Detailed Project Report (DPR) on Bio Coal from Waste (Capacity: 100 MT/Day)

BIO COAL FROM WASTE (CAPACITY: 100 MT/DAY)

[EIRI/EDPR/4541] J.C.: 2758XL

INTRODUCTION

Bio coal briquettes are one of the best alternatives to conventional coal. As we all know with an increased population it’s becoming more difficult to manage resources day by day. To understand the importance of bio coal briquettes let us first discuss the energy crisis. 

In today’s world the energy crisis is the major concern. The limited natural resources that are used to power industrial society are diminishing as the demand rises. These natural resources such as conventional coal are in limited supply. While they do occur naturally, it can take thousands of years to replenish. Clearly demands are increasing but supply is limited! So we need to look for an alternative and that’s bio coal briquette. Demand for coal briquettes in the world is increasing day by day as it’s an eco-friendly option to choose.

India in October 2021 faced a power crisis due to the dwindling supply of coal which is the primary source of electricity generation. Coal reserves are critically low in 12 states. This was due to the heatwaves across the country. Moreover, the increasing demand of electrical devices has raised the need for more electricity generation. The unexpected demand for energy has once again brought the country’s coal shortage to the forefront. The coal shortage was largely blamed on low supply of coal from mines. As per the data from the Union Ministry of Coal, this year, the production by Coal India Ltd has increased by 23 percent, from Singareni Collieries Company Ltd by 34.2 percent and from captive mines by 40 percent. The major role of bio coal briquettes is to tackle the energy crisis. I know that most of you don’t feel connected to reality unless the price of gas goes up or there are lines at the gas station. So we should amidst that ongoing energy crisis is getting worse, despite many efforts. But in recent years, it is observed that there has been a huge push to move toward clean energy sources. No doubt those bio coal briquettes are one of them. This alternative to conventional coal is not only great for the environment, but they’re also safer to use and have lots of different benefits.

Bio coal briquettes are a biofuel substitute to coal and charcoal. They’re made from organic biomass. Briquettes are mostly used in the developing world, where cooking fuels are not as easily available. Also there has been a move to the use of briquettes in the developed world. Where they are used to heat industrial boilers in order to produce electricity from steam. The briquettes are co fired with coal in order to create the heat supplied to the boiler. Connect with our biogas consultants here.

Bio coal briquettes, mostly made of green waste and other organic materials, are commonly used for electricity generation, heat, and cooking fuel. These compressed compounds contain various organic materials, including rice husk, bagasse, ground nut shells, municipal solid waste, agricultural waste. The composition of the coal briquettes varies by area due to the availability of raw materials. The raw materials are gathered and compressed into briquette in order to burn longer and make transportation of the goods easier. 

Bio-coal development is becoming important due to many factors including the rising cost of oil, natural gas and electricity and the scarcity of fossil fuels. The need to find alternatives to fossil fuels and reduce Greenhouse Gas emissions has prompted interest in Bio-coals by energy specialists around the world. Bio Coal Briquetting is the process of converting solid agricultural waste into high density and energy concentrated fuel briquettes. These Briquettes also called as White Coal are ready substitute of Coal/wood in industrial boiler and brick kiln for thermal application. Bio-Coal Briquetting plants are of various sizes which converts agricultural waste into solid fuels. Briquettes are ready substitute of Coal/wood in industrial boiler and brick kiln for thermal application. This development can significantly reduce greenhouse gases and heating costs and sustainably assist the development of rural communities.

Groundnut Shell is identified as ideal biomass for Bio-coal production due to low moisture contents, high net energy yield per hectare and low cost of production. These types of Shells are most favorably viewed, as it easily adapts to marginal soils and arid climates with minimal fertility and management requirements. Crushed Ground Nut Shells have a high Calorific value, hence, they are in most demand nowadays in the market. Ramit Bio-Coal (www.biocoalindia.com) having factories at Mumbai, Ahamadabad and Rajkot is specialized in making Bio-Coal from Ground Nut Shells. Bio-Coal made from Ground Nut Shells by Ramit Bio Coal is a viable energy option suitable for widespread application as it is energetically efficient, economical, convenient and user friendly. 

COST ESTIMATION

Plant Capacity            100 MT/Day  

Land & Building (10,000 sq.mt.)    Rs. 5.55 Cr    

Plant & Machinery                    Rs. 2.12 Cr 

Working Capital for 1 Month    Rs. 1.77 Cr 

Total Capital Investment          Rs. 10.35 Cr 

Rate of Return                          22%

Break Even Point                      71%

CONTENTS

INTRODUCTION

BRIQUETTES ARE CHEAPER THAN COAL.

RAW MATETRIAL FOR BIO COAL BRIQUETTES

BIO COAL TECHNIQUE

PROPERTIES OF BIOCOAL

B.I.S. SPECIFICATION

DIFFERENCE BETWEEN COAL AND BRIQUETTE

DIFFERENE BETWEEN BRIQUETTE AND PELLETS

IMPORTANCE OF NAPIER GRASS AS COMPARE TO OTHER BIOMASS

OTHER THAN THIS BIO COAL BRIQUETTES USES IN VARIOUS 

INDUSTRIES LIKE:-

ADVANTAGE OF BIO COAL

SALIENT FEATURE OF BIO COAL

TABLE: COMPARATIVE COST OF STEAM GENERATION

PROCESS FLOW DIAGRAM OF BIOCOAL

CALORIFIC VALUE OF RAW MATERIALS

COMPOSITION OF BIOMASS BRIQUETTESWITH OTHER FOSSIL FUEL

BIOMASS CO-FIRING FOR COAL POWER PLANT

COAL POWER PLANTS THAT SUCCESSFULLY CO-FIRED BIOMASS

SKEWED DEMAND-SUPPLY

GOVERNMENT INTERVENTION

BIOMASS ELECTRICITY

SPS BAKSHI, THE HEAD OF THE PLANT, SAID:

MARKET OVERVIEW OF BIO COAL

OPTION OF BIOMASS

1. RICE HUSK

2. SAW DUST

3. BAGASSE

4. GROUNDNUT SHELL

5. AGRICULTURAL WASTE

6. FOREST WASTE

7. WOOD BIOMASS

MARKETABILITY OF BIO COAL

BOILERS:

FURNACE & FOUNDRIES:

BRICK KILNS:

RESIDENTIAL & COMMERCIAL HEATING:

TRAINING AND VIABILITY

MARKET AND CONSUMERS

PRESENT MANUFACTURERS & EXPORTERS OF BIO COAL BRIQUETTES

COAL BRIQUETTES

MANUFACTURING PROCESS OB BIO COAL

PROCESS FLOW DIAGRAM

TESTING METHOD AND STANDARD

A) GCV (GROSS CALORIFIC VALUE):

B) MOISTURE CONTENT:

C) ASH CONTENT:

D) HGI (HARDGROVE GRINDABILITY INDEX):

E) FINES %:

PRINCIPLES OF PLANT LAYOUT

STORAGE LAYOUT:

EQUIPMENT LAYOUT:

SAFETY:

PLANT EXPANSION:

FLOOR SPACE:

UTILITIES SERVICING:

BUILDING:

MATERIAL-HANDLING EQUIPMENT:

RAILROADS AND ROADS:

MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:

PLANT LOCATION FACTORS

PRIMARY FACTORS

1. RAW-MATERIAL SUPPLY:

2. MARKETS:

3. POWER AND FUEL SUPPLY:

4. WATER SUPPLY:

5. CLIMATE:

SPECIFIC FACTORS

6. TRANSPORTATION:

A. AVAILABILITY OF VARIOUS SERVICES AND PROJECTED RATES

7. WASTE DISPOSAL:

8. LABOR:

9. REGULATORY LAWS:

10. TAXES:

11. SITE CHARACTERISTICS:

12. COMMUNITY FACTORS:

13. VULNERABILITY TO WARTIME ATTACK:

14. FLOOD AND FIRE CONTROL:

EXPLANATION OF TERMS USED IN THE PROJECT REPORT

1. DEPRECIATION:

2. FIXED ASSETS:

3. WORKING CAPITAL:

4. BREAK-EVEN POINT:

5. OTHER FIXED EXPENSES:

6. MARGIN MONEY:

7. TOTAL LOAD:

8. LAND AREA/MAN POWER RATIO:

PROJECT IMPLEMENTATION SCHEDULES

INTRODUCTION

PROJECT HANDLING

PROJECT SCHEDULING

PROJECT CONSTRUCTION SCHEDULE

TIME SCHEDULE

BIO COAL SUBSIDY

FOR BIO COAL SUBSIDING

SUPPLIERS OF PLANT AND EQUIPMENTS FOR BIO COAL BRIQUETTES

SUPPLIERS OF HAMMER MILLS

SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS

SUPPLIERS OF RAW MATERIAL

SUPPLIERS OF RICE HUSK

SUPPLIERS OF SAW DUST

SUPPLIERS OF COCONUT SHELL

APPENDIX – A:

01. PLANT ECONOMICS

02. LAND & BUILDING

03. PLANT AND MACHINERY

04. OTHER FIXED ASSESTS

05. FIXED CAPITAL

06. RAW MATERIAL

07. SALARY AND WAGES

08. UTILITIES AND OVERHEADS

09. TOTAL WORKING CAPITAL

10. TOTAL CAPITAL INVESTMENT

11. COST OF PRODUCTION

12. TURN OVER/ANNUM

13. BREAK EVEN POINT

14. RESOURCES FOR FINANCE

15. INSTALMENT PAYABLE IN 5 YEARS

16. DEPRECIATION CHART FOR 5 YEARS

17. PROFIT ANALYSIS FOR 5 YEARS

18. PROJECTED BALANCE SHEET FOR (5 YEARS)