The Solid Fuel Burner/Boiler Combination The Onix Corporation offers a full line of steam and hot water boilers to complement the WBB series solid fuel burner. These boilers wipe the energy from any hot (12-18 F) flue gas and produce ultra high pressure steam up to 45, lbs/hr (13 hp). Ideal for any industrial application requiring steam at a reduced cost. These systems are equipped with microprocessor control systems which automatically modify the fuel feed rate to match the desired boiler outlet pressure. A pressure controller on the boiler senses a demand for steam. Three things happen simultaneously: 1) fuel feed rate increases to burn more fuel; 2) combustion air to the burner increases in direct proportion to fuel feed rate; and 3) the induced draft fan's modulating damper opens to draw more hot gases through the boiler and generate more steam. Solid fuel fires very clean in the burner. There is no smoke, no malodor, no VOC's and no CO. Solid fuel combustion does produce some dead inert ash. Some of this ash remains in the base of the burner. It needs to be shoveled out every several weeks. The smallest ash particulates (too small to be visible) carry out of the burner and through the boiler. The tubes of the boiler get dusted with ash and have to be cleaned every several weeks. Steam soot blowers can automate this task. - The entire system is automatic and basically labor free. - System integrity is excellent for years of trouble-free performance.
SYSTEM FUNCTIONS A pressure control on boiler senses a demand for an increase in boiler pressure. Three things happen simultaneously: 1. Fuel feed rate increases to burn more fuel. 2. Combustion air to the burner increases in direct proportion to fuel feed rate. 3. The induced draft fan draws the energy into the boiler and the boiler outlet pressure is increased. The fuel fires very clean in the burner. If burner emissions from the dried sawdust are exhausted directly from the combustion chamber to atmosphere, only heat waves are visible. There is no smoke, no malodor, no VOC s and virtually no CO. The combustion process is extremely hot and exceptionally clean. Combustion does produce dead inert ash. Some of that ash remains in the base of the burner. It may need to be shoveled out once every month (at 1% ash). The smallest ash particulates (too small to be visible) carry out of the burner through the boiler. The tubes of the boiler get dusted with ash and may have to be cleaned every couple of weeks. Air soot blowers will automate this task, which will be performed on-line. The remaining airborne flue ash is separated from the exhaust gases by the high temperature bag filter collector. The two-pass heat recovery boiler Scotch boiler is designed and stamped 15 psig steam per ASME Section I. Also included are standard trim; water column, MAG; ALSCO Float, MAG; Pressure control, operating; Pressure control, limiting; steam pressure gauge, 8.5"; rear turnaround ash hopper; safety valves, loose; junction box assembly; auto air-operated soot blowers, ferrules at tube entry, 2" tubes; stack thermometer, 5" dial, 12" stem; feed water gate/check valves, 2."; feed water gate/check mounting; blow-down valves, 2."; and mounted blow-down valves. The exiting gas from the boiler will be routed to an economizer tolerant to particulate entrainment. The economizer will capture the remaining sensible heat in the flue gas and preheat boiler feed water from 18 F to 21 F. The system is integrated to the existing Allen Bradley/Wonderware UL-approved computer controls. This degree of control allows for touch screen display, control and manual or automatic equipment start/stop. The controls can download all parameters at pre-set time intervals to a networked PC for data recordkeeping of any tracked parameter. A modem and net-card connected to the controls allows for remote monitoring and adjustment of the system. Controls will volumetrically track inbound fuel consumption and outbound steam flow in lbs/hr. The entire system is automatic and basically labor free, requiring only the intermittent attention of one employee. System integrity is excellent for years of trouble-free performance.
SYSTEM FUNCTIONS (CONTINUED) The Solid Fuel System is designed for a wood fuel having a normal size distribution with 1/4 being the maximum particle size; a heating value of 7,5 Btu/lb or greater, an ash content of 6% or less, a moisture content of 12% or less and a consistent density of 6-25 pounds per cubic foot. These physical conditions are required for the fuel to combust in our cyclonic reactor. The chemical conditions are addressed by the phrase wood fuel or the chemical equivalent of wood. Many solid fuel alternatives exist other than 1% wood. Through careful testing and thorough analysis we have qualified and permitted alternative solid fuels such as OSB, MDF (fiberboard with a medium densification), charcoal, spent horse bedding, nutshells, corncobs, acrylic resins, plastics, papers, etc. Each case must be addressed on an individual basis. If two companies are producing MDF as a coproduct of manufacturing furniture, analysis may yield different chemical compositions relative to each industry s co-product. This analysis should contain both a proximate (refers to moisture percentage, ash percentage, and as-received Btu/lb heating value) and ultimate analysis (refers to carbon percentage hydrogen percentage, nitrogen percentage and oxygen percentage on an oven-dried sample) and should be conducted on all fuel used. Additionally, chlorine percentage should be included in this complete fuel analysis. Particle size and fuel moisture can be controlled through add on equipment to the Solid Fuel System.
The Onix Corporation is on the cutting edge of technology with its research on solid fuel. This research resulted in the development of the ONIX Series Solid Fuel Burners. These burners operate primarily on reclaimed wood, bringing the fuel cost to a minimum. Depending on the availability of in-house waste such as poly tailings, sawdust, etc., consumers may experience a negative fuel cost. These burners are capable of delivering between.5 MM and 15 MM Btu's per hour and can achieve temperatures of 2, degrees Fahrenheit while saving money on every Btu used. The Onix Corporation's ONIX Series Solid Fuel Burners have many industrial applications including replacing outmoded burners, dryer heat source, heat for kilns, heat source for boilers, as well as winter space heating. The Solid Fuel Burner The Onix Corporation prides itself on meeting or exceeding local, state, and federal air quality standards. Our emissions contain virtually no sulfur, NOx, or CO. 2 MM Btu/hr solid fuel burner for a There are over 1 ONIX Series Solid Fuel Burners presently in operation world wide providing capability of using natural gas as a fuel. drying system. Drying system retains millions of Btu's for a fraction of previous fuel costs. These burners can be operated on a number of recovered co-products of manufacturing, which represent an additional expenses to a company currently discarding the co-products.
Cyclonic furnaces have become a major alternative to conventional burners. Applications include both large-scale utility boilers and certain industrial processes where waste heat can be recovered profitably. The ONIX Series Solid Fuel Burner is operated by cyclonic combustion. In cyclonic combustion, the burning occurs at a positive pressure, rather than the slight negative pressure associated with most suspension fired wood systems. How it works The vigor of the cyclonic action forces the wood particles to the burner wall, facilitating not only rapid combustion but also solid product removal. Cyclonic burners typically remove 99% of the solid products of combustion. These solid products of combustion exit the burner then enter the boiler or other vessels and are removed as fly ash by a particulate control system. The combustion occurs in a specially designed cylindrical reactor which discharges hot gaseous combustion products directly into the boiler or other vessels. Pulverized wood is blown into the cyclonic burner where it oxidizes immediately. Centrifugal action forces the particles toward the cylindrical wall of the burner where char oxidation occurs. Very high turbulence is generated in the cyclonic burner and char oxidation occurs within milliseconds. Combustion intensity in cyclonic burners is considerably higher than combustion intensity in T/ conventional wood suspension fired furnaces. C 15 14a 14b 13 a 5 4 13 b 13 c T/ C 12 a 12b 1 11a 11 b 3 9-6" 8 2 7a 7b 1 6
Onix Fuel Delivery All units are priced to include 4-hours of fuel storage through incorporation of a top loading fuel deck. Tank feed systems can be substituted. The Onix Corporation 2 6 MM Btu/hr Solid Fuel Burner Typical Feeding Arrangement Solid fuel storage building Walking Fuel Floor, 2-hp Anti-bridging fuel feeder, 5-hp Fuel fan 2 hp Fuel hammer mill If required. 46 '-11 3/8" Fossil fuel pilots, automate burner start at the touch of a button An anti-bridging fuel feeder is automatically charged by a drag chain fuel deck holding 4- hours of fuel
Installation Assistance All units are priced to include our experienced staff of Onix engineers to assist in installation of any Onix related equipment to insure customer satisfaction. All pieces are pre-lined with refractory to speed up mechanical installation time. Copyright -- 27
Onix Controls Control packages integrated with the Onix-OS. Real-time data displayed on a secure web page allows you to view your company's dryer data from your LAN or internet connection. Integrated security cameras will allow you to watch the dryer operation from afar. The Onix OS Solid Fuel Burner Overview Screen Control Burner Loop Burner Temperature Burner Set point Burner Fuel Valve Output % 1,54 1,54 24 Solid Fuel Burner Data Burner System Faulted Burner Temperature Combustion Air Ratio Combustion Air Output % 1,54 1:1 16 Auto Manual Auto/Man M 1 CAF#1 Burner Ignition Failure M 7 M 2 CAF#2 M 3 CAF#3 M 4 CAF#4 M 5 CAF#5 M 6 Fuel Fan Fuel Hammer mill M 8 Fuel Auger VFD Burner 3 Second Stop System E Stop Pressed Burner Immediate Stop Burner Auto Start Dryer System Overview 4 2, 1,6 33 3 1,667 1,333 26 7 1,333 1,67 2 1, 8 13 3 66 7 53 3 67 33 3 26 7 Tue 8/2/22 1:22:27 PM :5: Description Scale Range Eng.Units Dryer Inlet Temperature /1,6 Degrees F Burner Temperature /2, Degrees F Dryer Outlet temperature /4 Degrees F Tue 8/2/22 1:27:27 PM 155 Deg. F. 18 Deg. F. Solid Fuel Burner Dryer I.D. Fan Exhaust Cyclone Collector Dried Product 181 Deg. F. Auger to Pellet Mil Wet Product Cyclone Airlock In Settling Chamber/Cyclone Screw 78 % Granulation Bypass Conveyer Magnetic Scrubber Pump Dryer Field Emergency Stop #1 Push Button Pressed Dryer Drum Dryer Field Emergency Stop #2 Push Button Pressed Dryer ID Fan #1 Panel Ultimate Emergency Stop Push Button Pressed Dryer ID Fan #2 Dryer Dryer 3 Second Dryer Cleanout Wet Stop and Shutdown Wet Product Feeder VFD Running Dryer Immediate Stop 22 Amps Dryer Auto Start Drying Process Screen Dryer Trends Rotary Dryer Data Drying System F Dryer Amps Dryer Inlet Temperature Dryer Outlet Temperature Dryer Outlet Set point Fuel Valve Output % Auto Auto Wet Product Feeder VFD Output % Motors 22 18 181 18 62 Wet Product Feeder VFD Start/Stop Dryer Feed Directed to Dryer Stockpile System Overview Man 78 Granulation #2 Emergency Stop Push Button Pressed Granulation #1 Emergency Stop Push Button Pressed 5 416 333 25 166 83 Dryer Outlet Temp. PV SP SP PV O U T P U T % 1% AUTO ALARM Dryer Inlet 2 1666 1333 1 6 6 6 3 3 3 Burner Temp. PV SP SP PV O U T P U T % 1% AUTO ALARM Start Stop Dryer Out SP PID Tuning Alm Setpoints Alarms 18 15 12 9 6 3 1 PID Setpoints Trends Motors
Onix OS The system features Allen Bradley/Wonderware Touch Screen controls. This degree of control allows for automatic and manual control. Controls will display fuel consumption in pounds per hour. The controls monitor dryer inlet and outlet temperatures and cause system safety shutdown in case of extremes. This level of automation offers burner trial for ignition at the touch of a button and a comprehensive operator 1" touch screen display for all dryer functions controlled. A networked PC will historically track burner and dryer temperatures and all operator settings. An alarm screen on the touch screen will track alarm history. A modem connected to the PLC/PC allows for remote adjustment and troubleshooting of the PLC/PC program via phone or internet. Technical support is only a few mouse clicks away. Future expansion of this program is possible to include all dryer functions. The graphic below presents an example of what the operator might see during system operation. The Onix-OS also historically tracks dryer inlet, outlet and burner temperatures indefinitely. The Onix OS can be upgraded to control all plant functions at anytime in the future or to display integrated existing values present, within the plant. The Onix-OS can be remotely monitored or accessed via telephone or internet, which then permits interaction with control and trend screens. Plant operators have a rugged 1" NEMA-4 touch screen interface to access all burner functions. Burner faults and alarms are tracked and recorded with a time and date stamp. This system integrates stopping of the wet product feeder and dryer i.d. fan in an ultimate high alarm condition. Drying Process Screen 155 Deg. F. 18 Solid Fuel Burner Wet Product In 78 % Dryer Dryer Field Emergency Stop #1 Push Button Pressed Dryer Field Emergency Stop #2 Push Button Pressed Panel Ultimate Emergency Stop Push Button Pressed 22 Amps 18 1 Deg. F. n Deg. F. I.D. Fan Exhaust Cyclone Collector Dried Product Settling Chamber/Cyclone Screw Granulation Bypass Convey Magnet Scrubber Pump Dryer Drum Dryer ID Fan #1 Dryer ID Fan #2 Running Rotary Dryer Data Drying System R Dryer Amps Dryer Inlet Temperature Dryer Outlet Temperature Dryer Outlet Set point Fuel Valve Output % Wet Product Feeder VFD Output % Wet Product Feeder VFD Start/Stop Granulation Auto Auto Dryer Feed Directed to Dryer Stockpile 22 18 181 18 62 Man 78 Dryer 3 Second Stop Dryer Cleanout and Shutdown Wet Product Feeder Wet Product Feeder VFDFD Running Dryer Immediate Stop Dryer Auto Start Dryer Trends Motors System Overview
Onix OS The Onix-OS boasts up to 64 PID loops having, for all practical purposes, no limit to the number of burners or system components which it can control. This system has touch-screen control and is capable of automatically tracking historical trends and data archiving. The Onix-OS can start and control all the motors at your plant, not just the dryer motors. The Onix-OS allows authorized plant personnel to dial into the system to retrieve data on plant operation during the night, the past week or years back. It can track any parameter and inform when and why the system shuts down due to any alarm extreme. Reports can be generated to outline plant wide production during any selected time interval. The Onix-OS can be modified to add motors or data items from a remote computer. This system will require the presence of an operator at start-up and during operation to properly maintain system functions. Existing MCC Plant Sensors i/o rack Corporate LAN Plant Motors Plant Control Computer Remote Computers
Solid Fuel Burner Dimensions B A C D T/C T/C E Model Number A B C D E HP ON-2 24 125 64 68 19 2 hp ON-4 24 152 75 68 12 4 hp ON-5 26 162 79 71 127 4 hp ON-1 33 198 93 81 152 45 hp ON-12 45 213 98 1 175 5 hp ON-2 59 248 112 122 21 55 hp ON-26 59 268 122 123 22 55 hp ON-3 59 28 127 123 224 55 hp ON-45 82 33 142 158 274 75 hp ON-52 82 344 148 158 28 8 hp ON-6 82 359 154 158 286 85 hp ON-75 91 384 166 173 31 1 hp All dimensions are in inches and are approximations contingent on approval drawing release. The number after the ON indicates the burner maximum output in Millions of Btu/hr.
Solid Fuel Burners-Boilers Model Number Approximate Horsepower Maximum Energy Input ON-2 2 hp 2 MM Btu/hr ON-4 4 hp 4 MM Btu/hr ON-5 4 hp 5 MM Btu/hr ON-1 45 hp 1 MM Btu/hr ON-12 5 hp 12 MM Btu/hr ON-2 55 hp 2 MM Btu/hr ON-26 55 hp 26 MM Btu/hr ON-3 55 hp 3 MM Btu/hr ON-45 75 hp 45 MM Btu/hr ON-52 85 hp 52 MM Btu/hr ON-6 9 hp 9 MM Btu/hr ON-75 1 hp 75 MM Btu/hr Typical budgetary proposal equipment listing. - Design and build one Solid Fuel Burner with fossil fuel pilot lighting system. - Design and build one automated ash removal system. (refractory lined) - Sealed bottom with 14 collection opening - Liquid reservoir - One angled auger for particle removal - One collection hopper located outside burner - Design and build one fuel feed system, includes: - One four hour capacity storage silo with Dutchman. - One feed auger w/drive - One Rotary airlock w/drive - One Hammer Mill w/drive - One Magnet - One Fuel feed fan - Up to 1 Ft. fuel feed duct included in budgetary pricing. - Design and provide one heat recovery boiler. - Design and provide one economizer. - Design and build one direct drive I.D. fan w/drive, vibration sensor and thermocouple sensors at drive bearing locations. I.D. Fan to be driven with VFD (supplied). - Design and build one HRS exhaust stack. - Design and build necessary HRS ductwork for system. - Onix will assist Buyer defining environmental permits. - Onix will provide one licensed copy of the Onix OS. - Onix will provide one PC or PLC touch screen for system control interface and data tracking * Items highlighted in red are add-on options.
Complete solid fuel burner-boiler packages come with a top loading tank feed system with 4 hours of fuel storage which includes an anti-bridging fuel feeder. A fuel deck may be substituted. All solid fuel burners have customer choice of natural gas, propane or #2 fuel oil fossil fuel pilots. All programs should undergo a thermodynamic analysis by the Onix Corporation to assure program viability and price. All system components come with a three-year warranty. Horsepower requirements are approximations. Price includes a fuel hammer mill for on-line size reduction, for 7/8 maximum lump size. All systems include PLC / PC for system control interface, data tracking and network wide control. Internet viewing of system is available with appropriate internet connection. THE ONIX CORPORATION Providing Cost Efficient and Effective Alternative Fuel Systems This transmission may contain information that is privileged, confidential and/or exempt from disclosure under applicable law. If you are not the intended recipient, you are hereby notified that any disclosure, copying, distribution, or use of the information contained herein (including any reliance thereon) is STRICTLY PROHIBITED. If you received this transmission in error, please immediately contact the sender @ 1-8-844-76 and destroy the material in its entirety, whether in electronic or hard copy format. Thank you.