BIOMASS BRIQUETTES (BAMBOO/WOOD CHIPS)
[EIRI/EDPR/4422] J.C.: 2624XL
INTRODUCTION
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.
India has approximately 141 million hectares of arable land and agricultural output is around 800 million tones, which in itself generates 750 million tones waste. Even after deducting 450 million tones, which is used as fodder, 300 million tones could be used for biomass generation. Crop residues which are not used as animal fodder, such as cane trash, paddy straw, coconut stalks, branches and mustard waste, are estimated to total around 75 million tons per annum.
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.
Not only does it put the agro-forest waste to good use, but it also becomes a source of revenue and saves the Global environment by producing clean and green energy.
The advantages of biomass briquetting are by no means limited to its use in modern industrial plants or solid fuel boilers. Indeed, in developing countries a far bigger percentage of the populations cover their energy needs with biomass alone, where their primary need is for heat energy for cooking and heating. International development cooperation has accordingly long been focused on improving the basic energy supply in many countries around the world. It is notable that biomass briquettes have played a bigger part in many projects over recent years, such as those for distributing better stove technologies, for example. Next to adapted cooking behaviors and improved cooking appliances, the fuel can play one important role in improving the overall situation of households. Biomass briquettes can be produced out of many field or process residues and burning them in cooking appliances instead of traditional fuels as logged and collected wood or charcoal can be an interesting alternative for business makers but a
lso for fuel clients.
A Briquetting machine allows you to compress wastes like sawdust, chips, sugarcane bagasse and other agro-wastes into briquettes that are environmental friendly and have high calorific value. Burning briquettes as a fuel completes a natural cycle; on combustion they only release as much carbon dioxide back in the atmosphere as was originally absorbed by the growing tree during photosynthesis. Biomass briquettes can be used for power generation or for thermal application but mostly they are used for thermal application in industries replacing conventional fuel.
At present two main high pressure technologies: ram or piston press and screw extrusion machines, are used for briquetting. While the briquettes produced by a piston press are completely solid, screw press briquettes on the other hand have a concentric hole which gives better combustion characteristics due to a larger specific area. The screw press briquettes are also homogeneous and do not disintegrate easily. Having a high combustion rate, these can substitute for coal in most applications and in boilers.
Briquettes have high specific density (1200 Kg/m3) and bulk density (800 Kg/m3) compared to 60 to 180 Kg/m3 of loose biomass. These can stand the ardors of long distance transport. Loading/unloading and transportation costs are much less and storage requirement is drastically reduced. Compared to fire wood or loose biomass, briquettes give much higher boiler efficiency because of low moisture and higher density.
It is intended to prepare a Feasibility Report to install 1200Tons/Year Biomass Briquettes (Bamboo/Wood Chips) production facility as a Green Field Project.
COST ESTIMATION
Plant Capacity 4 Ton/Day
Land & Building (495 sq.mt.) Rs. 37.60 Lac
Plant & Machinery Rs. 45.75 Lac
Working Capital for 0.25 Months Rs. 01.39 Lac
Total Capital Investment Rs. 94.59 Lac
Rate of Return 16%
Break Even Point 70%
CONTENTS
INTRODUCTION
BRIQUETTING TECHNOLOGIES
SUBSTITUTE TO COAL AND FIREWOOD
ADVANTAGES OF BIOMASS BRIQUETTE
SPECIFICATION OF BIOMASS BRIQUETTES
APPROPRIATE BIOMASS RESIDUES FOR BRIQUETTING
LOW MOISTURE CONTENT
ASH CONTENT AND COMPOSITION
FLOW CHARACTERISTICS
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
THE PROPERTIES OF THE SOLIDS THAT ARE IMPORTANT TO DENSIFICATION ARE:
COMPARISON BETWEEN FOSSIL FUEL & BIOMASS
COMPACTION CHARACTERISTICS OF BIOMASS &THEIR SIGNIFICANCE
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:
REDUCE FOSSIL GAS CONSUMPTION:
REDUCE COMMERCIAL WASTE PRODUCTS:
GENERATE ELECTRICITY:
CREATION OF NEW JOB OPPORTUNITIES:
LOCAL AND INTERNATIONAL CONTEXT FOR BRIQUETTE USE
STANDARDS
BIOMASS SOURCES
FORESTS
AGRICULTURE
FOREST AND AGRICULTURAL INDUSTRIES’ RESIDUES
ENERGY CROPS
MARKET OVERVIEW
DOMESTIC (INFORMAL) MARKET
INDUSTRIAL MARKET
MARKETS AND USERS FOR BRIQUETTES
BIOMASS BRIQUETTING IN INDIA
DISTRIBUTION OF BRIQUETTING UNITS IN THE COUNTRY:-
MANUFACTURING PROCESS
MOISTURE CONTROL PRIOR TO BIOMASS PROCESSING
MILLING
CRUSHER MACHINE
TYPICAL DESIGNS OF BAMBOO/WOOD CHIPPERS
DRYING
THE MAIN COMPONENTS OF DRIERS ARE:
BRIQUETTING
PISTON BRIQUETTING
DENSIFICATION BY EXTRUSION - SCREW BRIQUETTING MACHINE
THE MAJOR COMPONENTS OF THE SCREW TYPE BRIQUETTING UNITS ARE:
EXTRUSION MATRIX
PACKAGING
BRIQUETTES PACKING WITH THERMO SEALING
PALLET WRAPPING MACHINE
PROCESS FLOW
BIOMASS BRIQUETTING PLANT
BRIQUETTE MACHINE & BODY COMPONENTS:
MACHINE TYPE:
BINDER LESS PRODUCTION:
WORKING PARAMETERS
BRIQUETTE MACHINE & ACCESSORIES
MAIN UNIT:
SPECIFICATIONS OF BRIQUETTE MACHINE MODEL ECOSTAN® BULL 80
CHIPPER CUM GRINDER
CHIPPER GRINDER TYPE:
WORKING PARAMETERS:
GRINDER SPECIFICATION
SPECIFICATIONS OF CHIPPER CUM GRINDER MODEL
CHIPPER CUM GRINDER & ACCESSORIES
MAIN UNIT:
FLASH DRYER
FLASH DRYER SINGLE PASS BODY COMPONENTS:
DRYER TYPE:
HOT AIR FURNACE:
WORKING PARAMETERS:
SUPPLIERS OF PLANT & MACHINERIES
HEALTH AND SAFETY
INCREASING DEMAND OF BIOMASS BRIQUETTES
BIOMASS BRIQUETTING PLANT IMPROVE CURRENT ECOLOGICAL CRISIS
USE BRIQUETTING PLANT AND SAVE TREES
PRESENT MANUFACTURERS/SUPPLIERS FOR BIOMASS BRIQUETTES
CONCLUSIONS
PROPOSED IMPLEMENTATION SCHEDULE
PROJECT FINANCIALS
PRELIMINARY PLANT LAYOUT
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)
