Kob Pyrtec Brochure - Energy Systems Research Unit

Competent.The headquarters of KÖB & Schäfer GmbH islocated in the town of Wolfurt in Vorarlberg‘sRhine Valley, a region in which wood has alwaysbeen greatly valued as a fuel.The proverbial Alemannic sense of thriftinessand a distinct striving for quality have alwaysfallen on fruitful soil here for carefully designedproducts.PYROMAT ECO PYROMAT ECO PYROMAT DYN550 mm 1.080 mm PYROT PYRTECInnovations.KÖB carries out its own research and developmentand has contributed an importantshare toward the tremendous progress offurnace firing technology. For outstandingachievements in the field of modern furnacefiring technology, the company has receivedmany awards for its innovations in the environmentalsphere.Programme.PYROMAT ECO, 35 to 170 kW, thermal storageheating for logs, manual feed.PYROMAT DYN, 30 to 90 kW, perfect combinationfor automatic operations using wood chips,pellets and logs manual feed.PYROT, 80 to 540 kW, rotation heating for automaticoperations, for pellets, woodchips andshavings.PYRTEC, 530 to 1.250 kW, underfeed stokerwith automatic operations, for pellets, woodchipsand shavings.References.Köb has installed many thousands of systemswith satisfied customers all over Europe.Köb specialises in large-scale heating systemsand plant construction. Köb has a lot of experiencein biomass systems for district heatingand pellet systems for local heating networks.A great many references can be given especiallyfor co-operation link-ups with contractingfirms.Address of the factory:Köb & Schäfer GmbHFlotzbachstrasse 33A-6922 WolfurtTel +43 55 74 / 67 70-0Fax +43 55 74 / 65 7 07office@koeb-schaefer.comwww.koeb-schaefer.comSales and service branches:Great Britain3G Energi LtdCharlesfieldSt. BoswellsMelroseTD6 OHHTel +44 1835 82 42 01Fax +44 870 706 25 55office@3genergi.co.ukHolland and BelgiumLVB Energy Systems BVNL-4141 BE LeerdamTel +31 3 45 61 97 88Fax +31 3 45 61 69 05Marc@lvb-wood.nlCanada – British Columbia /AlbertaFink Machine Inc.CAN Enderby B.C.Tel 001 250 838 00 77Fax 001 250 838 00 68fink@jetstream.netOther branches are in: France,Switzerland, Germany, Italy,Austria, Norway, Sweden andJapan.All rigths reserved for technical changes 02/05Werbeagentur Nagel

All rigths reserved for technical changes 02/05Werbeagentur NagelGrate Firing

The bestprice for heat.Wood as a fuel is the most significant renewableenergy world-wide. With sustainable forestmanagement on the one hand and optimisation ofyour systems on the other, you secure your energyfuture.Heat requirementHeat output / Load typesHeat output, consumerskWAnnual curve1000 200055008400a.b.c.Typical case of loading in central Europeh/aThe wood-powered boilercan be designed for themaximum load (monovalent)or for the main orbase load (bivalent). Thesmaller the boiler output,the longer the operatingtime and also, however,the higher the stress onthe boiler.Heat output, generator100%Peak loadLoad typesa. Maximum loadb. Main load50c. Base loadLow-load proportion0a b ch/a1000 200055008400Area: Proportion of wood power, kWh/a (from 0 to c, b ,a)a) Heating for a single building;heating period: approx. 5,400 hb) Heating and hot water for a single building;year-round operationc) Heating & hot water via district heating network,year-round operation or heat production adds upto heat consumption plus network lossesTotal area: thermal energy to be produced■ Effective heat in kWh/a■ Network losses in kWh/aLoad System type Coverage of heat Hours of full Coverage by woodtype output [% of kW] operation [h/a] power [% of kWh/a]a) 1 stand alone 100 approx. 1750 100b) 2 base load 75 approx. 2500 approx. 97c) 2 base load 50 approx. 3600 approx. 70Other termsLow loadBoiler output below 30% of rated loadHeat availability System‘s delivery of heat during heating period [%]Boiler availability Operating time of the boiler during heating period [%]Track timeOperating hours between maintenance breaks [h]Redundancy Boiler output installed for reliability (boiler failure)Boiler systemsaacbca1 a2 c1) Monovalent- One wood-powered boiler (a) formaximum load- Heat availability: approx. 98-99%2) Bivalent- Wood-powered boiler (a) for base load- Oil or gas boiler for (b) peak load,low load and for redundancy- Heat availability: 99.5 to 99.9%3) Double-boiler system- Maximum load with two woodpoweredboilers (a1, a2)- Heat availability: approx. 99.6%- a1 & a2 alternately, peak load andbase load for split-up, 2 x 50%Advantages of heat accumulators (c)■ Boosts heat availability■ Coverage of brief peak requirements■ Optimises the connection of additional boilers■ Acceptance of excess heat when the heat is stopped■ Hydraulic separation: boiler system / consumersAdvantages of double-boiler system■ 100% sustainable wood energy■ Excellent controllability■ Maximum heat availability■ Gentle boiler operationEconomic efficiency / Heat costs, E/kWhThe aim of optimising systems is to minimise the expected heat costs (E perkWh).47% 10%26% 17%Example: Package boiler of approx.1,000 kW for large single building ormini-network with forest woodchipsConclusionThe heart of the biomass system, thefurnace, is only party to 10% of theheat costs. However, the furnacetogether with its degree of efficiency(fuel consumption), and the regularoperating costs decides the economicefficiency of the overall system!Breakdown of heat costs as a %/kWh■ Service of capital for furnace 10%■ Service of capital for remaining investment 26%Service of capital for total investment (10 yrs.) 36%■ Fuel – wood 47%■ Operation with full maintenance 17%Regular operation 64%Thus our recommendationOptimise your heat costs with aneffective boiler. The extra investmentthis requires will quickly pay for itself.With the PYRTEC furnace system youensure the economic efficiency of yourbiomass heating system and thusprofits for yourself!

Top Quality Furnace Technology.1112109845326171 Feed auger with isolatinglayer2 Burner trough with internalgrate and primary airflow 13 External grate with primaryairflow 24 Moving feed grateGrate firing with allits advantagesThe combination inthe PYRTEC of themoving feed grate withthe tried-and-trustedburner trough and thedrop-down externalgrate unites in optimumfashion the the advantagesof moving feedgrate firing with theadvantages of underfeedfiring.5 Secondary airflow6 Ignition fan7 De-asher8 High-temperature zone forburn-outThe advantages9 Firebox door10 3 - boiler shell(3.0 bar or 6.0 bar)11 Safety heat exchanger12 Pneumatic pipe cleaningsystem■ General-purpose use for all wood fuels fromdry (W5) to wet (W45), with pre-drying systemup to recently felled wet (W60)■ Outstanding controllability 30%-100%■ Excellent low-load behaviour with ignitionsystem■ Maximum safety against burn-back■ Fully automatic de-ashing of the furnaceNot shown:■ Flue gas recirculation system for dry fuels■ Exhaust gas deduster (multi-cyclone), incl.exhaust fanTechnical dataFurnacetypeTest certificatesRated Furnace dimensions mm 2) Weightoutput kW 1) Height Length Width empty kg 2)Pyrtec 530 530 2702 3237 1380 6575Pyrtec 720 720 2834 3877 1380 8054Pyrtec 950 950 3035 3835 1612 11013Pyrtec 1250 1250 3230 4380 1612 138091) Water content of wood fuel: W5-W402) Without attachmentsProduct and manufacturer completely tested andmonitored by TÜV with the following certificates:EMPA test reportVKF approvalFollowing EN-303- B Design and manufacture- C Heating engineering- E Electrical engineering- SR Fast shutting down- SP Operational safetyVHe type-tested

Made-to-measure energy.For all wood fuels …… and for all system prerequisites!■6-mm pellets with seal of qualityThe most compact form of wood energy.(Three to six times more energyper m 3 than forest wood chips). Lookfor brand quality complying withstandards (e.g. ÖNORM M7135).■Industrial pelletsMore cost-effective pellets with alarger diameter and a greater proportionof bark (max. ash content10%) for large-scale facilities.■Forest woodchipsUntreated, machine-shredded woodfrom forests. Stored for a summerbefore being shredded. Size: G50;water content: to W45; ash content:0.5% -1.0%, depending on the proportionof bark. With our patentedpre-dryer even chips from very wet wood (approx. W60)are possible.■Wood off-cutsNational regulations have to be checkedfor approval as fuel! Irrespectiveof such, the limits for chlorine,sulphur and sodium have to complywith KÖB‘s „Minimum Requirementsfor Wood Fuels“. In case of doubt,we will be happy to carry out an economical fuelanalysis.■Briquettes from off-cutsWith high proportions of fine particles,fuel should be compressed(briquettes). The size and solidityshould be geared to the loadersystem.Pellets in basementsExisting basement rooms or formeroil storage units are ideal for use aspellet storage units without majorreconstruction work. Pellets canbe blasted in over large distances.Special pellet augers convey themreliably, using little energy.Forest woodchips in bunkersBy means of large hydraulicallyoperated lids, the undergroundstorage unit (bunker) can be quicklyfilled from the top. The extractionis carried out by a hydraulic movingfloor conveyor to the subsequentconveyor augersOther accessories:■ Pre-dryer instead of ascendingconveyor auger■ Floor conveyor loader for insidebasement rooms with an attachedfilling bunker on the outside wall.Forest woodchips at ground levelIf an underground fuel storage unitcannot be realised, it is possibleto move lengthwise by means of amoving floor conveyor and thus fillthe storage unit at ground level.Wood off-cuts in silosThe to and fro motion of the pendulumsystem for silo extractionrules out not only bridge formationbut also compacting in the hopper.Fire-protection-tested rotary valvesreliably separate the silo and heatingsystem in all situations.Pre-dryer for forest woodchips (patented)Exhaust air 26°-30°CHow it worksWet forest woodchipsare pre-dried by warmair on the way to the furnace.The drying poweris automatically adjustedto the water content ofthe chips. The efficiencyof the entire system isincreased due to improvedcombustion resultingfrom pre-drying the fuel(less surplus air thanwith wet combustion).When to useWhenever the water contentof the chips might begreater than 50%The advantages (overwet combustion)■Higher degree ofsystem efficiency (plus10%))■Better output controlbehaviour■Better control behaviouron change of fuel■Better emission levelsin all phasesto the PYRTECSupply air (heating roomwaste heat used)Heat fromPYRTEC furnaceFuel intake

Tried, trusted & efficient.Fuel Loading Unita. Backflash safeguard(„RZS“)■Metering containerwith continuouslypresent, monitoredisolating layer■Permanent, monitorednegative pressureoperation (exhaust fanwith negative pressurecontrol system)b. Burn-back-inhibitingsystem („RHE“)■A solid auger in around insertion pipeautomatically completelyempties itselfif there is a danger ofback-burn (temperaturesensor).c. Burn-back safeguard(„RSE“)■A horizontally actingslide valve with springreturnmotor in case ofpower failure or thedanger of back-burn.■Rotary valve in case ofexcess or negativepressure in the wood(all-steel design).d. Automatic fire-extinguishingsystem(„SLE“)■20-l extinguishingwater tank with floatswitch■A thermal valve on themetering containerautomatically extinguishesthe fire as a lastsafety precaution.Rear■Drive for feed grate.■Primary airflow fan,phase 1■Ignition blower for fuelsup to W40 1) .Pneumatic cleaning system 1)Pneumatic cleaning of compressed air. Thisthe furnace. The heat extends the furnace‘sexchanger is periodicallycleaned by blasts of free operation in h) manytrack time (maintenance-times over.Perfect accessA large, air-cooledfirebox door with soliddouble hinge swingsway back. Ideal for maintenancepurposes.Automatic de-ashing 1)Automatic de-ashing ofthe combustion. Lightbarrier-controlled,goinginto a large-volume ashcontainer.High-quality materials■Brick lining with compressedand bakedfirebricks with highalumina content.■All the grate elementsare made of thick-walledcast chrome steel.(Material no. 1.4868)1) Accessory for the PYRTEC at an extra chargeExhaust gas de-duster 1)Exhaust gas de-dusterfor minimising dustemissions; multi-cyclone,fully insulated withexhaust fan mounted eitheron the side or on top,with 240-l ash container.Also available as 800-lcontainer for an extracharge.Flue gas recirculationsystem 1)Ideal for dry fuels (lessthan W20), with the followingadvantages:■High degree of efficiencydue to the lowamount of surplus air(pellets).■Lowering of the combustiontemperature,which is especiallyimportant for fuelsthat tend to form slag(wood off-cuts fromindustry).

Controlled & optimised.PyrocontrolControl cabinet with dooropen.Control system for the furnacefacilityA programmable control system for thecomplete PYRTEC furnace facility withmodulating output control system andoptimised combustion with lambda sensor.All the fans are speed-controlled!The firebox is monitored by:■ Light barriers for the fuel limitationsystem■ A pressure sensor for reliable negativepressure■ A firebox sensor for temperature limitation(addition of more secondary air orrecirculated flue gas)Image on monitor for visualisation and remotemaintenance (extra charge)DrycontrolControl system for the pre-dryerA separate control cabinet with programmablecontrol system for pre-drying wetfuel (over W50 to W60).The heat put out by the air heater is preciselyand automatically adjusted to thewater content of the fuel by detectingthe exhaust air. To do so, the air heater‘sfans are speed-controlled with continuousregulation of the heater temperature. Theauger moves according to the requirementfor fuel.Control panel with plain languagedisplay (like PyroControl)Image on monitor for visualisation and remotemaintenance (extra charge)Remote maintenance with data archivingHeat stationPyroControl with integratedPC and modemTransmission viaGSM or fixednetworkDistance maintenanceIT-workplacewith modemSoftware used :PC anywhereFor remote maintenance, the PyroControl canbe equipped at an extra charge to an integratedPC and integrated modem as well assoftware based on the facility to provide visualisation.As a result, the entire facility (incl.loader and pre-dryer) can be monitored fromany IT-workplace authorised to do so. KÖBnormally delivers the complete hardware andsoftware on the basis of the heat station.Ideal for monitoring the heating systems ofpublic facilities by contracting firms.

Customer-focussed.PartnershipOn the purchase of a KÖB heating systemcustomers not only obtain a product withtop quality engineering but also a sound,permanent partnership. Because KÖB‘ssuccess is due above all to our customers‘great satisfaction.ConsultancyKÖB attaches maximum importance to competentand comprehensive consultancy inthe interest of the operating organisation.This is why KÖB has extremely experiencedsales technicians in the region, who arecontinuously further trained at the KÖBorganisation and brought up to date onthe latest developments in the technology.These sales technicians will be happy toapply all their experience in optimising yournew heat station.Planning and project managementThe KÖB organisation has a separatedepartment for project management. Togetherwith the sales technicians responsible,our project management specialists drawup solutions adapted according to customerwishes, providing support for you from theinitial consultancy until the order is placed.PC-based data exchange (Auto CAD) is possiblewith no problem.Manufacture and deliveryWhen an order is placed, the facility componentsare produced using ultra-modernmethods and made available on schedule.The prerequisite for starting productionis confirmation by the client of the projectdrawn up. Transport and delivery arealways carried out according to arrangementswith the customer.Installation and commissioningThe installation is only carried out by specialistsin the KÖB organisation, or if theorder is handled by an authorised business,by fitters trained in the KÖB organisation.The same also applies to commissioning.It will only be carried out by specialistsfrom KÖB.KÖB has a very well developed network ofcommissioning and service technicians,who will always stand by our customersalso after the handover.Operational reliabilityDue to perfected engineering and therobust design, reliable continuous operationwith maximum operational reliability isprovided even for tough instances of use.The high degree of automation means thatmaintenance and operating work are reducedto a minimum but cannot be ruled outentirely. Be sure to operate and service thefacility according to the relevant directions.Customer serviceJust in case, there is reliable customer serviceon call and available to you in your vicinity.We recommend that you have our specialistscarry out an inspection, adjustmentand maintenance of your facility during thesummer months. You can then look forwardto the next winter, knowing that you will beheating reliably and effectively.Excellent experienceOptimising the costs of heat is a complexmatter. This is why local authorities in particularare handing over the constructionand operation of these systems more andmore to energy professionals (contractingfirms).KÖB‘s many years of co-operation with contractingfirms have produced hundreds ofreference facilities all over Europe – proof ofthe great trust held by contractors and themarket in performance by KÖB!