Mridaney S. Poudel et al. Screw Extruder Biomass Briquetting · Mridaney S. Poudel et al.: Screw...

Rentech Symposium Compendium, Volume 1, March 2012

Abstract

activities carried out by the Centre for Energy and

Environment Nepal (CEEN) under the project

“Production

wastes as substitute for fuel wood in domestic and industrial

sector of Nepal

managed by Renewable Nepal Programme of Kathmandu

University and S

traditional fuel resources such as fuel wood, agro

animal dung, which meet over 88% of the energy demand. To

relieve the pressure on these traditional fuels, biomass

briquetting was introduced in Ne

promising technology to produce briquette fuels. These

industries could not survive because of technical as well as

marketing problems. During those days,

by those industries were very costly and complicated.

includes equipment for drying the raw material and

transporting system as well. This package requires a big space

for installation and operation. Further the screw of the

briquetting system wears out very quickly due to the abrasive

nature of the raw m

ash. A comparative study of the production of rice husk

briquettes from the Taiwanese machine with that of the simple

extruder type of briquetting unit modified by the project is

presented.8

Index terms:

briquetting machine

HEPI Briquette Udhyog Pvt. Ltd. is the only surviving briquette industry in Nepal which was

established in 2050 B.been continuously producing the rice huskeight briquetting units/ machines briquette lowered. The Industry has been operating only two extruder units/machine at present.

Fig. 1: Layout of the Mhepi Briquette Industries Pvt Ltd,

* Corresponding a

M


Screw Extruder

Abstract —The paper describes an ongoing research



of biomass briquetted fuel based on agro


sector of Nepal” ID: RENP


University and SINTEF, Norway. Nepal still relies heavily on




briquetting was introduced in Ne









nature of the raw material rice husk containing more than 19%




Index terms: rice husk, fuel briquettes, screw extruder,

briquetting machine

I.


established in 2050 B. S. been continuously producing the rice huskeight briquetting units/ machines briquette lowered. The Industry has been operating only two extruder units/machine

Layout of the Mhepi Briquette Industries Pvt Ltd, Nawal

* Corresponding author: [email protected]


Screw Extruder Mridaney S

The paper describes an ongoing research



of biomass briquetted fuel based on agro


” ID: RENP-10-06-172 funded by NORAD and


INTEF, Norway. Nepal still relies heavily on




briquetting was introduced in Nepal in early 1980’s as a









aterial rice husk containing more than 19%




husk, fuel briquettes, screw extruder,

I. INTRODUCTION


in Kawasoti, Nawalparasi and has been continuously producing the rice huskeight briquetting units/ machines briquette lowered. The Industry has been operating only two extruder units/machine

Layout of the Mhepi Briquette Industries Pvt Ltd, Nawalparasi

[email protected]


Screw Extruder Mridaney S. Poudel, Krishna R




of biomass briquetted fuel based on agro-


172 funded by NORAD and



traditional fuel resources such as fuel wood, agro-residues and



pal in early 1980’s as a



marketing problems. During those days, the technologies used











NTRODUCTION


Kawasoti, Nawalparasi and has been continuously producing the rice husk briquette. It ran eight briquetting units/ machines briquette lowered. The Industry has been operating only two extruder units/machine

Layout of the Mhepi Briquette Industries Pvt Ltd,

[email protected]

Mridaney S. Poudel


Screw Extruder Biomass BriquettingPoudel, Krishna R. Shrestha



Environment Nepal (CEEN) under the project entitled

- forestry


172 funded by NORAD and



residues and



pal in early 1980’s as a



the technologies used

by those industries were very costly and complicated. It











Kawasoti, Nawalparasi and has briquette. It ran

eight briquetting units/ machines briquette lowered. The Industry has been operating only two extruder units/machine

Layout of the Mhepi Briquette Industries Pvt Ltd,

shed to house it. In addition to the cost of plant machinery and equipment, this increases the establishment cost of the industry, making

Some Details of the Industry

M

Shed area and size

Production capacity

Briquetting Plant cost

Power for briquette

Mridaney S. Poudel

Biomass BriquettingShrestha* and Ramesh M

The existing plant requires a big plot of land and big shed to house it. In addition to the cost of plant machinery and equipment, this increases the establishment cost of the industry, making


MAJOR TECHNICAL

Name of Factory (Location)

Owner Land area

Shed area and size

Production capacity (nominal)

Operation hoursOrigin of plant/

machinery Raw material

Briquetting Plant costManpower

No of briquette extruders

Heating of die

Power for briquette extruder

Other powerInitiatives from

owner

Fig. 2: Production of RH Briquettes to Heat the Die (Electric

Mridaney S. Poudel et al.: Screw Extruder

Biomass Briquettingand Ramesh M. Singh

The existing plant requires a big plot of land and big shed to house it. In addition to the cost of plant machinery and equipment, this increases the establishment cost of the industry, making briquetting business very expensive.


TABLE

ECHNICAL COMPONENTS

OF MATERIALS

Name of Factory

Mhepi Briquette Udhyog Pvt Ltd, Kawasoti, Shiva Mandir

Shed area and size

Production capacity

About 4.8 tons per shift average

Operation hours Origin of plant/

Raw material Rice husk, present cost of rice

Briquetting Plant cost ~USD 50,000.00 (1987 Skilled labour

No of briquette

8 (4 Taiwan made 4 Nepali Made)

Heating of die Originally Electric (4x3.4 kW), later

Power for briquette 4x 15HP (4x 15 horse power motors)

Other power Initiatives from Tried briquette production with square

die for better packing and delivery

Production of RH Briquettes to Heat the Die (Electric Heaters Removed)

Screw Extruder Biomass Briquetting

Biomass Briquetting . Singh

The existing plant requires a big plot of land and big shed to house it. In addition to the cost of plant machinery and equipment, this increases the establishment cost of the

briquetting business very expensive.


ABLE I OMPONENTS, POWER CONSUMPTION AND

ATERIALS

Mhepi Briquette Udhyog Pvt Ltd, Kawasoti, Shiva Mandir

Mr Surendra Gorkhali2.5 ropani

>2800 sq ft


One shift = 8hrsTaiwan made

Rice husk, present cost of rice 6 /kg

~USD 50,000.00 (1987Skilled labour-2, non

administration8 (4 Taiwan made 4 Nepali Made)

Originally Electric (4x3.4 kW), later briquettes were used

4x 15HP (4x 15 horse power motors)

See diagram belowTried briquette production with square


Production of RH Briquettes to Heat the Die (Electric Heaters Removed)

Biomass Briquetting


briquetting business very expensive.

ONSUMPTION AND F

Mhepi Briquette Udhyog Pvt Ltd, Kawasoti, Shiva Mandir-3, Nawalparasi.

Surendra Gorkhali 2.5 ropani

>2800 sq ft


One shift = 8hrs Taiwan made

Rice husk, present cost of rice husk = Rs 6 /kg

~USD 50,000.00 (1987-88 price)2, non-skilled-3,

administration-1 8 (4 Taiwan made 4 Nepali Made)

Originally Electric (4x3.4 kW), later were used


See diagram below Tried briquette production with square


Production of RH Briquettes to Heat the Die (Electric

Biomass Briquetting

27


FLOW

Mhepi Briquette Udhyog Pvt Ltd, 3, Nawalparasi.


husk = Rs

88 price) 3,

8 (4 Taiwan made 4 Nepali Made)

Originally Electric (4x3.4 kW), later


Tried briquette production with square die for better packing and delivery

Production of RH Briquettes to Heat the Die (Electric


II. P

Moisture problem

(required moisture content is ~10 %)

Wearing of screw (screw gets worn out after 4

Hard facing rods not available freely

(Indian rods)

technology and plant (Taiwanese technology cost ~US$50,000)

Size of plant is big (requires big land & huge amount of


PROBLEMS OF

PROBLEMS OF

Problem

Moisture problem in rice husk

(required moisture content is ~10 %)

Wearing of screw (screw gets worn out after 4-5 hrs)

Hard facing rods not available freely

(Indian rods) High cost of

technology and plant (Taiwanese technology cost ~US$50,000)

Size of plant is big (requires big land & huge amount of

space )


ROBLEMS OF RICE HUSK

TABLE

ROBLEMS OF RICE HUSK B

Effect

1. Smooth production not possible.

2. Production with explosions

3. Deformed briquettes

1. Briquette production stops

1. Always dependant on contact person

1. Complex technology requiring big investment

2. Production cost high

3. Difficult to payback bank loan

4. No subsidy or incentives

1. Cost of land & industrial shed increases

2. Manpower requirement increases


Fig. 3

USK BRIQUETTE

ABLE II BRIQUETTE PRODUCTION

Effect Request/Remarks of

Smooth production not possible. Production with

1. Any possibility of preheating of rice husk to control moisture.

2. Simplemeasure moisture

Briquette production stops

1. Technique or technology to increase life of screw

Always dependant on contact person

1. Alternative materials

requiring big

Production cost

payback bank loan No subsidy or

1. Cheap and simple technology

2. Subsidy andincentives

3. Market support & protection from govt

Cost of land & industrial shed

requirement

1. Simple cheaper affordable technology

2. Simply operable technology


3: Schematic Diagram with Technical Detail

RIQUETTE PRODUCTION

RODUCTION

Request/Remarks of Ind. partner

Any possibility of preheating of rice husk to control moisture. Simple equipment to measure moisture Technique or technology to increase life of screw

Alternative materials

Cheap and simple technology Subsidy and tax incentives Market support & protection from govt

Simple cheaper affordable technology Simply operable technology

Mridaney S. Poudel


Schematic Diagram with Technical Detail

RODUCTION

Request/Remarks of

equipment to

Alternative materials

protection from govt

Temperature adjustment of

combustion chamber for die heating

(Electric heaters for die removed because

of high cost)No stable

briquettes

High power consumption

Source:

Mridaney S. Poudel et al.

Schematic Diagram with Technical Details

Temperature adjustment of

combustion chamber for die heating

(Electric heaters for die removed because

of high cost) No stable Market for

briquettes

High power consumption

1

Annual Technical Report, for illustration purposes only

Fig. 4: Production Stops when Screw is Worn Out

et al.: Screw Extruder

s

1. Non-uniformity in

product 2. Pollution from

combustion

1. Reduction in production

2. No security of market

1. High cost of production


Production Stops when Screw is Worn Out

Screw Extruder Biomass Briquetting

uniformity in

Pollution from

1. System to control ToC

2. Mechanism to control pollution

No security of

3. Support in Market protection

4. Subsidy & promotion from govt

1. How to reduce



Biomass Briquetting

28

System to control

Mechanism to control pollution

Support in Market protection Subsidy & promotion from govt

How to reduce

power



Biomass Briquetting

Mridaney S. Poudel et al.: Screw Extruder Biomass Briquetting

Rentech Symposium Compendium, Volume 1, March 2012 29

Other problem related information

• The factory has production capacity of 4.8 tons per day /shift, but presently it is producing only 1.5 ton/day. A ton of rice husk can produce 650 kgs rice husk briquette. The price of briquette is Rs.16.00/kg. The machine is operated 8hrs/day with six staffs.

• The life of screw extruder life is very short. The screw wears out within 4-5 hours and needs to be repaired by hard facing welding rods of Indian origin. The brand name and the composition are not known as it is supplied on personal basis. It is believed to be a product of Larsen and Toubro, India.

• Even new screws needs repairing within 4-5 hours of operation. A screw could be repaired 8 to 9 times only and needs replacement in a month

TABLE III SOME COMPARATIVE DATA OF DIFFERENT FACTORIES (VISITED FOR STUDY)

Parameters/Name Ayesha Bikolpa Jalani, Daulatpur, Khulna

Tanvir Hasan Briquette factory

Mhepi Briquette Udyog, Nepal

Remarks/ conclusions

Established 2003 BS 2050 Rate of production 80kg/hr 80-90kg/hr 4 tons/shift Production is higher

because briquetting units are more

No of workers 3 persons: 1man permanent +1woman – daily wages +1 welder- repair of screws)

3 persons (same) man-Tks 6000/month Woman-3400/month

6 persons (2 skilled, 3 non-skilled & 1 admin staff, (welder- Rs 10,000/m)

Manpower cost is higher for Nepali industry, so cost of production will be higher

No of briquetting units 2 units 2 units 8 units Most of the time 2 units only operate in Nepali industry

Established 2003 BS 2050 Rate of production 80kg/hr 80-90kg/hr 4 tons/shift Production is higher

because briquetting units are more

Cost of one unit Takas 50,000.-/unit Takas 50,000/unit 4 Taiwan units US$ ~50,000/

Technology is very expensive in case of Nepali industry

TABLE IV

WORKSHOP CAPABILITY IN SCREW DIE FABRICATION IN NEPAL AND BANGLADESH

Parameters Rupali Engg works Ayub Ali Engineering works In Nepal (no specific workshops)

Cost of screw Tks2500/pc (Screw made from single rod)

Tks 1500/pc (Screw flight is welded to a rod)

~Rs 5000-8000.00

Cost of die Tks 700/pc Tks 700/pc ~Rs 5000.00 Time to make screw 6-8 hrs 3 hrs One day Time to make die (taper is 6 degrees)

1-2 hrs (Die made from readymade forms)

1.5 hrs (Die made from readymade forms)

Min 1 week

Pitch of screw 40 40 As per order Length of die 10.5 inches 10.5 inches As per order

Remarks

1. In Bangladesh there are many industries so there are many workshops serving these industries. Cost and time for making dies and screws is well established.

2. The capability of workshops is well developed and the products are cheap. In Nepal there are no particular workshops to serve briquette industries, so the information varies and the products area expensive.



Fig. 5: Stock of Unfinished Die/Muff Fig. 6: Making a New Screw from Rod

Fig. 7: Sectional Elevation of Screw Type Briquetting Machine



III. PROTOTYPE BRIQUETTING UNIT BY CEEN

Based on the knowledge gained from the visits to various organizations/institutions abroad and in Nepal the project came up with a different design of the briquetting unit for the RENP project. The briquetting unit was fabricated in Nepal using the housing unit provided by NAST and the screw and the die brought from Bangladesh. The technical AutoCAD drawing of the unit as well as the screw and the die is provided in Fig. 7. The details and dimensions of the machine will be provided in the final report after registration of the design with the Department of Industries.

Some New Points Taken up in the New Design

• Usually in most briquetting units (in Japan, Bangladesh, Thailand, Mhepi, etc) the Electric motor has been mounted on the top. Because of the vibrations created by the machine, the whole briquetting unit tends to move/shift sideways during briquetting. Because of this the briquetting units has to be fixed to the ground using some concrete and nuts and bolts. The unit thus becomes fixed.

• The electric motor in this design is concealed in the bottom case. It is secure from dust, smoke and pollution. Also it is protected from any water vapour which may accidentally fall on the motor.

• The weight of the motor holds the entire briquetting unit in place as if it fixed with nuts and bolts. This stabilizes the whole briquetting unit from shifting.

• Normally briquetting units use 2 fan belts to transmit the power. This unit has 3 fan belts, which good transmission of power without slipping.

• A temperature controller has been incorporated to the die, so that the temperature of the die during briquetting can be set at a definite value for research purposes.

• Based on the experiences/lessons learnt a 20 HP motor has been used to run the unit.

• Initially 2 collar heaters of 1kW each has been used to heat the die. Normally spiral heaters of high power were found to be used elsewhere.

The briquetting unit has been installed in the NAST biomass workshop for testing.

IV. CONCLUSION

The research output of the project in its first year showed that, rice husk briquetting industries could be run profitably in Nepal, if simple extruder machines are used instead of making huge investment on the import of complicated technology from abroad. Rice husk the basic raw material for briquetting, is very abrasive in nature with over 19 % ash which causes the wearing of the screw. The project is undertaking research to address the technical problem of wearing of the screw by the introduction of new type of spray welding techniques to enhance the life of screw. Further, the project will identify less abrasive and better raw materials including forest waste as alternative to rice husk. The project will fabricate and test heating and cooking devices to use the briquette fuels for domestic and institutional cooking purposes to replace firewood. Tests

of briquettes will also be conducted in different industrial applications to replace firewood where our industrial partner has been constantly promoting its products.

ACKNOWLEDGEMENT

The authors wish to thank NORAD and Renewable Nepal Programme of Kathmandu University for providing support to CEEN for conducting this research work. The contributions made by its research partner, Nepal Academy of Science and Technology (NAST) and the industry partner, Mhepi Briquette Udyog (P) Ltd and everyone involved in the project is gratefully acknowledged.

REFERENCES

[1] Grover, P.D and Mishra, S.K.,(1995). Proceedings of the International Workshop on Biomass Briquetting, FAO/RWEDP, Bangkok, Thailand.

[2] Moral, N.A,.(2005).Renewable Energy technologies in Asia, Department of Mechanical Engineering, Khulna University of Engineering and technology(KUET), Bangladesh

[3] WECS (2010), Nepal Energy Sector Synopsis Report, Water and Energy Commission Secretariat, Sigh Durbar, Kathmandu.

BIOGRAPHIES

Mridaney Sharma Poudel is a Researcher in the Current project and a Life Member of CEEN.

Krishna Raj Shrestha is Project Leader of the Current project and Chairman of CEEN. Dr. Shrestha is also a Professor at RECAST, Tribhuvan University.

Ramesh Man Singh is a Technical Expert and Senior Advisor to the project and Vice Chairman of CEEN. Dr. Sigh is formerly Chief of Technology Faculty at NAST.

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