Ecostan’s Range of Biomass Solutions: Products and Technology

Introduction

Ecostan, headquartered in Ludhiana, is a prominent name in the Complete Biomass Solution Manufacturing arena. The company’s core business objective is to provide sustainable and clean energy sources to the world. With years of deep expertise in converting agricultural and forest residues and waste into renewable fuel sources like briquettes and pellets, Ecostan stands as one of the leading Biomass solutions providers in the world. Our infrastructure, production facility, and machinery meet the global standards required for creating biomass products and solutions.

We are committed to supporting energy goals and zero-emission targets by striving for self-reliance in fuel sources. As an ISO 9001:2015 certified company, we ensure all our biomass products and technologies meet high standards of quality and innovation. At Ecostan, we maintain an in-house research and design facility dedicated to continuously advancing biomass machinery, products, and technologies.

This post provides a brief overview of our innovative products and technology in the Biomass solution segment. 

Ecostan: Pioneering Biomass Solutions

As the world moves towards an era of excessive fuel consumption, renewable energy sources are the need of the hour. Countries that want to become self-reliant in meeting their nation’s fuel requirements are now relying on energy sources like solar energy, wind energy, and biofuels. Due to global efforts, the demand for green energy solutions has increased substantially in recent years. However, the efforts are still far from making the world fossil-fuel-free. Every effort counts though, and therefore Ecostan founders have made it their mission to contribute to sustainable energy goals with a laser focus on biomass usage for creating biofuels.

Disposal of agricultural waste is already a problem in India and the incineration of this waste adds more to our existing climate woes. However, efficient conversion of farm residue to biomass fuel can solve the issue permanently. This solution presents a dual opportunity for environmentalists. On one hand, biomass usage can solve agricultural waste management and on the other, it can serve as a source of additional income for farmers. To top it all, environmental benefits further make biomass a highly prudent solution.

With a spacious 245000 square feet facility, robust machinery, quality professionals, experts, and experience, Ecostan delivers top-notch biomass products and solutions.

Ecostan’s Product & Biomass Solutions

Ecostan has a transformative suite of biomass processing products that are designed for the biomass-to-energy value chain. We are transforming biomass, such as forest materials, agricultural by-products, and other plant residues, into valuable eco-friendly fuels in the form of Briquettes and Pellets (alternatives to steam coal) with the use of Ecostan Briquetting and Pelletizing machinery.

Let us provide you with the details, features, and roles of our biomass products: 

1. Briquetting Machines

Ecostan’s briquette machines are designed to efficiently compress various types of biomass into dense, uniform briquettes. These machines are available in different models with production capacities ranging from 250 kg/hr to 2.5 TPH for briquettes.

Key Features:

• Durable construction for long-lasting performance
• High-density briquette production for efficient use
• User-friendly design with minimal maintenance requirements
• Versatility in processing various raw materials

Briquetting Machine Models: 

Briquetting Machine 100 HD

• Designed for heavy-duty performance
• Power Requirements: 115 HP
• Produces high-density briquettes with a 100 mm diameter,
• Production upto to 2.5 TPH for Briquettes & 1.5 TPH for Pellets

Briquetting Machine 90 HD

• Designed for high-volume production
• Produces briquettes & pellets in diameters of 8 mm, 10 mm, & 16 mm.
• Suitable for large-scale industrial applications
• Features advanced hydraulic systems for consistent pressure

Briquetting Machine 70HD

• Mid-range model balancing efficiency and output
• Production capacity: Briquettes Upto 1.3 TPH and  Pellets Upto 700 Kg/Hr.
• Ideal for medium to large enterprises
• Equipped with energy-efficient motors and robust gearboxes

Briquetting Machine 60HD

• Compact design for smaller operations
• Production capacity: Upto 1TPH for Briquettes (600 – 1,000 Kg/Hr)
• Perfect for small businesses and start-ups
• User-friendly interface with minimal maintenance requirements

Briquetting Machine 40 HD

• A perfect model for small-scale production
• Production capacity: Briquettes: 150 – 250 Kg/Hr
• Suitable for rural applications and small workshops
• Portable design for easy relocation and setup

Role in Biomass Energy Production:

Briquetting machines convert loose biomass into compact, easy-to-handle fuel sources. This process increases the energy density of the biomass, making it more efficient for transportation and combustion in power plants or industrial boilers.

2. DualFeed Briquetting Machines

The DualFeed Briquetting Machines represent Ecostan’s innovative approach to biomass processing. These machines feature a unique dual-feed system with simultaneous feeding of raw materials from both sides. DualFeed, as the name suggests, doubles the efficiency and productivity of the process.

Key Features:

• Increased and consistent throughput due to the dual-feed system
• Flexible production of both high-density briquettes and pellets
• Robust construction for reliable operation in demanding conditions
• Production capacities range from 700 kg/hr to 2.8 TPH for briquettes and up to 1.6 TPH for pellets

DualFeed Briquetting Machines Models

• Designed for large-scale operations with dual-feed capability
• Production capacity: Up to 2.8 TPH for briquettes, 1.6 TPH for pellets
• Power requirement: 119 HP
• Produces 100 mm diameter briquettes and 16 mm diameter pellets
• Suitable for a wide range of raw materials with 8-12% moisture content

DualFeed 90 Briquetting Machine

1. Ideal for medium to large-scale operations
2. Production capacity: Up to 2.0 TPH for briquettes, 1.5 TPH for pellets
3. Power requirement: 94 HP
4. Produces 90 mm diameter briquettes and 8, 10, or 16 mm diameter pellets
5. Features side feed capability for improved efficiency

DualFeed 70 Briquetting Machine

1. Perfect for small to medium-scale operations
2. Production capacity: Up to 1.5 TPH for briquettes, 800 kg/hr for pellets
3. Power requirement: 63 HP
4. Produces 70 mm diameter briquettes and 6, 8, 10, or 16 mm diameter pellets
5. Offers versatility in pellet size options

Role in Biomass Energy Production: 

DualFeed machines are more versatile, have high production rates, and can handle various types of Biomass raw materials. This flexibility is crucial for adapting to varying biomass feedstocks and market demands.

3. Ring Die Pellet Mill

Ecostan’s Ring Die Pellet Mills can make pellets from various biomass materials. These mills are available in two models catering to different production scales.

Key Features:

• Production of high-quality pellets consistently
• Adjustable to produce pellets in various sizes (6mm, 8mm, 10mm)
• Large build for high-performance
• Modern technology for minimal maintenance and efficient production
• Production capacities ranging from 1.0 TPH to 4.0 TPH

Ring Die Pellet Mill Models

Ring Die Pellet Mill 335

• Designed for large-scale pellet production
• Production capacity: Up to 2.5-4.0 TPH (depending on feedstock density and size)
• Power requirement: 335 HP
• Produces pellets in 6, 8, and 10 mm diameters with adjustable length (25-50 mm)
• Suitable for a wide range of biomass materials with 10-15% moisture content

Ring Die Pellet Mill 180

• Ideal for medium to small-scale operations
• Production capacity: Up to 1.0-2.0 TPH (depending on feedstock density and size)
• Power requirement: 191.5 HP
• Produces pellets in 6, 8, and 10 mm diameters with adjustable length (25-50 mm)
• Features user-friendly design and easy operations with advanced technology

Role in Biomass Energy Production:

Pellet mills convert biomass into uniform, dense pellets as required for automated feeding systems of power plants and industrial boilers. The standardized size and shape of pellets create more precise control of combustion processes. The result is better fuel generation and lower emissions.

4. Auxiliary Machinery 

Ecostan also offers a range of auxiliary equipment essential for a complete biomass processing line to cater wide range of raw materials:

a) Dual Shaft Shredder

The Dual Shaft Shredder is a robust machine that reduces the size of various biomass materials. It features two counter-rotating shafts with interlocking cutters. Ecostan’s dual-shaft shredder shreds materials into smaller, more manageable pieces.

Key features:

• Heavy-duty construction for handling tough materials
• Adjustable cutting gap for various output sizes
• Low-speed, high-torque operation for energy efficiency
• Automatic reverse function to prevent jamming
• Suitable for processing wood waste, agricultural residues, and industrial waste

Role in biomass processing: The shredder is often the first step in the biomass preparation process. It reduces large pieces of biomass to sizes suitable for direct use in biomass boilers.

Role in other waste processing: The shredder helps to reduce the size of different types of bulk waste into the required size, which helps in the easy disposal of a wide variety of waste.

b) SawDust Machine 

Ecostan’s SawDust Machine produces high-quality sawdust from wood waste. This specialized equipment is crucial for industries that require fine wood particles for various applications, including biomass fuel production.

Key features:

• High-speed cutting mechanism for fine particle production
• Adjustable output size for versatile applications
• Emergency stop/Overload protection features
• Suitable for processing various types of wood, including hardwoods and softwoods

Role in biomass processing:

The SawDust Machine produces fine wood particles that can be directly used in some biomass boilers. It is also further processed into pellets or briquettes. Ecostan’s Sawdust machines offer a valuable solution for wood waste management and biomass fuel production.

c) Hammer Mill 

The Hammer Mill is a versatile grinding machine used for fine grinding of various biomass materials. It uses high-speed hammers to pulverize materials into a consistent, fine particle size.

Key features:

• Interchangeable screens for different particle sizes
• High-speed rotor for efficient grinding
• Wear-resistant hammers for extended operational life
• Suitable for processing a wide range of biomass materials, including agricultural residues, wood chips, and more
• Optional cyclone system for dust collection and material separation

Role in biomass processing: 

The Hammer Mill is crucial for achieving the fine particle size required for efficient pellet production or for direct use in some biomass combustion systems. It ensures uniformity in the feedstock, which is essential for consistent fuel quality.

d) Flash Dryer

Ecostan’s Flash Dryer is an advanced system designed for rapid moisture reduction in biomass feedstock. It uses high-temperature air to quickly dry materials as they pass through the system.

Key features:

• Rapid drying process for high-throughput operations
• Precise moisture control for optimal fuel quality
• Energy-efficient design with heat recovery options
• Suitable for drying a wide range of biomass materials
• Compact design for easy integration into existing processing lines

Role in biomass processing:

Proper moisture content is crucial for efficient biomass fuel production and combustion. The Flash Dryer machine from Ecostan ensures optimal moisture levels for the biomass feedstock. It helps in maintaining the quality of the final fuel product.

e) Rotary Dryer 

The Rotary Dryer is a continuous-flow drying system designed for handling large volumes of biomass materials. It consists of a rotating drum through which hot air is passed to dry the material.

Key features:

• Large capacity for industrial-scale operations
• Adjustable drum speed and air temperature for precise drying control
• Suitable for drying a wide variety of biomass materials
• Rugged construction for long-term reliability
• Optional heat recovery systems for improved energy efficiency

Role in biomass processing:

The Rotary Dryer is ideal for large-scale biomass processing operations where consistent drying of large volumes of material is required. It ensures that biomass feedstock reaches the optimal moisture content for efficient fuel production or direct combustion.

f) Bale Unroller

The Bale Unroller is a specialized machine designed to efficiently unroll and handle baled agricultural residues, such as straw or hay.

Key features:

• High Unrolling capacity to match high-volume operations
• Adjustable unrolling speed to match downstream processing requirements
• Suitable for Unrolling of various bale sizes and types

Role in biomass processing: The Bale Unroller is a machine for handling baled biomass, which is a common form of agricultural residue. Ecostan’s Bale Unrollers unroll and help to feed baled material into the processing line.

g) Cow Dung Log Machine

Ecostan’s Cow Dung Log Machine is a screw press type machine designed to transform raw, semi-solid cow dung into cylindrical or square hollow logs without the need for binders or additives.

Key features:

• Eco-friendly solution for converting cow dung into renewable fuel logs
• No binders are required for producing fuel logs
• Processes 2-3 days aged cow dung efficiently
• Sturdy built to withstand heavy-duty operations
• Adjustable log length through manual selection of log collecting pipe size

Role in biomass processing:

The Cow Dung Log Machine converts organic waste (cow dung) into usable biomass fuel logs. This provides an alternative energy source and promotes waste management. The machine processes semi-solid cow dung with around 40% moisture content.

h) Pneumatic Stone Separator 

The Pneumatic Stone Separator is a crucial piece of equipment for removing contaminants, particularly stones and other dense materials, from biomass feedstock.

Key features:

• Uses air classification to separate materials based on density
• Adjustable airflow for optimal separation
• Continuous operation for high-throughput processing
• Suitable for various types of biomass feedstock
• Low maintenance requirements and energy-efficient operation

Role in biomass processing:

Removing contaminants from biomass feedstock is essential for protecting downstream equipment.  The Pneumatic Stone Separator effectively removes dense contaminants. This reduces wear on processing equipment and improves the purity of the biomass fuel.

Conclusion

Ecostan’s biomass solutions are contributing to carbon-neutral environment goals as Biomass fuels’ CO2 release is the same that is absorbed from the environment during the plant’s growth. We are also helping in mitigating challenges related to agricultural waste management and reducing crop burns. Compared to traditional coal-based power generation, biomass energy solutions from Ecostan offer advantages like lower emissions and low ash generation.

Ecostan uses the latest technologies in briquetting and pelletizing. Ecostan’s range of biomass solutions represents a significant step forward in providing efficient and innovative technologies for biomass processing. Ecostan is one of the few companies that contribute directly to India’s journey towards sustainable energy production.

For more details about our products and prices, contact us here.