TONY Design 4-5Ton/Hour EFB Production Line Specification

The palm is a versatile plant capable of producing a variety of biomass. The production of 1 kg of palm oil can be accompanied by the production of 4 kg of oil palm biomass, palm biomass and its by-products are seven times more than natural wood. Palm is mainly cultivated in Southeast Asia, with Malaysia, Indonesia and Thailand among the top three. In 2005, Asian palm plantations covered 7,599,000 hectares, producing 146,093,000 tons of fresh fruit bunches and 1,0224,000 tons of empty fruit bunches.

‌Countries Suitable For Setting Up Complete EFB (Empty Fruit Bunches) Pellet Plant Include

Palm Empty Fruit Cluster

Palm particles are oily and large, composed of cellulose and hemicellulose lignin, containing carbon, hydrogen, nitrogen, sulfur, oxygen and other elements, and have a high water content of about 65%. The physical properties of palms make them valuable, but also make them difficult to exploit.

Utilization Rate Of Empty Palm Fruit Cluster

Traditionally, empty fruit bunches are not highly utilized and are usually used in the following ways:

1. Burn. Their ash is recycled as fertilizer for plantations, but large-scale burning is now not allowed.

2, Return to the field for use as mulch, not only reduces greenhouse gas emissions, but also reduces the need for artificial fertilizers by improving carbon sequestration in soil organic matter.

3. Some of the empty fruit bunches were sent to landfill land.

Due to the limitation of traditional utilization of empty palm fruit bunches, a large amount of palm biomass energy is wasted. Now with the innovation of palm empty fruit cluster conversion technology, palm biomass can be successfully converted into pellet fuel for mixed-firing systems and biomass boilers to generate steam and electricity.

Relevant data show that in 2009, 88.74 tons of palm fruit in Asia produced 1,714 GWH of off-grid energy at a rate of 20 KWH/ton, with a total off-grid generation of 357 MW, 400 hours/month.

Palm fruit bunches are made into pellets

Why are palm fruit bunches made into pellets? Can't we put palm biomass directly into boilers or power plants? The reasons are as follows:

1. In general, after the conversion of palm fruit biomass into particles, its energy content will increase.

2.The caloric value of 4,200-4,900 kg cal/kg 28 palm pellet fuel or briquette can be used to replace coal to relieve energy pressure and environmental pressure.

3. Palm pellets are sustainable and renewable, can be produced on a large scale and are very friendly to the environment.

4.The palm particles are dense and clean, easy to transport and store, and the particles produce little smoke when burning.

The main reason for using palm nut bunches ‌ is that palm nut bunches (EFB) are a waste material which has great potential for being recycled and burned as boiler fuel ‌1. Palm fiber is produced from oil palm empty fruit cluster (EFB), which is generally considered to be a waste product after the processing and refining of palm fresh fruit cluster (FFB). Palm fiber itself is 100% natural product, no harm, can be naturally decomposed, will not damage the environment ‌.

Palm pellet production

Various palm pellets can be made according to the different requirements of consumers. When investing in the production of palm pellets, you can refer to the following advice from mature palm pellet plants:

1.A comprehensive understanding of the palm pellet production line is necessary.

2.Palm pellet production procedures should meet the requirements of the target market.

3.The raw materials should be sufficient to ensure the continuity of particle production.

4.The quality of raw materials to be guaranteed. The ideal moisture content of raw materials is 15%, and when it exceeds 15%, raw materials should be dried to control moisture.

5.The location of the palm pellet factory should be easy to transport raw materials.

6.Feasible research is required beforehand.

Palm pellets are discarded from palm fruit bunches; It's a short palm fiber. It is compressed and then extruded into a solid cylindrical form 6-8mm in diameter, which can be used to replace wood burning. This process does not use any adhesive, but the natural lignin components of the fibers are bonded together to form a solid. Burning palm pellets/coal cakes is more efficient than firewood. The moisture content is also less than 12 percent, while firewood can be as much as 65 percent. Palm briquette can be used in industrial or residential boilers and kilns for steam generation, power generation or heating purposes.

The advantages of palm pellets/coal cakes

Alternatives to conventional fuels

Environmentally friendly and renewable energy fuel

Higher calorific value: about 4500-5000 kcal/kg.

Pollution-free because it does not contain sulfur or any harmful substances.

Low ash content is 2% to 5%. When burned, no flying ash is created.

The combustion efficiency is relatively high due to the low moisture content.

High density and higher fixed carbon value.

Due to the uniform shape, easy to transport, and feed for combustion.

Because of the rising price of fossil fuels, it has a better market value.

• Shape: cylinder

• Diameter: 8 cm, 10 cm, 20 cm, 60 cm, 80 cm, 90 cm

• Length: 50 mm to 300 mm

• Moisture content: < 12%

• Calorific value: 4000 kcal/kg

• Ash content: 3.79%

• Volatile substances: 81.5%

• Fixed carbon content: 14.7%

• Packaging: Giant PP plastic bags

• Container weight: +-24 tons /40 feet high container

The advantages of palm granules are mainly reflected in the following aspects ‌ :

‌Low Cost And Abundant Supply ‌ : Palm fiber is 100% natural product, low cost and abundant supply, which makes palm pellets competitive in the market ‌.

‌Environmental Protection And Natural Decomposition ‌ : palm fiber is not harmful, can be naturally decomposed and does not damage the environment, in line with the requirements of sustainable development ‌.

‌High Calorific Value ‌ : palm pellet fuel has a high calorific value, which can reach 5000 kcal, which is suitable for biomass energy ‌.

‌Widely Used ‌ : palm particles can be widely used in food, medical treatment, mining, metallurgy, petrochemical, steelmaking, tobacco, fine chemical and other industries, has a wide market demand ‌.

‌High Value-Added Products ‌ : palm shell can be processed into biomass fuel and activated carbon, especially fine processed activated carbon, the value is higher ‌.

Technological Progress ‌ : The customized granulator can directly chop and dry the empty palm fruit clusters to make biomass pellet fuel, which meets the needs of large-scale production ‌.

In summary, the advantages of palm granules are not only reflected in its natural and environmental characteristics, but also in its high caloric value, wide application and high value-added products, while technological advances also make large-scale production possible.

‌The main process flow of palm particles includes the following steps ‌ :

‌Collection Of Raw Materials ‌ : First of all, we need to collect the shell of the palm fruit. After eating the pulp, the shell is bought by the merchants specializing in buying the shell and transported to the factory. In the factory, raw materials need to be sorted to remove impurities ‌.

‌Crushing Process ‌ : The palm nut shell is large in volume and needs to be broken first. Use a crusher to break the palm shell into small pieces, usually 10-20 mm in size ‌.

Drying Moisture ‌ : The crushed palm nut shell contains moisture and needs to be removed by a dryer. The dried material can be better used as fuel ‌.

‌Pelletizing ‌ : the dried palm nut shell particles are sent to the pelletizing machine, and the biomass particles are made into ‌1 through the pelletizing process.

‌Additional information ‌ :

In Southeast Asian countries, such as Malaysia, Indonesia and Thailand, there is a large number of palm trees. Palm empty fruit clusters are the main waste, the traditional pellet machine can not produce EFB particles in large quantities, but the customized pellet machine can directly cut the palm empty fruit clusters, after drying into biomass pellet fuel, the caloric value of up to 5000 kcal, and a large number of exports to Japan, South Korea and other places ‌.

The use of palm shell as biomass pellet fuel not only treats the waste, but also realizes the recycling of resources ‌.

TONY Brand  4-5Ton/Hour EFB (Empty Fruit Bunches) pellet manufacturing plant can process ‌EFB (Empty Fruit Bunches) materials with nails as raw materials, and solidifies them into high-density  pellet fuels through pre-treatment and processing , is an ideal fuel to replace coal and oil, which can save energy and reduce emissions.Now it is widely used by those customers who has ‌EFB (Empty Fruit Bunches).

1.Capacity: 4-5Ton/Hour

2.Raw materials: ‌EFB (Empty Fruit Bunches).

3.Moisture:Wet type ,about 40-55%.

4.Application: ‌EFB (Empty Fruit Bunches) Raw Materials With Wet And Dried Type.

Suitable customers: ‌EFB (Empty Fruit Bunches) Countires

5.Finished Pellets Markets:Large power plants (domestic customers, as well as Japan and South Korea, mainly South Korea more), domestic heating, industrial heating, combustion heat, heating heating, boiler room, school canteen, foundry heat source.

1.Project Name:EFB (Empty Fruit Bunches) Pellet Line                                                                                                                                                                                     

2.Raw Materisl: EFB (Empty Fruit Bunches)                                                                                                                                            

3.Moisture Of  Raw Material: Wet Type 45-55%                                                                                                                                                               

4.Capacity:4-5Ton/Hour                                                                                                                                                                                         

5.Process:Chipping Process→Crushing Process→Drying Process→Pelleting Process→Cooling Processs→Packing Process.

6.Main Machine:  TONY Comprehensive Chipper,Hammer Mill, Rotary Drum Dryer,TONY Pellet MachineTYJ551-III-132KW,Pellets Cooler,Packing Machine And Belt Conveyors.

7.Total Power: About 630KW                                                                                                                                                                                     

8.Need Area:  About 1500-1700㎡                                                                                                                                                                             

9.Project Country: Colombia                                                                                                                                        

10.Voltage:440V,60HZ                                                                                                                    

Project Layout For Customer

Project Brief Introduction:                                                                                                                                                      1.Product:EFB (Empty Fruit Bunches)Pellet Line 2.Capacity:4-5T/Hour                                                                                                          3.TONY Brand 4-5Ton/Hour EFB (Empty Fruit Bunches)   Pellet Line Project Process 4:Main Machine: Comprehensive Chipper,Hammer Mill, Rotary Drum Dryer,TONY Pellet MachineTYJ551-III-132KW,Pellets Cooler,Packing Machine And Belt Conveyors                                                                  5.Total Power: About 630KW 6.Need Area:  About 1500-1700㎡                                                  7.Country:Colombia.      8.Worker Needed:4-5Persons. 9.Water Needed: No Need For Any Water.

Following TONY Will Introduce For You For All The Necessary Machinery That Will Be Used For The Whole Pellet Production Line. Some machines can be custom made by customer according to different customer's detailed demand.Contact TONY for more details with quotation and layout. 

Comprehensive Chipper	High Effective Hammer Mill	Rotary Drum Dryer	TONY Dual Screw Storage Bin
1.EFB (Empty Fruit Bunches)  Into 30-40mm Palm Fiber.    2.Model: TPC1000-90KW-6 Baldes.  3.Capacity:4-9Ton/Hour.	1.Crush 30-40mm Palm Fiber Into 8-14mm Sawdust.      2.Model: TFD75-132-132KW  3.Capacity:4-5Ton/Hour/Set	1.To Dry The 45-55% Sawdust Into 10-15% Sawdust.   2.Model: THGD1.8*20  3.Capacity:4-5Ton/Hour/Set	1.To Stroage raw material before pellet machine. 2.Model: TLC-4 3.Capacity:4-5Ton/Hour/Set
Vertical Ring Die Sawdust Pellet Machine	Cooler Separator	Semi-Auto Packing Machine	Belt Conveyor
1.Model: TYJ551-III-132KW*2Sets 2.Capacity:4-5Ton/Hour/2Sets 3.New 304SS Type	1.To Cool Pellets From 80-90℃ to 20-30℃ 2.Model:TCN-2.5 3.Capacity:4-5Ton/Hour	1.Packing Pellets To 15-50KG/Bags. 2.Model:TBF-50 3.Capacity:4-5Ton/Hour	1.Transport Wood Chips,Sawdust,Pellets.   2.Width: 80cm *6 Sets 3.Capacity:Designed With The Whole Line

1.Chipping Process:    

A.This process is mainly used to Use TONY Comprehensive Chipper To Grind EFB (Empty Fruit Bunches)  Into 30-40mm Palm Fiber. The finish wood chips size can be adjustable by changing different sizes of screeners and adding flying knives inside the wood chipper.   

B.This customer use TONY Brand TPC1000-90KW model with 6 flying baldes type:

Main Parts: 

1).TONY's new Comprehensive Wood Chipper.

2). Feed and unload belt frequency control to prevent card material

3). Hydraulic system control for more thickness of raw materials

4). Electronic control system allows the equipment to be used normally      

5).Contact TONY for more details with quotation.   

5.Cooling Process:                                                                                                                       

A.This process is mainly used to To Cool Pellets From 80-90℃ to 20-30℃                                                                        

B.The Customer Chose 1Sets Of TONY Galvanized Cooler Separator With Capacity 4-5Ton/Hour.                                                                 

Main Parts:                                                                                                                                   

1）.TONY's new Galvanized Cooler Separator With Vibrating Screen.

2）. Cyclone and bags dust collectors.  

3）. Fan Blower.

4）. Connect Pipes.     

6.Packing Process:                                                                                                                       

A.This process is mainly used to Packing Pellets To 15-50KG/Bags.                                                                                       

B.The Customer Chose 1Sets Of TONY Semi-Automatic Packing Machine With 4-5Ton/Hour.                                                                 

Main Parts:                                                                                                                                   

1）.TONY's newTONY Semi-Automatic Packing Machine.

2）.  Sew Machine,Buyer Can Also Chose Hot Seal Machine For Chosen,To Confirm With TONY For The Price Difference.  

3）. Bags Transportation Conveyors.

4）. Feeding Inlet Silo With 1㎥.  

5） .Electrical cabinets.

TONY Detailed Design 3D Layout With Detailed Size For 4-5Ton/Hour EFB Pellet Line According To Cusomer Factor Size

‌EFB (Palm silk) can be processed into pellets. ‌ Traditional pelleting machines cannot produce EFB pellets in large quantities because palm silk fibers are tough and easily twisted. However, through a customized granulator, palm empty fruit bunches can be directly chopped and dried to make biomass pellet fuel, whose caloric value can be up to more than 5000 kcal ‌.

In the processing process, it is first necessary to chop the empty palm fruit bunches and then dry them. Due to the fibrous properties of palm silk, drying is a key step to ensure the formation and quality of the particles. Customized granulators are able to process the tough material, and the resulting particles can be used in energy production and are exported in large quantities to Japan, South Korea and other places ‌.

EFB particles have a wide range of applications, mainly for energy production. Because of its high calorific value, EFB particles have important applications in the energy field as a biomass fuel. In addition, due to its characteristics of resource utilization, EFB particles also promote the effective treatment and reuse of waste ‌.

Advantages of EFB as biomass pellet fuel：

‌The main advantages of palm pellets include environmental protection, low cost and high efficiency. ‌

Firstly, palm pellets are a high quality homogeneous fuel that is easy to burn and can be controlled automatically, comparable in convenience to light fuels ‌. Secondly, palm particle density is large, small volume, convenient storage, and low ash content, high boiler efficiency ‌. In addition, after drying and screening, palm particles do not contain impurities, which greatly reduces the problem of boiler gumming ‌. Finally, palm pellets do not add any additives and are more environmentally friendly than wood pellets ‌.

To sum up, palm pellets have a significant competitive advantage in the fuel market with their advantages of environmental protection, low cost and high efficiency.

The EFB pellets can also be used for feeding pellets,its advantages are as following:

Palm meal feed granulator can press out particles, but it is necessary to consider its characteristics and pressing principle, and there are some advantages and disadvantages.

I. Characteristics Analysis Of Palm Meal Feed

Palm meal feed is the residue of palm fruit after pressing, which contains high cellulose and protein, but also contains certain lignin, bitter substances, etc., which have a certain impact on the taste and digestion and absorption of feed.

2.Pressing Principle Of The Pellet Machine

The pellet machine uses mechanical action to press feed into pellets, and its pressing principle is to extrude the material through the interaction of the roll film. In the pellet machine, the commonly used roll film materials include carbide, graphite alloy, die steel and so on.

3. Feasibility Analysis

For palm meal feed, due to its high cellulose and lignin content, the following problems may occur when the granulator presses it:

1）. The shape and size of feed particles may not be uniform enough, affecting the taste and digestion and absorption effect of feed.

2）. When the pellet machine presses the particles containing lignin, there may be problems such as roll film wear and product leakage, which increases the production cost and equipment loss.

3）. The palm meal feed contains bitter substances, which need to be treated in the production process to avoid affecting the taste and digestion and absorption effect of the feed.

However, through the optimization of the production process and equipment, as well as reasonable operation methods, the palm meal feed pellet machine can be better granulated treatment, improve the use efficiency and nutritional value of feed.

4. Analysis Of Advantages And Disadvantages

The main advantages of palm meal feed pellet machine are:

1）. The feed with high impurities such as palm meal can be pressed to improve its utilization and nutritional value.

2）. Feed granulation can increase the taste and digestion and absorption effect of feed.

3）. The granulated feed has good additive properties and is easy to store and feed.

5.Conclusion

Through the analysis of the characteristics, pressing principle, feasibility and advantages and disadvantages of the palm meal feed granulator, it can be concluded that the palm meal feed granulator can complete the granulation treatment, but it needs to consider its characteristics and production cost to achieve the best benefit.