Drax plays a central role in the UK’s national energy system. Following its transformation from coal to sustainable biomass, the station generates approximately 6% of the country’s total electricity and 11% of its renewable power. The biomass fuel takes the form of compressed wood pellets, sourced primarily from North America.
Pulverized Fuel Ash (PFA) is a key by-product of the biomass combustion process. The material is sold to the UK construction industry for use in building materials, so reliable handling supports both operational continuity and a circular economy that repurposes what would otherwise be waste.
The Challenge
Drax had long relied on a system of eight loading spouts to transfer PFA from silos into trucks and rail cars. Over time, the existing equipment developed operational inefficiencies and reliability issues that called for a modern, precisely engineered replacement.
The project presented five primary requirements:
- Spatial constraints: the available installation space was exceptionally tight, ruling out costly structural modifications to the existing plant.
- Complex design: the application required a non-standard spout with an extraction point set at an unusual angle in the top of the pan.
- System integration: new hardware had to align with Drax’s existing legacy control systems without a complete control overhaul.
- Spares uniformity: all eight spouts had to remain identical in size and core components to simplify maintenance and inventory management.
- Installation support: Drax required a skilled external installation team to assist internal resources during the transition.
How the Partnership Began
The relationship began at the 2022 Hillhead exhibition, the UK’s premier event for the quarrying, construction, and recycling industries. Impressed by the engineering quality and robust construction of the Vortex loading spouts on display, the Drax team opened a dialogue to address its site-specific challenges.
A Collaborative Design Process
Vortex followed a client-focused consultation supported by detailed technical work. After an initial reference visit, during which Drax personnel observed Vortex systems operating in a live industrial setting, engineers conducted a series of on-site visits to gather precise measurements and refine the design with direct customer feedback.
The final solution comprised eight loading spouts, model VES-25-5-C-A-HN-SDX-E23138D. Each retractable, enclosed unit provides five feet of travel and loads at up to 250 CFM (424.5 CMH). Key specifications include a four-cable hoist drive system with a ten-year cable warranty, a 400 VAC three-phase 50 Hz brake motor rated to IP55, and material contact areas built from 235 BHN abrasion-resistant steel. A self-sealing discharge and scavenger seat into the container hatch to limit dust escape, and the control systems were tailored to interface directly with Drax’s legacy infrastructure. The custom configuration also accommodated the angled extraction point while adhering to the tight footprint and preserving uniformity across all eight units. A purchase order was finalized in January 2025.
Phased Installation
To protect the station’s 24/7 operations, the units are being installed in stages. As of early 2026, three of the eight spouts have been installed, commissioned, and are fully operational. The remaining five are scheduled for installation in April 2026, completing the upgrade while maintaining by-product handling capacity throughout the rollout.
The project demonstrates the value of tailored engineering for critical industrial infrastructure. By identifying specific operational pain points and working collaboratively, Vortex delivered a solution matched to Drax’s technical requirements and long-term maintenance strategy, supporting reliable and responsible handling of a valuable by-product.
