Project:Create a Wood Gasifier for VietnamLecturer: Dr. Peter Stammnitz
Group 2:Đặng Tiểu My- Factory plannerTrần Kim Ngân- EconomistTrương Thị Xuân Đào- Project coordinatorNguyễn Hồng Khánh- Factory plannerNguyễn Kim Ninh- Manufacturing expertNguyễn Quang Thanh-Designer
April 2014 1
Introduction
• Bio char can use as fertilizer when mixed with compost.
• Affordable design will encourage people use clean cook stoves .
• Reduce pollution because burning crop residue by Gasifiers only produces CO2
Solution: The role of Gasifiers
• Enormous demand of fertilizer because of soil degradation problems.
• Prefer cheaper but toxic coal cook stoves due to costs of LPG are rising.
• Burning crop residue is polluting the environment.
Consequences
• 79.5%(*) total land use is agricultural land.
• 68%(*) population lived in rural can not afford the LPG cookstove
• Heavily dependent on agriculture (69.5%(*) of labour force).
Facts
(*) Viet Nam statistics book 2012 2
Application of biochar
Bio char
Produce a soil
enhancer
Produce clean,
renewable energy
Reduce agricultural
waste
Fight global warming
(*) http://www.biochar-international.org 3
Part one
1 • Analysis material
2• Technical solutions
3• Analysis markets, prices, costs
4• Procurement analysis, sales strategy
5 • Stakeholder, value, jobs,protection of resources
6• Exist practical experiment results
4
Rice husk and straw• Location: 20% in Red river delta and 50% in Mekong river delta.• Current usage: Cooking (15%), brick kiln (40-45%),power plant, briquette (10%),
left over (20-25%)
Sugar cane• Location: Mekong River Delta, North Middle and Coastal Plain, and East South• Current usage: 50-60% combustion in Furnace, fertilization
Corn cobbLocation: 50% Northeast and 10% in south east
• Current usage: animal feed, cooking, fertilizer
Coconut husk• Location: 84% in Mekong Delta (Ben Tre 30%)• Current usage: 100% shell: activated carbon or domestic fuel or industrial thermal.
96% husks: processed into coir
Coffee husk• Location: the Central Highlands and the North• Current usage: Combusted, fertilizer, dumped
*Biomass Business Opportunities Viet Nam by SNV Netherlands Development Organisation Vietnam
Analysis of material in Vietnam*(2/2)
5
Analysis of material in Vietnam*(2/2)
Material Area ( Ha) Yield / Ha % residue TheoreticalAvailability
Rice husk
7,500,000 ha 5.32 t/ha20% 8 million ton
Rice straw85% (on average) 23 million ton
Sugar cane 266,000 ha 63.9 t/haTop: 30%, leaves:10%, Bagasse: 9%
Top: 4,110,150t;Leaves: 1,370,050t;Bagasse: 1,233,045t.
Corn cobb 1,125,000 ha 4.0 t/ha 20-50% 1,066,500 tons
Coconut husk 130,000 ha 13 t/ha 30% weight is
husk 975 tons
Coffee 500,000 1.8 t/ha 15% of the driedcherry weight 135,000 tons
*Biomass Business Opportunities Viet Nam by SNV Netherlands Development Organisation Vietnam
Conclusion: Rice straw can be identified as the largest potential.
6
Sustainable rice straw material flow
7
Part one
1• Analysis material
2 • Technical solutions
3• Analysis markets, prices, costs
4• Procurement analysis, sales strategy
5 • Stakeholder, value, jobs,protection of resources
6• Exist practical experiment results
8
Technical principle(*)
The updraft gasifier• Pros: Small pressure drop, good thermal efficiency, little tendency
towards slag formation• Cons: Great sensitivity to tar and moisture and moisture content of
fuel, poor reaction capability with heavy gas load.
The downdraft gasifier• Pros: low sensitivity to charcoal dust and tar content of fuel, flexible
adaptation of gas production to load.• Cons: Design tends to be tall, not feasible for very small particle size
of fuel
The Crossdraft gasifier• Pros: Short design height, very fast response time to load, flexible
gas production• Cons: Very high sensitivity to slag formation, high pressure drop.
(*) “Alternative Energy in Agriculture”, Vol. II, Ed. D. Yogi Goswami 9
Existing technical solutions(*)
Rocket stovePro: need less fuel, produce clean airCons: Must be used with a thermal mass for efficiency
Anila stovePro: very sturdy, easy to learn to use, works fineCons: not work well on clearly sub zero temperatures
Biochar rocket stovePro: can be used in door, easier to control the temperature Cons: increased emissions, possible incomplete pyrolysis
TLUD stovePro: absence of smokeCons: not ideally suited for use indoors
(*) http://www.soil-carbon-regeneration.co.uk/biochar/biochar-stoves-2/ 10
Part one
1• Analysis material
2• Technical solutions
3 • Analysis markets, prices, costs
4• Procurement analysis, sales strategy
5 • Stakeholder, value, jobs,protection of resources
6• Exist practical experiment results
11
Gasifier market Target groups: potential customers are farmers in
the Northern Highlands, Central Highlands, and Mekong Delta(*), especially ethnic minority groups who only can afford cook stoves with little to no subsidies.
In 2012, population in rural area is 60416,5 thousand person, with six members per household on average. Therefore, the number of rural households in Vietnam was about 10 million.
In conclusion, the Gasifier market is estimated up to 10 million.
(*)Vietnam Market Assessment by Global Alliance for Clean Cook stoves 12
Biochar Market
Agricultural land
26280,5 thousand ha
Application of 0.5ton biochar/ha
/year(*)
Quantity of biochar on
demand: 13.14 thousand ton/year
(*) http://internationalinventjournals.org/journals/IJASS 13
Biochar cost analysis
Biochar cost: 2.250 VND/kg
Risk ratio: 0.5
Costs toward rice straw
material: 300 VND/kg
Yield of biochar was
approximately 20-23% (*)
(*) http://www.biochar-international.org/profile/Stoves_in_Vietnam 14
Gasifier cost analysis
Gasifier cost: 600,000 VND
Labour cost:
150000 VND
Material cost:380.000VND
Manufacturing overhead:
70000VND
15
Part one
1 • Analysis material
2 • Technical solutions
3 • Analysis markets, prices, costs
4 • Procurement analysis, sales strategy
5 • Stakeholder, value, jobs,protection of resources
6 • Exist practical experiment results
16
Procurement
Material Price Technical data
Mild steel sheet 13500vnd/kg 5,0 x 1500 x 6000mm
Stainless steel sheet 13500vnd/kg 5,0 x 1500 x 6000mm
Roll steel 14500vnd/kg Ø8xroll
Rectangular steel 14500vnd/kg 4x40x100mm
Rectangular steel 14500vnd/kg 2.5 x25x25mm
Rectangular steel 14500vnd/kg 2x30x30mm
17
Sales & Distribution Strategy(*)
• The Northern Highlands, Central Highlands, and Mekong Delta
• Choose regions that have potential for longitudinal effects,
Determine which target regions
• Create incentive commission structure that motivates the promoter to encourage wide-scale adoption
Determine specific promoters have the best reach within
target regions
• Understand which channels have the best reach within target communities
• Focus on word-of-mouth marketing, which is key in Vietnam culture
Create marketing campaign to establish
branding and generate awareness
(*)Vietnam Market Assessment by Global Alliance for Clean Cook stoves 18
Part one
1• Analysis material
2• Technical solutions
3• Analysis markets, prices, costs
4• Procurement analysis, sales strategy
5• Stakeholder, value, jobs, protection of resources
6• Exist practical experiment results
19
Stakeholders analysisStakeholder Problem/
ConstrainMain Interest Potential
Projectgroup
Short of timeFinance securePractical experience
Profitable business but sustainabledevelop
Knowledge to approach new technology
Rural community
Lack of skillPovertySoil degradation
Increase income, Improve living qualification but low cost
Agricultural waste
Government Pollution, Soil degradationPressure on energy demand
Renewable energy,poverty reduction
Power of policymaker
ForeignNGOs
Direct contact to local people, unfamiliar to local habit
Sustainable rural development
Funding, project management experience
20
Our Gasifier remarkable value
Raw material
Production
Sales and distributionMaintenance
Product development
Gasifier
Stable supply, low cost
Low cost, portable,
easy to use
Provide training in self-repair
sustainable business models
Affordability ,last mile distribution, self-built construction
21
Job Creation ValueTransfer technologyto customers, farmers…
Built plant local labor absorption
(http://pamoja.se/)
22
PROTECTION OF RESOURCES (1/2)
23
PROTECTION OF RESOURCES (2/2)
24
Part one
1• Analysis material
2• Technical solutions
3• Analysis markets, prices, costs
4• Procurement analysis, sales strategy
5 • Stakeholder, value, jobs,protection of resources
6• Exist practical experiment results
25
Result of Biochar Treatment and its Effects on Rice and Vegetable Yields in Mountainous Areas of Northern Vietnam (*)
“Application of 0.5–2.5tons biochar/ha combined with NPK, average rice yield was increased by 17.6%.
Economic benefit from rice cultivation is estimated by 29.11- 37.05 million VND/ha/crop with net income of 2.64- 7.26 million VND/ha/crop.”
(*) by Vinh NC. , Hien NV., Anh MTL., Johan Lehmann, Stephen Joseph 26
Results of comparison test of CARE Vietnam
Gasifier stove Open fireThe amount of used wood (gram)
955 - 1235 2000
Total weight of food (gram)
1850 1850
Total weight food/total weight wood
1.5 – 1.94 0.93
Total time for cooking rice to simmer (minutes)
29 - 34 32
Conclusion: in the same period of time, with less used wood (955 to 1235 gram), gasifier stove can cook the same weight of food as the traditional open fire with 2000 gram. 27
Part two
1• Creation of Design
2• Design for manufacturing
3• Factory planning
4• Further expand project recommendation
28
Productivity (to generate
charcoal)Life time Indoor usable
Low cost Rapid heat transfer Safety
Portable Easy to ignite Cleanliness
MachinableFlexible with
various biomass
Easy to remove charcoal
Product requirement and technical specific
29
Evaluation for best solution
Rocket stove TLUD stove
Anila stove30
No Requirement Weight (%) TULD stove
Anila stove
Biochar rocket stove
1 Low cost 20 2 3 12 Portable 15 3 3 13 Easy to remove charcoal 10 2 3 14 Cleanliness 10 2 3 15 Productivity 10 3 2 1
6 Flexibility with raw material 5 1 1 3
7 Usable indoor 5 3 3 18 Easy to ignite 5 2 3 19 Rapid heat transfer 5 3 3 110 Life time 5 1 2 311 Safety 5 2 3 212 Machinable 5 2 3 1
Total 100% 225 275 125
Base on above analysis, we select Anila stove type to improve such feature for high adaptation with the requirement.
Evaluation for best solution
31
Principle Sketch Cross section
Principle sketch
32
Fuel
Biomas Biomas
Ambient Air Hot Air
Fan
Heat Exchanger (Optional)Heating by burning charcoal indoor cause many
deaths in winter in North Viet Nam
Our heat exchanger provide rural community a environmental and economic heating
solution33
Laminar Flow
Temperature higher in centre.
Insulating film on Tube surfacePoor heat transfer
Turbulent Flow
Good mixing
Breaks down insulating film
Better heat transfer
Spiral Tubes34
Comparing between Spiral Tubes and Straight Tubes
34
01.Top lid
02. Biomass chamber
03. Outer housing 35
Height: 600mmWidth: 420mmWeight: 25kgBiomass volume: 37 dm3
Part two
1• Creation of Design
2• Design for manufacturing
3• Factory planning
4• Further expand project recommendation
36
Bill of material
Biomass chamber coil
Combustion chamber coil
Outer housing
Bottom plate
Biomass chamber legs
Cover plate
Top lidBiomass chamber lid
Combustion chamber
Biomass chamber
37
Top lid Pot standTop Lid and Small Lid
Part Name Technical specific Material Process
Top lid Outer diameter: 430Inner diameter: 150Thickness: 2
Mild steel sheet CuttingDie Forging
Pot stand Length: 100Width: 30Thickness: 2
Rectangularsteel
Cutting
Biomass chamber lid
Outer diameter: 370Inner diameter: 100Thickness: 2
Mild steel sheet CuttingDie Forging
Biomass chamber lid handle
Length: 25Width: 25Thickness: 2
Rectangularsteel
Cutting
PROCESS FOR PRODUCE SINGLE COMPONENT
38
Biomass chamber (1/2)
Part Name Technical specific Material Process
Biomass chamber tube
Diameter: 360Height: 380Thickness: 2
Stainless steel sheet
Sheet cuttingFormingWelding
Biomass chamber coil
Diameter: 380Pitch: 50Revolution: 6
Roll steel Forming
Bottom plate Outer diameter: 360Inner diameter: 80Thickness: 2
Stainless steelsheet
Die forging
Biomass chamber leg
Height: 135Length: 50Width: 30
Rectangularsteel
Cutting
Biomass chamber tube
Biomass chamber coil
Bottom plate Biomass chamber leg
39
Combustion chamber
Part Name Technical specific
Material Process
Combustion chamber
Height: 420Diameter: 100Thickness: 210 Hole: D=30
Stainless steel tube
CuttingDrilling
Combustion chambercoil
Diameter: 96Pitch: 50Revolution: 6
Roll steel Forming
Combustion chamber
Combustion chamber coil
40
Cover:
Part Name Technical specific Material Process
Outer housing Diameter: 420Height: 550Thickness: 2
Mild steel sheet
CuttingDrillingForming
Bottom plate Diameter: 420Thickness: 3
Stainless steel sheet
Cutting
Handle Length: 160Width: 66Thickness: 3
Bar steel Cold forging
Outer Housing
Bottom plate
Handle
41
Sub Name
Part Name Process Equipment
1 Top lid + Pot stand Arc welding MIG Welder
2 Biomass chamber lid + Biomass chamber lid handle
Arc welding MIG Welder
3 Biomass chamber tube + Biomass chamber coil
Arc welding MIG Welder
JOINING PROCESS
42
Sub Name Part Name Process Equipment
4 Combustion chamber + Combustion chamber coil
Arc welding MIG Welder
5 Bottom plate + Biomasschamber leg
Arc welding MIG Welder
6 Sub 4 + Sub 5 Arc welding MIG Welder
JOINING PROCESS
43
Sub Name
Part Name Process Equipment
7 Sub 3 + Sub 6 Arc welding MIG Welder
8 Sub 7 + Cover Plate Arc welding MIG Welder
9 Cover housing + Handle Arc welding MIG Welder
10 Sub 8 + Sub 9 (Finish) Arc welding MIG Welder
JOINING PROCESS
44
Equipment and Machinery
http://kzwmachine.en.hisupplier.com/product-161793-steel-tube-cutter.html
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http://www.asia.ru/en/ProductInfo/1341682.html
http://www.rexhydraulics.com/general/Gallery.aspx?gid=14
http://www.alibaba.com/product-detail/air-hammer_338304017.html
Forging machine
http://www.directindustry.com/prod/steeltailor/portable-cnc-plasma-cutting-machines-35080-1172087.html
Cutting machineHydraulic plate rolling
machine
Drilling machine
MAG/MIG welding machineSteel tube cutter
45
Part two
1• Creation of Design
2• Design for manufacturing
3• Factory planning
4• Further expand project recommendation
46
Production programs planning
47
Production programs planning
48
ProductionProgram
Cutting Joining InspectionPackingFormingForming
Market forecast
Supplier 1
Supplier 2
Customer A
Customer B
Aaaaaa
• Implement the flow assembly: ‘one piece flow’• Highest flexibility on customer demand• Reduction of space, inventory and throughput time
Shipping
3 people 2 people 3 people 2 people
Cutting
Cutting
Cutting
C/T306s C/T312s C/T295s C/T280s
Capacity Planning
Population in Thai Nguyen: 1.1 millionPopulation in rural area: 0.8 millionDemand: 130 thousand productsFirst phase: 5 yearsCapacity: 26,000 products/year
90 products/day(300 working days/year)
Thai Nguyen is selected as first market due to:- Many experiments gasifier conducted in Thai Nguyen.- Local community’s awareness toward gasifier- Concentrates ethnic minorities.
Second phase: copy the first model from Thai Nguyen to Thanh Hoa after 2 years of first phase
49
Material flow in factory
50
Factory layout
51
Factory layout
52
Organisation chart
53
Director1 person
Accountant1 person
HR1 person
R&D2 persons
Production12persons
Cutting2 persons
Drilling1 person
Forming2persons
Joining3 persons
Inspect2persons
Part two
1• Creation of Design
2• Design for manufacturing
3• Factory planning
4• Further expand project recommendation
54
Expanding objective customers
1. BBQ restaurantsExisting restaurants and their current technologies : BBQ garden, Sumo
BBQ, Hana BBQ, BBQ Smoke, BBQ straw, …
Using char coal Using gas stove
55
Advantages of using gasifier stove
- Reduce cooking fuel expenditure :Material: compressed rice husk
(1620VND/kg),rice husk firewood (1290VND/kg), …Compared with: coal : 5000VND/kg
gas : 400 000VND/12kg
- Friendly environment -> Sustainable development-> Establish good reputation.
- No harmful exhausted gas
Expanding objective customers
1. BBQ restaurants
56
* Nowadays, people show their deep concernabout the environmental protection, especiallyeducated people, who have potential to possessour green villas project.
* Main reasons:- Harmful vegetable by overuse pesticide as well
as chemical fertilizer.need clean vegetable.- Energy saving- Establish good reputation
Expanding objective customers
2. Project to build green villas
57
Expanding objective customers
Project to build green villas
Using gasifier stove for cooking (Material: compressed rice husk, … bought from the market)
Using biochar for planting vegetable on garden around
Utilize heat from the output gas for heater or heating pool
58
Gasifier market: up to 10 million/year. Biochar market: over 13 thousand
tons/year. Technical solution: “Improved “Anila
Gasifier. Target cost: 600.000VND/gasifier
(approximately 29 USD). Factory capacity: 90units/day
Project Summary
59
THANK YOU FOR YOUR ATTENTION
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