By Shrikant Athavale Prathith Consultants Pune India Email : psatechno@gmail.com 06 Feb 2013

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The Common Rubber Products Molded products , Extruded products, Calendared Rubber sheets , Latex Dipped Goods

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The Machines used

Molding Press

Molding Press

Calendar Kneader /

Mixer 06-02-2013 3

The Machines used

Molding Press

Molding Press

Calendar

Cold feed

Extruder

Vulcanizer

Pre Cored Tread

press

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Continuous

Dipped Goods

Continuous

Conveyor Belts

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All these Machine need Heat Source For Vulcanization of Rubber Compound

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The common heat source is either Electricity , Hot air Or steam

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The Hot air / Steam is obtained from

Hot Air Generators,

Thermal Fluid Heaters , Or Steam Boilers.

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The required Heat Energy is obtained by burning fuel Such as High Speed Diesel ( HSD ) , Light Diesel Oil ( LDO ) , Furnace oil ( FO) or wood.

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In this Presentation I am going discuss about The Heat energy cost. The Fuel cost , for e.g. HSD , LDO , FO is raising every day. The fuel is one of the major cost incurred in today’s world. The raising fuel ( Oil based ) cost cannot be controlled by us .

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Now we are in a position not only to control the same but save / cut down to almost 50% , by making a smart choice.

But

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But How ?

The answer is

switch over to Biomass BriquettesFuel

and

Bio Mass Briquette Boilers

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What is Biomass?

• Biomass is any organic matter.

• Including trees, plants, plant fiber, and animal wastes.

• Biomass is a renewable energy source

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• The energy stored in biomass is called bioenergy.

• Bioenergy is very versatile: It can be used to provide heat, make fuels, and generate electricity.

• Many bioenergy sources are replenished through the cultivation of fast growing grasses, trees, and agricultural residues like vegetable oils, wheat straw, or corn.

What is Bioenergy?

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Future Prospects of Bioenergy

• Bioenergy is generally cost competitive with fossil fuel generated electricity when biomass residue prices are very low or negative.

• Transportation costs are key to the price so biomass power plants must be sited near an ongoing, reliable biomass source.

• Most analysts believe that the economics of bioenergy will improve with higher efficiencies.

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Technical Matters 1. What is a biomass boiler? Answer A biomass boiler is a boiler designed to burn solid fuels classed as biomass. Such boilers can be supplied to burn every form of biomass from woodchips, wood pellets or logs to waste agricultural materials such as straw and grain husks, olive kernels, rice and the dust from any of these including sawdust. Boilers need to be designed to burn specific materials, with any given boiler able to burn a limited range of biomass. 2. Can a biomass boiler be connected to my existing heating system? Answer Yes, in much the same manner as any other boiler. However, as many biomass boilers operate at a higher temperature, and hence pressure, than fossil fuelled boilers, with some operating at above 100C, it may be necessary to interpose a plate heat exchanger between the biomass boiler and the existing heating system.

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Technical Matters 3. How is a biomass boiler controlled? Answer In many respects biomass boilers can be controlled based on heat demand just as with fossil fuelled boilers. However, the much slower response of biomass boilers to changes in load mean that up to three control loops are used to control the fuel feed rate, the primary and secondary air fans, and the delivery of energy to the load including the charging/discharging of the buffer vessel. 4. Do I need another boiler as a back-up? Answer A properly designed and installed biomass boiler will be as reliable as a fossil fuelled boiler, and in this respect the usual rules for specifying back-up boilers should be applied.

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Technical Matters 5. What are the best applications for a biomass boiler? Answer Biomass boilers operate at their highest efficiency, and are most reliable, when operating continuously. Biomass boilers cannot be switched on and off like fossil fuelled boilers and need to operate in conjunction with a buffer tank if the boiler is to be able to handle modulating loads, particularly loads less than the minimum boiler output, whilst continuing to operate efficiently. 6. What maintenance does a biomass boiler require? Answer While fossil fuelled boilers usually require an annual maintenance visit only, biomass boilers require more attention. Biomass boilers burning even the most difficult of materials can operate unattended, but weekly inspection visits are required to carry out a visual inspection of the boiler and fuel feed system, to check the lubrication of bearings and to empty the ashbin. If the boiler is not fitted with automatic flue cleaning, regular cleaning of the flue tubes is required using a flue brush.

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Technical Matters 7. What are the main components of a biomass system? Answer In addition to the boiler itself, a biomass system will require a fuel store (silo) and a mechanism to extract fuel from the store and to feed it into the boiler. The flue gases may require treatment and a cyclone grit arrestor is the most common flue gas cleaning device. Where a cyclone or other flue filtration system is fitted, an induced draught fan will be required on the flue. Finally, a buffer vessel will be required for the majority of boilers in the majority of circumstances.

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Technical Matters 8. Can a biomass boiler work fully automatically? Answer All but the smallest of biomass systems can be configured to work fully automatically. Typical automated features include time switch or optimum start/stop, fuel feed, de-ashing and flue cleaning. The majority of boilers can operate for up to 1 week at a time without manual intervention. 9. Do I need a tall chimney? Answer The height of flue required depends on many factors including the boiler rating, whether an induced draught fan is installed and whether the boiler is to be installed in a Smoke Control Area.

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Technical Matters 10. Do biomass boilers produce any smoke or other emissions? Answer A well designed and operated biomass boiler burning fuel within the specification of the boiler should not produce any smoke, but black smoke may be produced if the fuel is too wet for the boiler. All biomass boilers produce some oxides of nitrogen (NOx), particularly nitrogen dioxide (NO2). While Nox emissions from gas boilers have been reduced significantly in recent years through the use of low Nox burners which burn at a temperature slightly below that at which NOx forms, the nature of biomass combustion, and the need to ensure the complete combustion of wood gases, means that combustion takes place at a temperature where atmospheric oxygen and nitrogen can chemically combine. The better the quality of the combustion control system on a biomass boiler, the lower the NOx emissions will be. In general, biomass boilers produce less NOx than oil boilers. Biomass boilers do not produce any oxides of sulphur (SOx).

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Technical Matters 11. How do I dispose of the ash which is produced? Answer The ash produced from biomass boilers is high is potash which makes the ash valuable as a top dressing by farmers or as a component of composts by horticulturalists. If ash cannot be disposed of in this way, or if the quantities are small, it can be disposed of to landfill with other wastes. On large boilers fitted with flue gas cleaning equipment, and where the fly ash is collected separately, it may need to be treated as special waste if the concentration of any heavy metal in the fly ash exceeds a threshold value.

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Technical Matters 12. How do I ensure consistent fuel quality? Answer Operators of wood pellet boilers rarely need to concern themselves with fuel quality as pellets are manufactured to a consistent size, moisture content and calorific value. Operators of woodchip boilers, however, need to be aware of the many fuel quality issues which can arise with the use of woodchips.

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Technical Matters 13. How reliable are biomass systems? Answer The reliability of a biomass system is closely allied to the quality of fuel being burned. Hence, wood pellet systems tend to be inherently more reliable and less prone to breakdown than woodchip systems for the reasons given in the answer above.

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Bio Mass Briquettes Advantages of Using Biomass Briquettes for Renewable Energy

There are many reasons for using biomass briquettes for renewable energy.

These briquettes are made by using agricultural waste that would otherwise not

be used productively at all.

There are several advantages to using them.

Biomass briquettes for renewable energy can replace wood as a fuel. To say that

wood is a renewable energy source is stretching the truth a bit. Of course, wood

will renew itself faster than petroleum or coal.

Biomass briquettes are made of grass, husks, corn stalks, hulls, leaves, food,

and animal wastes. These are materials that usually fall to the ground and go

back into the earth.

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Bio Mass Briquettes

There is another advantage of using biomass briquettes for renewable energy.

People who have been using firewood for heating and cooking will find that the

biomass briquettes are more efficient. In fact, they are 40% more efficient, as

well as hotter and longer lasting than firewood.

The biomass briquettes used for renewable energy can also create local industry

and jobs in developing countries. The materials for the presses can often be

obtained in the location needed.

Biomass briquettes may well be the energy source of the future for many

countries. They will reduce pollution, improve health, and provide a steady

source of fuel. They can preserve the forests of countries all over the globe. At

the same time, they will help local industry to flourish. Using biomass briquettes

for renewable energy is a good choice for many.

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Briquetting is a way to convert loose biomass residues, such as

sawdust, straw or rice husk, into high density solid blocks that can be

used as a fuel.

Biomass briquettes (including pellets, which are very small briquettes)

replace fossil fuels or wood for cooking and industrial processes. They

are cleaner and easier to handle, and cut greenhouse gas emissions.

High pressure briquetting plant can produce over 200 tonnes of

briquettes per day.

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Briquette is an Ideal fuel

because it is

Eco friendly and renewable energy fuel

economical than other solid fuels , i.e coal or

wood

pollution free , being sulpur free

lower ash content 2 to 5%

consistent high burning efficiency due to low

moisture content

easy for transportation , feeding and combustion

combustion is more uniform than coal

economical as compared to fossil oil

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Woody Bio

Mass

Non-Woody

Bio Mass

Process waste Processed Fuel

Tree

Shrubs &

Scrub

Bushes like

Coffee/ Tea

Sweepings

from Forest

floor

Bamboo

Palms

Energy corps

like sugar cane

Cereal straw

Cotton,

Cassava,

Tobacco stem/

roots

Grass

Bananas ,

plantains

Cereal husks

Bagasses

Waste from

pine apple /

other fruits

But shell

Saw mill waste

Municipal

waste

Charcoal

Briquette

Methanol /

ethanol

Plant oil from

palm/ sun

flower

Bio gas

Classification of Biomass

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Pros and cons The need for natural energy resources has increased manifold in the past few years. Natural energy resources like gasoline, diesel, natural gas, kerosene, coal, etc. are non-renewable resources. This means their supply is limited and overuse will lead to loss of these resources. Also, these natural energy resources lead to a lot of air and to some extent water pollution. In order to limit their use and supply, one has to look for alternative source of energy. These include solar energy, wind energy, geothermal energy, hydro energy, nuclear energy as well as biomass energy. What is Biomass Energy? Biomass is composed of organic material obtained mainly from plants and animals. Carbon is the main constituent of biomass energy. Other than carbon, nitrogen, oxygen, hydrogen, heavy metals and alkaline earth are also present in biomass energy. It can be generated from plants and animal wastes, wood, leaves of plants, agricultural wastes, organic wastes, waste paper and wastes from food processing industries.

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If one thinks about use of solar or wind energy, the problem lies with costs. This means elaborate setups are required to capture and convert solar energy into a usable form. Tidal energy tends to have very low potential commercially and nuclear as well as hydro plants may have many dangerous consequences. In such a situation, the most economical as well as safe form of energy is biomass energy. However, biomass energy has its pros and cons that one should weigh carefully before deciding if this is the most suitable and viable energy resource.

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Hot Air

Bio Mass Technology How does it work?

Curing

The most popular way to make biomass into Hot air is to burn it to produce heat because it is chemical energy.

The waste wood, tree branches and other scraps are converted into Briquettes

The Briquettes are fed into a furnace where it is burned and the heat produced

is used to heat Air / Oil in the boiler, and the energy is used for drying

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Operating cost comparison 200 LDO

Sr. No. Parameter Unit

LDO fired Thermal Fluid

Heater

Agrowaste fired Thermal Fluid

Heater

1 Heat output kcal/hr 200000 200000

2 Overall thermal efficiency % 88 75

3 Heat input kcal/hr 227273 266667

4 Fuel LDO Agrowaste Briquettes

5 Calorific value (CV) of fuel kcal/kg 10100 3500

6 Fuel consumption kg/hr 23 76

7 Fuel consumption lit/hr 26 NA

8 Purchase cost of fuel Rs./kg NA 5

9 Purchase cost of fuel Rs./lit 55 NA

10 Cost of fuel for heat generation Rs./hr 1456 381

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11 Electricity rate Rs./unit 6 6

12 Total connected electrical load kw 6.71 8.58

13 Normal electrical consumption kw 5.368 6.864

14 Electricity cost Rs./hr 32 41

15 Working hours per day hours 24 24

16 Number of working shifts 3 3

17 Number of firemen / helpers NA 4

18 Salary of 1 firemen / helper Rs./month NA 10000

19 Salary of all firemen / helpers Rs./month NA 40000

20 Salary of all firemen / helpers Rs./day NA 1333

21 Salary of all firemen / helpers Rs./hr 0 83

22 Total running cost Rs./hr 1488 505

Operating cost comparison 200 LDO

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23 Saving in running cost Rs./hr 983

24 % Saving in hourly running cost % 66

25 Total running cost Rs./day 35718 12131

26 Total running cost Rs./month 714353 242625

27 Total running cost Rs./annum 8572239 2911506

28 Net annual saving in running cost Rs./annum 5660734

29 % Net annual saving % 66

Operating cost comparison 200 LDO

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Operating cost comparison FO

Sr. No. Parameter Unit FO fired Thermal

Fluid Heater Agrowaste fired

Thermal Fluid Heater

1 Heat output kcal/hr 600000 600000

2 Overall thermal efficiency % 88 75

3 Heat input kcal/hr 681818 800000

4 Fuel FO Agrowaste Briquettes

5 Calorific value (CV) of fuel kcal/kg 9650 3500

6 Fuel consumption kg/hr 71 229

7 Fuel consumption lit/hr 79 NA

8 Purchase cost of fuel Rs./kg NA 5

9 Purchase cost of fuel Rs./lit 35 NA

10 Cost of fuel for heat generation Rs./hr 2748 1143

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11 Electricity rate Rs./unit 6 6

12 Total connected electrical load kw 21 18

13 Normal electrical consumption kw 16.8 14.4

14 Electricity cost Rs./hr 101 86

15 Working hours per day hours 24 24

16 Number of working shifts 3 3

17 Number of firemen / helpers NA 4

18 Salary of 1 firemen / helper Rs./month NA 10000

19 Salary of all firemen / helpers Rs./month NA 40000

20 Salary of all firemen / helpers Rs./day NA 1333

21 Salary of all firemen / helpers Rs./hr 0 83

22 Total running cost Rs./hr 2848 1313

Operating cost comparison FO

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23 Saving in running cost Rs./hr 1536

24 % Saving in hourly running cost % 54

25 Total running cost Rs./day 68364 31502

26 Total running cost Rs./month 1367272 630043

27 Total running cost Rs./annum 16407268 7560521

28 Net annual saving in running cost Rs./annum 8846747

29 % Net annual saving % 54

Operating cost comparison FO

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Space requirements for Agrowaste Fuel Storage

heat o/p = 600000 kcal/h

eff = 75 % heat i/p = 800000 kcal/h agro-waste fuel cal value = 3500 kcal/kg

Agro-waste fuel consumption = 229 kg/h 1 day = 24 hrs

daily fuel consumption = 5486 kg/day

storage area / shed height = 3 m

No. of days stock Area required for fuel storage (sq. ft.)

7 276 14 551 21 827

28 1102

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Please feel free to contact us For more Information Our website : www.psadhesive.com Personal Email : psatechno@gmail.com Cell : 00 91 9850242282

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Thank You

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