Drax Power Ltd., the United Kingdom’s largest power station by capacity, plays a critical role in the nation’s energy infrastructure, providing approximately 6% of the country's electricity supply. Following a strategic transition from coal to biomass, the facility faced operational hurdles regarding the handling of Furnace Bottom Ash (FBA), a by-product of wood pellet biomass combustion. This case study examines the collaboration between Drax Power Ltd. and Vortex to replace ageing loading equipment. By implementing tailored Vortex Loading Spouts, Drax successfully navigated complex spatial constraints and integration challenges, enhancing operational efficiency and ensuring continuity in their critical by-product logistics.

About Drax Power Ltd.

Located in North Yorkshire, England, between Selby and Goole on the River Ouse, Drax Power Ltd. stands as a pivotal asset in the UK energy sector. With a generating capacity of 2.6 GW dedicated to biomass, the station has undergone significant transformation, retiring its 1.29 GW coal capacity in 2021 to focus on sustainable energy generation.

The facility sources wood pellet biomass primarily from the United States and Canada. The combustion of this biomass generates Furnace Bottom Ash (FBA), a material valuable to the construction industry. Efficiently moving this by-product from the station to the market—via four truck loading points and four rail car loading points—is essential for maintaining smooth plant operations and supporting circular economy principles within the construction sector.

The Challenge

The handling of Furnace Bottom Ash presents specific logistical requirements. Drax utilised a system of eight loading spouts to transfer FBA into trucks and rail cars. However, the existing equipment began to present operational inefficiencies that required a robust solution.

The primary challenges included:

• Spatial Constraints: The existing installation footprint was exceptionally tight, requiring new equipment to fit within strict physical boundaries without necessitating major structural modifications.
• Complex Design Requirements: The application demanded a unique spout design featuring an extraction point located at an angle in the top of the pan, complicating standard spout geometries.
• System Integration: Any new hardware needed to align seamlessly with Drax’s existing control systems to ensure continuity of operations.
• Maintenance Continuity: To simplify future maintenance and inventory management, it was imperative that all spouts remain the same size, despite potentially varying installation conditions.
• Installation Support: Drax required an external installation team to assist their internal resources during the transition.

The Solution

The partnership began when Drax representatives encountered Vortex at the 2022 Hillhead exhibition—the UK's premier event for quarrying, construction, and recycling. Impressed by the engineering quality and specific features of the Vortex Loading Spouts, Drax initiated a dialogue to address their site-specific issues.

Vortex’s approach was characterised by detailed consultation and technical rigour. Following an initial site reference visit to observe Vortex systems in a live environment, the teams engaged in a series of site visits at Drax. This collaborative phase allowed Vortex engineers to refine the design iteratively.

The solution involved a tailored configuration of eight Vortex Loading Spouts. Vortex engineered a design that accommodated the angled extraction point within the top pan while strictly adhering to the tight footprint limitations. Crucially, the design maintained uniformity across all units to satisfy the requirement for spares continuity. The control systems were also tailored to interface directly with Drax’s legacy infrastructure.

A purchase order was finalised in January 2025, marking the transition from design to implementation.

Implementation

The project adopted a phased installation strategy to minimise disruption to the power station's critical operations. As of early 2026, three of the eight units have been successfully installed and commissioned. The installation process involved close cooperation between Drax personnel and the external installation team sourced to support the project.

The remaining five spouts are scheduled for installation in April 2026, completing the full system upgrade. This staggered approach allows for continuous assessment and ensures that by-product handling capacity is maintained throughout the upgrade period.

Loading Spout Details

Vortex Model Number: VES-25-5-C-A-HN-SDX-E23138D

• Retractable loading spout for enclosed loading with (5) feet of travel.  
• The unit includes a scavenger which seats into the hatch of the container being loaded.
• The unit is designed to load at up to 250 CFM (424.5 CMH).  
• This unit features the industry leading four (4) cable hoist drive system which incorporates custom CNC machined three (3) piece cable pulleys, heavy duty idler rollers with sealed bearings and comes with a ten (10) year cable warranty.
• The unit is driven by a right angle gear type reducer powered by a 400 VAC / 3phase / 50 hertz electric brake motor. Motor is IP55 rated.
• Control Voltage is 120 VAC / 1 phase / 50-60 hertz
• The unit is equipped with a IP67 upper limit switch and a NEMA-4 rated IP67 slack cable limit switch which are pre-set and factory wired into a NEMA-4 rated IP66 enclosure.
• A 6 inch (152.4 mm) diameter dust outlet to be connected to a remote dust collector (1000 CFM (1698 CMH) required for proper dust withdrawal).
• Material contact areas are constructed of 235 BHN abrasion resistant steel.  All other construction is mild steel.
• (HN) - Outer dust sleeve is constructed of 17 ounce (.48kg) hypalon nylon with aluminum inner and outer support rings.  Sleeve is rated for 220˚F (104˚C) maximum continuous service.
• (SDX) - Self-sealing discharge for use with enclosed loading spout.  The unit includes a scavenger which seats into the hatch of the container being loaded.  This unit is designed to seal the discharge opening when retracted from the container being loaded to eliminate dust escaping from the loading spout.  Material contact is abrasion resistant steel.
• Customization (E23138D) - SETUP FOR USE WITH A HYCONTROL #RP80820ACTG15000 (110 VAC) PADDLE SENSOR ENCLOSED IN A SAFETY CAGE. SCAVENGER SETUP FOR 450MM TO 490MM HATCH. DUST COLLECTION PORT TO BE AT 45 DEGREE ANGLE. TERMINAL BOX TO BE MOUNTED OPPOSITE OF STANDARD. HYPALON TO BE 35 OZ MATERIAL. TUB AND SENSOR CAGE MODIFIED TO MEET 1384mm RETRACTED HEIGHT.

Conclusion

The collaboration between Drax Power Ltd. and Vortex demonstrates the value of tailored engineering in critical industrial infrastructure. By identifying specific pain points and engaging in a thorough consultation process, Vortex delivered a solution that not only met the technical specifications but also aligned with Drax’s operational and maintenance strategies.

As Drax continues to lead the way in biomass energy generation, the reliability of ancillary systems like the FBA loading spouts ensures that their commitment to sustainability extends through to the efficient handling of by-products. With the final installation phase scheduled for April 2026, this project stands as a testament to forward-thinking engineering and successful industrial partnership.

For organizations seeking innovative solutions and sustainable practices in biomass energy operations, contact us today to learn how our expertise can drive efficiency and success in your projects.

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