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Production Launch of Mobile Wood Waste Power Plants

At a plant in Bashkortostan, JSC UGK-Energetika Group has commenced the design of an autonomous power plant fueled by wood waste, with block capacities starting from 2.5 MW, based on a bunker waste recovery furnace and an Organic Rankine Cycle (ORC) turbine module with a generator.

The project is designed to address the issue of multi-ton stockpiles of bark and wood waste (BWW) while simultaneously generating low-cost electricity.

To ensure maximum environmental sustainability, the updated “Neutron-ORC-TT” series mobile power plantfeatures a flue gas recirculation system that completely replaces traditional filtration systems.

Operating Principle and Recirculation Mechanics

In the new modification of the recovery unit, the developers have moved away from using thermally expanded graphite (TEG) sorption filters in favor of a dynamic combustion recirculation system.

During the combustion of pyrolysis gases inside the housing, a colorless gas stream is formed. A receiving hood is installed directly above the chimney, connected via an ejector to two pipes with high-pressure fans. This system captures residual smoke particles and draws them back into the point-source combustion loop.

1. Oxygen Supply: Up to 9,800 m³ of air per hour is supplied into the furnace (with a fuel volume of 9 m³) via blowers and nozzles.
2. Recirculation Volume: Due to reverse draft and ejector operation, two fans suction 1,840 m³/h of waste gases through the hood.
3. Closed Functional Cycle: The incoming oxygen stream picks up free flue gas particles and returns them to the high-temperature point zone.

Environmental and Operational Advantages

The flue gas recirculation system has proven to be significantly more efficient, simpler, and more reliable than mechanical and graphite filters.

1. Zero Maintenance: Unlike TEG elements, the recirculation line does not require regular flushing with soda solutions or the replacement of consumables.
2. Oxide Precipitation into Ash: All oxides, gases, and dust particles, upon passing through the thermal decomposition zone again, are bound and precipitate into a dry, inert ash residue.
3. Clean Exhaust: The output from the chimney is a completely transparent, heated, clean exhaust free of soot, smoke, and unpleasant odors.

Electricity from Woodworking Enterprise Waste

For pulp and paper mills (PPM) or timber industry complexes, the accumulation of BWW, bark, sawdust, and slabs at landfills creates a serious environmental and financial burden. This project demonstrates the transformation of non-liquid wood biomass into a highly liquid resource.

The “Neutron-ORC-TT” mobile waste-to-energy plant provides electricity production witha cost of 0.91 – 1.5 rubles per kWh..

Similar complexes can be installed directly at landfills across many regions of Russia. The generated power can be used to cover the internal needs of PPMs and woodworking facilities, power local infrastructure, or supply energy to crypto farms and modular data centers.

System Composition and Scalability

The mobile waste-to-energy center is designed as a complete technological solution, including:

1. Preparation Unit: Stoker hydraulic storage, wood shredder, and BWW storage.
2. Fuel Feed: Scraper conveyor and “oval-type” screw feeder from the stoker storage to the recovery reactor-furnace bunker.
3. Reactor Block: Bunker recovery furnace with a flue gas recirculation system and automatic ash removal.
4. Generation: Closed loop with an ORC module from 1 MW to 6 MW, with the possibility of cascade expansion of the complex up to 100 MW and beyond.

The use of flue gas recirculation allows such complexes to be located in close proximity to residential areas and logging sites without the risk of violating environmental regulations.