Flex Technologies Limited provides a wide range of services and are committed to accompany the clients in all stages of the development of biomass energy and biomass fuel projects from the feasibility study through conceptual design to equipment procurement and project implementation.


Service Capabilities

Our services include:

  • Feasibility studies including technical, environmental, and financial analysis
  • Biomass feedstock assessment
  • Applied technology identification
  • Conceptual design and layout
  • Process equipment sourcing
  • Project implementation
Our service portfolio is based on detailed know-how from many years of experience in biomass energy projects. Selected services and projects are shown below.

Project / Country

Services and Project Description

Bosnia
2 MW Grape Marc Biomass CHP PlantPre-Feasibility Study, Conceptual Design;

Feasibility study including testing of grape marc (grape pomace) as biomass feedstock; identifying appropriate technology to generate power from grape marc; evaluate loads to arrange grid interconnection; calculate NPV, IRR and payback period. Conceptual design of the heat and power plant including: fuel preparation (grape marc dewatering, drying, and briquetting); power plant sizing; equipment specifications; and design drafting. Conceptual design for gasification condensate evaporation system using Waste Heat Single Effect Forced Circulation Evaporator system with heat recovery from engine exhaust. The power plant designed to include two gasifier systems that run in parallel and generate syngas from grape marc briquettes to operate six IC syngas engine generators. The generators provide 2 MWh of electricity, and 500 kWh of recovered heat from engine exhaust for condensate evaporation.

Greece
500 kW Olive Pits Biomass Power PlantFeasibility Study, Conceptual Design;

Feasibility study including testing of olive pits as biomass feedstock; identifying two appropriate technologies – gasification and combustion/ORC – to generate power from olive pits; evaluate loads to arrange grid interconnection; calculate NPV, IRR and payback period. The first technology option includes one gasifier system that generates syngas from olive pits to operate one internal combustion syngas engine generator. The generator provides 0.5 MWh of electricity. The alternative technology option includes one 4 MW olive pits fired steam boiler and one low pressure steam fired ORC generator. The ORC generator provides 0.48 MWh of electricity. The study identified payback period less than four years for both options.

1.5 TPH Round Wood Chipping and Drying LineFeasibility Study, Conceptual Design;

Feasibility study including financial modeling for wood feedstock of various moisture contents; identify appropriate technology to produce dried wood chips at the lowest cost; calculate NPV, IRR and payback period. Conceptual design including: equipment specifications for chipping, drying, grinding sections, and design drafting. The study identified payback period of three years for round wood at 40% moisture and 3.5 years for round wood at 45% moisture.

Hungary
3.6 MW Round Wood Biomass CHP PlantFeasibility Study, Conceptual Design and Layout;

Feasibility study including testing of wood chips and corn stalk chips as fuel; identifying appropriate technology to generate power from round wood; evaluate loads to arrange grid interconnection; calculating NPV, IRR and payback period. Conceptual design of the CHP plant including: fuel preparation including round wood chipping, chip drying, sieving into two fractions – coarse chips for direct use in the gasifiers and fine chips for briquetting before use in the gasifier, fine chip grinding, and sawdust briquetting; power plant sizing; equipment specifications; and design drafting. Conceptual design for gasification condensate evaporation system using vacuum evaporators with heat recovery from syngas cooling. The designed CHP plant proposed to include three gasifier systems that run in parallel and generate syngas from wood chips and briquettes to operate six IC syngas engine generators. The generators provide 3.6 MWh of electricity, 3.2 MWh of recaptured heat from engine cooling for wood chip drying, and 800 kWh of recovered heat from syngas cooling for condensate evaporation.

Latvia
500 kW Wood Chip Biomass CHP PlantFeasibility study, Conceptual Design and Layout, Project Implementation;

Feasibility study including testing of wood chips as fuel; identifying appropriate technology to generate power from wood chips; evaluate loads to arrange grid interconnection; financial analysis using NPV, IRR and payback period. Conceptual design of the CHP plant including: power plant sizing, equipment specifications, and design drafting. The implemented project includes one gasifier system that runs and generates syngas from wood chips to operate two IC syngas engine generators. The generators provide 500 kWh of electricity and 700 kWh of recovered heat from engines for district heating. Project implementation including: assistance in civil engineering, equipment procurement and delivery to the site, technical support to the owner in start up and commissioning.

2.5 TPH Wood Pellet LineConcept Study, Conceptual Design;

Feasibility study including financial modeling for wood chip feedstock of various moisture contents; identify appropriate technology to produce wood pellets at the lowest price; calculate NPV, IRR and payback period. Conceptual design including: equipment specifications for grinding, drying, pelleting, sifting, cooling, and packing sections, and design drafting.

Russia
500 kW Sawmill Waste Biomass Power PlantFeasibility Study, Conceptual Design and Layout, Project Implementation;

Feasibility study including inventory of factory available sawmill wastes; identify appropriate technology to generate power from sawing scraps (slabs, edgings, end-cuts); evaluate loads and processes to optimize the use of renewable energy; calculate NPV, IRR and payback period. Conceptual design including: fuel preparation including scrap chipping and wood chips drying, power plant sizing, equipment specifications, and design drafting. The implemented project includes wood chipper, moving floor wood chip dryer using exhaust from engines, one gasifier system that runs and generates syngas from dried wood chips to operate two internal combustion dual fuel (syngas and diesel) engine generators. The generators provide 500 kWh of electricity and 600 kWh of recaptured heat from engine exhaust for chip drying reducing the factory operating costs. Project implementation including: assistance in civil engineering, equipment procurement and delivery to the site.

700 kW Sunflower Husk Biomass CHP Plant in Vegetable Oil MillFeasibility Study, Conceptual Design and Layout, Project Implementation;

Feasibility study including inventory of factory available sunflower seeds and soybean wastes; identify appropriate technology to generate power from sunflower husk waste; evaluate loads and processes to optimize the use of renewable energy, and financial modeling. Conceptual design including: power plant sizing, equipment specifications, and design drafting. The implemented project includes two gasifier systems that run in parallel and generate syngas from sunflower husk briquettes to operate three IC gas engine generators. The generators provide 700 kWh of electricity and 800 kW of recaptured heat from engines reducing the factory operating costs. Project implementation including: assistance in civil engineering, equipment procurement and delivery to the site, technical support to the owner in start up and commissioning.

Serbia
700kW Waste Heat Recovery from 3 x Caterpillar G3612 Natural Gas Engine ExhaustConcept Study, Conceptual Design;

Concept study of a waste heat recovery system to be constructed in a power plant with 3 x 2,900 kW natural gas engine generators. To achieve the owner’s objectives, a waste heat recovery system with three engine exhaust fired ORC generators has been proposed for generation of additional 700 kW gross (650 kW net) electricity that increases the power plant efficiency by 30%. The study identified payback period around four years and less than three years if using the ORC generators in CHP mode.

UK
Digestate Drying System for Biogas PlantFeasibility Study, Conceptual Design;

Feasibility study including inventory of digestate available at the biogas plant; identification of suitable technology to dry digestate using low temperature hot water captured from biogas fueled engine generator; financial analysis. Conceptual design including: system sizing, equipment specifications, and design drafting. The digestate drying line under study will use 600 kW low temperature hot water to dry wet digestate from the biogas plant.

The study identified payback period less than one year.

600 kW Biomass Syngas Fired Hot Water Boiler PlantConcept Study, Conceptual Design;

Concept study for appropriate technology to generate syngas from wood chips and fire hot water boiler; financial analysis to apply RHI 5.45p/kWh for biogas (including gasification) combustion boilers against RHI 2.27p/kWh for solid biomass combustion boilers. Conceptual design including: system sizing, equipment specifications, and design drafting. The plant under study will gasify wood chips and fire hot syngas in a directly coupled hot water boiler.

The study has shown that combination of a gasifier system with a hot water boiler gives much better IRR and payback period than wood chip fired boiler.

Ukraine
320 kW Waste Wood Biomass Power Plant in Hardwood Flooring FactoryFeasibility Study, Conceptual Design and Layout, Project Implementation;

Feasibility study including inventory of factory available wood wastes; identifying appropriate technology to generate power from the wastes; evaluate loads and processes to optimize the use of renewable energy, and financial analysis. Conceptual design including: power plant sizing, equipment specifications, and design drafting. The implemented project includes one gasifier system that generates syngas from parquet block trimmings to operate two IC gas engine generators. The generators provide 320 kWh of electricity reducing the factory operating costs. Project implementation including: assistance in civil engineering, equipment procurement and delivery to the site, technical support to the owner in start up and commissioning.

4 TPH Steam Boiler Conversion from Natural Gas to Biomass Syngas in Feed FactoryPre-Feasibility Study, Conceptual Design;

Pre-feasibility study of a biomass gasifier system to be constructed in a large feed factory for conversion of the existed 4 TPH steam boiler from natural gas to biomass syngas. To solve the task, a gasifier system using sunflower husk biomass available at the customer’s site has been specified for generation of hot syngas to offset 100% natural gas burned in the boiler. The gasifier under study will produce up to 2,000 Nm3 hot syngas per hour. Syngas from the gasifier is burned in a new syngas burner installed in the boiler offsetting up to 320 Nm3 natural gas per hour. Gasification char can be used as natural fertilizer or briquetted into fuel briquettes. The study identified payback period less than one year.

 

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