Coal and Biomass General Information

Part 1 : Coal and Biomass Pellet General Information.
Part 2 : Coal and Biomass Pellet Process and Area Details.
Part 3 : Coal and Biomass Pellet Machines Details.

layout design for a coal-biomass pellet production facility. This layout is optimized for a production capacity of 4–5 TPH, with coal and biomass as the raw materials.

Key Sections in the Layout

Raw Material Handling
- Coal Storage Hopper: For storing crushed coal.
- Biomass Storage Hopper: For storing shredded biomass.
- Feed Conveyors: SS/MS conveyors to transport raw materials to the mixer.
Crushing & Shredding
- Hammer Mill (Coal Crusher): Pulverizes coal to <1mm particle size.
- Shredder (Biomass): Reduces biomass to <3mm particle size.
Drying
- Rotary Drum Dryer:
  - Input: Moisture up to 25%.
  - Output: Moisture reduced to 8–12%.
  - Heat Source: Biomass, gas, or coal combustion.
- Includes a hot air generator and exhaust ducting.
Mixing
- Ribbon/Paddle Mixer: For homogenizing coal and biomass in desired ratios (e.g., 70:30).
- Positioned after drying for a consistent mix.
Pelletizing
- Pellet Mill:
  - Ring die with a 4mm die size.
  - Capacity: 4–5 TPH.
- Located centrally for easy access to raw material inputs.
Cooling
- Counterflow Cooler:
  - Cools pellets to near ambient temperature.
  - Positioned directly after the pellet mill.
Screening
- Rotary or Vibratory Screener:
  - Removes fines and broken pellets.
  - Returns fines to the mixer for reprocessing.
Finished Product Handling
- Storage Silos: For finished pellets.
- Bagging Section: Optional, for packaging pellets in bags (50 kg or jumbo bags).
Utilities & Ancillary Sections
- Control Room: For monitoring operations.
- Dust Collection System: Cyclones or bag filters at crusher, dryer, and pellet mill.
- Power Supply Unit: Includes transformers and switchgear.
- Workshop Area: For maintenance and repair.

Proposed Layout Design

Here’s a conceptual flow:

Input Section:
- Coal hopper → Coal crusher → Dried coal storage.
- Biomass hopper → Shredder → Dried biomass storage.
Processing Section:
- Dried coal + biomass → Mixer → Pellet Mill.
Output Section:
- Pellet mill → Cooler → Screener → Storage silo → Bagging.

Design Specifications

Area	Size (Approx.)	Remarks
Raw Material Storage	10m x 15m	Hopper height: 3m
Crushing/Shredding	10m x 5m	Includes dust collection systems
Drying Section	15m x 10m	Includes dryer and hot air generator
Mixing Section	5m x 5m	Mixer capacity: 5 TPH
Pelletizing Section	10m x 10m	Ring die pellet mill with rollers
Cooling Section	8m x 5m	Counterflow cooler and cyclone separator
Storage Silos	10m x 15m (per silo)	Sized for 50 tons per silo
Utilities	10m x 5m	Power and control room