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Accepted Manuscript

Biomass briquette manufacturing system model for environment

P. Balasubramani, V. Anbumalar, M.S. Nagarajan, P. Maheandera Prabu

PII: S0925-8388(16)31956-9
DOI: 10.1016/j.jallcom.2016.06.233
Reference: JALCOM 38102

To appear in: Journal of Alloys and Compounds

Received Date: 7 June 2016

Accepted Date: 22 June 2016

Please cite this article as: P. Balasubramani, V. Anbumalar, M.S. Nagarajan, P.M. Prabu, Biomass
briquette manufacturing system model for environment, Journal of Alloys and Compounds (2016), doi:
10.1016/j.jallcom.2016.06.233.

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BIOMASS BRIQUETTE MANUFACTURING SYSTEM MODEL FOR


ENVIRONMENT
P. Balasubramania, V.Anbumalarb, M.S. Nagarajanc, P. Maheandera Prabud
a
Department of Mechanical Engineering, Sona College of Technology, Salem, India.
Email:blsubramani25@gmail.com
b
Department of Mechanical Engineering, Velammal College of Engineering and Technology, Madurai, India.
Email: dranbumalarv@gmail.com

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c
Department of Mechanical Engineering, SBM College of Engineering and Technology, Dindigul, India.
Email: mail.nagarajanms@gmail.com
d
Department of Mechanical Engineering, Kurinji College of Engineering and Technology, Manapparai,
Trichy, Tamilnadu, India. Email: prabusita@gmail.com

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Abstract

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India depends mainly on indigenous coal for its power generation and imported oil
for its transportation needs. Most of the energy needs of rural poor are met by burning wood and

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other biomass in the least efficient manner adding to the GHG emissions. A comprehensive
system of utilizing biomass energy to replace or supplement coal usage in power generation and
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industrial heating systems is a pressing need. Converting rural population to better fuels or
efficient biomass burners will also help in reducing the growth of GHG emissions. An efficient
network of Biomass Briquette Manufacturing system could help addressing most of these issues
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in a sustainable manner. The briquettes made from biomass can be mixed with coal for co-firing,
used in gasifiers to produce syngas used for small scale power plants established in remote
regions. This paper discusses the elements and needs of briquetting system and proposes ways to
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improve the productivity of the biomass briquetting system by eliminating bottlenecks and
improving processes.
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Keywords: Briquette manufacturing, Bio mass, Energy, Productivity, System model

1. Introduction
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All over the world efforts are going on replacing fossil fuels with various possible
renewable energy options. Fast growing nations like India which does not have the luxury of
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easy availability of fossil fuels at low cost [17] a clean environment to release emissions are
constrained to go for renewable ways to add further development. It cannot follow the path of
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developed nations which have been proved to be unsustainable and it is not cheap anymore.
Avoiding the ways of industrialized countries is itself a challenge for India [17]. All countries
possess some form of renewable energy sources and developing them would help during global
level system failures [2]. At present India depends on highly pollusive indigenous coal for its
power generation and petroleum imports for most of its transportation needs. India has lot of coal
reserves and the power generated is very cheap if there is no penalty for its pollution. But a
growing economy without sufficient funds can’t stop using indigenous resources like coal.
Addition of Hydro electric power generation causes a lot of social unrest by the population
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displaced for the dam construction. After Fujiyama disaster local population are afraid to live
near the existing plants and new plants are unthinkable. Even in Japan “Biomass Town”, the area
where biomass is not wasted in anyway and used efficiently is being planned. Like special
economic zones these towns are required to improve agriculture, regional economy and reduce
pollution [19]. Wind energy is location dependent, seasonal and cannot be used for base load
operations. Solar power is costlier today but promising because of high level of solar irradiation

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and more number of sunny days in India. Biomass is another promising renewable energy source
which has low sulphur and nitrogen content in addition to being CO2 neutral. It is preferable due
to its suitability for base load operations and its ability to substitute all existing fossil fuel based

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applications with slight modifications in the equipments. Biomass can be converted to gases,
liquid and solid fuels to be used for all practical purposes existing today [3].

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Being an agrarian country around 80% of the energy needs of rural India is already met by
biomass like fuel wood, crop residues and livestock dung [13]. More than 50% of does not have
electricity and around 24,500 very remote villages may not get grid connection in near future

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[10]. Distributed power generation using biomass as fuel would be a feasible and rational option
[12]. If rural households are weaned away from burning wood for cooking with the help of better
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fuels, CO2 emission and smoke related diseases can be substantially reduced. All over the world
nearly two million deaths mostly women and children occur per year due to indoor air pollution
due to incomplete combustion caused by cooking over open fire [1]. Due to the adaptation of
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inefficient methods of energy usages and lack of infrastructure to market excess wastes, high
percentage of agro residues is underutilized. In many areas people are leaving agriculture and
land under cultivation is getting reduced. There is scope for using those lands and already
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existing marginal lands for producing grass and other fast growing biomass which can be used
for fodder and briquetting. As biomass cultivation and briquetting are labor intensive activities
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rural job creation can be improved which might improve village life standard. As per Ministry of
New and Renewable Energy about 120 to 150 million metric tons of biomass residues are
available and it translates to 20GW of renewable without creating strain on resources [10]. It
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cost only 3.55Rs/kWh without CDM and 2.8Rs/kWh with CDM benefits for biomass power
generated in Tamilnadu, India using coconut shells in a gasifier and sending the output to a
producer gas engine [6]. But issues of supply irregularity of raw material and lower plant load
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factors remain in most cases. By proper policy support biomass power can easily increase the
percentage of renewable energy usage.
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2. Biomass briquetting

The energy density of biomass is usually in the range of 14,651-16,744 KJ which is very less
compared to 20,930-29,302 KJ of coal. This small scale, decentralized availability of low energy
density biomass makes it hard to utilize it effectively [4]. Increasing the energy density by
Briquetting the biomass is generally proposed to be a viable and profitable option of utilizing the
waste biomass residues. By briquetting, the loose biomass is compacted to a more usable
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product. Particularly screw briquetting which is chosen as the default option in this paper
produces highest quality briquettes suitable for gasification and co-firing. When straw was
gasified first and used for power generation the impact on environment were found to be better
that direct combustion of straw or coal [18]. It might be inferred that for most biomass residues
briquetting and gasification would be an environmentally friendly solution than direct burning.
In fact Chinese government had prescribed replacing coal by briquettes as one of the main

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specific development orientations [3]. Though there are obvious benefits to be obtained by
densification of biomass to briquettes there is no organized system in India to cater to the needs
of its suppliers and end users. In this paper based on the conditions and habits of rural Indians

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and the behavior of the industrial and regulatory system, some possible solutions are proposed.
An effort is done to bring together all ideas and fit them into a model. Many times naming an
idea gives it a life and once a basic model for biomass briquetting system is proposed and

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accepted, there is every chance for it to be developed into a comprehensive system and be widely
used. Every individual element in the system can be worked upon and its contribution to the total
system can be analyzed. Various alternate scenarios for the future can be modeled and tested

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upon. We have tried to develop a biomass briquetting manufacturing system tailor made to
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Indian environment.

3. BBM System
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A comprehensive biomass briquetting manufacturing (bbm) system could aid India in the
transition from fossil based fuel usages to renewable energy based system. C.Z.Wu et[3] al have
recommended developing widely dispersed biomass energy systems and commercialization
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models suitable for developing countries [3] Biomass can compliment wind and solar power
generation very well and create a dependable network. Putting biomass in level field with coal by
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either putting penalty for fossil power generation or giving CDM credit for biomass usage will
make it competitive. Biomass applications like electricity or heat generation prerequisites a
stable supply of feedstock which is not there presently. A comprehensive BBM system can
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assure regular feedstock availability stand on its own even without any consumers like biomass
power plants. There are more than sufficient small scale usages for loose biomass, wood and
charcoal in both rural and urban sectors. Most of them are using inefficient methods of burning
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the loose biomass which could be greatly improved by moving to briquettes which have high
energy density. Usage of scientifically designed stoves and small boilers will increase with the
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availability of a stable supply of good quality biomass briquettes. Once a strong system of
biomass briquette manufacturing and supply is developed introduction of biomass power plant or
CHP plant will be viable and will have less negative consequences. A conceptual model of BBM
system is given in Figure 1. Without any strong BBM system the introduction of biomass power
generation may put undue pressure on the agricultural sector, fodder supply and land
management practices. In very short time the feedstock supply will be disturbed and the plant
may become unviable.
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4. Biomass Briquetting Cooperatives

Biomass residue is available in a scattered manner and it is best to use them to satisfy the energy
needs of scattered and remote rural areas. Introduction of biomass power generation or any
process heating application tends to increase the demand for waste biomass in those regions
raising fodder prices, wages, competing for land with food crops. It will most probably affect the

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livelihood of the local population inducing them to fight for closing those plants. Different social
groups will have different grievances for adopting and if not resolved properly those things may
emerge as powerful barriers [5]. The non native investors will care less about the welfare of local

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population and concentrate mostly on their profits. But if those plants are owned by biomass
cooperatives comprising of the natives they tend to share the benefits and will find ways to adopt
than oppose. Small scale renewable energy technologies under the control of local communities

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can make substantial impact on the overall energy consumption of the country [15]. A model of
biomass briquetting cooperative system is given in Figure 2. As per the model (BCC) Biomass
Collection Centers (n numbers) are established in villages and loose biomass is bought at an

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affordable price. Rural men and women would like to earn extra income by finding waste
biomass residues around the village and selling it. The collected biomass will be sent to (BBP)
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Biomass Briquetting Plants (m numbers). At BBPs the loose biomass will be densified to
briquettes and sold to rural industries, households or to central Biomass Power Plants established
to consume the output and provide electricity back to the villages itself. The benefits of
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employment generation, energy supply, logistic infrastructure and price for their wastes will help
power generation by second generation biomass outweigh the associated problem. Local people
will find ways to increase the crop yields, use better methods of harvesting, use land in
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economical ways and become self reliable.


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4.1 Assumptions

For the cooperatives to function effectively the following conditions are advised.
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Each collection center fixes its purchase price depending on the raw material available and its
quality
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Biomass is not stored in collection centers, they are sent to briquetting plants for storage
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Each biomass briquetting plant fixes the price for its product in consultation with biomass power
plant regularly.

Each biomass collection center should send the material only to its corresponding briquetting
plant.

Each briquetting plant can send its produce to the central biomass power plant or it can sell in the
retail market. But it is preferred to have an agreement to send minimum quantity of briquettes to
the Biomass Power Plant for stable operation.
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Central biomass power plant should accept all the collected biomass supplied from the
briquetting plants and for shortage of loads it may purchase raw material outside.

Money should be settled at real time at all stages of the network.

4.2 Cost Estimations

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Rough cost estimates are done with the available local data (Madurai District, Tamilnadu, India)
and tabulated and presented as table 1. Their break up is given as a pie chart in Figure 3.They are
bound to vary based on locations but that may not be significantly higher and those areas where

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it may be so may not be considered for implementing the proposals in the initial stages.

5. Energy plantations

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To have a commercially viable biomass based power plant run without supply disruptions the
fuel supply should be ensured. Any problem in supply chain will have severe consequences.
Availability of agro residues are seasonal and have competing uses. Unpredicted scarcity may

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lead to escalation of input costs and profitability will be hit. The solution proposed to handle
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these kinds of situations is to have energy plantations which could provide sufficient amount of
biomass to run the plant all through the year or to supplement the periods where there might be a
scarcity. But energy crop production may have adverse consequences by competing for resources
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with other food crops, fodder, put pressure on land, water and may impact biodiversity adversely.
But it has the potential to create jobs, eliminate rural poverty and mitigate GHG emissions and
reduce import dependency [8].When judiciously used most of the negative impacts can be
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eliminated. The preferred options are to use waste and marginal lands to cultivate draught
resistant varieties without straining resource. All biotechnological knowledge could be used to
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develop plants which could grow in saline lands and other discarded lands. In 20% of land in
India little agriculture is practiced and they can be considered as waste lands, around 55 million
ha of land is estimated to be waste or marginal land which was once cultivated [2]. Due to lack
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of job opportunities rural people are leaving agricultural even now and their land is abandoned
increasing the total wasteland. All these lands can be also used to develop dedicated energy crops
which can be briquetted and used for power or heat applications. Growing draught resistant
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varieties like Pongamia, Juliflora and Jatropha could yield tons of biomass and biodiesel. In
Spain waste from water treatment plants was used to grow Cynara cardunculus L and found to
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produce equivalent biomass yield as if cultivated in commercial manner [14]. Each and every
city in India releases substantial amount of sewage water and they help spreading diseases in the
suburban areas and to grow unhealthy vegetables. If that waste water is used for growing
biomass like elephant grass and by briquetting those biomass residues the existing issues can be
solved in a healthy manner. As logistics cost is the major portion of the biomass utilization,
growing fast growing biomass around small scale power plants, gasification plants or user
industries and utilizing then and there will be viable and profitable.
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6. Process Improvements

Other main element of the BBM system is the screw briquetting unit which produces briquettes
from the raw biomass. It normally consists of dryer to reduce excess moisture, a crusher to
reduce the size of raw material to suitable levels and the briquette making machine which
produces the output. There are issues in these processes and production is regularly being

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disturbed. To achieve continuous production and improve productivity each stage should be
properly monitored and parameters improved. The productivity depends on raw material size,
moisture content, the performance of screw and mould assembly and the heating method.

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Particularly the life of screw mould assembly acts as the bottleneck in process and major
improvements can be made only by improving the screw life. Further by applying quality control
and other industrial engineering practices the briquetting process can be made efficient and

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overall productivity can be improved. Once continuous production is achieved the best practices
could be documented and standardized.

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Experiments were conducted to improve briquetting process by 1.improving screw life,
2. Improving mould life, 3. Scheduling downtime to improve productivity. For the study, screw
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briquette machine supplied by Gongyi Hongji machinery factory, China, was used. It is shown in
Figure 3 and the specifications are, Machine capacity: 250 kg/hr, Screw Speed: 270 rpm, Motor:
22.5 kW and Briquette size: 65 mm Square with chamfered corners and 25 mm hole along the
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axis. A sample of briquettes is shown in Figure 4. Saw dust is chosen as the raw material for its
suitability to produce high calorific value briquettes [11]. and its local availability. The entire
saw dust used during this experiment is collected from a single source in single lot. The saw dust
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is sieved to -5mm, dried to less than 8% moisture in a hot air-current drier and the drier output
about 80oC to 90oC is fed directly to the briquetting machine. Only the briquettes of minimum
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acceptable quality were considered as output. The mould needs to be maintained at a temperature
about 250oC for the lignin content in the biomass to melt and act as a binder.
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6.1 Improving Screw and mould life

Initially the screw briquetting machine is run with the screw and mould supplied which are
made of mild steel and hardened on the surface. The normal life of a screw is about 4 hrs and
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after that it starts to break faster and hence the screw will be taken out and will be replaced with
a new screw. The average time to remove the screw and replace it with the new one and to bring
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the heater to the required temperature level took 45 minutes. After 4 trials the damage in the
mould become visible and the production became highly unstable. The mould life was improved
by various hard facing techniques. By using various electrodes for coating the screw to improve
its hardness its life has been improved and the improved screws were used along with the
improved mould. For reference the backup data for improvement works done in screw were
presented in table 2 and main relations are represented in Figure 4.The data for improvement
works done for the mould are provided in the table 3 and their effects are represented in the
graph Figure 5.
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From the experiments it was found that the improvement in the life of either screw or the mould
individually improves the output. The improvement in the life of the mould contributes to the
total productivity by improving the life of the screw also. The life of the normal screw increased
from 4hrs to 6hrs when used along with improved mould with fine finish and hardness. The
major factor which does the spoilsport is the time required to change the mould screw assembly
and reheat it to 300oC whenever a screw or mould got eroded, particularly the screw which needs

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regular replacement. Inability to control temperature, regularly changing raw material quality,
power fluctuation and the human errors will also affect productivity to a great extent in regular
production unlike experimental conditions. Specifically a major portion of productivity is lost

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due to the time taken to change the setup and further work is needed to device quick change
mechanisms to improve the productivity.

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Productivity for Normal Screw & Normal Mould = 0.6501

Productivity for Normal Screw & Improved Mould = 0.7157

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Productivity for Improved Screw & Improved Mould = 0.7647
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6.2 Downtime planning

The factor we have taken next for this paper is the problem associated with unexpected and
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frequent machine break down due to reduced screw life. In almost all industrial activities, cost
reduction, reliability and minimizing downtime are considered as central objectives [7]. The
factors like idle machines & manpower, machine break down and the machines which run below
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their specified speed are considered as examples of waste [16] which reduce the productivity.
There is sufficient scope to improve the productivity of the briquetting process and hence the
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profitability by concentrating on reducing the downtime losses in addition to improving the tool
life and other parameters. Once continuous production becomes the norm due to downtime
reduction, more and more entrepreneurs are likely to take up the venture and establish better
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practices. But government support will be required in terms of policy, subsidy and infrastructure
for survival of the biomass briquetting sector. The improvements in productivity parameters
made by replacing the screw sufficiently before it actually breaks down as a preventive
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maintenance strategy are studied for tools of varied life profiles and the results analyzed.
Finding the critical rates of machine breakdown and to take measures to continue production to
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meet deadline in spite of disturbances is advised by M.Ozkok [9] based on his study in turkey
shipyard.

For conducting the experiment screw and mould spares were kept ready for
replacement. For the first set of data the screw coated by Eutechtrode 700 from L&T was used
and it was allowed to run till it breaks down. The mould was also hardened by coating with
Eutectrode 700. As an average it took about 45 minutes to remove the screw, cool the system,
clean the system from debris of raw material, put the new screw and reheat the mould again to
desired temperature. Each trial took an average of 6 hrs and was repeated 8 times within 2 days
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and the damaged screws were sent for reconditioning again for further use. The mould lasts for
about 24+ hrs and it needed replacement after 4 trials along with screw otherwise the worn out
mould would accelerate the wear rate of screw. For the second set of readings the stoppages are
preplanned so that screw is removed before it was damaged considerably. The heater is stopped
earlier; very fine powder not suitable for briquetting was introduced inside to push the previously
formed matter out making the cleaning process easy and short. The system will be started again

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with the new screw in place and heated to required temperature about 250oC. The average down
time in this trial was considerably reduced to 31 minutes. The same kind of trials are repeated
with screws coated with VAUTID 302 which is a tungsten carbide electrode and its coating

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increased life of screw to more than 10 hrs. The same type of mould with Eutechtrode 700 was
used in this trial but replaced along with the second screw replacement. Readings were taken for
4 trials to keep the total duration similar to that of first set. The next set of trials with planned

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stoppages was also conducted for 4 trials in the similar way.

In this experiment the percentage output delivered per unit capacity of the machine is used as

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a measure of productivity. We have avoided using the term capacity factor which mostly
represents power generation equipments.
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PRODUCTIVITY FACTOR = (ACTUAL PRODUCTION/NOMINAL CAPACITY)*100

OPERATIONAL AVAILABILITY= (MTBF/ (MTBF+MDT))*100


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MTBF- Mean Time Between Failures


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MDT – Mean Down Time


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The details of the final results obtained for improvement in productivity by planned downtime as
a preventive strategy are given in table 4 and their change pattern is represented in Figure 6.

Once the standing time of few screws are found out, the minimum life time shown by the
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weakest screw is used to determine the safe downtime. Planning downtime and conducting the
process has shown the following impacts on production process.
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 The downtime per setup went down;


 Productivity has shown improvement;
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 Labor productivity & morale went up.


 The production of unacceptable quality briquettes at the last part of production was
reduced.
 Operational availability did not show significant improvement
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7. Discussions

The results of process improvements have already been discussed in their respective subheadings
and an overall view of the system’s strengths and weakness are discussed here. A brief SWAT
analysis could put BBM system in proper perspective.

Strengths: There are a lot of unemployed rural population and unutilized biomass material

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available. There is more than enough demand for briquettes by rural industries which use wood
or charcoal. Remote villages do not have any possibility of getting grid connection and other
modern facilities in the near future.

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Weaknesses: Rural people now prefer to migrate to cities than work in agricultural field. Basic
Infrastructure is very weak and credit availability is very poor which will discourage small rural

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entrepreneurs to participate in the program.

Opportunities: Government encourages all CDM initiatives and has announced many incentives

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to promote biomass based ventures. Carbon credits can be sold in the international market if
proper certification process is implemented. Reduction in CO2 emissions may stabilize the
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environment and increase the rainfall.

Threats: Due to worldwide recession oil price may not go up significantly in future hindering
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the off take of green power. Food vs fuel will always be raised even for second generation bio-
fuels as the cultivation pattern may have indirect effect on food supply. People may divert
resources like water and good cultivatable land to energy plantations. Loss biodiversity may
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result due to deforestation to grow biomass and grasslands may also be affected.
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8. Conclusions

Biomass collection can become a significant rural self employment method. A strong network of
biomass briquetting could act as a backbone to develop low carbon energy system and rural
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development. When the network is owned by the people through cooperative structure conflicts
will be minimized. The sewage water from cities when used for cultivating fast-growing biomass
to be used for briquetting could reduce cost and will not compete for water resources. There
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sufficient scope for improving tool life and other parameters to improve productivity and make
briquetting business a viable model. Notwithstanding all the technical developments still
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government policy support is needed to make biomass to have a level playing field with fossil
fuels.
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LIST OF TABLES

Table. 1 Cost of supplying briquettes to a Biomass Power Plant

Table. 2 Various hardening processes used for improving screw life

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Table. 3 The experimental data for all trials with various hard facing processes to improve mould
life

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Table. 4 Details of productivity improvement by planning downtime

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Table 1

Sl.No. Cost details – average market estimates Amount in


Rupees/ton
1 Cost of raw material 1000
2 Cost of transportation from the collection center to the briquetting plant (5 400
to 10 km radius.

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3 Cost of inventory at the briquetting plant ( 20% or raw material cost ) 200
4 Cost of processing at the briquetting plant ( screw briquetting technology ) 700
5 Cost of briquette from briquetting plant ( subtotal) 2300

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5 Transportation cost from briquetting plant to biomass power plant ( upto 300
100 km radius)
6 Total cost of supplying a ton of briquette to a power plant 2600

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Table 2

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Sl MATERIAL HARDNESS PROCESS LIFE IN
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no HRC Hours / tons
1 LT 700 58 arc welding 4/1
2 GEECOR 404 62 arc welding 10 / 2.5
M

(W2C)
3 Vautid Ultra 302 64 Arc Welding 16 / 4
D

(W2C)
TE

Table 3
EP

Sl MATERIAL HARDNESS PROCESS LIFE IN


no HRC Hrs
C

1 MS --- hardening 16
2 EN8 42 hardening 24
AC

3 HIGH Cr 54 Hardening 26
4 LT 700 58 arc welding 24 (per
coating)
5 GEECOR 62 arc welding 24 (per
404(WC) coating)
6 W2C coating Not known furnace bracing 100 hrs+
ACCEPTED MANUSCRIPT

Table 4

Trial Conditions Productivity Operational Average


no Screw life Operation factor availability setup time
hrs mode % % min
1 5-7 Till 66.43 87.91 44.4
breakdown

PT
2 5-7 4 hrs 78.16 88.45 31.35
3 10-12 Till 74.59 93.78 43.95
breakdown

RI
4 10-12 10 hrs 80.9 94.3 36.3

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LIST OF FIGURES

Figure. 1 Biomass Briquette Manufacturing System


Figure. 2 Biomass Briquetting Cooperative model
Figure. 3 Components of cost of making a briquette

PT
Figure. 4 The screw briquetting machine
Figure. 5 A sample of screw briquettes

RI
Figure. 6 Effect of type of welding rod on the screw life
Figure. 8 Effect of maintenance types on the productivity parameters

SC
Figure. 7 Effect welding process type of the life of forming mould

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PT
RI
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Figure 1

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Figure 2
C
AC
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Cost of Briquette in Rupees

300 Raw material


Transport to briquetting plant
1000

PT
inventory
700
Processing
Transport to power plant

RI
200 400

SC
Figure 3

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Figure 4
EP
C
AC

Figure 5
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200
180
160 Vautid Ultra 302 (W2C)

140
120

PT
GEECOR 404 W2C
100
80

RI
60
LT 700
40
20

SC
0
Hardness HRC Screw Life hours Production tons

U
Figure 6
AN
M

120
D

100
TE

80 MS
EN8

60 High Cr
EP

LT700

40 GEECOR 404 (W2C)


C

W2C furnace brazing

20
AC

0
Hardness HRC Screw Life in Hrs

Figure 7
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100
90
80
70
60 LT 700 till breakdown
50

PT
LT 700 for 4hrs
40
VAUTID 302 till breakdown
30
VAUTID 302 for 10 hrs

RI
20
10
0

SC
Production Factor Operational Average setup Time
% Availability % in minutes

Figure 8

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RESEARCH HIGHLIGHTS

 Regular feedstock availability in comprehensive Biomass Briquette Manufacturing


system.
 Biomass collection will minimize conflict of interest.
 Fast growing grasses cultivated with sewage water will reduce cost of briquetting.

PT
 It will improve productivity and profitability.

RI
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