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Pellet plant operators often struggle with moisture control when running their processes. However, KPM Analytics can deliver a solution with an online sensor that offers continuous moisture measurement throughout the entire process.

Acting fast and being proactive with moisture measurement delivers cost savings in the manufacturing process and reduces the risk of packaging wet or poor quality products. It is KPM Analytics' aim to assist mills in the production of a high-quality pellet by offering advanced, sophisticated moisture measurement with NIR technology.

Waste sawdust and wood chips are typically supplied by truck or rail car delivery to the pellet plant and then stacked outside in large mounds. A front loader is used to transport the sawdust from the various piles and load the plant’s feed system.

The tractor operator selects wet and dry sawdust to maintain a balanced load of moisture heading into the dryer system. This green wood typically has a moisture content of between 20 to 50%. If the sawdust is being stored outside, the moisture content can be higher or lower, depending on the weather conditions.

The loader operator is faced with the challenge of keeping a relatively even mix of wet and dry sawdust that is fed into the feeder system.

Using one of KPM Analytics' moisture meters, like the MCT460 on-line sensor, is an extremely effective way to monitor moisture levels as a sensor is installed on the screen infeed conveyor, and a large display is mounted outside for the operator to see.

Firstly, the sawdust and wood chip mixture is screened before separating the fine chips from the coarse chips. The coarse chips are then ground up to reduce their size for rapid, even drying. They are then remixed for temporary storage.

After a second screening, to separate any of the remaining fine chips from the coarse chips, the coarse chips are further reduced in size with the hammer mill.

Subsequently, the hammer mill output and fine chips are mixed together and stored in bins by moisture content. The sawdust is then transferred into a large drum dryer, where the moisture content is reduced to less than 10%.

High-speed swirling air removes additional water vapors from the sawdust once conveyed into a cyclone dryer which also cools the product down. Typically, one of KPM Analytics' on-line moisture is typically fixed on the dryer outfeed to make sure the moisture content is approximately 10%.

If the moisture content is greater than 10%, the sawdust will be placed into a moist bin. Generally, the contents of moist bins and dry bins will be amalgamated for the optimal moisture level going into the pellet press.

Installing KPM Analytics on-line NIR sensor onto each of the bin outputs can provide users with additional information to supplement the blending process. One of the most crucial measurements is the final mixture after blending and before being fed into the press.

A KPM Analytics on-line NIR sensors continuously measures moisture levels being fed into the pellet mills. The analog output signals from the sensor can be applied to forward feed a PLC. The PLC can then be programmed to control the speed of the press and power level, thereby creating a more stable product.

MCT460 on-line NIR sensor. Image Credit: KPM Analytics

Once ready, the mixture can then be pressed into pellets or returned to the dryer as fuel for the burner. The processed sawdust is then fed into the pellet press, where the pellets are produced under extreme pressure.

This high pressure expels additional water and prompts the binding of the natural wood lignites to the sawdust, thus producing shiny hard pellets. After the pressing, the finished pellets undergo one final screening to recover any remaining sawdust for recycling.

The screened and cooled pellets are stored in silos while awaiting bagging and shipping. The conventional package is a 40 lb moisture-protected bag for household heating. One of the key markets is Europe, where a significant number of homes and power plants use wood pellets as their energy source.

This information has been sourced, reviewed and adapted from materials provided by KPM Analytics.

For more information on this source, please visit KPM Analytics.

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