Rice Husk/Wooden Waste to Briquette (7.5 MT per day)

RICE HUSK/WOODEN WASTE TO BRIQUETTE

[EIRI/EDPR/4627] J.C.: 2844XL 

Briquetting is the technology to convert all types of agricultural and forestry waste into solid fuel. Briquettes are formed in cylindrical logs using high mechanical pressure without the use of chemical or binder. The product is a replacement to conventional fossil fuels and can be used across various manufacturing industries such as boilers, furnaces and kilns. Bio-Briquette is an eco friendly solid biofuel which helps to reduce pollution, contributing to greener environment and save worthy foreign exchange. Briquetting works on the basic concept of “Wealth from Waste”. The briquettes are used for energy generation helping farmers to earn money from the waste. Briquetting of residues takes place with the application of pressure, heat and on the loose materials to produce the briquettes. No addition of any binder / chemicals is required so it is 100% natural.

Fuel is the primary need for any country that whose backbone lies in the Industrial sector. More and more exhaustible sources of energy are diminishing each day. As a result, there is an immediate need to adopt new sources of energy which can help sustain the economic growth without any negative repercussions.

All the biomass and wood wastes are collected in large storage units and are recycled to produce solid fuel that can be used to heat industrial boilers. This is a renewable source of energy and is perfect in countries that produce tones of agriculture and forest waste each year. Every year millions of tons of agricultural waste are generated. These are either non-used or burnt inefficiently in their loose form causing air pollution. Handling and transportation of these materials is difficult due to their low bulk density. These wastes can provide a renewable source of energy by converting into high-density fuel briquettes without addition of any binder.

COST ESTIMATION

Plant Capacity            7.5 MT/Day  

Land & Building (1200 sq.yard)    Rs. 75.00 Lac    

Plant & Machinery                    Rs. 47.00 Lac

Working Capital for 1 Month    Rs. 23.73 Lac

Total Capital Investment          Rs. 1.61 Cr 

Rate of Return                          15%

Break Even Point                      82%

CONTENTS

INTRODUCTION

PURPOSE AND GENERAL DESCRIPTION OF PROJECT:-

AT PRESENT TWO MAIN HIGH PRESSURE TECHNOLOGIES:

BRIQUETTING TECHNOLOGIES:

SCREW PRESS AND PISTON PRESS TECHNOLOGIES:

A SUBSTITUTE TO COAL AND FIREWOOD

AGRO WASTE BRIQUETTES

WOOD BRIQUETTES

SAW DUST BRIQUETTES

RECYCLED BRIQUETTES

ALTERNATIVE FUEL FOR ENVIRONMENTAL CONSERVATION

PHYSICO-CHEMICAL COMPOSITION OF REFUSE DERIVED FUEL

ADVANTAGE OF BIOMASS BRIQUETTE

SPECIFICATION OF BIOMASS BRIQUETTES

BIOMASS MATERIALS AND THEIR TYPICAL CHARACTERISTICS

PLEASE NOTE: ABOVE BIOMASS IS SUITABLE FOR USING SEPARATELY

OR IN A MIX FORM AS AN INPUT OF RAW MATERIAL FOR CONVERTING

FINISHED BRIQUETTES CALORIFIC VALUE MAY VERY DUE TO

DIFFERENT QUALITY OF RAW MATERIAL

APPROPRIATE BIOMASS RESIDUES FOR BRIQUETTING

LOW MOISTURE CONTENT

ASH CONTENT AND COMPOSITION

APPROX. ASH CONTENT OF DIFFERENT BIOMASS TYPES

FLOW CHARACTERISTICS

RICE HUSK

OTHER BIOMASS MATERIALS

GROUNDNUT SHELL:

COTTON STICKS:

BAGASSE/BAGASSE PITH:

COFFEE HUSK:

MUSTARD STALKS:

OTHERS:

FUNDAMENTAL ASPECTS OF BRIQUETTING

PRESSURE COMPACTION

ON THE BASIS OF COMPACTION, THE BRIQUETTING TECHNOLOGIES CAN BE DIVIDED INTO:

FIG. BELOW SHOWS SOME OF THE BINDING MECHANISMS

BINDING MECHANISMS OF DENSIFICATION

MECHANISM OF COMPACTION

A SIMPLE EXTRUDER FEATURES THREE DISTINCT ZONES:

THE PROPERTIES OF THE SOLIDS THAT ARE IMPORTANT TO DENSIFICATION ARE:

COMPARISON BETWEEN FOSSIL FUEL & BIOMASS

MOREOVER

COMPACTION CHARACTERISTICS OF BIOMASS & THEIR SIGNIFICANCE

THESE ARE DISCUSSED BELOW:-

EFFECT OF PARTICLE SIZE

EFFECT OF MOISTURE

EFFECT OF TEMPERATURE OF BIOMASS

EFFECT OF TEMPERATURE OF THE DIE

EFFECT OF EXTERNAL ADDITIVES

BRIQUETTE COMPETITIVENESS

FOLLOWING ARE FIVE OF SUCH EXAMPLES:

I. REDUCE FOSSIL GAS CONSUMPTION:

II. REDUCE COMMERCIAL WASTE PRODUCTS:

III. GENERATE ELECTRICITY:

IV. CREATION OF NEW JOB OPPORTUNITIES:

LOCAL AND INTERNATIONAL CONTEXT FOR BRIQUETTE USE

STANDARDS

CLASSIFICATION OF WOOD BRIQUETTES

CLASSIFICATION OF NON-WOOD BRIQUETTES

BIOMASS SOURCES

FORESTS

AGRICULTURE

FOREST AND AGRICULTURAL INDUSTRIES’ RESIDUES

ENERGY CROPS

BIOMASS BRIQUETTES INDUSTRY AND CHALLENGES

USES AND APPLICATION

MARKET OVERVIEW OF BIOMASS BRIQUETTE

ADOPTION OF BIOMASS BRIQUETTES IN THE DEVELOPED COUNTRIES

THE RISING NEED FOR BIOFUEL ALTERNATIVES

MARKET SEGMENTATION

MARKET PLAYER

RECENT DEVELOPMENT

BRIQUETTING

BRIQUETTE MANUFACTURING PROCESS

MOISTURE CONTROL PRIOR TO BIOMASS PROCESSING

FIXED MOISTURE METER        MOBILE MOISTURE METER

MILLING

CRUSHER MACHINE

TYPICAL DESIGNS OF WOOD CHIPPERS

DRYING

THE MAIN COMPONENTS OF DRIERS ARE:

HOT AIR SOURCE –

DRYING CHANNEL –

CYCLONE SEPARATOR-

ROTATOR DRUMS (TROMMEL) OR INDIRECT DRIERS

BRIQUETTING

THE MAJOR COMPONENTS OF BRIQUETTING PISTON UNITS ARE:

DENSIFICATION BY EXTRUSION - SCREW BRIQUETTING MACHINE

THE MAJOR COMPONENTS OF THE SCREW TYPE BRIQUETTING UNITS ARE:

PACKAGING

BRIQUETTES PACKING WITH THERMO SEALING

PALLET WRAPPING MACHINE

FLOW CHART

RAW MATERIAL (BIOMASS) SPECIFICATIONS FOR BRIQUETTING PLANT:-

OUTPUT BIO-COAL/BRIQUETTES SPECIFICATION

PROCESS FOR DIFFERENT AGRO WASTE

ELECTRICAL DATA

BIO-MASS BRIQUETTING PLANT BULL 80 (ECOSTAN)

BRIQUETTE MACHINE & BODY COMPONENTS:

MACHINE TYPE:

BINDER LESS PRODUCTION:

WORKING PARAMETERS:

BRIQUETTE MACHINE & ACCESSORIES

MAIN UNIT:

SPECIFICATIONS OF BRIQUETTE MACHINE MODEL ECOSTAN® BULL 80

CONSUMABLE PARTS WITH MACHINE:

1. CHIPPER CUM GRINDER

• CHIPPER GRINDER TYPE:

WORKING PARAMETERS:

RAW MATERIAL PARAMETERS:

GRINDER SPECIFICATION

SPECIFICATIONS OF CHIPPER CUM GRINDER MODEL ECOSTAN® CCG2

TECHNOLOGY FEATURES:

CHIPPER CUM GRINDER & ACCESSORIES

MAIN UNIT:

CHIPPER CUM GRINDER MODEL ECOSTAN®CCG2

1. FLASH DRYER

FLASH DRYER SINGLE PASS BODY COMPONENTS:

DRYER TYPE:

HOT AIR FURNACE:

WORKING PARAMETERS:

FLASH DRYER SINGLE PASS & ACCESSORIES

MAIN UNIT CONSISTS OF:

SCREW CONVEYOR CASING:

TABLE OF CALORIFIC VALUES

CALORIFIC VALUE:

CONCLUSIONS

PRODUCE BIOMASS BRIQUETTES AND LEAVE TRADITIONAL SOURCE

OF ENERGY

INCREASING DEMAND OF BIOMASS BRIQUETTES IN MANUFACTURING

INDUSTRY

BIOMASS BRIQUETTING PLANT IMPROVE CURRENT ECOLOGICAL CRISIS

USE BRIQUETTING PLANT AND SAVE TREES

INDUCEMENT OFFERED BY GOV.

PHOTOGRAPHS

PRODUCT PHOTOGRAPHS:-

MACHINERY PHOTOGRAPHS (SUPPLIER- ECOSTAN):-

BRIQUETTE MACHINE    SHREDDER

CHIPPER GRINDER    HUMMER GRINDER

ROTARY DRUM DRYER      FLASH DRYER

STONE/DUST SEPARATOR VIBRATOR MACHINE

CONVEYOR SYSTEM

RAW MATERIAL:-

ADDRESSES OF PLANT AND MACHINERY SUPPLIERS

PRESENT MANUFACTURERS/SUPPLIERS FOR BIOMASS BRIQUETTES

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)