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“Design and Fabrication of Briquetting Machine for Saw Dust”

Conference Paper · December 2010

DOI: 10.13140/RG.2.1.1036.5200

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DESIGN & FABRICATION OF BRIQUETTING MACHINE FOR SAW DUST

DR. PUSHPA JHA1 , MR. PRAMOD YADAV2

1. Deptt. Of Chem. Tech., SLIET, Longowal, Sangrur-148106, Punjab, India

2. Deptt. Of chem. Tech., BCET, Gurdaspur-143521, Punjab, India

E-mail ID:Pushpa_jha@rediffmail.com

ABSTRACT

Briquettes produced from agro-residues are fairly good substitute for coal, lignite and
firewood. Briquettes have high specific density (1200-1450 kg/m 3) compared to 60 to 180
kg/m3 of loose agro-residues. Loading/unloading, transportation and storage costs of agro-
residues are drastically reduced if they are converted in the form of briquettes. Formation of
briquettes at the very site of its production stops air pollution to a large extent.

In this paper an attempt is made to design and fabricate briquetting machine for saw dust.
The machine has been designed to produce briquette at the rate of 7kg/hr.Effect of moisture
content in agro-residues and binders used have been studied on briquette density, power
consumption/kg of briquette produced and calorific value/kg of briquette. Thermal
efficiency of chulha (local stove) using prepared briquette was obtained to be 5%.

Key Words: Briquettes; Briquettes Density; Design; Calorific Value.

1. INTRODUCTION

Huge quantities of agro-residues are produced after the harvest by many of the
developing countries but they are used inefficiently causing extensive pollution to the
environment. The major residues are rice-husk [1], coffee husk, coir pith, jute sticks,
bagasse, groundnut shells, mustard stalks and cotton stalks [2, 3].Saw dust, a milling residue
is also available in huge quantity in India. Problems associated with the utilization of these
residues are for transportation, storage and handling. The direct burning of loose agro-
residues in conventional grates is associated with very low thermal efficiency and
widespread air pollution [2].In addition, a large percentage of unburnt carbonaceous ash has
to be disposed off. Briquetting of agro-residues at the very site of its production can solve
these pollution problems with the advantage of making use of them as a source of non-
conventional energy.

Briquetting is in fact converting the low bulk density agro-residues into high density
and energy concentrated fuel .Briquettes are good substitute for coal and wood [4] in
industrial boiler and brick kiln for thermal applications. Apart from being non-coventional,
these briquettes are renewable, eco-friendly, non-polluting, economical [5] and high calorific
value compared to fire-wood or loose agro-residues.

Briquettes can replace conventional fuel for thermal applications [6] in various
industries like: Ceramic, Solvent Extraction Plant, Dyeing units, Food Processing industries,
Textile Unit, Chemical Industries, Milk Plants, Leather Industries, Rubber industries etc.

In this paper Screw Extrusion machine is designed and fabricated to get briquettes of
saw dust at the rate of 7kg/hr.Effects of binder percentage have been studied on briquette
density, power consumption/kg [7] of briquettes produced and calorific value/kg of
briquette. Thermal efficiency of chulha (local stove) using prepared briquette is also
determined.

2. MATERIALS AND METHODS

2.1 Design of Briquetting Machine: Designing the machine for compaction of Saw dust,
detailed study has been done on different part of the machine and its function.
Sectional view of briquetting machine is shown in Fig.1 .Technical specification has been
considered to fabricate the machine on lab scale for biomass densification
production. The details of design procedure & technical specification are given below:

2.1.1 Design [8] of Motor Shaft Pulley & Shaft Diameter: Motor Output Power=1 hp

Designed Power=Power Output * 1.3

Service Factor=1.3

Torque (T) =Designed Power *9550/ N

Where N= RPM of Motor & Shaft

For N1= 1400 RPM of Motor; Torque (T) =0.746 KW *1.3 * 9550/1400=6.6 Nm

Torque on Shaft=0.746 KW*1.3 *9550/352=26 Nm

For N2= 352 RPM on Shaft; Maximum Shear Stress induced on motor shaft is given by

Ks * T = (3.14 *d13/ * fs)/16

Where Ks=1, for uniform Load, fs= Design Stress=56 MPa

Design Stress with Keyway=56 *0.75 MPa

d1=diameter of shaft On Motor= d1= (1* 6.6 *16/3.14 * 56 *.75 *106) .33 =9.3 mm
Diameter of Motor Shaft Pulley=D 1=38 to 42 (Torque on Motor Shaft) 1/3
Hence D1=40 *(6.6)1/3=74.54 mm

Diameter of Larger Pulley on Moving Shaft=D2=D1 *VR =D1*N1/N2= 298 mm

2.1.2 Belt Speed: On this Machine V-Belt has been used. The belt speed is calculated by,

V1 on Motor Shaft =3.14 * D1 *N1/60=3.14 * 0.0745 *1400/60=5.45 m/s

V2 on Large Pulley =3.14 * D2 *N2/60=V2=3.14 * 0.298 * 352/60= 5.48 m/s

Selected Centre Value of Belt (C) =35cm=0.35m

The belt speed is less than 10 m/s, therefore centrifugal force is neglected.

2.1.3 Length of Belt: L=2 *C + (D2-D1)2/4 *C+1.57 * (D2 +D1) =1.3 m

2.1.4 Angle of Contact on the Smaller Pulley: θ= π-2 * sin-1((D2-D1)/2 * C) =149.87 o=2.61
radian. As θ > 2.1 radian, Hence this parameter is suitable for the design .

2.1.4 Maximum Belt Tension: Designed Power = Maximum Belt Tension (F1-F2) * V1/1000

Hence (F1-F2) =1.3 * 0.746 *1000/5.45=178 N

A number of belt option was tested & a belt of number of 53 was considered,
which was found suitable for this machine.The belt used has width of 15 mm &
thickness of 10 mm , which provides proper tension & grip on the pulley to run
the machine smoothly without Failure .

2.1.5 Design of Screw: Flight width=5mm; Flight Depth at Feed =9 mm; Flight Depth at
End=6.5 mm; Screw Flight Diameter= 40 mm; Screw Overall Length= 320 mm; Screw
Hub=20 mm; Screw Shank=40 mm; Screw Root Diameter at feeding Section =22 mm;
Screw Root Diameter at Die Section= 20 mm; Pitch =20 mm.

Screw Zone Length= 220 mm Length to Diameter Ratio=220/40=5.5

Compression Ratio(C.R): = Flight Depth at Hopper End/ Flight Depth at Die End

=9/6.5= 1.38

FIGURE 1: Assembled Sectional View of Briquetting Machine.

2.2 Technical Specification of Fabricated [9] Briquetting Machine

2.2.1 General Specification of Machine: General Details of fabricated machine is given in

Table 1.

TABLE1: General Specification of Briquetting Machine for Production Rate of 7 Kg/hr

Weight Length Width Height Motor Power Speed of Screw Die Heater

45Kg 60cm 30cm 75cm 1HP 352RPM with Heating Element

2.2.2 Specification of Screw: Specification of Screw is shown in Table2

TABLE 2: Specification of Screw

LENGTH DIA. OF THREAD TOP MATERIAL WEIGHT

320mm 40mm EN8 (Mild Steel) 1.5Kg

2.2.3 Specification for Die: Specification for Die [10] is shown in Table 3

TABLE3: Specification of Die

__________________________________________________________________________________

LENGTH INTERNAL DIA EXTERNAL DIA NO. OF GROOVES WEIGHT MATERIAL

100mm FRONT: 43mm FRONT: 77mm ZERO 2.468 Kg EN 24

BACK : 55mm BACK: 80mm (Hard Chroming Material)

Photograph of assembled machine designed and fabricated is shown in Fig. 2

FIGURE 2: Assembled Briquetting Machine

3. RESULTS AND DISCUSSION

3.1 Testing of Briquettes Produced from Machine[3,8,11]: Quality of briquettes produced
was tested for its density, Power consumption, Calorific Value & Thermal efficiency.
The results are shown in Fig. 3 and Fig. 4.

3.1.1 Effects of Moisture Content in Feed: The saw dust which was used for compaction,
has moisture content of 7- 8 %. But for appropriate briquetting of saw dust (as shown in
Table 4) moisture content is maintained in the range of 12- 13%. Moisture content is
maintained by adding sugar molasses & some amount of water. It was possible to obtain
smooth densification process and good strength of briquette.

3.1.2 Effect of Particle Size of Feed: Particle size and shape are of great importance for
densification[12]. On screen analysis, the size distribution of particles was done. It was
decided to use saw dust and binder in the size range of 0.15-1.5 mm as feed .The presence
of different size particles improves the packing dynamics and also contributes to high static
strength.

3.1.3 Effects of External Additives/Binders: With the help of additives, densification of

biomass becomes easy [8]. A 15-20 % of binder (sugar molasses) amount was used along
with the saw dust for producing good quality of briquettes. Also it upgrades the calorific
value and combustibility of briquettes.

3.1.4 Briquette Density: As per the data shown in Fig. 3, briquette density remains constant
around the value 1.4 gm/cm3 for the composition of binder in the range of 12-20%

3.1.5 Power Consumption: As per Fig. 4 the power consumption (Wh/kg) to convert feed
material into briquettes for different composition of saw dust and binder, is observed to
be varying from 900Wh/Kg to 790Wh/Kg.It is very clear from the Fig. 4 that as the
percentage of binder (Sugar molasses ) increases, the power consumption decreases.

3.1.6 Calorific value: The calorific value determinations of briquettes were done in the bomb
calorimeter. It is observed from Fig.4 that calorific values of briquettes increase with increase
in the percentage of binder from 12 to 16 %. But beyond binder percentage of 16 % the
calorific values of briquettes remain constant.
3.1.7 Thermal Efficiency: The Thermal Efficiency for all binder compositions was determined.
As per the observation from Fig. 3 almost constant thermal efficiency of 5 % is obtained for
all binder compositions of briquettes.

TABLE 4: Specifictions of Briquettes Produced with various Binder Content in Feed

PERCENTAGE OF BINDER IN THE MIXTURE

12 14 16 18 20

LENGTH (mm) 65 65 65 65 65

MASS (gm) 95 104 105 106 107

6
5
4
3
2 Briq. Density(gm/cm3)
Thermal Eff.(%)
1
0
12 13 14 15 16 17 18 19 20 21
Binder Composition (%)

FIGURE 3: Effect of Binder composition on Briquette Density and Thermal Efficiency

4000

3000

2000
Power Consumption(Wh/kg)
1000 Calorific Values(Kcal/Kg)

0
12 13 14 15 16 17 18 19 20 21
Binder Composition

FIGURE 4: Effect of Binder Composition on Calorific Value and Power Composition

4. CONCLUSIONS

The good quality briquettes of Saw Dust can be produced by controlling a number
of process variable like moisture content of feed mixture , particle size of the feed,
composition of additives added in the feed mixture. The power consumption can be
decreased by increasing the percentage of binder in the feed. Briquettes produced from Saw
dust are economical and have high potential as an alternate fuel for household cooking. The
application of briquetting technology can contribute significantly to the rural
population. It has a great potentional as a renewable source of energy and is a good
substitute for wood & coal.

5. ACKNOWLEDGEMENTS

Authors acknowledge all help and fascilities provided by Deptt. Of Chemical

Engineering and Workshop of BCET, Gurdaspur, Punjab.

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