A sugar factory in Uttar Pradesh was equipped with a 30 TPH bagasse-fired boiler, requiring a 30-day fuel reserve (21,600 tons) to ensure consistent operation. However, due to bagasse’s low density, even a 3-meter-high heap would cover approximately 11.8 acres. By baling and stacking the bagasse, the required area was reduced to just 4 acres. Once our automated debaling system was installed, it efficiently broke the ties around the bales, loosening the material and enabling smooth feeding into the boiler via belt conveyors.
Biomass-fired boilers are a sustainable choice for steam and heat generation across industries, utilizing fuels like rice husk, bagasse, paddy straw, wood chips, and even municipal solid waste (MSW). However, their low bulk density and high volume create challenges in storage, transport, and boiler feeding. Effective sourcing, storage, and handling are crucial to reducing space usage, streamlining material flow, preventing fuel degradation, and minimizing environmental risks. With government incentives and mandatory 5-7% biomass co-firing regulations from FY 2024-25, industries must upgrade fuel storage and handling systems to remain compliant and competitive.
This article explores optimized storage techniques, including briquettes, pellets, bale systems, and mechanized handling solutions such as moving floor systems, heap creators, and reclaimers, which are implemented in many facilities across India. It also addresses critical concerns such as fire prevention and the environmental benefits of efficient biomass storage systems.
Belt conveyor
The Challenge – Space Constraints
A 30 TPH biomass-fired boiler requiring 30 days of backup storage would need 21,600 tons of biomass. With a heap height of 3 meters, low-density material such as rice husk would occupy 72,000 m² (~17.8 acres), while bagasse would require 48,000 m² (~11.8 acres). Optimizing storage is essential to making biomass-fueled boilers viable and efficient. The following solutions can significantly enhance space utilization:
- Bale Storage and Debaling Systems
- Briquettes and Underground Disintegrators
- Ground Storage Solutions with Moving Floors
Bale Storage and Debaling Systems
Loose biomass, such as paddy straw and bagasse, can be compressed into bales, effectively doubling or tripling its original density. This not only reduces storage space but also preserves fuel quality by protecting it from moisture. Automated debaling systems break down the bales into loose material, enabling smooth feeding into boilers via conveyors or screw feeders.
Key Benefits:
- Space Optimization: Compressed bales reduce storage space requirements.
- Enhanced Logistics: Easier transportation and handling improve supply chain efficiency.
- Fuel Quality Preservation: Prevents degradation, ensuring consistent boiler performance.
- Automation & Efficiency: Automated debaling reduces manual labor and operational delays.
- Cost Reduction: Minimizes labor costs, downtime, and material wastage.
Bales straw
Underground Disintegrators for Briquettes
Biomass briquettes (400–600 kg/m³) and pellets (650–850 kg/m³) significantly reduce storage volume, making transport and handling easier. However, briquettes require crushing before they can be fed into boilers. Underground briquette disintegrators efficiently break down the briquettes at the feeding point, maintaining a consistent fuel supply while reducing operational costs.
Key Benefits:
- Optimized Space Utilization: Underground placement reduces surface clutter.
- Seamless Fuel Feeding: Direct crushing ensures steady boiler operation.
- Cost Efficiency: Reduces handling costs and labor requirements.
- Improved Boiler Performance: Ensures a steady 24-hour fuel supply.
Ground Storage Solutions with Moving Floors
Traditional storage bunkers often face poor material flow issues. Ground storage solutions with moving floors ensure seamless biomass handling through automation. Heap creators mechanize the stacking process, improving organization, while moving floors automate biomass feeding into boilers. Reclaimers further streamline retrieval, reducing manual intervention and downtime.
Key Benefits:
- Improved Material Handling: Eliminates blockages and ensures smooth flow.
- Automation & Efficiency: Reduces reliance on manual labor.
- Consistent Fuel Supply: Maintains a steady feed to boilers.
- Space Optimization: Enables efficient ground-level storage.
- Reduced Downtime: Closed-loop reclaimers streamline retrieval.
Synchronisation with Direct Bale Feeding Systems
Optimised biomass storage solutions enhance the efficiency of direct bale feeding and firing systems by:
- Ensuring Consistent Fuel Supply: Proper storage prevents feeding disruptions.
- Reducing Handling and Downtime: Automation minimizes manual intervention.
- Preserving Fuel Quality: Controlled storage prevents biomass degradation.
- Optimizing Space and Logistics: Structured layouts enhance efficiency.
- Integrating with Automation: Smart storage solutions align with automated conveyor systems for just-in-time feeding.
Safety: Fire Prevention Measures
Biomass is prone to spontaneous combustion, making fire prevention a critical aspect of storage solutions. Key safety strategies include:
- Moisture Control: Reducing ignition risks by maintaining optimal moisture content.
- Temperature Monitoring: Sensors detect hotspots for early intervention.
- Fire Breaks: Physical barriers prevent fire spread.
- Suppression Systems: Automated sprinklers, misting systems, and foam suppression enhance safety.
Biomass briquettes
Environmental Impact of Efficient Biomass Storage
Optimized biomass handling contributes to environmental sustainability by:
- Reducing Emissions: Proper storage minimizes methane and CO₂ emissions.
- Waste Utilization: Repurposing agricultural by-products reduces landfill waste.
- Improving Air Quality: Dust suppression systems lower particulate matter levels.
Several industrial facilities across India have successfully adopted Rollcon’s advanced biomass handling solutions to improve efficiency and reduce space requirements. For instance, a milk plant in Bareilly achieved significant space savings—requiring only one-third of the usual area—by implementing Rollcon’s bale handling system. In Ranjangaon, Maharashtra, a beverage manufacturing unit optimized its fuel handling process with Rollcon’s underground briquette disintegrators. Similarly, a dairy plant in Uttar Pradesh reduced downtime and maintained a steady supply of dry, high-quality bales by integrating Rollcon’s direct bale feeding system with an optimized storage infrastructure.
Conclusion
Efficient biomass storage and handling are crucial for the reliable operation of biomass-fired boilers. By implementing advanced technologies such as bale storage and debaling systems, underground briquette disintegrators, and moving floor storage solutions, industries can significantly reduce space requirements, enhance fuel quality, and streamline material flow. These innovations not only improve operational efficiency but also align with regulatory mandates for biomass co-firing, ensuring compliance while maintaining cost-effectiveness.
Solutions such as bales, briquettes, pellets, and advanced systems like moving floor storage, heap creators, and reclaimers offer cost-effective, sustainable, and practical methods for managing large volumes of biomass. By incorporating mechanized systems, fire prevention measures, and optimized truck unloading management, facilities can ensure uninterrupted operations, reduce operational costs, and enhance environmental sustainability.
As industries transition towards cleaner energy solutions, adopting optimized storage systems will be critical in maximizing boiler performance, reducing emissions, and supporting a more sustainable energy landscape. With government support and automation advancements, biomass remains a viable, eco-friendly alternative to conventional fuels, driving long-term efficiency and environmental benefits.
Author:
Rajiv Dhawan
Managing Director
Rollcon Technofab India Pvt. Ltd.
