PYRTECWood chips & shavingsW20 – W50100 – 1200 kWPYROTWood chips, shavings & wood pelletsW10 – W3580 – 540 kWPYROMAT DUOWood chips, shavings, wood pellets & logsW10 – W3540 – 95 kWPYROMAT ECOLogsW10 – W3535– 150 kW

PYROT Rotation Heating System:A technological head start for pellets burners larger than 150 kW

Table of Contents

1. Köb & Schäfer GmbHOur Company, its Strategy and Structure

2. PyrotThe History of its Success

3. PelletsA very special Wood Fuel

4. Control AccuracyThe #1 Criterion for the Quality of Wood Heating Systems

5. Pyrot: Where is the Head Start?

6. The Physics of IncinerationA bit of theory to make the subject clear

7. DataEmissions & System Design Figures

8. Images from actual Practice

The Company Köb & Schäfer GmbHThe Owners / Business Volume

Partners Siegfried Köb 52%Bernhard Schäfer 24%Heinz Böhler 24%

2000 2002 2004

EUR Mio.0

5

10

15

Turnover 2000 9.6 m €2002 12.1 m €2004 14.9 m €

Export share 84% (2004)Germany, Switzerland, Italy, France, Scandinavia

Employees A: 68 D: 6 CH: 3 I: 2Total: 80

The Company Köb & Schäfer GmbHIts Strategy & Structure

10 kW 100 kW 1000 kW 10 MW Burner output

"Small-scale burners"PYROMAT ECO PYROMAT DYN

Medium systemsPYROT, PYRTEC

150-1250 kW

Focus of business with market penetration

High-priced niche!

Structure: Optimised for the medium range (150-1250 kW)

Production: Serial product / Facility construction with close to serial productionSales: Factory specialist in the region (closeness to customers),

hands-on central sales managementInstallation: Factory assembly / Installing heating engineers, regionalService: Factory specialist in the region; central service management

PYROT Rotation Heating SystemThe History of its Success

1996 Discovery of the "link head blower", an invention of the Swabian tinkererPaul Christian - ACV - Umwelttechnik

1997 Pilot testing, first Prototype; involvement of University of Stuttgart IVD (Institute of Process Engineering and Steam Boiler Studies)

1998 Austrian innovation prize awarded by Dr Farnleitner, the Austrian Minister for Economic Affairs at that timeAward of European Patent Specification EP 0 905 442 B1

1999 Extensive testing of the entire series by TÜV Munich[TÜV = Technical Control Association]

2000 Provisional conclusion of the technical developmentwith admixture of recirculated flue gas

2002 The threshold of 100 units of the Pyrot p.a. is exceed for the first time

Pellets A very special Wood Fuel

Water content Thermal value Bulk density Transport Energyw Hu absolute density density% kWh/kg kg/m³ kg/srm kWh/l

Wood pellets 5 5.0 1200 650 3.25

Forest wood chips, dry: 30 3.5 587 235 0.822Forest wood chips, wet: 60 1.68 775 310 0.521

Heating oil, EL - 11.8 850 850 10.0

Pellets have 4 times the energy density of forest wood chips, pre-dried w 30 6.2 times the energy density of forest wood chips, wet w 60

Bottom line: - Pellets are the most high-grade form of wood energy. - Pellets require a new incineration technology.- The degree of system efficiency determines the economic efficiency.

Control AccuracyThe #1 criterion for the quality of wood heating systems

What is "control accuracy"?Control accuracy is the quality of the firing system's ability to adapt its output to the heat consumers' output requirements.

With oil and gas, this is easily done by turning the burners on and off.

Unlike oil and gas, there is a comparatively long delay in the ignition of wood.Unlike oil and gas, wood fire consists of an inert mass with high energy content.

The control accuracy of wood heating systems is produced by two linked factors:

1.) The control accuracy of the water-bearing systemThe control accuracy of the water-bearing system can be produced by hydraulic measures in the system.

Abrupt fluctuations in the performance of heat consumers (connecting and disconnecting)can be smoothed out by additional volumes of water. As a result, the route controlled by the firing control system gets the time required to carry out the adaptation of output, without leaving the regulating circuit optimised in terms of emissions.Solution: Hydraulically switched heat storage tank.

Approx. 10 l storage volume per 1 kW of burner output

Control Accuracy The #1 criterion for the quality of wood heating systems

2.) The control accuracy of the firing system:The control accuracy of the firing system is a combination of constructional design features of the firing system with control technology geared to it:

- Control speed High without leaving the regulating circuit optimised in terms of emissions(combustion chamber with fuel and air monitoring systems)

- Output control range Wide 1: 4 (modulating control with frequency converter operation)

- Emissions Low CO near to zerowith low excess air: less than 1.5 in the entire control range(fundamental characteristics of how the firing works with control equipment geared to it)

The Pyrot Rotation Firing System is characterised by the yet unsurpassed quality of its control accuracy.

Excellent incineration with ultra-low emissions along with maximumeconomic efficiency are the result from high control accuracy.

The dependence of exhaust gas losses onexhaust gas temperature and excess air

0

5

10

15

20

25

30

120 140 160 180 200 220 240 260 280 300

6 % O2

8 % O2

12 % O2

14 % O2

10 % O2b)

b)

a)

a)

Exhaust gas temperature [°C]

Exha

ust g

as lo

sses

[%

]

a) High control accuracy of the water-bearing and firing systems (economical)

b) Poor control accuracy of the water-bearing firing systems (uneconomical)Exhaust gas losses (average value over performance behaviour) depending on

exhaust temperature and excess air. (These calculations are based on the "Siegert formula" with an assumed combustion air temperature of 20°C.)

Where is the Pyrot Rotation Firing System's technological head start?

The incineration of wood fire works on the basis of gasificationand burn-out.

These are easy to distinguish between in a candle flame with:- The black core of the flame (gasification)- The yellow outer flame (burn-out)

The head start provided by the patented Pyrot firing system is demonstrated by:

1.) Low hypostoichiometric gasificationWith gasification of a rich mixture (λ < 0.5), it is possible to:- reduce the NOx levels by up to 30%(see study by University of Stuttgart, DI Zuberbühler 2000)

2.) Preventing a reflux of secondary airflowWhen reflux of the secondary airflow is prevented at the same time, it is possible to: - reduce the fine particles by up to 50%(see study by Verenum Schweiz, Dr. Nussbaumer 2003)

3.) Very intensive blending with secondary airflowThis produces perfect burn-out with gas burner quality.(ultra-minimal emissions of CO and Σ HC) (see simulation at University of Stuttgart, Dr. Günther Baumbach 2002)

The PYROT Rotation Firing System- in a sectional drawing -

On 1) Hypostoichiometric gasification- The primary airflow is drawn in via vents, not blown in!- The special movement of the grate distributes the fuel over the

gasification zone in optimum fashion.(“Air leakage” is ruled out.)

On 2) Preventing reflux of the secondary airflow- The reduced combustion gases rise upwards and are swept along

by the secondary airflow flowing in at the top by injection.- Any reflux of the secondary airflow is ruled out.- One other point: the ash is forced to move against the flow of gas,

downward into the cold zone!

On 3) Very intensive blending with secondary airflow- The secondary airflow streaming in with a high rotational impact

blends perfectly with the reduced combustion gases.- Demonstrably complete blending already after the first

third of the combustion chamber

The PYROT Rotation Firing System - in a sectional drawing -

Re-incineration in the Rotation Combustion ChamberAdiabatic Temperature as a Function of Excess Air

0

200

400

600

800

1000

1200

1400

1600

1800

2000 Fuel: pellets u = 6 %Hu = 5.0 kWh/kg1660

1550

PYROT

Theoretical temperature after burn-out

With heat dissipation to approx. 1000°C

Stoichiometric point

1.0 1.31 2.0 3.0 5.0

1886

[°C]

2 4 6 8 10 12 14 16

Residual 02 [Vol % dry]

Air ratio [λ]> 1.0 Excess air1.5

Gasification in the primary Firing SystemAdiabatic Temperature after Air Turnover (simplified)

1175

H in H2OC in CO CO in CO2

(Incineration process, simplified)

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.2 1.4

Fuel: pellets u = 6 %Hu = 5.0 kWh/kg

[°C]

Stoichiometric point

Air ratio [λ]< 1.0 rich mixture

With recirculatedflue gas< 1000!> 800

PYROT

20001886

1800

1600

1400

1200

1000

800

600

400

200

0

Comparison of Emissions (test-stand figures)

Rotation Firing PYROT Oil/Gas BurnersPYROT 300 PYROT 540 Buderus GE 350Nominal Partial Nominal Partial Oil Gasload load load load100% 30% 100% 30%

CO 6 4 6 1 2.3 14.8NOx 81 63 91 90 78.2 44.5Dust 24 3 12 11 0 0Σ HC <1 <1 <1 <1 3 0

Figures in mg/Nm³ based on 13% O2

The tests were carried out by TÜV Munich [Technical Control Association] in February 04 (with recirculated flue gas,without deduster)

The PYROT Rotation Firing SystemBurner Series

Burner Model Output Burner Dimensions mm WeightkW Height Length Width Empty kg

PYROT 100 80-100 1765 2194 1050 2143

PYROT 150 120-150 1765 2444 1050 2448

PYROT 220 180-220 2013 2444 1330 3344

PYROT 300 250-300 2013 2794 1330 3832

PYROT 400 340-400 2270 2850 1590 4878

PYROT 540 460-540 2340 3080 1590 6244

The PYROT Rotation Firing System

Output range:80 – 540 kW

Specialised for dry to moist fuelsMinimal emissions

Maximum degree of automation

The Pneumatic Pipe-cleaning System

The Exhaust Gas Deduster

Optimised in terms of costs and reliable

Integration of additional heat generators and consumers

Remote maintenance for the operating organisationBurner control equipment

The PYROT Rotation Firing System in the Ulm Communal Heating System: Passive Houses in Sonnenfeld (D)

PYROT 100in combination with thermal solar system

The PYROT Rotation Firing System in the Ulm Communal Heating System (D)

Output: 100 kW

Fuel:Wood pellets

Combination with thermal solar system

The PYROT Rotation Firing System in thePliezhausen Communal Heating System (D)

Output 220 kW

Fuel: Wood pellets

Combination with thermalsolar system

The PYROT Rotation Firing System in the Krailling Elementary School Community Heating System (D)

Output: 300 kW

Fuel: Wood pellets

Container Heating System in Boras (Sweden)

The PYROT Rotation Firing System in Thörishaus School Building (CH)

Output: 200 kW

Burner with pneumatic pipe-cleaning system

Ash conveyance system with vacuum cleaner and fixed pipework in external 240-l ash container

Portable building package boiler for production building in Wolfurt (A)

Output: 300 kW

Fuel: pellets

Fuel storage and conveyanceExtraction from pellet bunker

Extraction with two extraction augers, collecting auger, conveyor auger on burner

Fuel storage and conveyanceConnection pieces for filling wood pellets

Maximum filling is achieved with several connection pieces for filling.

Fuel storage and conveyanceConnection pieces for filling wood pellets

Maximum filling is achieved with several connection pieces for filling.

Excerpt from our reference list of contractors

Bibliography

A. Jenni, H. Gabathuler, J. Good: Hydraulische und regeltechnische Einbindung von automatischen Holzheizanlagen: Standard-Schaltungen und Anwendung. In: Nussbaumer, Th. (Hrsg.): Wege zur Nachhaltigkeit und Massnahmen zur Emissionsminderung und Wirtschaftlichkeitsverbesserung, 8th Wood Energy Symposium on 15 October 2004 at the ETH Zurich, Federal Energy Agency, Bern 2004, ISBN 3-908705-10-X, 83–95.

M. Oser, Th. Nussbaumer, P. Müller, M. Mohr, R. Figi: Grundlagen der Aerosolbildung in Holzfeuerungen, Beeinflussung der Partikelemissionen durch Primärmassnahmen und Konzept für eine pratikelarme automatische Holzfeuerung (low-particle firing), Federal Energy Agency, Federal Environmental Agency,Wald und Landschaft, Concluding Report April 2004, ISBN 3-908705-02-9.

U. Zuberbühler: Maßnahmen zur feuerungsseitigen Emissionsminderung bei der Holzuverbrennung ingewerblichen Feuerungsanlagen, Institut für Verfahrenstechnik und Dampfkesselwesen IVD, Clean Air Maintenance Department, University of Stuttgart, 2002, ISBN 3-928123-49-1.

U. Zuberbühler, G. Baumbach: Entwicklung eines Feuerungskonzeptes zur Verbesserungdes Ausbrandes bei gleichzeitiger NOx-Minderung bei der Holzverbrennung im gewerblichen Bereich,Institut für Verfahrenstechnik und Dampfkesselwesen IVD, Clean Air Maintenance Department, University of Stuttgart, 2000.

G. Baumbach, U. Zuberbühler, M. Struschka, D. Straub, K.R.G. Hein: Feinstaubuntersuchungenan Holzfeuerungen, Institut für Verfahrenstechnik und Dampfkesselwesen IVD, Clean Air Maintenance Department, University of Stuttgart, 1999, ISBN 3-928123-38-6.