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Shri AMM Murugappa Chettiar Research CentreTaramani, Chennai –600113.
December 2010
Booklet on
BIOMASS CHARCOAL BRIQUETTING
Technology For Alternative Energy Based Income Generation In Rural Areas
Title : BIOMASSCHARCOALBRIQUETTING TechnologyforAlternativeEnergyBased IncomeGenerationInRuralAreas
Authors : Dr.P.Sugumaran,ProgrammeOfficer Dr.S.Seshadri,Director(R&D) ShriAMMMurugappaChettiarResearchCentre, Taramani,Chennai600113. Email:[email protected] Web:amm-mcrc.orgFinancialSupport: DST-CoresupportProgramme SEEDDivision-SP/RD/044/2007 DepartmentofScienceandTechnology(DST) MinistryofScience&Technology, Block-2,7thFloorC.G.OComplex, LodiRoad,NewDelhi-110003. Publisher : ShriAMMMurugappaChettiarResearchCentre, Taramani,Chennai600113. Email:[email protected] Web:amm-mcrc.org Phone:044-22430937;Fax:044-22430369
Printedby : JRDesigning,PrintingandAdvertisement Solutions,Palavakkam,Chennai-600041. Ph.+91-9962391748 Email:[email protected]
YearofPublishing: December2010
Contents
I. Introduction 2a. Whatischarcoal? 5b. Howitisprepared? 5c. Whatisbiomasscharcoalbriquetting? 5II. Biomasscharcoalbriquetteproduction 6III. Materialsandmethods 6IV. Materialsrequired 64.1. Biomasscollection 74.2. Carbonizationofbiomass 74.2.1FabricationofCharcoalkiln 74.2.2Carbonizationprocess 94.2.3 Charyield 104.3. Binderpreparationsandmixing 104.4. FabricationofBriquettingmachine 114.5. Briquetting 134.6. Drying,Packingandmarketing 134.8. BiomassBriquettesusedasalternativefuel 13V. Capitalinvestments 13VI. Costbenefitanalysis 14VII. Whowillgetbenefited 14VIII.Advantagesofthetechnology 15IX. CharcoalUses 15X. TechnologyTransfer 16
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Biomasscharcoalbriquetting-Analternativeenergybasedincomegenerationbyruralpeople
I.Introduction
Worldeconomyisdominatedbytechnologiesthatrelyonfossilenergy(petroleum,coal,naturalgas)toproducefuels,power,chemicalsandma-terials.Whiletheuseofconventionalenergylikeoil,coalandelectricityhasincreasedenormouslyinthelast25yearsinASEANeconomies,In-diastillimportscrudeoil&petroleumover111.92milliontonesperyear.This heavy dependence on imported oil leads to economic and socialuncertainties.Currentlythereisastrongworldwideinterestinthedevel-opmentoftechnologiesthatallowtheexploitationofrenewableenergysources,bothforenvironmental(releaseofpollutantsandfossilreservesdepletion)andeconomicalreasons.
Biomass, adomestic energy source isnaturallyabundant andpresentspromisingrenewableenergyopportunitythatcouldprovideanalterna-tivetotheuseoffossilresources.Biomassbeingthethirdlargestprimaryenergyresource in theworld,aftercoalandoil (Bapatetal.,1997), itstillmeetsamajorfractionoftheenergydemandinruralareasofmostdevelopingcountries.Inallitsforms,biomasscurrentlyprovidesabout1250million tonnes oil equivalent (mtoe) of primary energywhich isabout14%oftheworld’sannualenergyconsumption(Halletal.,1991;Wertheretal.,2000].Theuseofbiomassfeedstock(s)forthesubstitutionoffossilfuel(s)hasanadditionalimportancefromclimatechangecon-siderationsincebiomasshasthepotentialtobeCO2neutral.Anumberofresearchanddevelopmenteffortstowardstheconversionofrawbiomassfeedstocksintoimprovedqualityfuels(solid,liquidorgas)throughbio-logicalandthermo-chemicalconversionprocesseshavebeenmadeglob-allyinthelastthreedecades.
Thedecreasingavailabilityoffuelwoodinmostofthedevelopingcoun-trieshasnecessitatedtheeffortsbemadetowardsefficientutilizationofagricultural residues (Grover andMishra, 1996;Tripathi et al., 1998).Rawagriculturalresidueshavemanydisadvantagesasanenergyfeed-stock(Balatinecz,1983).Theseinclude(i)relativelylowcalorificvalue,(ii)difficultyincontrollingtherateofburning,(iii)difficultyinmecha-
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nizingcontinuousfeeding(iv)largevolumeorarearequiredforstorage,and(v),problemsinitstransportationanddistribution.Severalofthesedisadvantagesmaybeattributedtothelowbulkdensityofagriculturalresidueswhichcanbeconvertedintohighdensityfuelbriquettes(Bio-mass charcoal briquettes).Charcoal is a premium fuelwidely used inmany developing countries tomeet household aswell as a variety ofotherneed(Goldstein,1981;Demirbas,2001).Recentimprovementsintechnologyforcharcoalbriquettesproductionwithincreasedefficiencyhasrenewedtheinterestintheuseofcharcoalbriquettesasafuelthatcanbeeasilystoredandtransported(SugumaranandSeshadri,2009).
Agricultural residues constitute one of the important biomass feedstocksinIndia.Ingeneraltheagriculturalresiduescanbedividedintotwogroups;cropresiduesandagro-industrialresidues.ThemajorcropresiduesproducedinIndiaarestrawsofpaddy,wheat,millet,sorghum,pulses,oilseedcrops;maizestalksandcobs;cottonandmustardstalk;jutesticks;sugarcanetrash;leaves;fibrousmaterials;roots;branchesandtwigswithofsizes,shapes,formsanddensities.Theagro-industrialresi-duesarericehusk,groundnutshell,cottonwaste,coconutshell,coirpith,tamarind shell,mustard husk, coffee husk,Cassava peel etc. Someofthecommonagriculturalby-productsavailableinlargequantitiesincludebagasse,ricehusk,groundnutshell,teawaste,Casuarinaleaflitter,silkcotton shell, cottonwaste, oil palmfiber and shells, cashewnut shell,coconutshell,coirpith(Iyeretal.,2002;SugumaranandSeshadri,2009)etc.
MCRCworkingonseveraltechnologieshasdevelopedandexpertiseinbiomasscharcoalbriquetting technologyover thepast fewyears.Thistechnologycanprovetobeoneamongthesolutionsforsupplementingthefuelrequirementsandsocio-economicdevelopmentoftheruralareasbyprovidingemployment toruralpeople. It iscosteffective,environ-mentfriendlyandimproveourairquality,andsupportruraleconomies.Atthesametime,thenaturalforestwouldalsobesaved.Bio-charpro-ductionprogrammecould lead toestablishmentofnewsmallemploy-mentorientedbusinessesinruralareasandraisingtheincomeofpeopleengagedinsuchactivities.
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a.Whatischarcoal?
Charcoalistheblackishresidueconsistingofimpurecarbonobtainedbyremovingwaterandothervolatileconstituentsfromanimalandvegeta-tionsubstances.
b.Howitisprepared?
Charcoal is usually produced by slowpyrolysis, the heating ofwood,bonechar,orotheragriculturalsubstancesintheabsenceofoxygenen-vironmentat450°-510°Cbyusingeitherinakilnoracontinuously-fedfurnacecalledaretort.Theresultingsoft,brittle,lightweight,black,po-rousmaterialresemblescoalandis85%to98%carbonwiththeremain-derconsistingofvolatilechemicalsandash.
c.Whatisbiomasscharcoalbriquetting?
Briquettingis theprocessofconvertinglowbulkdensitybiomassintohighdensityandenergyconcentratedfuelbriquettes.
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II.Biomasscharcoalbriquetteproduction
ThebiomasscharcoalbriquettingtechnologydevelopedatMCRCusesamodifiedkilnandabriquettingmachinethatcanbefabricatedlocallytoproduceBio-charfromvariousbiomasssamples.Thetechnologyin-volvesuseofacosteffectivebindertopreparethebriquettes.
III.Materialsandmethods
Briquettingprocess
Materialsrequired
1.Biomasswaste-Agricultural,industrialorforest
2.Charcoalkiln/drum(150cmx100cm)
3.Briquettingmachine(15kg/hr)
4.Bindingmaterials(eg.starchorcassavaflour)
Biomass collection
Drying
Carbonization
Preparation of Char powder
Binder preparation & Mixing
Briquettes production
Drying & Packing
Marketing
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4.1.Biomasscollection
Collectdifferenttypeofwastebiomasssuchaspaddy,wheat,millet,sor-ghum,pulses,oilseedcrops;maizestalksandcobs;cottonandmustardstalk;jutesticks;sugarcanetrash;leavesorindustrialwastessuchasricehusk,groundnut shell, cottonwaste, coconut shell, coirpith, tamarindshell,mustardhusk,coffeehusk,Cassavapeel,bagasse,teawaste,Ca-suarinaleaflitter,silkcottonshell,cottonwaste,oilpalmfiberandshells,cashewnutshell,coconutshell,coirpithorcommonlyavailableplantslikeProsopistwigs,Ipomoeastem,Lantanacamarastem,coconutfronds,Eucalyptusleavesanddryundersunlight.
4.2.Carbonizationofbiomass
4.2.1FabricationofCharcoalkiln
The largesize-charringkilnordrumisaportablecylindricalstructurewiththetopcutouttoplacethechimney.Thedrumsizeisabout100cmheightand150cmwidthmadeupof16gaugeironsheets.Inthelowerside,twofireportswithadoor(12”heightx20”width)areprovided.Abovethefiringportionanironperforatedsheetwithholesisfixed.Thebottomsideofthedrumisclosedwithironsheetsandprovidedwith4legs(seetheschematicdiagram).
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Advantagesofthekiln
Easy to operate and maintain; easily viewable during carbonization;highercharyield&lessertimeofoperation;Costeffective;Savesextrabiomass
4.2.2Carbonizationprocess
Separate the biomassinto stems, leaves andfruitsandcut them intoshort pieces. Use eachwastes separately forcarbonization.
For carbonization,looselypackthecollect-edbiomassintothekiln.Thekilnwillaccommo-date ~ 100kg dry bio-mass.After loading thebiomass into the kiln,closethetopofthekilnwith metal lid attachedto a conical chimney.Use little amount ofbiomass in the firingportion to ignite in thekilnandclosethedoorstightlytostartthepyrol-ysis process. In the ab-senceofair,theburningprocess is slow and thefire slowly spreads tothebiomassthroughtheholes in the perforatedsheets.
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4.2.3Charyield
Afterthebiomassgetsfullycarbonized(~1-2hrs;dependinguponthebiomass),removethelidandsprinklewateroverthechar.Usetheresul-tantcharpowderforpreparationofbriquettes.Thoughthecarbonizationprocessproduces@30-45%charpowderonanaverage,thecharyieldvariesaccordingtothebiomassused.
4.3.Binderpreparationsandmixing
Abinder isused for strengthening thebriquettes.Thecarbonizedcharpowdercanbemixedwithdifferentbinderssuchascommercialstarch,ricepowder,ricestarch(riceboiledwater)andothercosteffectivemate-rialslikeclaysoilandmixedindifferentproportionsandshapedwiththehelp of briquettingmachine.
For preparation ofbindingmaterialaddstarchtowaterintheratio of 10:1 and al-low it to dispersewithout any clumps.Then heat the solu-tion for 10 minutesanddonotallowittoboil (the final stagecan be identified bythe stickiness of the
Binder preparation
Binder mixing
Charcoal powder
Solution adding
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solution).Afterboiling,pourthetheliquidsolutionontothecharpowderandmixtoensurethateveryparticleofcarbonizedchariscoatedwiththebinder.Thisprocessenhancescharcoaladhesionandproduceidenti-calbriquettes.
4.4.FabricationofBriquettingmachine
Ameatmincermould(ModelNo.32)alongwitha1HPelectricmotorfit-tedappropriatelyisusedasabriquettingmould.Thebriquettingmachineisdividedintotwodifferentportionssuchaslowerandupperportions.
Thelowerportionisfittedwitha1HPsingle-phaseelectricmotorfixedonaflatplatform.Theupperportionhasthebriquettingmould(modelno32,cylindricaltype;10kg/hr)fixedontoawoodenplateplaced1ft.abovethelowerplatform.Boththeplatesarefixedonironanglesandcoveredfullyusingstainlesssteel sheets. Themotor and the bri-quetting mould areconnected using awheel and V-belt.To control the mo-tor,apowerindica-tor and a 5 Ampsswitchwereprovid-ed in the front sideof the briquettingmachine (see theschematicdiagram).
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4.5.Briquetting
Thecharcoalmixturewithbindercanbemadeintobriquetteseitherman-uallyorusingmachines.Forthemechanicaloperation,loadthemixturedirectlyintothebriquettingmould/machinetoformuniform-sizedcy-lindricalbriquettes.
4.6. Drying, Packing and mar-keting
Collectthebriquettesinatray,drytheminsunlightfor2or3daysandpacktheminsealedplasticbagsforsale.
4.8. Biomass Briquettes used asalternativefuel
Charcoal briquettes can be usedas fuel in rural houses for cook-ing, laundering and in boilers inteashopsandTtandoorChulhas insmallhotels.
Cooking tests conducted usinga non-pressurized cooker (Saraicooker,ARTI)showsthat200-250gofbriquettesisenoughtocookfoodinabout45-60minutes.Theheatwasstablefor2hours.Feedbacksur-veyconductedatThiruvidanthai,Kovalam,MahabalipuramandnearbyvillagesinTamilnaduindicatethatthebiomasscharcoalbriquettesshowshigherenergy,quickheatinginlesstimewithlesssmokeandcomparabletothewoodcharcoal.
V.Capitalinvestments 1.Charcoalkilnwithchimney1nos.~Rs.20,000/- (Size:150cmwidthx100cmheight) 2.Briquettingmachine1no-~Rs.20,000/- (Model:prototype,1hpmotor,10kg/hr) TotalinvestmentmaximumRs.40,000/-only
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VII.Whowillgetbenefited• Un-employedpeopleinruralareas• Selfhelpgroups(SHGs)-men&women’s• Farmers• Ruralenterprises
VI.Costbenefitanalysis
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VIII.Advantagesofthetechnology
1. Smokeless:Thecharcoalbriquettesburnwithoutmuchsmokeduringignitionandburning.
2. LowAshcontent:Minimumresidualashformedislessthan5%oftheoriginalweightofthecharcoal.
3. Calorificvalue:~6243.58Kcal/Kg (woodcharcoal -6592.52Kcal/Kg).
4. Odourless:Containsminimumevaporativesubstancesthuseliminat-ingthepossibilityofodour.
5. Sparkless:Nosparksareproducedlikewoodcharcoal.
6. Lesscrack&betterstrength:Helpsburnforalongertime.
IX.CharcoalUses
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X.TechnologyTransfer
ThetechnologyonBiomasscharcoalbriquettesproductioncanbetrans-ferred to unemployed people in rural areas and rural entrepreneurs.MCRCcanprovidenecessaryassistanceinsetting-upofaBiomasschar-coalbriquettesproductionfacility.However,theendusershouldunder-takemarketstudyattheirowncostandestablishtheirownmarket.
ForMoreInformation,Contact:
ShriAMMMurugappaChettiarResearchCentre(MCRC)Taramani,Chennai600113Fax:+91-44-22430369
Email:[email protected]:www.amm-mcrc.org
References
1. AntalMJ,GrønliM. Theart, science, and technologyof charcoalproduction.Ind.Eng.Chem.Res.2003;42:1619-1640.
2. BalatineczJJ.Thepotentialofdensificationinbiomassutilization.In:CoteWA,editor.Biomassutilization.London:PlenumPress;1983.p.181–9.
3. BapatDW,KulkarniSV,BhandarkarVP.Designandoperatingexpe-rienceonfluidizedbedboilerburningbiomassfuelswithhighalkaliash.In:PretoFDS,editor.Proceedingsofthe14thinternationalcon-ferenceonfluidizedbedcombustion,VancouverASME,NewYork,NY,1997.p.165–74.
4. BardE.ExtendingtheCalibratedRadiocarbonRecord.Science,2001;292:2443-2444.
5. BudavariS.MerckIndex.WhitehouseStation,NJ:Merck.1996;1316.
6. ElmenhorstWR.Kilnfordryingandrevivifyingboneblack.USPat-ent.1880;235:942
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7. GroverPD,MishraSK.Biomassbriquettingtechnologyandpractic-es.FoodandAgricultureOrganization(FAO),UNDocument,No.46;1996.
8. HallDO,Rosillo-CalleF,WoodsJ.Biomass,itsimportanceinbalanc-ingCO2budgets.In:GrassiG,CollinaA,ZibettaH,editors.Biomassforenergy, industryandenvironment,6thE.C.conferenceElsevierScience,London,1991.p.89–96.
9. SmisekM,CernyS.ActiveCarbonManufacture,PropertiesandApplications,ElsevierPub.,Comp.,NewYork.1970;562-563.
10.SugumaranP,SeshadriS.Evaluationofselectedbiomassforcharcoalproduction.J.Sci.Indu.Res.2009;68(8):719-723.
11.Tripathi AK, Iyer PVR, Kandpal TC. A techno-economic evalua-tionofbiomassbriquettinginIndia.BiomassBioenergy1998;14(5–6):479–88.
12.WertherJ,SaengerM,HartgeE-U,OgadaT,SiagiZ.Combustionofagriculturalresidues.Prog.EnergyCombust.Sci.2000;26(1):1–27.
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Photographs
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Trainingprogrammephotos
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ForMoreInformation,Contact:
ShriAMMMurugappaChettiarResearchCentre(MCRC)Taramani,Chennai-600113.Fax:+91-44-22430369
Email:[email protected]:www.amm-mcrc.org
