Biomass Briquettes manufacturing with different...

Final Report

On

Biomass Briquettes manufacturing with different compositions

Period: 20 July 2017 to 31 October 2017

Submitted to

GIZ-ENDEV

Date of Submission Date: 26 October 2017

Submitted by

Josna Ara

Executive Director

Khaya (Samaj Unnayan Sangstha)

Satkhira

Background: Biomass is the primary source of fuel for a large portion of the world’s

underdeveloped countries. Biomass is used for a variety of purposes in the

developing world, the primary of which is for cooking. Bangladesh is one of the most

energy starved countries of the world. The natural resources of the country are fast

depleting. Given this scenario, biomass is considered an important source of

renewable energy for the country. Biomass still accounts for over 50% of the total

energy supply of Bangladesh. It is the primary source of fuel for the rural

households. An average Bangladeshi household burns about 2.5 tonnes of biomass

a year, since only 6% of the total population of Bangladesh have access to natural

gas. In addition, businesses and institutions are also interested to use biomass for

cooking as well as other purposes.

More than 90% of the people of Bangladesh use traditional biomass such as non-

carbon neutral fuel wood, wood residue and leaves; agricultural residue such as rice

husk, rice straw, rice bran, wheat straw, maize stalk and maize cob, jute stalk, lentils

residue, sugarcane bagasse; and others like cow dung and poultry dropping for

cooking. Alternative fuels for cooking such as briquettes and pellets from biomass

are still at a very early stage of development in Bangladesh. However, in the

neighbouring countries such as Nepal and India, briquette and pellet manufacture

process and technology is at a much more developed stage. Though briquettes do

not enhance the heat value content of the used biomass, thermal efficiency is known

to be doubled compared to cooking with biomass in conventional way. Biomass

briquette production from refused and collected biomasses from open atmosphere

has an immense potential to be replicated in Bangladesh especially at rural and

semi-urban areas from waste stream. People in rural and slum areas along with

floating people of urban areas, may be engaged in handmade biomass briquette

production using tree leaves & twigs, agricultural and other biomass wastes.

Machine-made briquettes are already available in the market, as such the focus will

be to assess the current production processes and potential alternatives to it, as well

as potential other sources of raw material for briquettes, such as diverse agricultural

wastes, rice husk and water hyacinth or sugarcane bagasse at low cost. Currently

there is no mentionable market for briquettes in Bangladesh, yet there is an urgent

need to act on this considering the availability of raw materials and scarcity of dry

biomass during rainy season.

As an agricultural country along with a large population we have lots of biomass

waste.75% of energy comes from biomass in rural area are agricultural waste and

residues. These residues are used in a non-efficient and non-hygienic way. Mainly

this energy consumption is happened in rural area’s cooking system with only 8-12%

efficiency. The main problem with that biomass is low density and high moisture

content. By making briquette mixing a wide range different raw materials e.g Rice

husk, Saw dust, waste paper, cow dung, leaf etc. this problem can be solved. By

producing high efficiency briquette we can solve energy crisis, assuring hygiene in

rural

cooking and save the environment. Study in Kheya Samaj Unnayan Sangstha

conducted research on briquette to produce high burning efficiency briquette as well

as to mitigate fuel crisis in cooking system of Bangladesh.

Objective

Basic application of handmade briquettes is thinkable for domestic use and small

businesses in rural areas I\in order to develop the alternative fuel market in

Bangladesh, it is essential to understand different types and combinations of raw

materials that can be used for production of briquettes, Specifically, the study should

identify and focus on the lowest cost options for briquette production for the local

market.

Scope of Work:

1. Select three different compositions of hand press Biomass Briquette as recommended by GFA Advisor in Charge.

2. Designate a particular area for briquette manufacturing in existing facility. 3. Manufacture 200 pcs briquettes for each selected composition (total 600 pcs) 4. Find out optimum manpower requirement for briquette manufacturing 5. Find out production capacity per day per person. 6. Sun dry each briquette and find out average drying time 7. Calculate unit production cost (per kg) of briquette from raw materials local

price (Rice husk, saw dust, waste newspaper, agricultural waste and cow dung etc)

8. Determine average labour cost for production 9. Identify in include other costs involved in production of briquettes including

carrying, transportation, overhead and miscellaneous cost. 10. Access the quantity of briquette required to cook a complete meal with three

items and compare with other machine-made briquette available in market 11. Finalize pcs of biomass briquettes per kg and cost pf briquettes per kg

Primary Raw materials of Briquettes:

1. Saw Dust

2. Rice Husk

3. Agricultural Waste

Binder materials:

1. Waste Paper

2. Cow dung

3. Rice Starch/ waste wheat power

Socking binder materials:

Pasting Binder materials:

Raw materials Mixing with Binder:

Manufacturing Biomass Briquettes:

Selection of Composition:

GFA has Selected 04 no of Compositions for hand press Biomass Briquettes:

Composition ID Composition

Kheya/ Bio- Briquette / 01

Saw Dust : 30 % Rice Husk: 30 % Waste Paper: 40% Rice starch: 01 kg


Saw Dust : 50% Waste Paper: 40% Cow dung : 10%


Rice husk: 25 % Sawdust: 25% Leaf: 5% Waste paper: 35% Cowdung: 5%


Rice Husk : 50% Waste paper: 40% Wheat powder (Atta): 2.5%

Raw Materials

(Saw dust, Rice Husk Agricultural

Waste)

Mixing with Binder (3:2)

(Waste Paper, Cow dung)

Compression

(Hand Press machine)

Sun Drying of

Briquettes

Packaging

Flow Diagram of Hand Press Biomass Briquette:

Wet Briquettes

Socking Waste

Paper (Binder)

Different Types of Hand Press Biomass Briquette:





Production of Hand Press Biomass briquettes:

Composition ID

Composition Production Production time

Manpower Sun Drying Time

Remarks


Saw Dust : 3kg Rice Husk: 3 kg Waste Paper: 4 kg Rice starch: 01 kg Total : 10 Kg

Day-1 70 pcs briquettes

5 hrs (Rainey day)

2 persons

6 days (Rainey day)

02 persons can manufacture at least 250 pcs biomass briquettes per day @ 100tk/ day/ person (Not the professional market labour )


6 hrs 2 persons


Saw Dust : 5kg Waste Paper: 4 kg Cow dung : 01 kg Total : 10 Kg


6 hrs 2 persons 3-4 days Sun drying Day-2

97 pcs briquettes

6 hrs 2 persons


Rice husk: 2.5 kg Sawdust: 2.5 kg Leaf: 0.5 kg Waste paper: 3.5 kg


7 hrs 2 persons 3-4 days Sun drying


5 hrs 2 persons

Cowdung: 0.5 kg Total: 9.5 kg


Rice Husk : 5 kg Waste paper: 4 kg Wheat powder (Atta): 0.25 kg

Day 1 178 pcs briquettes

10 Hrs 2 persons 3-4 days Sun drying

Disable People manufacturing Biomass Briequettes

Briquette Sun Drying

Briquette Storage

Cost of raw Materials

Description Cost/ kg Purchase Quantity

Carrying cost

Unit price /kg Remarks

Rice Husk 6 Tk 20 kg 80 TK 10 TK Carrying cost can be minimize : 40 Tk

Sawdust 4 Tk 70 kg 80 TK 5.14 TK Carrying cost can be minimize : 40 Tk

Waste Paper 12 Tk 50 kg - 12 TK

Cow dung Free 5 kg - -

Cost of Charcoal (Compressed Rice Husk ): 9.25 TK/kg

Composition ID: Kheya/ Bio- Briquette / 01

Description Quantity

Unit Price Price

Total Price

Total no Briquette Manufacture

Labour Cost Total Manufacturing Cost for 10 KG

Manufacturing cost/kg

Rice Husk 3 kg 10 TK 30 TK Day 1 = 70 Day 2 = 112

2x 100 TK (2 persons)

Raw materials = 93 TK Labour= 200 TK

Sawdust 3 kg 5.14 TK 15.42TK

Waste Paper 4 kg 12 TK 48 TK

Rice starch 1 kg - -

Total 10 kg 93.42 182 pcs 2x 100 TK 293 29.3 TK /kg


Description Quantity Unit Price

Total Price Total no Briquette Manufacture

Labour Cost

Total Manufacturing Cost for 10 KG


Sawdust 5 kg 5.14 TK 25.7TK Day 1 =99 Day 2 = 97

2x100 TK (2 persons)

Raw materials = 73.7 TK Labour= 200 TK

Waste Paper 4 kg 12 TK 48 TK

Cow dung 1 kg - -

Total 10 kg 73.7 196 pcs 2x100 TK

273.7 27.37 TK/kg


Description Quantity Unit Price Price

Total Price


Labour Cost

Total manufacturing Cost for 10 KG


Rice Husk 2.5 kg 10 TK 25 TK Day 1 = 105 Day 2 = 79



Sawdust 2.5 kg 5.14 TK 12.85 TK

Waste Paper

3.5 kg 12 TK 42 TK

Leaf Cow Dung

0.5 kg 0.5 kg

- -

- -

Total 9.5 kg 79 184 pcs 200 TK 279 TK 27.9 TK/kg


Description Quantity Unit Price Total Price


Labour Cost

Total manufacturing Cost for 10 KG


Rice Husk 5 kg 10 TK/kg 25 TK Day 1 = 178



Waste

Paper 4 kg 12 TK/kg 42 TK

Rice starch/Wheat

0.25 kg 28 TK/kg 07TK

Total 9.25 kg 74 184 pcs 200 TK 274 TK 27.4 TK/kg

Cooking (Complete meal) testing with Biomass briquettes and Compressed

Rice Husk

Composition ID

Composition Meal Total Bracket for cooking

Remarks



1 kg Rice 1 kg chicken

1.68 Kg




1.79 kg Calorifie value: 3056 k cal/kg Volatile Mater w/w (%): 60.07


Rice husk: 2.5 kg Sawdust: 2.5 kg Leaf: 0.5 kg Waste paper: 3.5 kg Cowdung: 0.5 kg Total: 9.5 kg


1.81 kg




1.78 kg Calorifie value: 2932 k cal/kg Volatile Mater w/w (%): 61.4

Charcoal 1 kg Rice 1 kg chicken

1.79 kg

Weight of Biomass Briquette in Wet and Dry Condition:

Composition ID

Composition Wet Condition Dry Condition



10 pcs/kg 22 pcs/kg



08 pcs/kg 18 pcs/kg


Rice husk: 2.5 kg Sawdust: 2.5 kg Leaf: 0.5 kg Waste paper: 3.5 kg Cowdung: 0.5 kg Total: 9.5 kg

09 pcs/kg 19 pcs/kg



Feedback on Local fuel seller:

1. Most of the seller wants to know its selling price.

2. Want to know its raw materials

3. It should be good for tea-stall and restaurant.

4. Can they manufacture briquette by shop owners.

5. Want to know user feedback.

Conclusion:

There is significant effect on binding materials. If use less than 40 % binding

materials, production of briquette goes slow because of broken finished product. For

production of briquette we need at least two person. And two person can produce

maximum 250 pcs briquettes per day. If can use semi-automatic machine production

cost will be less. It’s not user friendly for single people. For cooking it is good for

Improved cook stove because of its great. Fuel concussion is almost same compare

to CHC. Presently its production cost is 25-29 Tk/ kg. it’s too high. Because of high

labour cost and slow production. In the local market Compressed Rice husk(CRH)

cost is around 09.30 TK/kg. In this condition I recommend hand press biomass

briquette price should not more than 9-10 tk/Kg .

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