Briquettes:

Every year millions of tons of agricultural wastes and forest residues are generated. These are either wasted or burnt inefficiently in their loose form causing air pollution. Handing and transportation of these materials is difficult due to their low bulk density. These wastes can provide renewable source of energy by converting in to high density fuel briquettes with out addition of any binder

Briquettes have high specific density (1200kg/m3) and bulk density( 800kg/m3) compared to 60 to 180 kg/m3 of loose bio mass. These can stand the ardors of long distance transport. Loading/ unloading and transportation cost are much less and storage requirements is drastically reduced. Compared to firewood or loose bio- mass, briquettes give much higher boiler efficiency because of low moisture and density

Briquettes produced from briquetting of biomass are fairly good substitute for coal, lignite, firewood and offer numerous advantages.

Briquettes are cheaper than coal ? Oil,coal or lignite once used can’t be replaced ? High sulfur content of oil and coal, when burnt, pollutes the environment. There is no sulfur in briquettes. ? Bio mass briquettes have a higher practical thermal value and much lower

ash content(2-10% compare to 20-40% in coal). ? There is no fly ash in burning briquettes ? Briquettes have a consistent quality, have high burning efficiency are ideally sized for complete combustion. Combustion is more uniform compared to coal and boiler

response to changes in steam requirements is faster due to higher quantity of volatile matter in briquettes. ? Briquettes are clean to handle and can be packed in bags for ease of handling and storage. ? Briquettes are usually produced near the consumption centers

and supplies don’t depend on erratic transport from long distances.

Briquetted fuel has some shortcoming also:

It can’t withstand direct contact with water hence storage facility for keep briquettes required. Maximum attainable temperature is 1000`C due low carbon content. Burning capacity per unit volume of furnace is low compared to coal.

BRIQUETTES A COMPARISION WHAT CAN BE BRIQUETTED

FUEL Cal. Value COST( Rs) Effiy Saw dust 4200 K al/kg

Furnace oil 9900kcal/kg 85% Ground nut shell 4800 kcal/kg

Kerosene 8900 “” 30/ltr 85% Coffee husk 4200 kcal/kg

dIesel 9400 “” 35/ltr 85% Rice hus 3500 kcal/kg

LPG 10000 35/kG 90% Tamarind shell 4100 kcal/kg

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Coal grade B 5000 “” 5.5/kg 75% Castrol hask 4200 kcal/kg

Coal grade C 4000 4.5/kg 75% Turmeric waste 3700 kcal/kg

Briquette 4200 ‘’ 2.5/kg 75% Tapioca stick 3700 kcal/kg

Firewood 2500 ‘’ 2.0/kg 60% Flower waste 3500 kcal/kg

APPLICATION OF FUEL BRIQUETTES

Agro waste briquettes are the best substitute of coal and fire wood. It can be used wherever coal, lignite, furnace oil and fire wood is used for thermal energy either for domestic or for industrial purposes. Briquettes can be used efficiently as industrial fuel in boilers, furnaces, Brick kilns, hot air generators, and etc it can also meet the demand of fuel in hotels, restaurants , laundries and even in domestic ovens.

2. Technical details

Proximate analysis of briquettes Ultimate analysis of briquettes

Moisture 7.20 to 8 % Carbon 47.10 %

Volatile matter 62 to 68 % Ash content 6.78 %

Ash content 6 to 8 % Hydrogen 5.52 %

Fixed carbon 20 to 26 % Nitrogen 1.87 %

Sulphur 0.26 %

Oxygen ( by differ ) 8.86 %

Fuel briquette in comparison with other fossil fuels

ParticularsCalorific valueAsh contentPollutionPoisonous effluent

AGGNI4300 – 4800 K Cal/kg0.43- 8% ( max)No smoke, No sulphurNone

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COAL3500 – 5800 K cal/Kg34 % - 57%( max)Sulphur , aromatic contentCo2 , c flu gases

LECO6500 k CAL /Kg15 to 20%SulphurCo2, C and flu gases

FIRE WOOD2300 to 3000 k cal /kg20 to 25 %Smoke Nil

Densification of loose biomass (viz., agricultural and agro-industrial wastes) is called biomass briquetting. It facilitates easy transportation, better handling and storage besides being efficient in use as an alternative fuel to coal and firewood. The high temperature developed during the high-pressure densification process assists the inherent lignin present in the biomass to bind the biomass and form a densified fuel called briquettes.

In India, briquettes are mostly manufactured from groundnut shell, saw dust, coffee husk, bagasse, mustard stalk, cotton stalk and press mud. While the southern region of India produces briquettes mostly from groundnut shell, Coffee husk, castrol husk and saw dust, western and northern regions produce bagasse, groundnut shell, cotton stalk, mustard stalk and press mud briquettes. As a recent addition, municipal solid waste is also densified for use as a fuel in process industries (tea, tobacco, textile, chemical, paper, starch, tyre retreading, tiles, etc) for thermal applications.

Briquettes find applications in process industries of any scale using either coal or firewood and in commercial and domestic sectors. In addition, briquettes are widely used in brick kilns in the northern region. Recently, briquettes have also been successfully tried in steel rolling mills and for gasification for power generation.

The two most common and prevalent briquetting technologies are (1) screw extruder and (2) die and punch. Screw extruder technology produces briquettes in a continuous fashion using a pre-designed extruder and a barrel. The briquettes have a carbonized outer surface with a hole at the centre, facilitating easy travel of air around the briquettes, ensuring better combustion. Die and punch technology produce briquettes consisting of punches of briquettes locked together as a perfect cylindrical log without a central hole. The briquettes are brownish in colour without carbonized surface.

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While the screw extruder technology was successful in briquetting rice husk and saw dust in Europe, Japan, Malaysia, Taiwan and Thailand, it miserably failed in India and Nepal due to various reasons. The main reason attributed to this failure was the easy wear on the screw extruder (in one case it did not even last for an hour), besides high specific power consumption. Efforts by experts from various established countries on working with different hard faced alloys and coating on the screw extruder did very little to improve its life.

Further, the variety of biomass in India posed a major threat to the ‘briquettability’ (compatibility) of the screw extruder as different biomass called for different screw extruders and barrel designs. Moreover, briquetting of pyrolysed biomass (char) posed a severe threat to the wear and tear of the screw extruder. Considerable R&D efforts by the Indian Institute of Technology, New Delhi – sponsored by the University of Twente, The Netherlands – reported improvement on the life of the screw and reduction in specific power consumption, but unfortunately remained on a lab scale. These results are yet to be proved commercially, as there is literally no market for screw extruders in India.

However, India gained good operating experience in the die and punch briquetting machines as there are more than 150 plants installed in India with a success percentage of about 70–80. The major reasons for the failure of such plants during the early periods of 1990s were due to poor machine design, poor quality of machines, poor service backup, poor availability of spare parts and little awareness among the fuelwood/coal users (about the benefits of briquettes). Added to these woes was the outright discouraging signals from the bankers for lending working capital for stocking biomass.

Nevertheless, the briquetting plants implemented in India since the mid ‘90s, most of them being self-financing briquettors are doing excellent business, especially in the western and southern regions. A raw estimate says that around 50 000 tonnes of briquettes are consumed annually by the tea industry alone in the state of Tamil Nadu, and 20 000 tonnes by the Indian Tobacco Company in the state of Karnataka. On an average, a typical briquetting plant of die and punch (standard capacity of 750 kg/hour for saw dust) type produces between 250 and 300 tonnes per month which fetches a market price between Rs 2000 per tonne to Rs 3000 per tonne. The profit margin is so good that the payback period is well within 12 months.

Briquettes when replaced for firewood and coal provide a direct cost savings on the fuel to the tune of 25% to 30 % as the combustion efficiency improves remarkably. In addition to such direct savings are the benefits of easy transportation, handling and storing during rainy seasons besides saving labour for sizing the firewood.

These die and punch plants have established their viability and quick return mainly due to the availability of improved machine design and quality, good upkeep of the machinery, continued efforts on expanding the market for briquettes and continued search on sourcing biomass for consistent production and sales.

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This concept gives an opportunity for the briquetting sector to be looked as a means of providing a sustainable livelihood for the rural population as a means for receiving energy from briquettes based gasification besides running a rice mill, marketing of surplus briquettes to the nearest process industry and develop the habit of collecting and storing biomass (an employment generating/ labour intensive exercise).

Once the right sourcing of biomass and market (for briquettes) are established, the right kind of machinery falls in place at a competitive price from AGNI ENGG. & INDUSTRIES, ERODE, TAMILNADU and the project is an assured success.

We make briquetting presses at various capacities from 500 to 1400 kg/hr with briquettes sixe varies from 50 to 90 mm diameter. These briquettes can be made form any of agro wastes either separately or with some combination. The physical and thermal charactersistic value is changed according to the raw materials selection.

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Briquetting PlantBriquetting Plant

Briquetting is a process of fuel manufacturing system from Agro wastes like groundnut shells, cashew nut shells, saw dust, coir pith, coffee husk, cotton stalk et.,

The best and cheif process found in experience is manufacturing briquettes from a mixture of 80% saw dust and 20% groundnut shell. In other cases like 100% groundnut shell briquettes, pulvarised is to be done which increases the production cost.

Briquetting Plant

The Biomass Briquetting plant produce Briquettes from Agricultural waste, Forestry waste.

The Briquetting plant consists of

Feedling system with screw conveyor Press Lubrication system Cooling line Electrical Panel The above system is a Semi-Automotive one with less labour.

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The Briquetting Press is the main machine forming solid bio-fuel briquettes from loose agro wastes. The press consists of main body called Skelton fabricated from 25mm steel plates which approximately weighs 1.50 M.T%. The other parts are two casting fly wheels each weighs 800kg.

Why Briquetting Plant ?

Due to the added benefits and the highlights of the project most developing countries appreciate and endorse the use of non conventional energy to substitute the rampant use of conventional fuels, and at the same time encourage resarch and development of finding newer ways

Attractiveness of the project

High Profitability Excellent Growth potentiality Ready Market. Wide variety and easy availability of agro waste from various crops. short generation and quick returns Employment potentiality Conversion of natural resources (wastage) into hi-tech energy & maintenance of

ecological balance

Government incentives

The Indian Government has offered various incentives for implementation of the Briquetting Plants. Some of the highlights of the incentives offered by the Indian Government for Briquetting Plants.

100% income tex free for the First five years. A subsidy of 35% on the cost of the plant is provided by the Government. 80% depreciation on Capital cost in the First years itself. No Requirment of NoC from State pollution Boards.

Super - 60 Model

Production Capacity 600-750 kg/hrFinished Product Size 60mm DiameterFinished Product Shape CylindricalRaw Material Form PowderyProcess Cost/MT (Approx)

IRs.450/

Super - 75 Model

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As above mentioned that both models will accept only powdery form of Raw Material so, it must required powder making unit. Powder making unit consist parts of:

Super - 90 Model

As above mentioned that both models will accept only powdery form of Raw Material so, it must required powder making unit. Powder making unit consist parts of:

Comparison with other Fossil Fuels

S.NoParticulars Firewood First Rank Coal B1 Calorific Value 2500 to 3000 4200 to 4500 4500 to 60002 Ash 20 to 28% 0.5 to 6% 25 to 50%

3Pollutions Poisonous effluent smoke

SmokeNo Smoke & Sulphur

Sulpur, Co2, Phosphorous Fumes

4 Moisture 25 to 35% 8% 10%5 Cost Rs 2.5/Kg Rs 3.5/kg Rs 6/kg

Cost / Cal Val Rs 4.50 Rs 3.50 Rs 6.506 Efficiency 50% 75% 70%7 Wastages 20% 10% 15%

8 Labour usageRequire Maximum Persons in handling and cutting

Single person is enough

Requires two persons

9 Bolier EfficiencyRequire regular maintanance

Normal fly ash deposit on tubes

High wear & tear

10 Handling Tough require more areasEasy because of packed material

Tough

Country wise Availability of Raw Materials

Malaysia Palam Husk, Rice Husk Char Rice Husk

NepalLabakshi, Lantana, Banmara Water Hyacinth, Agerntum Ficus, Thakal Kanada Katra Ghass

NetherlandsMiscalthus (Elephant grass)Thailand Corn Cob, Corn Cob WasteU.K Ceder ConesU.S.A Commerical BriqVietnam Rice Husk, Rice Char (Ash) Rice Steam, Rice Busha

India

Amla seed, Babool, Bambo Dust briq, beehive briq, Cashew shell, Wheat stalk Coconut shell, Coir pith, Jute Waste, Palm Fonds, Saw dust, Sugarcane, Tobacco Waste, Almonds Bagasee, Bark, Besaram, Castor seed shell, Coffee husk, Cotton shells, Paddy straw, Rice husk, Soyabean husk, Tea Waste,

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Biomass BriquetteBiomass Briquette

Biomass Briquettes are made from the Agricultural waste, Forest Waste and Industrial Waste. It is converted into solid cylindrical shape. The major residues are Rice Husk, Coffee Husk, Coir Pitch, Jute Sticks, Sugarcane Baggasse, Groundnut Shell, Mustard Stalks, Cotton Stalks, Sawdust, Caster Sedd Shells / Stalk, Wood Chips, Bamboo Dust, Tobacco Waste, Tea Waste, Paddy Straw, Wheat Straw, Sunflower Stalk, Palm Husk, Soyabean Husk, Veneer Residues, Barks and Straws, Forestry waste, Seeds Cases etc., Briquettes are the only Binding. Biomass briquettes are eco-friendly renewable source of energy and avoid adding fossil carbon to the atmosphere.

A number of companies in India have switched from furnace oil to biomass briquettes to save costs on boiler fuels. The use of biomass briquettes is predominant in the southern parts of India, where coal and furnace oil are being replaced by biomass briquettes. A number of units in North India are also using biomass briquettes as boiler fuel. Use of biomass briquettes can earn Carbon Credits for reducing emissions in the atmosphere. Biomass briquettes also provide more calorific value/kg and save around 30-40 percent of boiler fuel costs.

Bio-mass briquette is one which takes a waste products such as saw dust, compresses it and then extrudes it to make a reconsistuted log which can replace firewood. It is a very similar process to forming a wood pellet but on a larger scale. There are no binders involved in this process. The natural lignin in the wood binds the particles of wood together to form a solid. Burning a wood briquette is far more efficient than burning firewood. Moisture content of a briquette can be as low as 4%, where as green firewood may be as high as 65%.

Raw Materials used

Groundnut Shell Saw Dust Coir Pith Sugarcane Bagasse Coffee Husk Tobacco stems. Charcoal Powder

Depending upon the customer's requirement of using Raw materials and availability, it can be tried and presented. The above material can be individually Briquetted or in mixed form also.

Products and its Advantage

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Fuel Briquettes are used to replace conventional fuels like coal, firewood in heating and steam generation etc.,

Briquettes have the advantage of having high risk colorific value ranging 3500-5000 K cal.Kg depending upon the raw material used.

Briquettes do not emit smoke with sulfur or phosphorus and also fly ash. Hence no need of pollution control equipments.

Briquetted fuel is sized 80mm in diameter and 50-350mm in length screw type and 45-60mm in diameter in ram type to get complete combution.

Easy handling, storage and transportation as the briquettes are uniform in diameter and can also be packed in bags.

Employment potentiality Conversion of natural resources (wastage) into hi-tech energy & maintenance of

ecological balance • Briquetted fuels, as it is made out of agro waste can be made easily available

and there is an advantage of bulky garbage reused with high fuel efficiency.

Uses of Finished Briquettes in various Industries [ Thermal Application ]

Gasifier System applications Refractory Industries Chemical Industires Vegetable Plants Leather Industries Milk Plant Spinning Mill Rubber Industries Textile Units Dyeing Units Brick making units Ceramic Industries Solvent Extraction Plant Food Processing Industries Lamination Industries Any Industrial Thermal Applications Bio coal is a forth coming fuel of the world. It's a high quality assest towards

economical, ecological and advanced environmental company policy.

A Briquette is an Ideal Fuel due to

Eco friendly and Renewable Energy Fuel. Economical and Cheaper than other solid fuels ie. Coal and Wood. Higher Thermal calorific value around 4000 Kcal/Kg. Pollution free because there is no sulphur or any hazardous materials. Lower ash content 2 to 5%. There is no fly ash when burnt. Consistent high burning efficiency due to the low moisture. Contain High Density and Higher Fix Carbon Value.

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Easy for Transportation, feeding & combution due to unique shape. Combution is more uniform compared to other fuels. Good Market due to rise in price of Fossile Fuels.

Agro Waste briquettes have benifits over coal like

Easy handling, packing and transportation of briquettes can be made in any conventional length and diameter.

Low ash content below 10% in comparison to coal 25 to 40% resulting in less boiler ash disposal problems.

Regular supply of briquettes do not suffer from transportation bottle necks as the plant can be set up near raws areas.

There will be no corrosion effect on boiler equipments resulting in negligible maintanance cost. Coal on the other hand produces sulphur dioxide, which on mixing with moisture produces sulphuric acid an corrosive acid.

It has low ignition point, when compared to coal. It gives sutained combution and more efficient combution than loose agro

wastes. It is a clean fuel. No gas and effuluents like coal. So no health hazards. Easy Handling compared to loose husk and fire wood. Can be mixed with coal

and fire wood of inferior quality which improves burning. Bruquettes are Cheaper than coal. High Sulphur content of oil and coal, when burnt, pollutes the environment.

There is no sulfur in briquettes. Biomass briquettes have a higher practical thermal value and much lower ash content 2-10% compared to 20-40% in coal.

There is no fly ash in burning briquettes. Briquettes have a consistent quality, have high burning efficiency are ideally

sized for complete combution. Combution is more uniform compared to coal and boiler response to change in steam requirements is faster due to higher quantity of volatile matter in briquettes.

Briquettes are usually produced near the consumption centers and supplies don't depend on erratic transport from long distances.

Briquetting MachineBriquetting Machine

Briquetting is a process of fuel manufacturing system from Agro wastes like groundnut shells, cashew nut shells, saw dust, coir pith, coffee husk, cotton stalk et.,

The best and cheif process found in experience is manufacturing briquettes from a mixture of 80% saw dust and 20% groundnut shell. In other cases like 100% groundnut

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shell briquettes, pulvarised is to be done which increases the production cost.

The Machine which produce Briquettes is called Briquetting Machine.

A Briquetting Machine Normally Consists of :

1. Briquetting Press with reduction gear. 2. Cooling Line 20' with supports. 3. Foundation Bolt set. 4. Machine & Cooling Line Joint 5. Die Holder-1 6. Tool kit 7. Screw Conveyor. 8. Screw Conveyor & machine Joint. 9. Screw Conveyor cover sheet. 10. Oil Pump with cooler & filter. 11. Pulleys & Belts 12. Motor Railing 13. Motor Railing Adjustment Bolts 14. Die Set Remover from D/Holder 15. Flexible water pipe for die holder cooling 16. Std. Spares Main die, Split die, Ram, Tikki, T/bolt, Collate17. With all Electrical Accessories

Super -60 ModelSUPER 60 DIA MODEL AN INTRODUCTION

Production Capacity600- 700 Kg /hour (average 650 Kg)

Finished Product Size 60mm DiameterFinished Product Shape CylindricalRaw Material Form Powder/ 1-3mm lengthTotal Weight 4.5 tonne (Approx)

RAW MATERIALS CAN BE USED:Wooden Saw Dust : up to 100%Groundnut Shell, Bagasse (Sugarcane Waste), Press mud, Tamarind Waste, Coffee Husk, Paddy Husk, Coir Pith etc. These raw materials can be mixed up to 30 % along with Sawdust.

SPACE REQUIRED (FOR BRIQUETTING MACHINE & DRYER)

Sheltered 100X40 ft Open Space as per requirement

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Power 60 HP

LABORER REQUIREMENT:

Per Shift I operator + 6 helpers

BRIQUETTE MACHINE SPECIFICATION: (approx)

Overall Length 5.5 mtrsWidth 1.8 mtrsHeight 4 mtr (with conveyor)Total Weight 4,500KgOil Capacity 40 Ltr (Apprx)Oil Alpha ZN220

 

Super - 75 ModelAs above mentioned that both models will accept only powdery form of Raw Material so, it must required powder making unit. Powder making unit consist parts of:

SUPER 75 DIA MODEL AN INTRODUCTION

Production Capacity800- 900 Kg /hour (average 1,000 Kg)

Finished Product Size 75mm (dia)Finished Product Shape CylindricalRaw Material Form Powder/ 1-10mm lengthTotal Weight 5.5 tonne (Approx)

RAW MATERIALS CAN BE USED:

Wooden Saw Dust : up to 100%Groundnut Shell, Bagasse (Sugarcane Waste), Press mud, Tamarind Waste, Coffee Husk, Paddy Husk, Coir Pith etc. These raw materials can be mixed up to 30 % along with Sawdust.

SPACE REQUIRED (FOR BRIQUETTING MACHINE & DRYER)

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Sheltered 100X40 ftOpen Space as per requirementPower 80 HP

LABORER REQUIREMENT:

Per Shift I operator + 6 helpers

BRIQUETTE MACHINE SPECIFICATION:

Overall Length 6 mtrsWidth 2 mtrsHeight 4 mtr (with conveyor)Total Weight 5,500Kg

Oil Capacity 50 Ltr (Apprx)

Oil Alpha ZN220

Super -90 ModelAs above mentioned that both models will accept only powdery form of Raw Material so, it must required powder making unit.

Production Capacity 1,100- 1,250 Kg /hourFinished Product Size 90mm (dia)Finished Product Shape CylindricalRaw Material Form Powder/ 1-10mm length

Raw materials Can be Used:

Wooden Saw Dust : up to 100%

Groundnut Shell, Bagasse (Sugarcane Waste), Press mud, Tamarind Waste, Coffee Husk, Paddy Husk, Coir Pith etc. These raw materials can be mixed up to 30 % along with Sawdust.

Space required (for Briquetting Machine & dryer)

Sheltered 100X40 ft Open Space as per requirementPower 75 HP

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Laborer requirement:

Per Shift I operator + 6 helpers

Briquette Machine Specification:

Overall Length 6 mtrsWidth 2 mtrsHeight 4 mtr (with conveyor)Total Weight 7,000 Kg

Oil Capacity 60 Ltr

Oil Alpha ZN220

Briquetting PlantThe Biomass Briquetting plant produces Briquettes from Agricultural waste, Forestry waste.The Briquetting plant consists of

Feeding system with screw conveyorPressLubrication systemCooling lineElectrical PanelThe above system is a Semi-Automotive one with less labor.

The Briquetting Press is the main machine forming solid bio-fuel briquettes from loose agro wastes. The press consists of main body called Skelton fabricated from 25mm steel plates which approximately weights 1.50 M.T.. The other parts are two casting fly wheels each weighs 1000kg.

Maintenance:

A. Change the spares like Taper Die, Split Die, Ram in 160 Hrs. and 40 Hrs.Once Change the wear ring.

B. Change oil (Alfa ZN 220) in 2000 Hrs. (40Lts.)

C. Change the all Phosphor Bronze bush in 5000 Hrs.

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Dryer:For moisture content control you have to install one dryer also

Moisture Evaporation Capacity 1,000 hg/hourInput moisture level 35%Outlet Moisture level 5%

Agro Wastes can be used as a fuel for furnace.

awdust Drying Machines

Drying is significant for the good preparation of resources previous to their briquetting. To build superior quality briquettes with high mass, it is very vital to manage the wetness content of raw stuff to 8-12% before loading the them into briquette machine, so sawdust and other kinds of biomass want to be dried first.

Operation principle: The entire systems consist of fan blower, motor engine, fuel boiler, steel pipe, cyclone and air lock.In this structure, wet objects is input into the hopper by screw feeder; Fuel boiler produces large amount of hot air, that hot air is motivated into steel pipes, varied with wet sawdust and moved through twist pipes and ventilation chamber by the power of fan blower. Fast moving hot air sustains and is mixed with raw material sent by twisting feeder in the suspending state through the steel pipe; moisture evaporates as the material traverses along the steel pipe and is rendered dry at the discharge end. Humid air is continuously exhausted, thus the material is dried. The air lock in the outlet stops the hot air to be exhausted to the atmosphere, but release the dried material via cyclone.

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Typical Applications:Ultimate for subtraction of moisture from free of charge smooth materials which is light and tiny like sawdust, rice shell, milled stalks etc.; suitable for small production scale below 700kgs per hour.

It is suitble for drying materials of moisture 30-35%. It takes the advantages of low cost consumption and high efficiency, reducing the moisture to 8-12%. Wet material is input into the hopper.The stoves (boilers) generate hot air which mixes with wet materials and then is sucked into the pipes by the exhaust blower (fan) quickly. And then hot air are flowing and going though the curving pipes and buffer (drying chamber) of dryer, thus wet materials is finished to dry, and the dried materials are discharged from the outlet with air lock.

Technical data :

Output 1000-110kg./H.Diameter of Rawmaterial 3 AND 5 mmTemperature of Hot Air 180°- 250°CConsumption of Waste 70 Kgs.

Power : Centrifugal Fan + Converyor+ Air Lock + Exhaust

  ( 15 HP) ( 1 HP) ( 1 HP) ( 2 HP)

Height of the Pipeline 18 Ft.Dimension of Boiler 11' X 7'Gross Weight 2850 / 3080 KgConsumption of Waste 70 Kgs.

Disintegrator

Real TEch Disintegrator are well designed Disintegrator mills of simple and sturdy Construction, They re ideally suited where coarse grinding of soft and medium hard products is required.The main shaft is the only revolving parts, which require no adjustment. This main shaft runs on Ball/ Roller bearing and it contains fix/swing type hammers.

The fineness of the finished products is controlled by te replaceable screens fitted on the lower of the disintegrator body. The screens of desire mesh can be easily changed. All portions of the body where wear and abrasin is expected are lined with replaceable hard alloy liners.The screen is adjustable.

The grinding (disintegratin) is achieved by the impact of hammers against the liner fitted in the body,and the fine products passes through the screens of desired fineness

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Manufacturers of :

  Bio Mass briquetting Machine.

  Saw Dust Drying Machine .

  Heavy Machinery Spares

  Disintegrator

Fore more details please visit <="" a=""> www.realtechbriquettingmachines.com

Production Cost per TON   

Average Material Cost 2000/-Die Spares 120/- Per TonLabour Cost 200/- Per TonCurrent 200/- Per TonGunny Bags 50/- Per TonAdministration 100/- Per TonOil and etc., 15/- Per TonPB Bush 15/- Per TonProduction Cost per Ton 2700/-

The Selling rate is Rs. 4000.00The Profit per Tonne isRs.  700.00Maintanance  

Change the spares like Taper Die, Split Die, Ram in 160 Hrs. and 40 Hrs. Once change the wear ring.Change oil ( Alfa ZN 220 ) in 2000 Hrs. (40 LTs.) C. Change the all Phosphor Bronze bush in 5000 Hrs.

Requirement of Power  :  50 HP.Plant Size                   :  100 Feet length and 40 Feet Width.

Die Cost  

Taper Die 2800.00Split Die 1500.00Ram 2800.00Wear Ring 320.00Scrapper Ring320.00

The Machine capacity is 0.7 Ton/Hr. If the machine runs for 10 Hr per day the production is 7 Ton/day and for 20 Hr 14 Ton/day. The cost of machine will be Rs. 7.75 lakhs(approx). Building required with roof 100 sq.feet open area for sundry 4000 sq.feet. Raw material storage and finished goods stock area are to be provided.

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Benefits of this project

The demand of finished product briquettes is increasing day by day. It is available in various type of raw material easily in bulk. It is promoting to the Industries as a prime renewable energy project throughout the world. The project gives excellent viability. 

The total paybackperiod of the project is approximately 2 year. It is pollution free and no hazard in this project. It is eco friendly renewable green energy project.

Governments are declared Incentives and Tax Benefits time to time for this project. The incentives are such as income tax, Depreciation, Sales Tax, VAT and Excise Duty. The pollution Control Board also granted to run the plant without NOC from the board. NGO or Nationalized banks are giving priority to finance the project

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Preparation For installing a Briquetting Plant:

In order to put up a briquetting plant these are the few things that need to be taken care of after which would be no problem in running the business successfully

1 Raw Material:

It is of paramount importance that the availability of raw material in seen though. Raw material is the lifeline of any briquetting plant. It should be confirmed as to how much and in what state would it be available. This will help to decide the pre processing equipments that may be required in the plant to ensure continuous supply of finished goods. Plant should be located in such a way that maximum raw material can be obtained within an area of 100 kms. Transportation more than this can increase the prices of raw material significantly.

2 Power:

After the size of plant and pre processing equipments have been determined and one has a fair idea of the electrical power required, steps should be taken to procure the same. Thus, it also implies that the plant should be located in an area where connection is easily available.

3 Sales:

Raw material once converted in to briquette can than be transported over long distance without major increases in cost, it is not necessary to sell in one particular area. Major consumers include brick kilns. Dyeing factories and Cement industry.

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BENEFITS :

1 Briquettes are cheaper than diesel, LDO and coal, so selling would not pose a major problem. Small scale industries like bakeries, milk treatment units and other industries using boilers or furnaces of any make can be approached and easily converted.2 Income Tax Holiday: under 80 JJA of the Income Tax Act, with effect from April, 2000. 3 Excise Exemption: Solid fuel briquettes and Briquetting Plants Machinery are completely exempted from excise duty. 4 Low Rate of Interest: Term loans & working capital limits from financial institutions are available at low rates of interest. The Govt. has for this purpose also set up Indian Renewable Energy Development Agency to provide funding for such projects. 5 Delicencing of Industry: The whole industry on non-conventional energy sources has been delicensed and no license is required for setting up the same.6 Benefits of Priority & SSI Sector: Energy being a priority sector and considering the cost of project, benefits of both the priority and SSI are available.

Essential requirements for putting up a Briquetting plant are:

1) Capital2) Availability of sufficient raw material.

Market for briquettes is everywhere where coal or oil is used and is not a factor to be considered.

If the material is seasonal and arrangement for storing adequate material for off season is not possible, alternative raw material has to be arranged.

material being briquetted:1 saw dust2 Bamboo dust 3 Mustard stalk4 Cotton stalk5 Coffee husk6 Rice Husk7 Groundnut shell 8 Pine needles9 Bagasse10 Coir pith11 Sugar mill pressmud 12 spent tan13 Pine needles14 Rice Husk15 Jute waste16 Coir Pith

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*** Briquettes can be made from all types of agro waste. Certain parameters of raw material have to be ensured. These are as follows:

1. Material should not have moisture more than 12%.2. Material size should not be more than 5-6mm in dia(machine specific).

If the raw material meets these criteria then it can be easily converted into bio fuel using a briquetting machine. The material has to be fed to the machine for which a screw is provided. This screw regularizes feeding and is adjustable to control the feed to the machine. The material passes through the screw and is deposited into a funnel where another screw compresses it into the feeder box. From the feeder box the material is then pushed into the die by a ram. The die, which is placed inside a heated die holder, then compresses the raw material and squeezes out the lignin which acts as the binding agent and densifies the material. The material thus comes out of the die hlder and travels through a cooling line and briquetting is complete

This is based on the High Pressure Ram Type Binderless Extrusion Technology. There are reliable heavy duty ram type press designed for continuous operation, equipped with a sturdy crank gear, cross head and two flywheels. One of the fly wheels acts as a pulley and is driven by the main motor through flat belt. Forced lubrication is provided by oil circulating system with dual filtration and forced cooling. Material is continuously fed through a hopper by means of a vertical feeder with its own gear box and motor. Regulated feed to the press is provided by independently driven feeding system.

Dry ground or granulated material is fed to the top of the vertical feeder by screw conveyor. The vertical screw pre-compresses and forces the material downwards into pre-compression chamber. Here the material is forced by the ram through a die system into briquettes to the cooling line. The total operation is continuous and controlled from the main electrical panel.

For the binderless production of high density solid fuel briquettes i.e BIOCOAL from all types of granulated degradable biomass, residues and wastes such as rice husk, ground nut shells, wood waste, cotton shell/stalks, mustard husk/stalk, sugar cane trash and bagasse etc.

Technical specification

Model BP6175 BP652 Production Capacity (On Saw Dust Basis, 160 kg/ M3)

750 kg/hr. 1000 kg/hr.

Swept Volume (M3/hr.) 7.5 10

Operating Parameters Input bulk density 140 to 200 KG/M3140 to 200 KG/M3

Moisture Contents <15% <15%Briquetting Pressure 1200 kg/CM2 for binderless

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briquettingVolume Displaces (M3/hr.) 4.2 4.2Size of BriquetteDiaLength

60-63 mm15-200 mm

65-67 mm15-200 mm

Stroke per minute 200 200 Stroke Length 175 mm 200 mmPower Load (H.P)Main Motor Oil Pump Vertical Screw Inclined Screw

400.7521.50

50121.50

DimensionLengthWidth Height

2100 mm900 mm1800 mm

2100 mm900 mm1800 mm

Nett Weight 3350 kg (Approx)m3550 kg (Approx}

*Technical modifications reserved.

Table of Briquetting models: Press Model BQ4125 BQ6175 BQ65200 BQ75200

Bqt diameter,mm 40 60 65 75Stroke length,mm 125 175 200 200RPM 275 230 200 200Rated Production Kg/Hr 250 750 900 1200Power HP 20 40 50 60*Rated production is based on saw dust of 180 Kg/M3 bulk density as raw material.

DRYERFlash drying is a pre-process to densification much like grinding. Flash dryer is used for suspension drying of powdery, ground or granulated material such as saw dust, coir pith and baggasse pith which are usually materials with moisture content of 35% of less

The second type of dryer is the concentric coloumn turbo dryer which consists of a jacketed drying column. the drying column is actually a pipe inserted inside another bigger pipe and hence the material passes through the same drying column twice. As a result this dryer can dry materials having moisture upto 50% on wet basis. Basic turbo dryer system consists of Screw Conveyor, Feeding Hopper, Main Drive, Conveying line including insulated drying column and conveyor through which wet or moist material is transported in the presence of hot air to the cyclone. A powerful low pressure centrifugal fan assures sufficient resiliance time for complete removal of excess moisture. Material is discharged through cyclone by means of a Rotary Air Lock

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HAMMER MILL GRINDERHammer Mills are used for shredding of biomass, horticultural and forest residues. Medium speed heavy swing hammer mill chops the biomass into granular size which is passed through a screening area Hammer Mill is placed on anti-vibration mounting for vibration less operation and structural safety of building. Power is provided by directly coupled TEFC motor. Feeding screw to the Hammer Mill is provided with frequency control device to control the input feed.

Material is fed into the Hammer Mill by the Feeding Conveyor. Wide opening feed mouth is suitably designed for safe feeding. Swinging Hammer Mill forces the material on to the stationary grinding bars. Material is shredded to desired size by having restricted air gap between swinging Hammers and Grinding Bars.

For grinding biomass waste and residues such as rice husk, ground nut shells, woodchips, cotton shell/stalks, mustard husk/stalk, sugar cane trash and bagasse etc. with maximum moisture contents 25% having a maximum size 50mm length and 20 mm dia.

Technical specifications:

Model HG2816 Capacity (M3/hr.) 5Motor 40 HPOperating Speed 2000-2400 RPMGrinding Area DiaWidth

710 410

DimensionsLength>br/>WidthHeight

1000 mm800 mm1250 mm

PILLETTING MACHINE

HERE A Roller run on a slow speed and press the material in die holes and extrudes the material. Length of pellet can be adjusted by knife provided below the die. Pellets so formed are cooled on cooling conveyor and send for storage. Most of the biodegradable materials like Ground Nut Shell, Wood Waste, Bagasse, Straw, Grass etc can be pelletised.

PNUMATIC CONVEYING SYSTEMPneumatic conveying system for use in conjunction with hammer mill grinder. Low sped centrifugal fan, high efficiency cyclone for optimum separation of ground material, totally enclosed screw conveyor for feeding the grinder, closely machined Rotary air lock for system separation piping dampers diverters are in heavy gauge construction, discharge chimney, return ducts of open dust bag filter can be provided to control the dust

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within SPM standards.

Technical details :

Capacity (M3/hr.) 57.0-10.0Conveying Distance:Horizontal (Mtr.) 3-4Vertical (Mtr.) 8-10Fan Motor 7.5 HPRotary Air Lock Motor 1 HPScrew Conveyor Motor 1.5 HP

TURBO DRYERFor Suspension drying of ground material such as saw dust, coir pith, bagasse pith etc having maximum moisture of 35% (wet basis).

Model CCTD CCTD15 Capacity* (kg/hr.) 750 1500Max. Moisture of Output Material (%) 12-15% 12-15%Electric Motor (HP)Centrifugal FanRotary AirlockScrew Conveyer

7.511

1511.5

- * Based on suitable material's and continuous operation input material moisture maximum 35%- Technical modifications reserved.

Rahul Choraria, Sales Head New Life Engineering Co.5/ 1, Motilal Mullick Lane,Kolkata | West Bengal - 700 035 | India +91 33 25785795 / +91 9830 787 985-------------------------------- ----------------------------- ----------------------------- -------------------------

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