Biomass. Range. Wood Chip & Pellet Boilers BIOMASS. TreadLightly BROAG-REMEHA GILLES BIOMASS RANGE

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1 Made in Austria BROAG-REMEHA GILLES BIOMASS RANGE A practical guide to choices of fuel, storage, fuel transport and biomass boiler installation up to 2000 kw. Outputs: KW Larger outputs available on request. Biomass BIOMASS Range Wood Chip & Pellet Boilers TreadLightly ON THE PLANET

2 Introduction The most efficient way of getting heating equipment to run on low to zero carbon fuel (woodchip & pellet). When heat is required on demand, the Broag-Gilles modulating fully controllable automatic Biomass boilers are the solution. The boilers have an increased service life because of their modulating outputs which range from 12.5kW- 2000kW (output up to 5000kW available subject to project circumstances-contact Broag Ltd). Climate change Global climate change is the most pressing environmental challenge of our time and one of the major causes of climate change is emissions of carbon dioxide (CO2) from burning fossil fuels. One of the most important environmental benefits of using sustainably produced wood for energy in place of fossil fuels is its positive impact in moderating long-term global climate change. Fossil fuel combustion takes carbon that was locked away underground (as crude oil, gas, or coal) millions of years ago and transfers that carbon to the atmosphere as new CO2. When wood is burned, on the other hand, it recycles carbon that was already in the natural carbon cycle, which is recaptured through sustainable forest growth. Consequently, the net long-term effect of burning wood fuel is that considerably less new CO2 is added to the atmosphere, as long as the sources from which the wood came are sustainably managed. Since wood burning uses a LZC fuel source and burning fossil fuels causes climate change, when wood replaces fossil fuelled heating the net impact should be that, over the long term, CO2 levels in the atmosphere are reduced. If a fossil fuelled heating system is converted to wood, net CO2 emissions for heating are reduced. For this reason we believe, heating with wood is one of the most powerful tools for an institution or community interested in meaningfully addressing climate change and renewable energy through its own energy use. Contents page Introduction 2 Climate change 2 Fuel choices 2 Wood fuel storage 3 Pellets boiler HPK-RA 4 Pellets minimum distances 6 Discharge systems for pellets facilities 7 Day container 10 Spiral conveyers 11 Wood chips storage 13 Wood chips and pellets boiler 14 Wood chips minimum distances 15 Discharge systems for wood chips facilities 16 Containers for heating systems 18 Control of wood chips and pellets boilers 20 Blower couplings 21 Other products 22 What capacity does the fuel store need to be? 22 Piping a biomass boiler up to a heating system 23 Water treatment 24 Wood chips and pellets boilers HPKI-K 25 Control unit for pellets and wood chips boilers HPKI-K/R 27 Bucket wheel/rotary valve 27 Discharge systems for pellets facilities 28 Discharge systems for wood chips facilities 29 UTSK minimum distances 33 Data sheet HPKI-K kw 33 Other products 34 Silo cover 2000mm x 3000mm 35 Fuel choices This guide is to help the designer decide which wood fuel to choose and assumes that the choice to burn wood chips or pellets as a fuel has been made and that the different characteristics of the fuel need to be considered before making a final decision. Wood pellets vs wood chips - Pellets flow freely whereas chips do not- chips can require some manual labour input once or twice a year - Pellets are a more dense form of fuel than chips therefore take less storage space per kw/hr - Pellets are more expensive per kw/hr than chips - Chips are more environmentally friendly than pellets as they take less energy to create - A wood chip boiler can burn pellets whereas a pellet boiler can t burn chips Wood pellets Wood chips Natural gas 35 sec oil Density kg/m3 approx Heat output kw hr/m3 approx Emissions kg CO2/Mw hr

3 In brief summary It can be seen that wood chips are more environmentally friendly but take up more storage space. At the time of writing (Summer 2008) chips are about 60% of the cost per kw/hr of Natural Gas and pellets are about the same as Natural Gas, therefore chips do have the possibility of giving a payback as well. Pellets are about 50% the cost of Gas Oil per kw/hr. But if fuel storage space, on site labour or a local supply of chips are unavailable, it is evident that pellets will give a significant carbon reduction over traditional heating fuels. Wood fuel storage Consideration now needs to be given to the type of fuel store suitable for the different fuels as each has a different requirement. There is however one overriding consideration to bear in mind for both fuels: it is easier to move the heating system water than wood fuel, so try and keep the fuel store as close to the wood boiler as possible, the simpler the fuel route the better!! Wood pellet storage As mentioned earlier pellets will free flow so they can be kept in a fuel store with a sloping floor to a central feed auger as shown below (A) - ideal slope 35 degrees or more. A B C D BROAG-REMEHA GILLES BIOMASS RANGE The fuel can then be moved using augers (worm screws) to the boiler (B). Or feed another auger to take the fuel further using extra augers (C). Pellets can also be stored in a silo similar to the one shown (D). Broag are able to put the customer in contact with suppliers of silos which can be delivered to site and bolted down to a pre-prepared base, the dimensions of which they will supply. 3

4 Pellets boiler HPK RA (also able to burn logs) HPK-RA kw This high-performance boiler is produced as a tension-free welded construction. The heat insulated front door opens outwards. The cleaning of the boiler tubes is fully automatic by means of an individual motor via 6 mm wide screws. Nominal heat output - see chart Minimal partial load: 30% of nominal heat output Welded high-performance multiple-draught boiler in thick-walled boiler plate St (6 mm width) Horizontal heat exchanger in seamless drawn thick-wall boiler pipe 70 mm thick external insulation; Incl. heat exchanger with all pipe collars required plus a cleaning device Operational pressure max. 3 bar Automatic ash discharge integrated in boiler base Incl. flue gas fan Incl. wheeled ash container Incl. ash stirrer HPK-RA 12.5/ / /5.1 SET PRICE includes: - HPK boiler Nominal heat output kw Max working pressure bar Switch box intended for Max flow temperature C installation onto wall Min return temperature C Pellet burner with Number of heat exchange tubes automatic ignition Heating area m Back burning protection Boiler volume (water) L Boiler weight kg Flue gas temp. nominal load C Electrical supply 230V 230V 230V Incl. ash container 43 L 43 L 43 L Item number PL PL PL

5 HPK-RA kw This high-performance boiler is produced as a tension-free welded construction. The heat insulated front door opens outwards. The cleaning of the boiler tubes is fully automatic by means of a separate drive via 6 mm wide screws. Suitable for automatic combustion of pellets and without any adjustments. Suitable also for using pieces of wood in case of emergency operation, thanks to an additional combustion chamber opening and grate. Nominal heat output - see chart Minimal partial load: 30% of nominal heat output Welded high-performance multiple-draught boiler in thick-walled boiler plate St (6 mm width) Horizontal heat exchanger in seamless drawn thick-wall boiler pipe 70 mm thick external insulation; HPK-RA (Pellets, without fire bricks) 20/6.1 25/6.1 30/9.1 35/9.1 40/9.1 49/8.1 Nominal heat output kw Max working pressure bar Max flow temperature C Min return temperature C Number of heat exchange tubes Incl. heat exchanger with all pipe collars required plus a cleaning device Operational pressure max. 3 bar Automatic ash discharge integrated in boiler base Incl. flue gas fan Incl. wheeled ash container Incl. ash stirrer Heating area m Boiler volume (water) L Boiler weight kg Flue gas temp. nominal load C Electrical supply 230V 50 Hz 230V 50 Hz 230V 50 Hz 230V 50 Hz 230V 50 Hz 400V 50 Hz Inc. ash container 43 litres 43 litres 43 litres 43 litres 43 litres 43 litres Item number PL PL PL PL PL PL BROAG-REMEHA GILLES BIOMASS RANGE HPK-RA (Pellets, incl. fire bricks) 60/2.1 75/3.1 85/3.1 95/ */ */ / /4.1 Nominal heat output kw Max working pressure bar Max flow temperature C Min return temperature C Number of heat exchange tubes Heating area m Boiler volume (water) L Boiler weight kg Flue gas temp. nominal load C Electrical supply (240V optional extra) 400V 50 Hz 400V 50 Hz 400V 50 Hz 400V 50 Hz 400V 50 Hz 400V 50 Hz 400V 50 Hz 400V 50 Hz Incl. ash container 43 litres 43 litres 43 litres 43 litres 43 litres 43 litres 43 litres 43 litres Item number PL PL PL PL PL PL PL PL SET PRICE includes: HPK boiler Switch box intended for installation onto wall Pellets burner with automatic ignition and back burning protection Over 60 kw fire bricks included 5

6 Pellets minimum distances kw kw 49 kw *620mm *765mm *765mm 60 kw 75 and 85 kw 100 and 120 kw *935mm *935mm 145 and 160 kw *935mm Note: Space in front of boiler only needed for annual removal of ashaugers. If outward opening door(s) available then * = width of boiler. eg (935mm) *935mm 6

7 Discharge systems for pellets facilities Standard auger for pellets kw Fuel discharge conveyor standard screw. Suitable for HPK-RA boiler, pellets screw with gear motor and multiple bearings plus support feet for stability. Screw channel for conveying the pellets with progressive screw blade and three-part screw shaft. Connection to pellets burner from above. To move pellets from store directly to boiler or to a rising auger. Standard screw kw kw kw Screw length Item number Item number Item number Up to 2.0 m PL PL PL m PL PL PL m PL PL PL m PL PL PL m PL PL PL m PL PL PL m PL PL PL m PL PL PL m PL PL PL m PL PL PL m PL PL PL m PL PL PL m PL PL PL BROAG-REMEHA GILLES BIOMASS RANGE Motor technical data kw kw kw up to incl. 5 m from 5.5 m up to incl. 8 m up to incl. 8 m Type FGA 103/4DEKG 63 as-4 FGA 333F/4EK 71L4x-6 FGA 423F FGA 423F Output 0.05 kw 0.25 kw 0.25 kw 0.25 kw Driver revolutions 4.5 min min min min-1 Driver torque moment 100 Nm 234 Nm 420 Nm 420 Nm Voltage / Frequency 230 V / 50 Hz 230 V / 50 Hz 400 V / 50 Hz 400 V / 50 Hz 7

8 Rising auger for pellets kw Fuel discharge conveyor rising screw. Suitable for HPK-RA boiler, pellets screw with gear motor and multiple bearings plus support feet for stability. Screw channel for conveying the pellets with progressive screw blade and three-part screw shaft. Connection to pellets burner from above. To move pellets from a standard auger to the boiler. Rising screw kw kw kw Screw length Item number Item number Item number Up to 1.5m PL PL PL m PL PL PL m PL PL PL m PL PL PL m PL PL PL m PL PL PL m PL PL PL m PL PL PL m PL PL PL m PL PL PL m PL PL PL m PL PL PL m PL PL PL m PL PL PL Motor technical data kw kw kw up to incl. 5 m from 5.5 m - 8 m up to incl. 8 m up to incl. 8 m Type FGA 103/4DEKG 63 bs-4 FGA 333F/4EK 71L4x-6 FGA 423F FGA 423F Output 0.09 kw 0.25 kw 0.25 kw 0.25 kw Driver revolutions 10.2 min min min min-1 Driver torque moment 100 Nm 234 Nm 420 Nm 420 Nm Voltage / Frequency 230 V / 50 Hz 230 V / 50 Hz 400 V / 50 Hz 400 V / 50 Hz 8

9 Bent auger for pellets kw Fuel discharge conveyor elbow (bend) screw. Suitable for HPK-RA Boiler system. Pellets conveying screw with gear motor and multiple bearings plus support feet for stability. Screw channel for conveying the pellets with progressive blade and three-part screw shaft. Including channel/screw elbow (bend) for directional deviation, with internal screw connection provided by universal (cardan) joint. Connection to pellets burner from above. To move pellets from the store directly to the boiler or via a rising auger. Elbow arm screw kw kw Screw length Item number Item number 3.0 m PL PL m PL PL m PL PL m PL PL m PL PL m PL PL m PL PL m PL PL m PL PL m PL PL m PL PL BROAG-REMEHA GILLES BIOMASS RANGE Motor technical data kw kw from 5.5 m up to incl. 8 m Type FGA 333F FGA 423F Output 0.25 kw 0.25 kw Driver revolutions 10.2 min min-1 Driver torque moment 234 Nm 420 Nm Voltage / Frequency 230 V / 50 Hz 400 V / 50 Hz 9

10 Elbow arm sweep auger for pellets kw Discharging of pellets from the on-site built silo or bunker. The two sturdy elbow arms can work in a small radius; incl. pressure plate, gear motor and pre-tensioning device. Max fuel depth for pellets: 2.5 m Worm screw elongation Diameter adjustment Incl. diameter adjustment part - full shaft Ø 50 mm, - screw blade thickness - 8 mm - continuous welded screw blade - suitable for material size of G50 at maximum ATTENTION: If silo diameter is less than 2.6m, there is a danger of overbridging! To move pellets from a square store directly to the boiler or via rising auger. Standard elbow arm discharge system kw Motor technical data Producer Type Output Driver revolutions ABM FGA663F/ 4D80a kw 10.2 min-1 Driver torque moment T2 = 702 Nm fb = 0.9 Voltage / Frequency Screw elongation Item number PL Length Per 0.5 m 230/ 400 V // 50 Hz Total screw length - max. 6 m (elongation + adjustment) Item number PL PL PL PL PL PL PL PL PL PL PL PL PL PL PL PL PL PL Diameter adjustment 2.6 m 2.8 m 3.0 m 3.2 m 3.4 m 3.6 m 3.8 m 4.0 m 4.2 m 4.4 m 4.6 m 4.8 m 5.0 m 5.2 m 5.4 m 5.6 m 5.8 m 6.0 m Day container 650 over burner Consisting of - conveying screw with channel (channel upon requirement) - ejector shaft with cover switch - ejection side or bottom - volume litres Day container (over burner) Item number PL Output range kw Stores manually loaded pellets and meters them into boiler

11 Spiral conveyers HP 30i - up to 60 kw Delivery tube: plastic with mount Delivery bend: plastic with mount Bottom part, e.g. loading hopper, material ST 37 zinc coated Spiral: HP 30i Conveyed material: wood pellets Granulate size: 6 x 40 mm Apparent density: ca. 700 kg/m 3 HP 30i Spiral conveyer 30 with outlet 70 mm consisting of:.. HP-A 1 piece driving shaft incl. tightening clamp, 1 pc. angle bracket, 1 set of screws, rubber dampers and ABM-shaft, 1 piece H-PVC tube coupling with 2 pieces of tube clamps, 1 pc. end cap, 1 pc. sensor 220 V, 1 pc. sensor holder, 1 m outlet hose, 2 pcs. hose clamps.. HP 30i Spiral (coil 60 m) up to 60 m.. HP 30i assembly manual To move pellets from the store directly to the burner or a rising auger. Spiral conveyers HP 30i up to 60 kw Item number Fuel store length/m* PL PL PL PL PL PL * and a maximum length from the internal fuel store wall to the fuel outlet as per drawing below (1240mm)! Awaiting new technical drawing - please consult your local Area Sales Manager for exact dimensions BROAG-REMEHA GILLES BIOMASS RANGE 11

12 SF 30i kw - Available for larger boilers, please consult local Broag Area Sales Manager. Conveyer tube: metal tube (in bunker PE-tube) Conveyer bends: metal bends Bottom part, e.g. loading hopper, material ST 37 zinc coated or painted Spiral: SF 30i Motor: geared drive engine, 0.18 kw/47 U/Min Conveyed material: wood pellets Granulate size: 6 x 40 mm Apparent density: ca. 700 kg/m 3 Spiral conveyers SF 30i kw Item number Fuel store length/m* PL PL PL PL PL * and a maximum length from the internal fuel store wall to the fuel outlet as per drawing below (1400mm)! SF 30i Driving unit 30 with 200 mm, outlet maintenance opening, switching of overfilling, geared drive engine kw 47 U/min with TW, driving shaft.. SF 30i metal tube.. SF 30i metal bend 15.. SF 30i metal bend 45.. SF 30i HD metal tube fitting.. SF 30i spiral - up to 60 m.. SF 30i support for driving unit SF30i to ground with adapter for carrier To move pellets from the store directly to the burner or a rising auger. 12

13 Wood chips storage As mentioned earlier, chips don t free flow so are not suitable for the sort of storage used for pellets. To move chips from the store to the transport system, a Sweep Auger needs to be used - see below. Worm screw elongation Gathers and delivers wood chips from store Diameter adjustment In operation the auger, which is driven by an electric motor, transfers its drive into a gearbox underneath the circular disc which then makes the arms rotate and drag the fuel to the auger. The fuel is then transported to the boiler via the auger(s) like wood pellets. Choose the largest diameter sweep collector that will fit between the fuel store walls to minimise fuel left around the edge. Sweep collector operation undermines fuel causing it to fall inwards and then be fed into the feed auger 1 motor drives sweep collector and feed auger. The wood chip store should be as square as possible to minimise fuel left in the corners. BROAG-REMEHA GILLES BIOMASS RANGE Above: As mentioned in Fuel Choices wood chip stoking equipment is more robust than pellet equipment- here we have fully welded auger flights on a solid 50mm shaft. Left: Circular flat bottomed bins similar to these also suit sweep augers. 13

14 Wood chips and pellets boiler HPK-RA kw This high-performance boiler is produced as a tension-free welded construction. The heat insulated door at the front swings out completely permitting free access for cleaning all the boiler flues. It is constructed in accordance with the natural combustion process of the wood fuel. The combustion chamber is lined with ceramic (replaceable) radiant fire bricks. The high combustion temperatures and the length of time the gases persist in the furnace guarantee clean combustion. The boiler is suitable for automatic combustion of both wood chips and pellets. Also, thanks to an additional combustion chamber opening and grate, pieces of wood may be used in case of emergency operation, without the necessity of any adjustments to construction. Nominal heat output - see chart Minimal partial load: 30% of nominal heat output Welded high-performance multiple-draught boiler in thick-walled boiler plate St (6 mm width) Horizontal heat exchanger in seamless drawn thick-wall boiler pipe 70 mm thick external insulation; Incl. heat exchanger with all pipe collars required plus a cleaning device Operational pressure max. 3 bar Automatic ash discharge integrated in boiler base Incl. flue gas fan Incl. wheeled ash container Incl. ash stirrer HPK-RA (wood chips) 15/7.1 20/7.1 25/7.1 30/8.1 35/8.1 40/8.1 49/8.1 Nominal heat output kw Max working pressure bar Max flow temperature C Min return temperature C Number of heat exchange tubes Heating area m Boiler volume (water) L Boiler weight kg Flue gas temp. nominal load C Electrical supply 400V 50 Hz 400V 50 Hz 400V 50 Hz 400V 50 Hz 400V 50 Hz 400V 50 Hz 400V 50 Hz Incl. ash container 43 litres 43 litres 43 litres 43 litres 43 litres 43 litres 43 litres Item number PL PL PL PL PL PL PL

15 HPK-RA (wood chips) 60/2.1 75/3.1 85/ */ */ / /4.1 Nominal heat output kw Max working pressure bar Max flow temperature C Min return temperature C Number of heat exchange tubes Heating area m Boiler volume (water) L Boiler weight kg Flue gas temp. nominal load C Electrical supply 400 V 50 Hz 400 V 50 Hz 400 V 50 Hz 400 V 50 Hz 400 V 50 Hz 400 V 50 Hz 400 V 50 Hz Incl. ash container 43 litres 43 litres 43 litres 43 litres 43 litres 43 litres 43 litres Item number PL PL PL PL PL PL PL SET PRICE includes: HPK boiler Switch box intended for installation onto wall Wood chips burner with automatic ignition and back burning protection Fire bricks Note: 240 V available as optional extra. Wood chips minimum distances kw kw 60 kw Note: Space in front of boiler only needed for annual removal of ashaugers. If outward opening door(s) available then * = width of boiler. eg (935mm) BROAG-REMEHA GILLES BIOMASS RANGE *620mm *765mm *935mm 75 and 85 kw 100 and 120 kw 145 and 160 kw *935mm *935mm *935mm 15

16 Discharge systems for wood chips facilities Spring assembly discharge system for wood chips kw Discharging from the on site-built silo or bunker, suitable for conveying wood chips, splinters, scobs. Two compound spring assemblies; incl. pressure plate, gear motor and pre/tensioning device. Max fuel depth for chips: 3 m Not suitable for pellets Price includes mains water fed thermostatic valve set to open at 55 C. of valve To protect boiler from fire originating in fuel store. Valve supplied loose for fitting by others. Screw elongation Spring assembly discharge system kw Diameter adjustment To move wood chips from the store directly to the boiler or a rising auger. Incl. diameter adjustment - full shaft e Ø 40 mm, - screw blade thickness - 5 mm - continuous welded screw blade - suitable for material size of G30 Item number PL PL PL PL PL Diameter adjustment 2.0 m 2.5 m 3.0 m 3.5 m 4.0 m Motor technical data Producer ABM Type FGA663F/ 4D80a-4 Output 0.75 kw Driver revolutions 10.2 min-1 Driver torque moment T2 = 702 Nm fb = 0.9 Voltage / Frequency 230/ 400 V // 50 Hz Screw elongation Item number PL Total screw length - max. 6 m (elongation + adjustment) Length Per 0.5 m Rising or delivery screw for wood chips kw Fuel discharging conveyor standard screw. Suitable for HPK-/RA boilers. Conveying screw with gear motor and multiple bearings plus support feet for stability. Screw channel for conveying pellets or wood chips by a progressive screw blade and threepart screw shaft. Connection to the wood chips burner from above. Motor technical data Producer Type Output Driver revolutions ABM FGA663F/ 4D80a kw 10.2 min-1 Driver torque moment T2 = 702 Nm fb = 0.9 Voltage / Frequency 230/ 400 V // 50 Hz Rising screw - wood chips kw Item number Length PL m PL m PL m PL m PL m PL m PL m PL m PL m PL m PL m PL m To move wood chips from sweep auger outlet to boiler inlet. 16

17 Elbow arm sweep auger kw Discharging from the on site built silo or bunker, suitable for conveying wood chips, splinters, scobs, pellets, etc. Two compound spring assemblies enable to work in a small space radius; incl. pressure plate, gear motor and pre-tensioning device. Max. fuel depth for wood chips: 6 m Max. delivery height for pellets and wood briquettes: 2.5 m Price includes mains water fed thermostatic valve set to open at 55 C. of valve To protect boiler from fire originating in fuel store. Valve supplied loose for fitting by others. Incl. diameter adjustment - full shaft Ø 50 mm, - screw blade thickness - 8 mm - continuous welded screw blade - suitable for material size of G50 at maximum Motor technical data Producer Type Output Driver revolutions ABM FGA663F/ 4D80a kw 10.2 min-1 Driver torque moment T2 = 702 Nm fb = 0.9 Voltage / Frequency Screw elongation 230/ 400 V // 50 Hz Screw elongation Item number PL PL PL PL PL PL PL PL PL PL PL PL Diameter adjustment To move wood chips or pellets from the fuel store directly to the boiler or a rising auger. Standard elbow arm discharge system kw PL PL PL PL PL PL Diameter adjustment 2.6 m 2.8 m 3.0 m 3.2 m 3.4 m 3.6 m 3.8 m 4.0 m 4.2 m 4.4 m 4.6 m 4.8 m 5.0 m 5.2 m 5.4 m 5.6 m 5.8 m 6.0 m BROAG-REMEHA GILLES BIOMASS RANGE Total screw length - max. 6 m (elongation + adjustment) Screw elongation Item number PL Length Per 0.5 m 17

18 Containers for heating systems kw Incl. installation (VL+RL), incl. electro-wiring. Incl. chimney of high-grade steel, incl. safety devices, incl. blowers junctions incl. all fire protection doors, Boiler and fuel delivery equipment to suit customer requirements. Variation 1: Heating container kw Variation 2: Heating container kw - pellets 18

19 Variation 3: Heating container kw - pellets only BROAG-REMEHA GILLES BIOMASS RANGE 19

20 Control of wood chips and pellets boilers Supplied as standard with all boilers up to 160kW - Standard switch box - SPS-control system - Automatic ignition and reverse equipment for stoker and bucket wheel - Modem for remote control - External heating circuits regulation (2 heating circuits, hot water) - Control of boiler, flue gas, fuel feed quantity - Summer-, Winter-, Boiler-, Storage tank, manual operation and night drop - Operational hours counter - Measured operation - Protection against blocking by means of initiator - Motor Electrical control Regulation HPK Item number Output Range PL kw Cable connection with the switch box possible within the distance of 3 m from the boiler. Connection of all gear and blowers motors. Electric wiring incl. cable channel. Incl. VISUALISATION with Fire View This integrated program developed by GILLES enables a complete view of the performance process of the heating system and an immediate detection of any possible defect remotely by the customer. Also remote engineer is able to access boiler control if boiler is connected to dedicated analogue phone line. Figure Item number Description PL PT 1000 sensor (for storage tank) (Length 10m) Per piece PL Visualisation (only Program) PL Visualisation by means of CAN BUS (Program incl. CAN-BUS Interface) PL PL PL Fill up level detector for storage room up to 160kW (3 pcs. sensors + receiving box) FU design for wood chips boilers kW and pellets boilers kW To convert a 415V boiler to 240V. Must be fitted from new, not retrofitable. FU discharge or rising screw conveyors To convert a 415V boiler to 240V. Must be fitted from new, not retrofitable. 20

21 Blower couplings Blower couplings for pellets Figure Item number Description PL PL PL PL PL Blower coupling sets (straight) 2 pcs. of tank car couplings with turn protection, incl. cover Length: 0.5 m For building into wall as is - no extra pipe to be added 1 pc coupling incl. cover 110 mm Storz 1 m tube Ø 100 mm 1 x 45 elbow Ø 100 mm 2x45 = 1x90 Stroke protective pad 1 stroke protective pad inc. holder To stop pellets breaking against fuel store wall BROAG-REMEHA GILLES BIOMASS RANGE Blower couplings for wood chips Figure Item number Description PL pc coupling incl. cover 150 mm Storz PL m tube Ø 150 mm PL x 45 elbow Ø 150 mm 2x45 = 1x90 21

22 Other products Figure Item number Description PL Fall tube Incl. flange per m Used when fuel store is above boiler. PL Fall tube with access door Incl. flange per m PL PL Delivery container up to 160kW for 2 deliveries (suitable for pellets and wood chips) Used when one fuel store needs to feed two boilers. Ash container - large (80 litres) PL Ash container small (43 litres) What capacity does the fuel store need to be? Calculation is dependent upon a number of factors: - What output is the biomass boiler in kw? - How many hours a week will it be in operation? - Which type of fuel chips or pellets? - How often is it desirable to have fuel deliveries? - What capacity is the delivery lorry? For example A 145kw boiler in a primary school working say 6hrs a day at full output burning wood chips will burn the following amount of fuel per week 145kw x 6hrs per day x 5 days per week = 4350 kw/hrs per week 4350 divided by 800 (the amount of kw/hrs per m3 of chips) = 5.43m3 per week. Most fuel delivery lorries carry about 30m3 of fuel so in this instance if a 36/38m3 store could be created a delivery would be needed about every 6 weeks without the store needing to be fully empty to receive a full load. A suitable store would be about 3.5m x 3.5m x 3m deep. Another example A 100kw boiler in a sports centre working say 12hrs a day at full output burning pellets will burn the following amount of fuel per week 100kw x 12hrs per day x 7 days per week = 8400kw/hrs per week 8400 divided by 3000 (the amount of kw/hrs per m3 of pellets) = 2.8m3 per week That would be a full lorry load approx every 10 weeks or a half load every month or so. 22

23 Piping a biomass boiler up to a heating system Uniquely, the Broag-Gilles biomass boiler has the combustion process under full control - please ask local Broag Area Sales Manager for full explanation if required, contact details on This means that a buffer vessel doesn t need to be fitted if the boiler is piped into a low loss header as shown below. BROAG-REMEHA GILLES BIOMASS RANGE Typical Broag-Gilles biomass schematic showing option of extra boilers if required. Biomass boiler pump and divert valve supplied as standard- up to 160 kw, position of 3 port valve varies depending upon boiler output (isolation valves etc omitted for clarity). The diagram above shows that the biomass boiler can be piped up like any other boiler and also in conjunction with any other boiler. The 3 port mixing valve and boiler pump are supplied with the boiler(up to 160kW) and are designed to get the nominal flow through the boiler and keep the return temperature up to deg C. They are controlled by the boiler so require no extra electrical supply. When would a buffer vessel be desirable? A buffer vessel can be used for 3 main reasons: - If instant heat is required at any time e.g. in a greenhouse that has to be kept warm immediately once the inside set temperature falls in the evening. - A buffer vessel can be used to effectively increase the size of a boiler by letting it create and store heat overnight ready for the cold morning start - this applies to all boilers not just biomass. - If the boiler is connected only to a Plate Heat Exchanger/s and there is a possibility of the demand for heat being taken away without any overrun e.g. only looking after air handling units which may all switch off at the same time once a set outside temperature is reached or similar situation. Any other hydraulic considerations? No, this is the main benefit the Broag-Gilles boiler has over its competitors, treat it as if is a normal boiler with pump overrun at the end of the heating day and it will operate correctly. It is best operated on a pressurized system which should be connected as per the manufacturer s instructions. 23

24 Water treatment It is generally considered good practice to treat the system water. The biomass boilers have a steel heat exchanger so a suitable inhibitor should be used for steel and all other metals in the heating system. Combustion air requirements The combustion air requirement for the biomass boilers is as follows: - Kw output of the boiler(s) x cm/2 - For example a 145 kw boiler would need 547cm/2 of free area air inlet - A 100 kw and 45 kw together in the same boiler house would also need 547cm/2 Any conventionally flued appliances e.g. pressure jet, water heater, atmospheric or conventionally flued Quinta/210 etc will need their combustion air in addition to the above in accordance with standard BS6644 calculation. Flueing requirements Reference should be made BS 6644 & the clean Air Act. Only clean wood fuel may be used & can generally be regarded as a Very Low Sulphur (VLS) fuel. - The boilers must have their own flue, they cannot share with other boilers, water heaters or biomass boilers. - The flue gas temperature is between 130 deg C and 200 deg C, the flue fans have quite high residual duty so this should be borne in mind when choosing a flue. - Consideration should be given to smoke control areas - currently all boilers up to 300 kw are Exempt Appliances for S.C. areas. In Autumn 2008, kw will be exempt. It is anticipated that in Spring 2009 the 2000 kw boiler will also be exempt. Boilers operating in these zones must burn fuel derived from clean wood containing no halogenated compounds. - The services of a specialist flue company should be considered for final flue design, which should include clean out hatches. Flueing environmental issues All combustion causes pollution. When selecting your fuel you are also inevitably selecting the pollution that comes as a consequence of that decision. All Broag-Gilles boilers when correctly installed are certified by AEA Technology* as suitable for use in Smokeless Zones and meet with all UK regulatory standards. All equipment certification is given based on the use of clean fuel. Clean fuel is essential otherwise you may be in breach of emission regulations and cause harm. Other air pollutants of concern, but by no means exclusive to biomass combustion include: PM10 Particles - Broag-Gilles fully automated boilers are class leaders with low PM10 emissions. PM10 Levels will vary significantly with fuel quality. Pellets produce less PM10 than chips and may be a more suitable fuel choice for built up areas. PM10 emissions are of less concern in rural and suburban areas where existing PM10 levels are likely to be low Sulfur Oxides (SOx) cause acid rain. Modern wood systems have 1/6 the SO2 emissions of fuel oil. Nitrogen Oxides (NOx) produced by all combustion processes cause ozone, smog, acid rain and respiratory problems. Carbon Monoxide (CO) is produced by all fuel combustion processes. The level produced by wood combustion depends very much on how well the system is set up and maintained. CO emissions from wood burning are of relatively minor concern to air quality, except in some areas that already have high levels of CO in the air from traffic exhaust. Volatile Organic Compounds (VOCs) are a large family of air pollutants, some of which are produced by fuel combustion. Some are toxic, others are carcinogenic. VOCs elevate ozone and smog levels in the lower atmosphere, causing respiratory problems. Both wood and oil combustion produce VOCs wood is higher in some compounds and oil is higher in others. VOC emissions can be minimized with good combustion practices. Most of these issues are relevant to all combustion processes not solely wood biomass and can be resolved by ensuring the correct chimney height. As with all installations, reference to the Clean Air Act and BS6644 is recommended. AEA Technology* can carry out an on-site environmental impact study to fully asses all of the air quality issues surrounding an installation if the client feels this is necessary. * 24

25 Wood chips and pellets boilers HPKI-K HPKI-K kw (Underfeed stoking) This high-performance boiler is produced as a tension-free welded construction. The heat insulated door at the front swings out completely permitting free access for cleaning all the boiler flues. It is constructed to optimise the natural combustion process of wood fuel. The gasification combustion chamber, built on the direct-electrical principle, is lined with a ceramic variable (replaceable) radiant ceiling. The high combustion temperatures and the length of time the gases persist in the furnace guarantee clean combustion. Regulated rotation speeds of primary and secondary air blowers. Performance regulation by means of exhaust gas temperature, lambda probe sensor, combustion chamber temperature and boiler temperature. Ceramic lining in high-temperature resisting special chamotte concrete. Incl. multi-cyclone flue dust interceptor Flue dust interceptor for removal of dust from flue gases. The interceptor is installed compactly in the boiler. - Housed in the flue-ways with installed cast metal cyclones. - Ash discharge cone with appropriated outflow from discharge system/ separated position of ash container. Underfeed fuel stoking with combustion retort in heat resistant steel, incl. grate rods in fire resistant cast alloy. Combustion grate incl. grate rods in fire resistant cast alloy with pull-out ash removing box under it. Combustion chamber door in front wall. Incl. flue gas fan. For creating and regulating negative pressure in the boiler. - Sturdy housing in steel - Radial running wheel welded and balanced dynamically - Motor with shaft and heat diversion panel designed to cope with high temperatures - Insulation class F. BROAG-REMEHA GILLES BIOMASS RANGE Incl. automatic cleaning of boiler tubes The cleaning of the interior of the boiler tube is carried out by means of an intensive compressed air shock. This cleans the tube at high speed and loosens any ash sticking on the walls. Special valves with a very high air throughput and a very short opening time are used to achieve the air cleaning. The tube stays clean as a result of the application of this cleaning principle, keeping the expense and effort involved in additional cleaning work to a minimum. The flue gas temperature is low. The efficiency of the boiler is kept up between services. - Special air jets with fast closing valves are built into the boiler doors - Compressed air tank directly adjacent to valves with pressure sensor and safety valve - Automatic valve control for optional setting up of the cleaning interval - Compressor included in price 25

26 HPKI-K kw Incl. stoker, blowers, automatic cleaning, automatic ignition (up to 550 kw), ash removal, incl. 2 x 240 L containers and compressor HPKI-K kw Incl. stoker, blowers, automatic cleaning, incl. central ash discharge, incl. 1 x 800 L container and compressor HPKI-K Nominal heat output kw Normal operational pressure bar Max flow temperature C Min return temperature C Heating area m Boiler volume (water) L Boiler weight kg Flue gas temp. nominal load C Electrical supply 400V 50 Hz 400V 50 Hz 400V 50 Hz 400V 50 Hz Item number PL PL PL PL HPK-K Nominal heat output kw Normal working pressure bar Max flow temp temperature C Min return temperature C Heating area m Boiler volume (water) L Boiler weight kg Flue gas temp. nominal load C Electrical supply 400V 50 Hz 400V 50 Hz 400V 50 Hz 400V 50 Hz 400V 50 Hz 400V 50 Hz 400V 50 Hz Item number PL PL PL PL PL PL PL Central ash discharge L (Grate and cyclone ash discharging into the same 800 L container). Standard 1200 kw and above. Item number PL PL Output Range kw kw Heat conveyance safety device Mains water fed emergency cooling. Item number Output Range PL kw PL kw PL kw PL kw PL kw PL kw 26

27 Control unit for pellets and wood chips boilers HPKI-K/R HPKI-K/R kw - Continuous output regulation in the range from 30 to 100 % - Combustion optimisation; - Lambda sensor O2 control; - Negative pressure regulation; - Air quantity regulation; - Control and regulation of the complete process, starting in silo by fuel discharge up to the heating boiler by means of SPS suitable for industry usage; - Programming in compliance with the standard IEC of world-wide validity - The control may be set up via CAN-Bus or modem locally and externally at any time. Central fault notification as a standard with the possibility of putting out alarm messages as emergency phone communications in spoken text or SMS form. No start-up faults in autumn, because no batteries are necessary to retain the storage unit. Control cabinet circuitry wiring at 3 m circumference distance from boiler. Connection of all gear and ventilator motors, electric cabling incl. cable shaft. Item number Description Output range PL Control equipment kw PL Control equipment kw PL Control equipment kw PL Switch box extension Push rods discharge - Bucket wheel/rotary valve BROAG-REMEHA GILLES BIOMASS RANGE Solid cast metal construction with steel bucket wheel. Running wheel inclined to direction of turn with hardened and sharp-ground metal laminates. Counter cutter in hardened tool grade steel. Fully tested burn-back safety device. Figure Item number Description PL Bucket wheel ZRS 3 for HPKI-K/R/W incl. motor (large) Meters fuel into boiler and cut oversize fuel to size. Burn back protection. PL Bucket wheel ZRS 1 for HPKI-K/R/W incl. motor (small) Meters fuel into boiler and cut oversize fuel to size. Burn back protection. 27

28 Discharge systems for pellets facilities for HPKI-K/R/W kw Standard auger Fuel discharge conveyor standard screw, suitable for HPKI-K/R/W system. Pellets screw with gear motor and multiple bearings plus support feet for stability. Screw channel for conveying the pellets with progressive worm screw blade and three-part worm screw shaft. To move pellets from store directly to boiler or to a rising auger. Rising auger Fuel discharge rising screw, suitable for HPKI-K/R/W systems. Pellets screw with gear motor and multiple bearings plus support feet for stability. Screw channel for conveying the pellets with progressive auger blade and three-part worm screw shaft. To move pellets from a standard auger to the boiler. Standard screw Rising screw Screw Length Item number Item number Up to 1.5 m PL PL m PL PL m PL PL m PL PL m PL PL m PL PL m PL PL m PL PL m PL PL m PL PL m PL PL m PL PL m PL PL m PL PL m PL PL m PL PL m PL PL m PL PL

29 Discharge systems for wood chips facilities Elbow arm sweep auger HPK-IK/R/W kw Discharging from the side built silo or bunker, suitable for conveying wood chips, splinters, small pieces of bark, etc. Two robust elbow arms can work in a small space radius. Incl. pressure plate, gear motor and pre-tensioning equipment. Max. fuel depth for wood chips: 6 m Max. fuel depth for pellets and wood briquettes: 2.5 m Price includes mains water fed thermostatic valve set to open at 55 C. of valve To protect boiler from fire originating in fuel store. Valve supplied loose for fitting by others. Incl. diameter adjustment part - Full shaft Ø 50 mm, - Screw blade thickness - 8 mm - Continuous welded screw blade - Suitable for material size of G50 at maximum To move wood chips or pellets from a square or circular store directly to the boiler or to a rising auger. Motor technical data Screw elongation kw Item number PL061110I PL061111I PL061112I PL061113I PL061114I PL061115I PL061116I PL061117I PL061118I PL061119I PL061120I PL061121I PL061122I PL061123I PL061124I PL061125I PL061126I PL061127I Diameter adjustment Worm srew standard discharge system Diameter adjustment 2.6 m 2.8 m 3.0 m 3.2 m 3.4 m 3.6 m 3.8 m 4.0 m 4.2 m 4.4 m 4.6 m 4.8 m 5.0 m 5.2 m 5.4 m 5.6 m 5.8 m 6.0 m BROAG-REMEHA GILLES BIOMASS RANGE Producer ABM Type FGA663F/ 4D80a-4 Output 0.75 kw Driver revolutions 10.2 min-1 Driver torque moment T2 = 702 Nm fb = 0.9 Voltage / Frequency 230/ 400 V // 50 Hz Screw elongation Screw elongation Item number PL061128I Length Per 0.5 m Elongation of the diameter adjustment part possible up to 6 m! To extend the sweep auger to meet boiler or rising auger. 29

30 Elbow arm discharge system for HPKI-K/R/W kw Discharging from the side built silo or bunker, suitable for conveying wood chips, splinters, small pieces of bark, etc. to the silo s centre by means of two automatic retractable elbow arms. Incl. pressure plate, gear motor and pretensioning equipment. Price includes mains water fed thermostatic valve set to open at 55 C. Screw elongation Diameter adjustment of valve To protect boiler from fire originating in fuel store. Valve supplied loose for fitting by others. Incl. diameter adjustment part - Continuous welded worm screw blade - Progressive worm screw movement - Suitable for material size of (G50) - 60 mm full shaft - 8 mm screw blade - Max fuel depth up to 3 x diameter (Chips) To move wood chips or pellets from a square or circular store directly to the boiler or to a rising auger. Sturdy elbow arm discharge system kw Item number Diameter adjustment PL m PL m PL m PL m PL m PL m PL m PL m PL m PL m PL m PL m PL m PL m PL m PL m Motor technical data Capacity up to 400 kw up to 600 kw up to 900 kw Producer ABM Type FGA663F/ 4D80a-4 FGA663F/ 4D90Sa-4 FGA663F/ 4D90Sb-4 Output 0.75 kw 1.1 kw 1.5 kw Driver revolutions 10.2 min min-1 20 min-1 Driver torque moment T2 = 702 Nm fb = 0.9 T2 = 710 Nm T2 = 716 Nm Voltage / frequency 230/ 400 V // 50 Hz 230/ 400 V // 50 Hz 230/ 400 V // 50 Hz Screw elongation Elongation of the diameter adjustment part up to 7 m is possible! Screw elongation Item number Length PL Per 0.5 m To extend the sweep auger to meet boiler or rising auger. 30

31 Rising and conveying screw wood chips HPKI-K/R/W HPKI-K/R/W kw Fuel discharge rising auger. Suitable for HPKI-K/R/W systems. Conveying screw with gear motor and multiple bearings, plus support feet for stability. Screw channel for conveying pellets or wood chips with progressive screw blades and three-part screw shaft. Motor technical data Producer Type Output Driver revolutions ABM FGA663F/ 4D80a kw 10.2 min-1 Driver torque moment T2 = 702 Nm fb = 0.9 Voltage/ frequency 230/ 400 V // 50 Hz Item number Product Description Rising and conveying screw kw Item number PL PL PL PL PL PL PL PL PL PL PL Length 1.0 m 1.5 m 2.0 m 2.5 m 3.0 m 3.5 m 4.0 m 4.5 m 5.0 m 5.5 m 6.0 m PL Special pressure bearing from 30 rising and at the screw length from 5 m from 20 rising PL Standard input channel with sight window, maintenance opening and safety end switch PL Standard output channel - Used to move woodchips from outlet of sweep auger or walking floor to boiler or possibly to another rising auger. BROAG-REMEHA GILLES BIOMASS RANGE 31

32 Walking floor system kw The data in the following table should be observed when considering the push rods discharge system: static calculation was made for wood chips of size G 50 and W 50, the maximum apparent density of 440 kg/m 3. Width of push rods 3.0 m 2.5 m 2.0 m 1.5 m Length/rod Delivery height (max) Delivery height (max) Delivery height (max) Delivery height (max) 12 m 2.3 m 2.8 m 3.5 m 4.7 m 10 m 2.8 m 3.4 m 4.2 m 5.6 m 8 m 3.5 m 4.2 m 5.3 m 7.0 m 6 m 4.0 m 5.6 m 7.0 m 9.0 m The permissible width of the push rods depends on the required length and intended delivery height. Example: Intended bunker length is 10.0 m, intended delivery height is 4.0 m. Push rod may be used within 2.0 m at maximum. In order to avoid the over bridging, the distance between push rods or wall should be 10cm - 15cm at maximum. A-Length 6.0 m 8.0 m 10.0 m 12.0 m B-Width 1.5 m 2.0 m 2.5 m 3.0m ATTENTION: Choosing and specifying a walking floor system must be done after consultation with Broag, who will liaise with Gilles to ensure satisfactory product selection. To move fuel from store to rising auger which then delivers fuel to boiler. Used on larger installations. 32

33 UTSK minimum distances 240L ash bin 800L ash bin *The minimum distance for opening the heat exchanger door is equivalent to the width of the boiler, but **for maintenance reasons we recommend a clear space, equivalent to the length of the heat exchanger, is left in front of the boiler - outward opening plant room doors in front of boiler can help achieve space required. Data sheet HPKI-K kw BROAG-REMEHA GILLES BIOMASS RANGE Output Flow/ Ø Total weight Weight heat Water in Kpa at Kvs in in kw L B H return DN mm in tons exchanger in tons litre t20 C m 3 /h

34 Other products Figure Item number Description PL Ash container HPKI (800 litres) Awaiting image PL Ash container HPKI (240 litres) PL Ash container HPKI (50 litres) PL PL PL061185I Switch box up to 1600 kw (without oil burner) For mounting of temp oil burner. Can t be retrofitted. Feeder tank HPKI-K for 2 charges (suitable for pellets and wood chips) Used where one fuel outlet needs to supply two boilers. SMS-Dialog (Mobile - cell telephone) Data transmission terminal GSM 900/1800 MHz PL Visualisation HPKI-K/R/W Summer 2008 on PL Optical message device of the filling level for storage room HPKI-K/R/W 34

35 Silo cover 2000mm x 3000 mm - Carrying capacity (car running) up to 20 kn/m 2 (40kn/m 2 and 75kn/m 2 upon request ) - Protective grate and water drainage - Hydraulic cylinder lifts hatch from below - Zinc coated finish - Upper surface of cover made of aluminium plate or it can be treated with asphalt or stones - Incl. hydraulic drive, hydraulic oil - Internal opening 2000x3000 mm To allow fuel to be tipped into fuel store from above. Silo cover Item number PL061763I Internal opening 2000 x 3000 m BROAG-REMEHA GILLES BIOMASS RANGE 35

36 TreadLightly ON THE PLANET BIOMASS The data published in this technical sales leaflet is based on the latest information (at date of publication) and may be subject to revisions. It should be read in conjunction with our full technical brochure (available on request). We reserve the right to continuous development in both design and manufacture, therefore any changes to the technology employed may not be retrospective, nor may we be obliged to adjust earlier supplies accordingly. Issue 1 date: 18/08/08 Please note: all advice in this booklet is given in good faith. However Broag-Remeha will not be held liable for information which subsequently is found to be outdated or inaccurate. Broag Ltd. Head Office Remeha House Molly Millars Lane Wokingham Berkshire RG41 2QP T: F: E: boilers@broag-remeha.com Broag UK is committed to carbon offsetting Designed and produced by Sans Frontiere Marketing Communications