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Dome Technology has built all the operational wood-pellet domes worldwide. Here, a description of those projects and how pellet storage […]
Dome Technology has built all the operational wood-pellet domes worldwide. Here, a description of those projects and how pellet storage has evolved
By Rebecca Long Pyper for Dome Technology
In 2011 Dome Technology completed construction on the first wood-pellet storage domes in the world. Since then the company has built every operational pellet dome, and facilities continue to advance in sophistication 10 years in. Here is a timeline of that work and a look at projects moving forward.
Peeples 2011
Domes really werenโt on the radar for Peeples Industries in Savannah, Georgia, USA.
The company was seriously considering a 50,000-ton A-frame for storing wood pellets, but an A-frame would require deep foundations that raised financial concernโand there were rumblings that a better option might be on the market.
So Peeples Industries owner Frank Peeples Jr. made contact with Dome Technology, โand they did a lot of things for us. They cheapened our price up because we didnโt have to put in a deep-pile foundationโโa system that for the A-frame would have carried the same cost as one entire dome, Peeples Industries project manager Brad Orwig said.
Enviva 2011-2014
In 2011 and 2012 two domes were completed for biomass manufacturer Enviva at the Port of Chesapeake in Virginia, USA (seen above).
The domes feature systems that continuously monitor and control interior temperature. Through close collaboration with Enviva, Dome Technologyโs team completed construction ahead of projected completion, even though the project started a month later than planned.
โEnviva is the biggest wood-pellet producer in the world. Itโs just a joy to work with such a large, progressive company,โ said Dome Technology sales manager Lane Roberts.
In 2014 the team was contracted to build two additional, almost identical domes at Port of Wilmington, North Carolina, USA. These domes can withstand winds up to 300 mph.
Drax UK 2012
Thereโs big, and then thereโs staggering.
Drax chose the latter in a project that was a first of its kind for the United Kingdom, Europeโs single largest decarbonization project, and Dome Technologyโs largest project to date.
The size and scale of the project required unprecedented biomass storage: four domes each holding 80,000 metric tons of biomass. Dome Technologyโs team was responsible for the overall design of the dome system, including reclaim tunnels, floor slabs, dome foundation, DomeSilos and waterproofing.
QSL 2013
From the beginning of its portside project in Quebec City, Quebec, Canada, the challenge for maritime terminal operator and stevedore QSL was selecting a wood-pellet storage solution that checked the boxes as both a smart financial investment and a good steward of the community.
First, the company required 75,000 metric tons of total storage. Steel silos were an option, but a pack of six to eight would be needed to store that tonnage. Since the site is located near a historic district with a park and residential area, something more aesthetically pleasing was in order, and a DomeSilo fit the bill.
โWe needed something nicer than a series of silos, so that was the main concern. Then also because of the size of storage, we needed something solid that would last a long, long time,โ QSL director of engineering Eric Lapointe said.
Drax Port Allen 2014
The United Kingdom project helped secure another Drax project in 2014, where Dome Technology built two wood-pellet domes for the companyโs Port Allen Facility in Baton Rouge, Louisiana, USA. The total storage volume is 80,000 metric tons.
โThe overall facility has less material handling equipment due to the domes. The domes also require less maintenance and fewer equipment issues, which allow the ships to be loaded on time. All these factors combined reduce the operational costs as well,โ said senior project manager Daniel Pittman, who works for Gray Construction, the EPC Drax selected for the facilityโs development.
Albioma 2016
In Fort-de-France, Martinique, Dome Technology built a storage dome for independent energy producer Albioma in building the islandโs first 100 percent biomass power plant.
The single dome stands 108 feet (33m) tall and 115 feet (35m) in diameter, with the ability to store as much as 19,900 metric tonnes of biomass wood pellets. Dome Technology oversaw work for the deep-pile foundations, pile cap, dome shell and one above-grade tunnel. The dome achieves approximately 70 percent reclaim by gravity alone and has access for a front-end loader to reclaim the remaining 30 percent.
2020 Barrette-Chapais
Wood-pellet producer Barrette-Chapais first contacted Dome Technology about a ship-loader project for a new transload facility in Quebec, Canada, but when portside availability changed, so did their plans.
Flat storage was Plan A for the Port of Saguenay site, but after weighing a reduction in available space against storage requirements, the decision was made to shift to a dome, said Granule 777 general manager Yann Sellin.
Dome Technology was contracted to build two DomeSilos, measuring 120 feet (36.5 m) in diameter and 131 feet (39.9 m) tall and each capable of storing 21,000 metric tons. Because of their geometry, DomeSilos are able to store more product in a smaller footprint, stacking pellets deeper and storing them all the way to the structureโs apex.
Current work
At present Dome Technology is building pellet domes for three companies. In an era when innovation and customization arenโt extras, theyโre expected, more bulk-storage companies seek a structure that will last, that fits within the budget and that will maintain product integrity. Dome Technology delivers an innovative, turnkey solution.
โCustomers have, in the past, used different systems to store wood pellets until they found the dome. As a result, the dome has become the standard for storing pellets, and everyone knows it,โ said Dome Technology CEO Bradley Bateman. โWeโve been able to create solutions when others could not.โ
Editor’s note: This article ran in the 2020 edition of World Biomass.
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Agricultural-product provider Gavilon hired Dome Technology to repair and recoat four existing concrete silos storing corn and soybeans in Creston, […]
Agricultural-product provider Gavilon hired Dome Technology to repair and recoat four existing concrete silos storing corn and soybeans in Creston, Iowa, guaranteeing 10 more years of exterior life.
The silos, built in 1978, were deteriorating, particularly two that had been spalling for three years, said Gavilon superintendent Britt Boozer.
Another company worked on interior upgrades simultaneously, and โwith extending the liners and doing what we did on the outside, (our company) felt like that was a more economical wayโto repair the bins rather than tear them down and build new,โ Boozer said.
The Gavilon concrete silos required light concrete-crack repair, and the Dome Technology team began the project by pressure washing and prepping the structure, then shotcreting and patching all cracks in exposed areas. Silicone sealant was applied to the entire building including the roof, where a nonslip surface was also added.
โWeโre basically encasing the whole structure with this casing, so we shouldnโt see the spalling continue any longer,โ Dome Technology sales manager Heath Harrison said. โThe selling point is making silos truly watertight; paint and other restoration processes fail to do that long term.โ
Cost savings are the biggest benefit to this kind of silo repair. According to Harrison, silos otherwise destined for teardown can be salvaged in only a few weeks.
In addition to repairing the silos, Dome Technology can apply coatings in fade-resistant colors. After exterior concrete is repaired, this coating preserves and extends the concrete life. In the case of Gavilon, the charcoal-gray coating the company chose gives the silos a fresh look. โIt can serve as an aesthetic solution as well, so itโs a two-for-one,โ Harrison said.
Boozer agreed, stating that if people were seeing the silos for the first time, โthey would go, โThese have just been put up three, four, five years ago.โ Aesthetically they look a lot better.โ
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Dome Technology is building a fifth dome for biomass manufacturer Enviva, this time at the Port of Pascagoula on the […]
Dome Technology is building a fifth dome for biomass manufacturer Enviva, this time at the Port of Pascagoula on the Gulf of Mexico in Mississippi, USA.
The dome will store 45,000 metric tons of sustainably sourced wood pellets and stands 157 feet tall and 175 feet in diameter. Pellets will be delivered to the site by rail, then stored within the dome. Gravity will draw 70 to 75 percent of the stored pellets to the reclaim tunnel, and front-end loader will be utilized to collect the rest as needed. Upon reclaim, pellets will be loaded into ships to be sent to Enviva customers in Asia and Europe.
Repeat collaboration with Enviva took shape in the spring of 2011 and November 2012, when Dome Technology built two domes for the company at the Port of Chesapeake in Virginia, USA (see photo below). These domes, which stand 157 feet high and 176 feet in diameter and store 45,000 metric tons of pellets apiece, include systems for continuous monitoring and temperature control. Dome Technologyโs team completed construction ahead of projected completion, even though the project started a month later than planned.
Five years later Enviva again contracted Dome Technology to build two additional, almost identical domes at the Port of Wilmington, North Carolina, USA (pictured below). This pair of domes stand 170 feet tall, boast a capacity of 45,000 metric tons each, and can withstand hurricane-force winds. The Pascagoula dome has been engineered with the same wind resistance.
โWe chose to collaborate with Dome Technology not only because of their reliable and well-proven technology, but also because they know our industry and team well,โ said Norb Hintz, Envivaโs senior vice president and chief engineer. โThe Pascagoula dome is their fifth installation with us. They have become familiar with our operating procedures and share the same discipline and commitment to safe work practices.โ
Dome Technology strives to embrace innovative ideas with every project. One example shows up in the design of the Pascagoula aeration troughs. Originally these were designed to be wide and shallow to allow for the necessary volume of air. But with a wide opening, the thickness of the grate on top had to be substantial to remain rigid when front-end loader traveled across, and the grate cost was surprisingly high. Dome Technology suggested shrinking the troughsโ width and adding to their depth. This will allow the troughs to have efficient airflow and for the grates to be narrowerโand more economical.
Adopting creative solutions has helped secure multiple Enviva projects. โEnviva trusts us. They know that weโre competent, that we will perform, that we bring value to their projects and look at lowering costs,โ said Dome Technology sales manager Lane Roberts.
Dome Technologyโs scope of work at Pascagoula includes overseeing the deep-foundation system built by Berkel & Company, dome and floor construction, tunnel construction, aeration troughs, heat sensors, elevated entryway and the drain around dome.
Construction of the Pascagoula dome is set for completion in May 2021. Inflation is critical to a domeโs construction; this airform establishes the shape of the structure, and once inflated, polyurethane foam insulation is applied to the interior of the airform.
Steel reinforcement is attached to the insulation, and concrete is then applied using the shotcrete method. When completed, the dome is a robust reinforced concrete structure that can withstand even the most aggressive weather at portside locations.
Sealed and seamless, the dome provides ideal storage conditions for products, like wood pellets, that require a controlled environment. The airform surrounding the dome prevents water and moisture entrance. No other silo option offers this level of waterproof protection, and the domeโs exterior requires almost zero superficial maintenance. Also, the domeโs insulated nature reduces heating and cooling of the walls and air inside, preventing condensation from forming on the interior.
Dome Technology is driven by the pursuit of innovation and advancement. The current Enviva project highlights Dome Technologyโs breadth of expertise.
โFor nearly four decades weโve relied on a collaborative approach with companiesโtheyโre in the driver seat, and we help navigate,โ said Dome Technology CEO Bradley Bateman. โIn every project Dome Technology incorporates innovative technology to maximize storage capacity and system performance with an economical solution.โ
Editorโs note: This article was published in the October 2020 issue of Dry Cargo International.
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For fertilizer companies in areas where construction schedules typically depend on decent weather, thereโs no need for building to be […]
For fertilizer companies in areas where construction schedules typically depend on decent weather, thereโs no need for building to be delayed if a new storage dome is selected. A dome can be built any time of year, with work marching right through the calendar. This all-weather construction schedule is made possible by dome building methods. A dome is built using the shotcrete method, and much of the process is completed from the inside out.
How a dome is built
Once the foundation system is established, a ring beam or pile cap (if needed) is constructed at ground level to form the foundation for the dome structure above. The PVC airform, custom sized based on the customersโ specifications, is attached to the ring beam and inflated, forming the exterior dome shape; the high-strength fabric will remain in place indefinitely as it becomes the outer waterproofing membrane.
With the airform inflated, construction moves inside. Polyurethane foam insulation is applied to the interior of the airform, forming a layer 1 to 1.5 inches thick.
Concrete and steel reinforcement are placed on top of the foam, using the shotcrete method, and when completed, the dome is a robust reinforced concrete structure that can withstand even the most aggressive weather.
Sealed and seamless, the dome provides ideal conditions for fertilizer requiring a controlled environment. The airform surrounding the entire dome prevents water and moisture entrance. No other silo option offers this type of waterproof protection, and this exterior requires almost zero superficial maintenance. Also, the domeโs insulated nature reduces heating and cooling of the walls and air inside, preventing condensation from forming on the interior.
Corrosion protection
A concrete structure is ideal for fertilizer storage because corrosion is highly unlikely. In fact, some fertilizer domes built by Dome Technology have been around for 30 years and are still structurally sound.
Concrete may develop hairline cracks that can be penetrated by fine fertilizer dust. This concern can be mitigated by spraying a polyurea coating on the interior surface of the dome. A corrosive-resistant powder can also be mixed into the concrete when pouring the floor.
Water wreaks havoc on fertilizer, and since most fertilizers are hygroscopic, they attract moisture that dissolves the product and corrodes it too, producing weak acids that break down steel. To account for this, corrosive-resistant rebar and/or additional concrete over rebar are used.
To protect product from humidity, a dehumidifier is also highly recommended. Housed on top of the dome, humidity in the headspace can be controlled, and the ideal interior climate can be maintained. Humidity monitors can also be installed, allowing site managers to survey and adjust interior conditions.
Protection from rust and moisture on the storage side is one thing, but there are ways to extend a facilityโs life span by protecting other components from corrosion too. While many fertilizer companies utilize front-end loaders, those who select integrated reclaim systems can protect metal components from rust in multiple ways. Stainless steel is always an option, especially ideal for food- or pharm-grade fertilizer products, but can be cost prohibitive. Another route is to paint the metal so corrosion isnโt an issue; the main thing to remember is to keep up on maintenance so chips and scratches in the surface donโt allow an access point for moisture.
Editorโs note: This is an excerpt from the November/December 2020 issue of World Fertilizer. For the full online edition, click here.
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For new construction, a DomeSilo provides robust strength equal to the task of mixing and blending. A monolithic concrete dome […]
For new construction, a DomeSilo provides robust strength equal to the task of mixing and blending.
A monolithic concrete dome makes grain storage and shipment easier by storing more and accommodating mix and blend. Dome Technology builds these domes all over the world, and the most popular model is the DomeSilo, a dome that is as tall or taller than it is wide. Thanks to its brute strength, a dome is a more durable structure than traditional steel structures or flat storage and can also store more than a silo with similar dimensions.
The domeโs tolerance for cyclic throughput is high because of its structural integrity. Filling and emptying will stress any structure, but a domeโs monolithic design accepts the force without fatigue problems; stress is not channeled to weak spots like bolts or seams because there arenโt any. A dome doesnโt require regular maintenance, and the concrete domeโs lifespan is indefinite.
For processors, shuttle loaders and exporters, blending can be key to operations. The domeโs strength makes blending and mixing and blending possible. A dome is cost competitive with silos while providing the ability to pull from multiple gates, an option limited with steel tanks and one that keeps barge, rail, and export shipments running smoothly.
The typical grain dome features multiple gates within the foundation; to circulate, product is drawn out of these gates, then conveyed to the top of the dome and reloaded. Terminal managers can also select specific gates to address hot spots, and monitoring systems help identify those. If certain pockets are lower in quality, corresponding gates can be opened to various percentages with gates adjacent to high-quality product opened as well.
โThe domeโs blending capability will create a consistent product for the customer or end user,โ Dome Technology sales manager Heath Harrison said. โDomes allow you to maximize blending capability, giving companies the opportunity to maximize profits and efficiencies. The grain industry operates on tight margins, so sometimes throughput and mix and blend are all we have to increase the bottom line. Domes and DomeSilos will maximize that bottom line.โ
In addition to these benefits, recent construction advances are making domes more resilient than ever. For instance, Dome Technology has pioneered round explosion panels that channel pressure out of the structure, preventing structural damage in the event of an explosion.
Companies eager to secure no-entry options can explore different reclaim systems that make this possible; Dome Technologyโs in-house engineers work closely with customers to determine reclaim that delivers necessary throughput and keeps employees safe.
Editorโs note: This is an excerpt from an article published in Dry Cargo International in September.
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Two powerful elements at the Barrette-Chapais wood-pellet terminal in Quebec, Canada, are the 100-meter Belt Conveyor and 250-meter Tubulator that […]
Two powerful elements at the Barrette-Chapais wood-pellet terminal in Quebec, Canada, are the 100-meter Belt Conveyor and 250-meter Tubulator that stretch from the domes near the mountain all the way to the dock. Bruks Siwertell provided the system and has written about it in detail here.
Wood-pellet producer Barrette-Chapais contracted with Dome Technology to build two DomeSilos, measuring 120 feet (36.5 meters) in diameter and 131 feet (39.9 meters) tall and each capable of storing 21,000 metric tons, at the Port of Saguenay. Because of their geometry DomeSilos are able to store more product in a smaller footprint, stacking pellets deeper and storing them all the way to the structureโs apex.
Dome Technology also acted as construction manager, supervising Canadian crews on all equipment installationโload-out system, bucket elevator, and conveyance. The Belt Conveyor and Tubulator are central to the reclaim system, and according to Granule 777 general manager Yann Sellin, the Bruks conveying system is the most exciting new feature for the company.
The new air-supported conveyor system can convey pellets at 800 tons per hour. The complete Barrette-Chapais project summary can be found here.
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No doubt biomass companies are some of the savviest out there. After all, products perceived as โgreenโ are hot and […]
No doubt biomass companies are some of the savviest out there. After all, products perceived as โgreenโ are hot and will just get hotter, and these companies had the foresight to get involved early.
With any booming business, time is of the essence, and big biomass-storage projects demand a lot of it. Thatโs why Dome Technology specializes in designing and building turnkey facilities. Streamlining the process of securing state-of-the-art storage complements a forward-thinking industry, saving companies time and money.
Systems that work together
Selecting the right structure is just one part of the puzzle for bulk storage. At the same time, companies have to make decisions on conveyance, throughput, conditioning, monitoring, and more. But by working with a turnkey-construction company like Dome Technology, guesswork is eliminated, and the likelihood of a seamless facility is extremely high. Itโs a process that helps customers maximize their time.
Dome Technology oversees complete storage projects, though customers can also seek support in specific portions and receive innovative options. By working with a one-stop shop, each element is planned with the others in mind.
Domes and biomass storage
Selecting a dome is a key way to bolster efficiency. The flexible DomeSilo model complements biomass, providing product protection and resisting deflagration, even coming equipped with innovative explosion panels that prevent major structural damage should an emergency occur.
Just like it sounds, a DomeSilo is tall and narrow with a domed top. That dome is important; its geometry allows for significantly greater storage capacity than available with silos of similar dimensions because it can support product stacked right up to the apex. The DomeSilo also rivals silos in cost efficiency.
A dome can be built quicklyโonce the outer weatherproofing membrane is in place, construction work is completed from the inside, so the project can proceed regardless of the weather.
Then automation is added, another measure designed to save time and cut man hours. Domes are engineered with systems to monitor temperature, humidity, sparks and off gasses and to halt operations should something be amiss. Dust collection also comes standard with a dome.
Want more information about how a dome can help grow your biomass business? Contact our sales team today.
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When youโre a company executive, time is of the essence, and thereโs never enough of it. Thatโs why more companies […]
When youโre a company executive, time is of the essence, and thereโs never enough of it. Thatโs why more companies are opting to hire a turnkey builder for new storage projects. Itโs a decision that keeps the team size manageable, allows the customer to call the shots, and yields cost savings.
As bulk-storage companies get leaner, theyโre outsourcing more. According to Dome Technology sales manager Heath Harrison, many customers who once employed in-house engineers have shrunken those teams; often, those who remain are there to verify construction plans created by outside entities.
Working with an experienced design-build team streamlines the construction process. Plans are cleaner from the start, and the resulting structure is built seamlessly as all parts are planned with the others in mind.
An increased demand for turnkey building
One of the real drivers in turnkey construction is the rise in third-party investment companies, many times bankers and market analysts, who donโt necessarily know the bulk industries. Bringing together several different engineering groups and making sure theyโre on the same page for a new project is tricky when the industry and product are โnewโ or not well understood, Harrison said. Plus, each additional player brought to the project brings an additional cost. When one makes a change to the plan, the others have to adjust theirs too. As the plan evolves, so does the priceโon an upward trajectory.
The converse is that when a turnkey builder is chosen to provide an entire project, costs go down. When the plan changes, it isnโt taxing to spread the word because everyone who needs to know already does. But sometimes changes arenโt necessary at all; if a single team oversees every element, itโs easier to spot gaps. โWhen itโs confined under one umbrella, itโs much easier to define those missing links,โ Harrison said.
Decision makers with expertise in their industry are eager to get projects rolling in a way that saves money. Price per unit is the bottom line, Harrison saidโโcost is driving everything. The tighter they can get, the better.โ
First steps in a turnkey project
The first part of building a turnkey facility will be a review of the basics. Dome Technology, for instance, asks customers these five questions:
- Capacity requirements: How much product needs to be stored and transported annually?
- Geographical and geological position: Define the site requirements and determine the site-specific geotechnical information.
- Expansion: Is this a project extending a facilityโs original scope? Is future growth likely?
- Product consideration: Especially important for third-party groups new to their industry, a turnkey builder can provide counsel on designing the unique storage for each specific stored product.
- Operations: What are your plans for filling, reclaim, product management, and controlling inventories? If these arenโt known or defined, help is available.
Turnkey construction is about more than combining individual parts to create a cohesive whole. Itโs really about building trust and empowering the customer.
โWhat youโre actually doing is becoming a partner because most of these end up becoming repeat customers. Ultimately it always comes back to price and efficiency, not just in the short term of the project, but also for the life of the facility. It saves time, and that saves money,โ Harrison said.
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A reinforced-concrete storage dome is a natural choice for companies eager to minimize their environmental impact by utilizing green storage. […]
A reinforced-concrete storage dome is a natural choice for companies eager to minimize their environmental impact by utilizing green storage. Dome Technology customers in a variety of bulk industries are realizing the benefits of sealed dome storage that lasts indefinitely and is designed to withstand natural disaster and even deflagration.
A sealed envelope
Sealed and seamless, a dome keeps product inside and prevents interaction with the environment. This envelope is multi-layered; a dome is built using the shotcrete method, so concrete is sprayed in place without any construction joints. On the exterior, a high-strength PVC membrane covers the entire structure. Between the membrane and the concrete, urethane foam protects the life of the structure as well as the stored product.
The PVC membrane ensures complete waterproof protection for the reinforced concrete shell and, consequently, the material stored within. A mold-resistant UV-protective resin coats both sides of the membrane, providing long-term protection from these two common sources of degradation. No other silo or bulk-storage system offers this type of waterproof protection, and this exterior requires almost zero superficial maintenance.
An increasing number of grain producers are contracting with Dome Technology to build domes that provide product protection. A dome โis proven to be an economical and reliable solution for long-term grain storage. Itโs a sealed vessel that protects against rodents, bugs and moisture,โ said Dome Technology CEO Bradley Bateman.
Additional advantages apply to coal companies. The double curvature of a dome provides strength at all points of the structure, even near the apex. With strength at the top, a coal company has no problem securing adequate space for dust-collection systems that thwart particulates trying to escape.
For those in the fertilizer industry, concrete can develop hairline cracks that can be penetrated by fine dust. These concerns are mitigated by spraying a polyurea coating on the interior surface of the dome. A corrosive-resistant powder can also be mixed into the concrete when placing the floor concrete.
Domes are always built without rivets, fasteners or mechanical connections found in other storage, thus eliminating potential sources for leaks and rust. This comprehensive approach to waterproofing promises long-lasting protection for stored product and the structure itself.
Robust and long lasting
Domes have an unlimited lifespan, which prevents teardown and minimizes material headed for the landfill. Measures designed to protect a domeโs structural integrity are essential to its longevity.
The structure itself can survive a disaster other types of storage might not and will likely reward customers with insurance-premium savings. A dome has inherent strength other bulk-storage structures do not. Should an earthquake, tsunami or tornado occur, the structure has a better chance of survival than a traditional building, and the stored product inside will not be introduced into the environment.
Dust is a concern with many stored products, but it simply canโt escape a monolithic dome since joints or seams donโt exist. Inside, the truss-free interior discourages dust build up, and
a host of dust-control systems exist in the marketplace to manage dust production. Automatic dust-collection systems can be designed to convey dust back into the product stream.