Bio Coal from Super Napier Grass (Cap: 30 MT/Day)

BIO COAL (CAP: 30 MT/DAY)

[EIRI/EDPR/4478] J.C.: 2693XL

Every year millions of tons of agricultural wastes and forest residues are generated. These are either wasted or burnt inefficiently in their loose form causing air pollution. Handing and transportation of these materials is difficult due to their low bulk density. These wastes can provide renewable source of energy by converting in to high density fuel Briquettes without addition of any binder.

Biomass can also refer to our newest source of renewable energy and the best way to recycle biological matter.

All plants, including those from the sea and other water bodies, are considered to be biomass. Though, usually, the term refers to what they leave behind that we do not use for food or materials. For example, straw, corncobs, husks, animal waste, garbage, and other things that we usually throw away and forget about.

These materials are not useless, as most people believe them to be. Although they are the left-over pieces from industrial processes and natural waste, they can be used for many different uses. And though most people wouldn't think it, these are the key to creating a better world and a better future.

Biomass is all of the matter which is organic, contains carbon, and has gone through photosynthesis and other processes. Biomass is mostly made up of plants which make use of the light from the sun to create energy through photosynthesis many of the developing countries produce huge quantities of agro residues but they are used inefficiently causing extensive pollution to the environment. The major residues are rice husk, coffee husk, coir pith, jute sticks, bagasse, groundnut shells, mustard stalks and cotton stalks. Sawdust, a milling residue is also available in huge quantity. 

Apart from the problems of transportation, storage, and handling, the direct burning of loose biomass in conventional grates is associated with very low thermal efficiency and widespread air pollution. The conversion efficiencies are as low as 40% with particulate emissions in the flue gases in excess of 3000 mg/ Nm In addition, a large percentage of un burnt carbonaceous ash has to be disposed of. In the case of rice husk, this amounts to more than 40% of the feed burnt. Most of this biomass goes to waste by being dumped into landfills and even burned, which causes air pollution. Instead of making use of the precious land that we have and polluting the air, we can use biomass to create energy and fuel, as well as feed and other agricultural necessities.

Biomass is definitely a great way to help fix our earth. It is completely natural, and we can use it for fuel biomass, and many other things. There are many ways that we can get this biomass and use it to its full capacity. First of all, we should collect the residue that comes from agricultural and forestry processes. This can be used for manure, fuel, and even feed stock. Industrial waste such as used fuel can be reused to create more fuel that can be used in other fields.

The great thing about biomass is that it can be grown for our needs. Growing plants to use as biomass will not only give us biomass to use, but it will also help clean out our land and air resources.

COST ESTIMATION

Plant Capacity            30 MT/Day  

Land & Building (4000 sq.mt.)    Rs. 2.88 Cr    

Plant & Machinery                    Rs. 72.50 Lac 

Working Capital for 3 Months    Rs. 2.29 Cr 

Total Capital Investment          Rs. 6.28 Cr 

Rate of Return                          23%

Break Even Point                      64%

CONTENTS

INTRODUCTION

THERE ARE MANY DIFFERENT USES

CONCEPT AND TECHNOLOGY

TECHNOLOGY

BRIQUETTES ARE CHEAPER THAN COAL

BENEFITS AND APPLICATION OF BIOMASS BRIQUETTES

BENEFITS OF BIOMASS BRIQUETTES

COST

STORAGE AND HANDLING

POLLUTION

EFFICIENCY

PROPERTIES OF BIOCOAL

B.I.S. SPECIFICATION

IMPORTANCE OF NAPIER GRASS AS COMPARE TO OTHER BIOMASS

PROCESS FLOW DIAGRAM OF BIOCOAL

CALORIFIC VALUE OF RAW MATERIALS

COMPOSITION OF BIOMASS BRIQUETTESWITH OTHER FOSSIL FUEL

FUTURE OF NAPIER AS BIO FUEL

SIGNIFICANCE OF NAPIER GRASS

MARKET OVERVIEW OF BIO COAL

ENERGY FROM AGRO WASTE (BRIQUETTING OF BIOMASS)

WHY BIO-MASS BRIQUETTE?

MARKET POTENTIAL OF COAL

COAL USE FORECAST, 2024

COAL PHASE-OUT – BAN COAL MOVEMENT

LOW-COST COMES AT A HIGH ENVIRONMENTAL COST

HOW URGENT IS TO PHASE OUT COAL?

THE MOVE TO RENEWABLES:

VARIOUS 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

PROCESS FLOW SHEET

PROCESS TECHNOLOGY

MBTC 1TH GENERATION TECHNOLOGY

PROCESS BLOCK DIAGRAM

STEP 1

1. THE BRIQUETTING TECHNOLOGY IS BASED ON COMPACTION MECHANISM

BRIQUETTING PROCESS

STEP 2

BRIQUETTES ENRICHMENT PROCESS

PROCESS FLOW DIAGRAM

QUOTATION OF BIOMASS BRIQUETTING MACHINE –JUMBO 90

OVER ALL SUPPLY 415 VOLTS + - 10% IN WORKING

APPROXIMATELY AVERAGE DATA OF CONTINUOUS RUNNING OF BRIQUETTING PLANT

KEY FEATURES OF BRIQUETTING MACHINE

BENEFITS OF OUR BRIQUETTING PLANT

TECHNICAL BRIEF OF MAIN MACHINE SPARES

BRIQUETTING MACHINE JUMBO -90 SPECIFICATION (RONAK ENGINEERING SCOPE)

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

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)