and the construction area is 5900m2. The composition of the construction project is detailed in the table below.

The details of the buildings are shown in the table below:

Product plan

This rice husk straw pellet plant in United States project is the production of biomass pellet fuel, with an annual output of 30,000 tons. The specific product plan is detailed in the table below.

The composition analysis of biomass pellets is shown in the following table:

Main straw pellet processing equipment list

The main equipment of this rice husk straw pellet plant in United States project is detailed in the table below.

Main raw and auxiliary materials

The main raw and auxiliary materials consumption of this rice husk straw pellet plant in United States project is detailed in the table below.

Production process design of the project

1. Raw material collection
   The raw materials used in this rice husk straw pellet plant in United States project are corn stalks, corn cobs and rice husks. They are purchased locally and transported to the factory by the raw material supplier. The raw materials are stored in the raw material warehouse and unpacked.
2. Screening
   The raw materials are sent to the drum screen through a conveyor to remove impurities. The drum screen is sealed and the impurities are cleaned regularly.
3. Crushing 1st
   The screened raw materials are crushed by a straw unpacking straw crusher. The straw unpacking crusher mainly adopts the pulling and shearing crushing theories, which overcomes the weakness of materials with high humidity (such as corn stalks and other straws) that are easy to suffocate.
   Since this machine adopts multi-axis crushing and the crushing chambers at each level are staggered, each straw will undergo multi-level crushing, and the crushing directions are complementary. It can adapt to various straw bales, especially whole straw bales, and there is almost no leakage of broken straw after crushing, thus ensuring the qualified particle size of the material.
4. Crushing 2nd
   The crushed raw materials are put into the hammer mill crusher for further crushing. The crushing process will generate dust. The dust is collected by the dust hood and discharged from the 1#15m high exhaust pipe after being treated by the bag dust collector (removal rate 99%).
5. Drying
   The crushed raw materials are put into the biomass dryer for drying. The hot air is provided by the hot air furnace. Since the collected straw and other raw materials have high humidity, the crushed straw needs to be further dried until the moisture content reaches ≤11%. This process will generate noise and water vapor (natural evaporation).
6. Feeding
   The dried straw and other raw materials are sent to the buffer silo by the conveyor to ensure uniform feeding of the biomass pellet machine. The feeding adopts closed conveying by auger feeding.
7. Pressing pellets
   The dried straw is pelletized by the rice husk straw biomass pellet machine. The fuel pellet machine needs to be electrically heated in advance. The straw and other raw materials are fed from the buffer silo into the pellet machine through the conveyor for pressurization and densification to form biomass pellet fuel with a diameter of 9mm.
   This process will generate dust and noise. The dust generated in this process will be collected by the dust hood, treated by the bag filter (removal rate 99%) and discharged from the 1#15m high exhaust pipe after meeting the standard.
8. Discharge and storage
   The molded biomass fuel discharged by the straw rice husk pellet machine is sent to the finished product warehouse through a conveyor to reduce the temperature through natural cooling.
9. Packaging
   The cooled finished pellets are packaged by an automatic packaging machine, and the products produced on the same day are shipped and sold on the same day.

Environmental prevention measures

Abundant corn straw resources in the United States

The main reasons for the abundant corn straw resources in the United States are as follows:

• First, the United States is a major corn-growing country in the world. Corn planting is one of the strategic crops in the United States. The government provides heavy subsidies to corn farmers every year to support corn planting and production.
• Secondly, corn straw contains 70-75% cellulose and hemicellulose, and 15-20% lignin. These components make corn straw have a high utilization value.
• In addition, the strong support of the US government for biofuels is also one of the important factors in promoting the utilization of corn straw resources.

The United States uses corn straw in a variety of ways, including feed, fuel, base material, and raw material. The comprehensive utilization rate of straw in the United States has reached more than 90%, of which the utilization rate of returning to the field is 70% and the utilization rate of leaving the field is 20%.

How to build a biomass straw pellet production line in the United States?

There are many factors to consider in the production process of biomass straw pellet plant in United States, such as equipment selection, raw material quality, process flow, etc.

1. Factory layout design
   The production process of rice husk straw pellet plant in United States generally includes raw material processing, mixing, granulation, drying, packaging and other processes.
   Therefore, when designing the factory layout, the equipment of different processes should be reasonably distributed according to the production process.
2. Equipment selection
   The main equipment in the pellet factory includes mixers, granulators, dryers and packaging machines.
   When selecting equipment, factors such as equipment performance, production capacity, stability, and maintenance costs should be considered to ensure that the equipment can meet production needs and have profit margins.
3. Raw material selection
   The quality of pellet substances produced by the biomass pellet production line is greatly affected by raw materials.
   Therefore, when selecting raw materials, high-quality raw materials should be given priority, and corresponding management measures such as raw material procurement, acceptance, and storage should be formulated to ensure that the raw materials meet production requirements.
4. Process design
   The production process of the straw pellet factory generally includes material crushing, screening, mixing, granulation, drying, screening, packaging and other links.
   When designing the process flow, the corresponding process flow should be formulated according to the production process and raw material characteristics, and corresponding quality control measures should be formulated to improve production quality.
5. Personnel training
   The production management of the straw pellet production line in United States is the key to ensuring production quality and efficiency. Therefore, professional technicians or engineers are required to manage and operate the production line.
   At the same time, corresponding training plans should be formulated to cultivate the skills of managers and operators and improve the work skills and quality awareness of personnel.
6. Quality control
   During the production process, a sound quality management system should be established to ensure that the pellet materials produced meet the relevant national standards and quality requirements.
   At the same time, detection points should be established in different production links to strictly control the quality of raw materials and products in the production process.
7. Equipment maintenance
   The production equipment of the husk straw pellet factory should be regularly maintained to ensure that the equipment is in good working condition and reduce the impact of equipment failure on production.
   At the same time, there should be a dedicated person responsible for equipment maintenance and timely handling of equipment failures.

The construction of a rice husk straw pellet plant in United States is a complex task that requires consideration of many factors.

Through reasonable layout design, equipment selection, raw material selection and process design, and strengthening management measures such as personnel training, quality control and equipment maintenance, production efficiency and product quality can be improved, thereby achieving the goal of sustainable development.