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Gaia Association
Holistic Feasibility Study of a National Scale-up Program for
Ethanol Cook Stoves and Ethanol Micro Distilleries in Ethiopia:
Assessment of Ethanol Micro Distilleries and Alcohol Stoves Manufacturing Capacity in Ethiopia
Authors: John Loke1, and Endalkachew Mekonnen2
Collaborators: Harry Stokes, Desalegn Getaneh, Mussie Tesfay, Alex Milano, Getinet Alemaw, Feven Solomon and Dereje Petros
1 John B. Loke; EMD and Stove Technologist; Tropical Agricultural Engineer (B.Sc.), Plant Breeder (M.Sc.) and Technician in Plant Production; [email protected]; Skype john.b.loke 2 Endalkachew Mekonnen; Mechanical Engineer (M. Sc) (Manufacturing Specialization), Lecturer; Addis Ababa University /AAiT; School of Mechanical Engineering; [email protected]
Table of Contents Chapter 1.................................................................................................................................................. 1
International Trend and Technological Options in Production of EMDs .......................................................... 1
1.1 International trends in bioethanol production ................................................................................ 1
1.1.1 Production of ethanol from cellulosic biomass by cellulolysis or gasification ........................... 1
1.1.2 Concentration of fermentable sugars of raw materials by pervaporation ................................ 1
1.1.3 Ethanol from sugar without fermentation .............................................................................. 1
1.2 International trends in bioethanol production technology of EMDs ................................................ 1
1.3 Small-scale production ................................................................................................................... 2
1.4 Roots vs. stems .............................................................................................................................. 4
Chapter 2.................................................................................................................................................. 7
Selection of the most suitable technical options of EMDs for Ethiopia ........................................................... 7
2.1 Selection criteria of EMDs technologies for Ethiopia ....................................................................... 7
2.2 Available Technological Options ..................................................................................................... 7
2.3 Scaling of Production...................................................................................................................... 8
2.4 Implications of Using Different Feedstock on Technology selection ................................................ 8
Chapter 3................................................................................................................................................ 10
Material Balance, Process Description, Equipment List and Plant Layout of EMDs ....................................... 10
3.1 Material balance .......................................................................................................................... 10
3.2 Process description and equipment list ........................................................................................ 10
3.3 Discussion on EMD list of equipment............................................................................................ 13
3.4 Plant layout .................................................................................................................................. 17
Chapter 4................................................................................................................................................ 18
Technological and Manufacturing Capacity of EMDs in Ethiopia .................................................................. 18
Chapter 5................................................................................................................................................ 20
Investment Cost, Production Cost, Identification of Providers and Bill of Quantities of EMDs ...................... 20
Chapter 6................................................................................................................................................ 26
Cost of Manufacturing EMDs in Ethiopia vs. Import ..................................................................................... 26
Chapter 7................................................................................................................................................ 28
Alcohol Stoves ............................................................................................................................................. 28
Chapter 8................................................................................................................................................ 30
International Trends & Technological Options of Alcohol Stoves .................................................................. 30
Chapter 9................................................................................................................................................ 32
Selection of Suitable Alcohol Stoves Technologies to Ethiopia ..................................................................... 32
Chapter 10 ............................................................................................................................................. 33
Alcohol Stove Components, Manufacturing Process, Cost, and Plant Layout ................................................ 33
10.1 Equipment List, Material Balance and Manufacturing Methods .................................................... 33
10.2 Process Planning Activity for Alcohol Stove Production ................................................................ 39
10.3 Cost Study of Alcohol Stoves ........................................................................................................ 41
Chapter 11 ............................................................................................................................................. 44
Recommended Technology Transfer Options .............................................................................................. 44
11.1 Technological requirements ......................................................................................................... 44
11.2 Risks and challenges ..................................................................................................................... 44
11.3 Recommendations and technology transfer methods................................................................... 45
Chapter 12 ............................................................................................................................................. 46
Capacity Building Needs for Local Manufacturers ........................................................................................ 46
12.1 Capabilities to be addressed in the short term ............................................................................. 46
12.2 Capacity-capability that need to be addressed in medium and long term ..................................... 47
12.2.1 Capacity building issues ............................................................................................................. 47
12.2.2 Strategic objectives ................................................................................................................... 47
Chapter 13 ............................................................................................................................................. 48
Policy Analysis on Manufacturing EMD and Ethanol CS in Ethiopia............................................................... 48
13.1 General policies in Ethiopia on projects requiring EIA & labor regulation ...................................... 48
13.2 MoWIE and MEF in the area of CS ................................................................................................ 48
13.3 Tax incentives by Ethiopian government on machinery & raw materials manufacturing/ importing for developmental projects...................................................................................................................... 49
13.4 Ethiopian government support & action to enterprises and individuals working on CS ................. 50
13.5 Project area and land availability for EMD and Stove projects in Ethiopia ..................................... 50
13.6 Expected challenges and bottlenecks towards working EMD and CS in Ethiopia ........................... 51
REFERENCES ................................................................................................................................................ 52
APPENDIX .................................................................................................................................................... 54
Annex 1: Instruments required by operators for EMD. ............................................................................. 54
Annex 2: Specification for steam generator/ boiler to distillation. ........................................................... 55
Annex 3: List of equipment of a double-column distiller design. .............................................................. 56
Annex 4: Area (expressed in m2) needed by a bioethanol production facility............................................ 58
Annex 5: EMD, CCS components: technological and industrial manufacturing capacity in Ethiopia study format: Questionnaire, results of visited workshops and suppliers ........................................................... 59
Annex 6: EMD capital cost form interantional quotation: ......................................................................... 71
Annex 7: List of organizations Visited and interviewed. ............................................................................ 72
Annex 8: Machine Tools requires for Alcohol Stove Canister production .................................................. 73
Annex 9: Machine Tools requires for Alcohol Stove Heat shield and Body production .............................. 75
Index of Tables Table Title Page TABLE 1: COMPARISON OF TECHNOLOGICAL EQUIPMENTS IN FEED STOCK
PROCESSING .......................................................................................................................... 6 TABLE 2 EMD CAPACITY: FACILITY DEPENDING ON MARKET SIZE AND FEEDSTOCK 8 TABLE 3 : TECHNOLOGICAL AND MANUFACTURING CAPACITY OF EMD IN ETHIOPIA
............................................................................................................................................... 18 TABLE 4 : METAL WORKSHOPS AND CONSTRUCTION FACILITIES STRENGTH -
WEAKNESS .......................................................................................................................... 19 TABLE 5 : INVESTMENT COST: 150 TO 5,000 L/DAY ROOTS, TUBERS, RHIZOMES, AND
MOLASSES ........................................................................................................................... 20 TABLE 6 : INVESTMENT COST: 150 TO 5,000 L/DAY; STEMS .............................................. 21 TABLE 7 : EMD OPERATION COST PERSONNEL ................................................................... 23 TABLE 8 : EMD OPERATION COST WATER ........................................................................... 23 TABLE 9 : EMD OPERATION COST ELECTRICITY ................................................................ 24 TABLE 10 : EMD OPERATION COST CHEMICAL .................................................................. 24 TABLE 11 : SUMMARY LOCALLY MANUFACTURED, SUPPLIED OR IMPORTED ........... 27 TABLE 12 : SUMMARY OF 1000 LIT/DAY INTERANATIONAL QUOTATION .................... 27 TABLE 13 : SUMMARY OF VARIOUS ALCOHOL STOVES .................................................... 31 TABLE 14 : BILL OF QUANTITY CANISTER ........................................................................... 35 TABLE 15 : BILL OF QUANTITY HEAT SHIELD ..................................................................... 37 TABLE 16 : BILL OF QUANTITY STOVE BODY ...................................................................... 38 TABLE 17 : BILL OF QUANTITY FLAME SPREADER ............................................................ 39 TABLE 18 : FACTORY JOB SHOP / FABRICATION FLOOR PLAN MACHINE TOOLS ........ 40 TABLE 19 : STOVE MATERIAL COST ANALYSIS BASED ON BOQ ..................................... 42 TABLE 20 : SUMMARIZED STOVE TOTAL COST, RAW MATERIAL AND PRODUCTION
COSTS ................................................................................................................................... 43 INDEX OF FIGURES
Figure Title Page FIGURE 1 : PROCESS SCHEME OF PRODUCTION OF BIOETHANOL USING DIFFERENT
FEED STOCK ........................................................................................................................ 11 FIGURE 2 : BALANCE TO PRODUCTION OF 1,000 L BIOETHANOL AT 90% (V/V) USING
DRY CHIPS OF TUBERS OF SWEET POTATO AND MOLASSES .................................... 12 FIGURE 3 : PLANT LAYOUT OF AN EMD TO PRODUCE 2,400 L BIOETHANOL PER DAY
............................................................................................................................................... 17 FIGURE 4: FACTORS INFLUENCING ETHANOL COOK STOVE EXPANSION PROGRAM IN
A COUNTRY (ZUZARTE 2007). .......................................................................................... 29 FIGURE 5 MANUFACTURING METHOD PROCESS FLOW FUEL TANK .............................. 34 FIGURE 6: PLANT LAYOUT RECOMMENDED, ALCOHOL STOVES PRODUCTION ......... 41
ABBREVIATIONS UNITS AND PREFIXES
ASTM American Standard for Testing and Materials Standard BOM Bill of Materials BOQ Bill of Quantity CS Cook Stove EMD Ethanol Micro Distillery EMLSA Ethiopian Ministry of Labor and Social Affair EMWUD Ethiopian Ministry of Works and Urban Development EU European Union FOB Free on Board gals Gallons, unit of volume ha Hectare of Land hp Horse power Hz Hertz Kg Kilo gram Kw Kilo watt LPD Liters per Day MEF Ministry of Environment and Forest MoEPF Ministry of Environmental Protection and Forestry MoWIE Ministry of Water, Irrigation and Energy MT Metric ton MTd Metric ton per day MTh Metric ton per hour MoTI Ministry of Trade and Industry QMS Quality Management System Qty Quantity USD US Dollars v/v Volumetric ration w/w Weight ration W Watt °C Degree Centigrade [unit of temperature] ° F Degree Ferranti [unit of temperature]
Executive Summary
It is vital in Ethiopia to implement a program of local constructed Ethanol Micro Distilleries and operate these EMDs in clusters nationwide using different feedstocks. In this study technologies are described which are most suited. Development of EMDs in tropical countries is uncommon and do not integrate modern technology with simple operation. This study intends to present a strategy based on previous experience. Trends in bioethanol production technology of developed countries are not easy to implement in countries like Ethiopia. Only a selection of technologies will lead to positive broad impacts on society. This include: selection of equipment capable to process different raw materials to produce ethanol during the whole year; conversion of starch to fermentable sugars at ambient temperature (without cooking and cooling); use of plastic containers for fermentation instead of metal; low pressure instead of high pressure boilers; precise and fast cutting of metal laminates by laser; and use of continuous monitoring of production using electronic devices in order to limit the expensive experienced experts at EMDs.
A system of small-scale production is characterized by its low investment cost and small amount of energy needed to recycle sub products of bioethanol production to the soil where raw materials are grown. The advantages of small-scale production compared to large-scale can be many in Ethiopia. These include less transport of raw material and bioethanol, high speed of innovation development and implementation, diverse funding sources, sustainable growth of local economies, expansion and return-on-investment during a constant growing EMD system, sizing production to local available feedstock, multiple feedstock processing, shut-down of some modules not the entire production system for cleaning and maintenance, and cost controls in energy use according to actual need. Benefits for a broad part of Ethiopian society applying appropriate technology will justify the implementation of a robust production strategy.
The identification of appropriate technology taking in to account the Ethiopian context is based on criteria of safety and easiness to production. The importance of starting small and increasing (both scaling up and out) is fundamental and requires analysis on how technology can meet production goals set by number of ethanol stoves. Initial production during a startup phase can be realized by a boiler producing as low as 150 L/day. Capacity largely depends on type of raw materials; dry tubers (e.g. sweet potato) have much higher yield than stems (e.g. sugar cane). This production capacity during startup will allow selling ethanol from 90 to 190 households. Later boiler and other equipment can be scaled to a higher capacity, e.g. using four boilers to produce between 1,600 and 3,200 Lit/day. Production can be further increased to 3,200 and higher Lit/day (5000) by operating more equipment such as two hammer mills, more fermentation tanks (10,000 L each), four steam generators and two rectification columns. Feedstock can be processed either by hammer mills or crushing mills.
The best startup system for EMD is to process roots, tubers and fruits mixed with molasses because existing Ethiopian sugarcane industries have access to highly efficient juice extraction equipment. Grains are not considered to be alternative feedstock because they have high value for human consumption by Ethiopians. For feasible feedstock flow scheme and a detailed mass balance is presented to simplify the complexity of modern, multi feedstock EMDs designed for production in the tropics. An important observation is that both milling of dry sweet potato tubers mixed with molasses at beginning of the process will result in ethanol concentration in the wine as high as 13.6% ethanol (v/v). Using raw materials separately, concentration of ethanol will be approximately
6.8% which is -unfortunately- common in bioethanol production using sugarcane. Considering the need to market a low cost fuel, high concentrations are not necessarily required to fuel stoves. A concentration at 95% (v/v) requires more expensive equipment and two times more energy for distillation compared to 85% which is still viable for Cookstoves.
Construction of EMDs requires appropriate selection of building materials. Therefore, it is imperative to use high quality equipment and materials. Stainless steel is used for the components of equipment in contact with ethanol (vapor and liquid). On the other hand, polyethylene is applicable for mixing, fermentation, filter and sedimentation; iron for building structures and equipment not in contact with ethanol; refractory material for boilers; concrete panels for walls and gravel for floors.
General plant layout is proposed which will be fundamental to construct EMDs locally at an affordable cost. To assess the technological and manufacturing capacity of EMDs and alcohol stoves in Ethiopia a questionnaire was used. In Addis Ababa at least six companies possess the capacity to construct important parts of EMDs and also stoves. Most of the materials can be purchased locally like safety equipment, roofing, electric motors, structural metal profiles, vessels, sheets (laminates) of stainless steel, tubing of PVC, refractory bricks and cement for high temperature insulation and others. Milling systems to process sugarcane and sweet sorghum need to be imported in the short term; but there is also progress in capacity building to manufacture in Addis Ababa, considering sugar projects which the government is expanding.
Investment cost to process roots and tubers (it is designed to process dry roots, tubers, rhizomes, fruits, juice and molasses) range from 1,020,000 (150 lit/day) to 16,768,750 (5000 lit/day) Birr for equipments and machinery. Considering local manufacturing capacity, more than 80% of this investment can be on locally manufactured products with the exception for measuring and instrumentation devices. For EMD processing stems (sugarcane or sweet sorghum), investment ranges from 4,720,000 to 13,000,000 Birr (with Diffuser) and from 3,820,000 to 12,000,000 Birr (with milling). Local manufacturing capacity in this case will be at lower percentage according to our survey, because of the demanding large scale production facility for milling and thermal diffuser juice extraction mechanisms.
Considering construction of EMDs, a number of justifiable recommendations are presented. Preferred strategy is introduction of a business driven model in which an entrepreneur will lead production and sales. To start at different sites in Ethiopia many activities will be realized including availability of raw materials. EMDs need to be complete - as safe as possible - easy to operate - multi feedstock - multi output -local constructed - geographically decentralized – low capital - certified technology. The recommended strategy by the team is to invest as low as possible amount for startup and expand after proven experience during nine months of production and sales. It is also encouraged to design and construct equipments locally directed by experienced international constructors who form part of an interdisciplinary team.
In the latter section of the study document, Alcohol Stoves are focused. Alcohol stoves international trend especially in developing countries is revised. The study has come up to the conclusion that countries in Africa such as Malawi and South Africa are very good example in manufacturing Alcohol Stoves and could be considered as benchmark.
There is encouraging experience and capability in Ethiopia too that has been reviewed. Based on the experience in manufacturing these stoves and further engineering personnel, a detailed technical specification, scope of the work, manufacturing processes, and miscellaneous equipments required are studied. Accordingly, make or by decisions in the short, medium and long term for alcohol stove components is suggested; such as for a critical component canister. We have come to conclusion canister manufacturing with the required quality and operational safety requirement need capacity building under the current condition. However, there are plenty of factories and medium scale workshops that can build their capability in a very short period of time to produce locally. Regarding other components of stove, there study has reveled there is capability to manufacture them.
Also, it is presented based on a proposed facility layout and equipments designed for manufacturing, the cost of double burner Alcohol Stove at time of study was 1165.5 Birr (58.3USD) if material used is plain carbon steel (common steel plate). Cost study for stove fabrication is based on raw material expense and production cost. It is highly recommend using already existing workshops and facilities for fabrication and assembling components. But if complete new plant establishment is required for the stove production only, an estimated ETB 707,520 (USD 35,376) initial investment is required as per the market price during the study.
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Chapter 1
International Trend and Technological Options in Production of EMDs
Although brewing and distillation are very old practices and well known technologies, EMDs developed in tropical countries are scarce and do not integrate modern technology with simple operation. This study intends to present a strategy based on previous experience.
1.1 International trends in bioethanol production The following sections present some international trends in bioethanol production technology:
1.1.1 Production of ethanol from cellulosic biomass by cellulolysis or gasification
In the USA, Canada, Germany, Spain, Sweden and Italy, several companies are in the process of building an industry with methods that turning cellulose-containing organic matter to ethanol (Pernick and Wilder 2007). Depending on the location, cellulose is extracted from agricultural and municipal wastes, citrus peels, and corn cobs, husks, stover, switch grass, sweet sorghum, municipal solid waste, waste rice straw, wheat straw, wood, wood chips and wood waste (Lammers 2007). Production of ethanol from lignocellulose has the advantage that abundant, low cost, non food raw material can be transformed into ethanol. Technical and economic challenges are that production requires high investment of capital, sophisticated equipment and constant (local) production of enzymes and other chemicals.
1.1.2 Concentration of fermentable sugars of raw materials by pervaporation In ethanol production, distillation is the most energy demanding part of the process (Nagy and Boldyryev 2013), especially when fermentation is done at a relative low concentration of sugar. Pervaporation -pumping of a liquid through membranes- can be an energy saving solution because the concentration of sugars in the substrate to ferment can be higher (Wang and Chung 2012). The same technology can also be applied to filter the beer or wine during and after fermentation: this to increase ethanol concentration. Both applications make separation of ethanol from water less energy intensive. In other words applying pervaporation less wood chips are needed for fueling the boilers.
1.1.3 Ethanol from sugar without fermentation Royal Dutch Shell PLC has built a pilot plant at their Technology Center in Houston, USA, to produce biofuel that do not need to be blended with petrol or diesel (Royal Dutch Shell PLC 2012). This eliminates the need for additional blending and storage infrastructure, as well as engine modifications. The plant uses a process that converts plant sugars and inedible biomass into a range of products, including gasoline, diesel and jet fuel. 1.2 International trends in bioethanol production technology of EMDs A wide range of different technological components are globally available to realize the different steps to process raw materials and convert it in bioethanol. Important ethanol micro distillery technologies available in the international market are:
1. Integration of bioethanol production with production of livestock, wood, etc. An example in Brazil worth to mention is published by Ortega et al. (2007).
2. Long lists of potential feedstock do exist but only sugar cane and cassava are used industrially. Sweet sorghum, sweet potato and tropical sugar beet are some crops which do receive some attention.
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3. Sugar cane vs. root (e.g. cassava) and tuber crops (e.g. sweet potato). 4. Alpha amylase and glucoamylase combination for the conversion of uncooked starch at
ambient temperature (no cooking needed) (Lantero et al. 2006). 5. Use of plastic (polyethylene containers) for fermentation instead of metal e.g. in Nigeria
(Obueh and Askin 2012). 6. High vs. low pressure boilers (Blume 2007) or in other words: scaling down of large scale
production versus scaling up small scale alcohol production. 7. Production of biogas from vinasses (España-Gamboa et al. 2012). 8. Use of low cost stainless steel material e.g. from India (Anonymous 2009) for e.g. tubing,
laminates, flanges and valves. 9. Cost effective equipment from China, e.g. digital thermometers (Anonymous 2014). 10. Low cost, precise, fast cutting of metal laminates by laser (Bromberg 1991). 11. Hybrid between centralized and geographically decentralized EMD allows investors to scale
their production to different regions which increases revenue.
1.3 Small-scale production According to Ortega et al. (2007) in Brazil the capacity of a micro distillery is 100-1,000 L/day of ethanol. A mini distillery is defined to produce between 1,000 and 5,000 L/day and medium-scale is between 5,000 and 20,000 L/day. Both micro and mini distilleries are considered to be small scale. In this study production capacity of EMDs was defined between 150 and 3,200 liters of bioethanol per day. The most relevant factor to classify distilleries according experience is economic development, not production volume. The definition of enterprises according to staff headcount and turnover or balance-sheet total is essential for identifying businesses able to benefit from aid program or policies specifically designed for small and medium-sized enterprises (Anonymous 2007a).
A system of small-scale production is characterized by its low investment cost and small amount of energy needed to recycle sub products of bioethanol production to soil where raw materials are grown (adapted from Sanders et al. 2005). The advantages of small-scale production can be many such as:
● Less transport ● Regulations ● Speed of innovation ● Diverse funding sources ● Stimulates local economies ● Expansion and return-on-investment during a growth stage ● Sizing production to local -very close- available feedstock ● Multiple feedstock processing ● Shut-down of some modules not the entire production system for cleaning and maintenance ● Cost controls in energy use according to actual need
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More specifically:
● It is not required to achieve optimal efficiency in different steps of production process: ○ Production may be started with yeast available locally which at a later stage can be
replaced by imported yeasts with a higher performance ○ It is easy to start production of bioethanol, and then select best workers; because the
training of employees is a process characterized by flexibility (methodologies are standardized, not the people and their work culture)
● Vertical integration, e.g.: ○ The bioethanol producer sells bioethanol as fuel for clean cooking stoves ○ Marketing of bio fertilizer obtained from vinasses (stillage), filter cake and effluent of the
bio digester ○ Agro-tourism
● Optimizing the recycling of products with high moisture contents:
○ Biogas from vinasses
● No losses because time and distance of transport of raw materials is short:
○ One area cultivation of 150 ha feed stoke requires approximately 5 km of public road
● Production of raw materials in a sustainable and environmentally friendly way with high yields: ○ The use of for example three different raw materials reduces the risk of losses due to
pests and diseases; and also reduces management costs ○ To start production of feedstock, it is easier to collect high quality planting materials of
three different energy crops than from single crop
● No concentration of unwanted substances: ○ A production facility of 100,000 L of bioethanol produces approx. 500,000 L of vinasse
per day which is very costly to neutralize acidity, transport and apply to all the fields of the crops.
○ Using biomass crops like Euphorbia tirucalli (petroleum plant) and Pedilanthus tithymaloides (Devil's backbone) as a fuel source for the distillation avoids the use of nonrenewable sources. These crops cultivated as agroforestry can be harvested in 6 to 18 months after planting.
● Regulations and permits less expensive and faster to obtain: ○ No concentration of unwanted substances ○ Small amounts of bioethanol to store
● An unfinished process can start production: ○ Raw materials available already locally can be used ○ The system to neutralize acidity of vinasse by a bio digester can be started after a year of
starting bioethanol commercialization
● Lower investment means a low barrier to introduce production of renewable energy:
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○ To start production of raw materials and purchase of production equipment at a small scale offers the possibility to finance at a low interest rate and/or receiving a grant
○ Large plants are only feasible if huge areas to produce feedstock are available. Small scale production can be done in many places because less land is needed to grow feedstock.
● High speed of innovation: ○ Monitoring the production at different EMDs makes it possible to detect process
improvements and introduce these to other EMDs ○ In medium term it will be feasible to separate bioethanol from water through
nanotechnology which obsoletes distillation by steam
● Mass production requires more equipment
○ Equipment for large volumes requires import, local construction of EMDs is feasible in Ethiopia
● Time, space and labor is relatively cheap ○ The construction, installation and staff training of a EMD can be possible in two months
or less because it will be a routine activity by a specialized team ○ Less transportation costs to recycle minerals and components required for soil fertility
● No dependence on harvest seasons of one crop
○ Unlike other systems EMDs should be able to process roots, tubers, stems and grains of different types of crops which can be harvested/stored throughout the year
● Securing raw materials and marketing channels
○ An increased production of bioethanol (in a volume per day of 100 L to 5,000) over time can develop local markets and export of surpluses for special markets
The small scale approach also creates the opportunity for fuel production close to the end-user, e.g. distributed production, meaning production of bioethanol close to or in the market where the fuel will be used: the fuel can be retailed directly from the distillery. This very short fuel supply chain with no middlemen represents a distribution innovation as well as a processing innovation.
1.4 Roots vs. stems
This section will discuss the selection of feedstock to produce bioethanol by classifying raw materials into roots and stems. In the tropics -including Ethiopia- sugar cane (and sweet sorghum) is commonly used to produce bioethanol. Is this reasonable in the Ethiopian context? Sweet potato (and other crops that produce tubers, roots and rhizomes) has many significant advantages compared to sugar cane especially for various segment of rural communities:
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Farmers and their communities:
1. Sugar cane needs much more water to grow than tuber or root crops (Anonymous 2007b).
2. Yearly burning of sugarcane enhances local climate change, because health problems and effect on soil, fauna and flora. This practice is common in Ethiopia and is considered to be the only way of removing leaves; it is also done to increase sugar concentration in stems before milling.
3. Tubers, roots and rhizomes can be harvested the whole year which allows ethanol production every day. Unlike sugarcane which is not available in e.g. January, February and March, Root farmers will benefit during the whole year, not only a certain season.
4. Tubers, roots and rhizomes can be sun dried easily and stored during months by farmers. Canes get spoiled from one day to another.
5. In many (marginal) regions the expected bioethanol yield of sweet potato per hectare is very high, possibly higher than sugar cane. Less land, the lower the production cost of ethanol and the higher the incomes for the farmers. See also the feedstock assessment report titled Holistic feasibility study of a national scale up program regarding bioethanol stoves and micros distilleries: Feedstock resources of bioethanol in Ethiopia written by Dr. G. Alemaw, Senior Researcher at Ethiopian Institute of Agriculture Research in Addis Ababa.
6. If there's a shortage of cassava, sweet potato or corn for human consumption, then these crops can be consumed directly by farmers or market much more easily than sugar. Canes are hard to bite both by teeth and mills; this applies to all sugarcane varieties.
Bioethanol producer:
The following points are general facts and considerations ethanol producers should consider before.
1. Transport cost of sugar cane is much higher than transport of dry roots and tubers.
2. Ethanol from sugar cane is profitable when both sugar (and molasses) and ethanol is produced. An example of this strategy is production in Colombia (Toasa 2009).
3. Crushing sugar cane needs much (500 KVA) more electricity or diesel fuel than milling dry roots and tubers (20 KVA).
4. Equipment to process (milling, crushing, grinding) sugar cane is up to twenty times more expensive than processing root and tuber crops. It is common that the investment of processing equipment of sugar cane equalize a complete distillery facility. In most cases sugar cane extraction at a small scale is inefficient because it is difficult to extract all juice from the stems. Using one mill efficiency is usually very low because after milling only 65% of all sugars are available for the yeasts. To process, e.g., four ton per hour (max. 6,000 L/day), a high capital is required; equipment for the three options is shown in Table 1.
5. Maize (corn) contains protein to feed animals (Goldman and Kole 2014).
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6. Bagasse of sugarcane is not effective fuel for distillation (8.1 MJ/kg; Anonymous 1996), it is better to use wood and stems of Euphorbia tirucalli (16.2 MJ/kg) grown as a hedge around the compound of bioethanol production facility. This applies specially in semi arid regions in Ethiopia where biomass is scarce or not available.
7. The ethanol content in each fermentation container using dry roots or tubers will be twice as high then the fermentation of sugar cane juice.
8. Distillation of fermented sugarcane juice requires almost double the distilling mash by roots/tubers.
Table 1: Comparison of technological equipments in feed stock processing
Feedstock Stem Feedstock Roots and Tubers
By crushing canes By diffusion Preparation of roots for fermentation
1 Cane carrier 1 Cane carrier 2 Portable chippers
2 Cane choppers 2 Cane choppers 1 Screw conveyor
1 Reverse cane cutter 1 Reverse cane cutter 1 Hammer mill
1 Feed rake carrier 1 Feed rake carrier 1 Electricity generator (20 KVA)
3 Cane crusher mills 1 Cane crusher mills
1 Intermediate carrier 1 Intermediate carrier
1 Bagasse elevator 1 Bagasse elevator
8 Electric motors, 6 Electric motors,
1 Electricity generator (500
KVA)
1 Electricity generator (100
KVA)
1 Clarification system of juice 1 Diffuser
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Chapter 2
Selection of the most suitable technical options of EMDs for Ethiopia 2.1 Selection criteria of EMDs technologies for Ethiopia
A great diversity of technology does exist, mostly for large scale industry related to sugar production. By analyzing carefully our needs it will be easier to select technology which will be effective to apply to EMDs. The most relevant features of the bioethanol production facilities to implement in Ethiopia are:
Processes safe for the operators. Technology designed to make the production of bioethanol for stoves profitable and
sustainable. Bioethanol suitable as a fuel in stoves for cooking. Complete and autonomous production system integrates sustainable production of
raw materials. It transforms into bioethanol in the distillery and use as a fuel in stoves for cooking.
Designed to operate 24 hours a day, 6.5 days a week, and 50 weeks a year. Half a day per week, and two weeks a year will be available for cleaning and preventative maintenance.
Multi feedstock: capable to process locally available raw materials. Scalable: gradually increasing production capability which allows a relative low
capital investment at the start. Geographically decentralized. Safe and easy to operate. Locally constructed. Certified bioethanol production system. Appropriate technology with minimum moving parts and/or dependence on parts to
be imported. Multi output: different products and services. Efficient in the use of water, electricity and heat.
2.2 Available Technological Options
EMD technology is offered by several companies based in different countries. These companies are Advanced Micro Energy, Balrampur Chini Mills, Blume Distillation, Cecachemicals, Ecoenergy Business Group, Ethanol India, Green Social Bioethanol, Indian Compressors, International Process Plants, Interra Global, Limana Poliservicos, Maguin, Mansego, Navitas Viride, Praj, Rajshreesugars, Renuka do Brasil, Soluciones y Suministros para Ingeniería, Spectrum Canada, Sustainable Tech Systems, UOP, Vogelbusch, Wenzhou Taikang Evaporator, Wintek, Zhejiang Sunny Machinery Technology and Zeochem. The diversity of offered technology is high and the most relevant are mentioned in Chapter 3.
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2.3 Scaling of Production
The importance of starting EMD in small scale and increasing production is fundamental. Table 2 below analyzes how technology can meet this specific selection criterion. Initial production can be realized by one boiler producing a few hours per day between 70 to 150 L of ethanol a day. The amount of ethanol to produce per day will depend on type of raw material to use. This production capacity will allow marketing ethanol from 90 to 190 households. After a successful startup period boiler and other equipment can be scaled to a higher production capacity. A practical example is using four boilers to produce between 1,600 and 3,200 L/day of ethanol.
Table 2 EMD capacity: facility depending on market size and feedstock
Raw material(s) Size of the market to supply (households)
Production capacity (LPD) No. of boilers: 1 – 2 – 3 - 4 – 5
Mixture of molasses, juice, dry roots, tubers or grains
190 – 4000 150 – 800 – 1600 – 2400 – 3200 - 5000
Dry roots, tubers or grains 125 – 3000 70 – 600 – 1200 – 1800 – 2400
Molasses or juice 90 – 2000 400 – 800 – 1200 – 1600 – 2400 – 3200 - 5000
2.4 Implications of Using Different Feedstock on Technology selection
Different feedstock (sweet sorghum, cactus pear, sugar cane, roots and tubers) require different technology and equipment for ethanol production.
The technology is generally categorized in two groups as with hammer mill and crushing mill:
1. Hammer mills to process roots, tubers, rhizomes, fruits and grains (all available in Ethiopia):
a. Roots include: cassava and tropical sugar beet b. Tubers: sweet potato and yam c. Rhizomes: taro, dieffenbachia and swiss cheese plant d. Fruits: prickly pear cactus (Opuntia), cashew apple and melon e. Seeds: mango
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2. Crushing mills of stems of sugar cane and sweet sorghum (or a diffuser) to extract juice After milling roots, tubers and grains enzymes are required to convert starch in sugars which enhances fermentation by yeast. These enzymes are commercially available in USA and Europe; and can be continuously imported to Ethiopia. The following are additional factors supporting the hypothesis:
1. Roots can be stored during months guaranteeing ethanol production during the whole year;
2. Enzymes are less expensive than the diesel or electricity needed to crush sugar cane stems;
3. Enzymes can be imported together with other supplies like Bitrex, yeasts and nutrients needed for fermentation at a high efficiency.
Other factors in selection this feedstock over sugarcane is: 1. Juice of sugar cane and sweet sorghum need to be clarified after crushing costing extra
labor compared to roots. 2. Requirement of metal vessels that need to be adjust pH of the juice between 7.5 and 8
using chemicals such as lime, pumping, heating (100° C) and sedimentation system before preparing the substrate to ferment.
Milling of roots, tubers and grains will generate small solids in suspension of the fermented product (wine) which requires filtration and sedimentation before introducing it to first distillation column. This process requires extra labor too. When wine is introduced in a vertical column, not in a boiler (which is a preferred option); it will probably cause extra time for frequent cleaning of distillation plates.
In conclusion: the best startup system for an EMD is to process roots, tubers and fruits (no grains because these have a high value for human consumption) mixed with molasses because existing and planned sugar cane industry do have access to highly efficient juice extraction equipment.
The technological implication of this recommendation is described in the next Chapter. Remarks on construction in Ethiopia using materials from local retailers and which materials and equipment should be imported is analyzed in Chapter 4.
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Chapter 3
Material Balance, Process Description, Equipment List and Plant Layout of EMDs
This section of the feasibility study is synopsis to the types of equipment used in EMD, quantitative aspect of feedstock consumption in order to produce a certain volume of ethanol, and sequence of operations in extraction of ethanol from feed stock. It also presents the layout of EMD plant with the help of 3D technical drawings and other form of representations. Accordingly the three sections presented below are ‘Material balance’, ‘Process description and equipment list’, and ‘Plant layout’.
3.1 Material balance
A material balance, also called a mass balance, is an application of conservation of mass to the analysis of physical systems. By summing up the materials entering and leaving the EMD, flows of materials can be identified which might have been unknown, or difficult to measure without this technique. The objective of presenting the mass balance in this study is to simplify the complexity of modern, multi feedstock EMDs designed for the tropical production regions.
Figures 1 and 2 show process scheme and flows of materials in the production of 1,000 L of bioethanol at 90% (v/v) using dry chips of tubers of sweet potato (1.0 MT) and molasses from sugar cane (1.7 MT). Instead of molasses, the juice/fiber or jaggery of fruits (e.g. prickly pear) can be used too. At a later development stage of EMD, if required, sugar cane or sweet sorghum process equipment can be added.
Important to observe is that both meal of dry sweet potato tubers and molasses are mixed at the beginning of the process. By doing this, ethanol concentration in the wine will be high: 13.6% ethanol (v/v). Using raw materials separately, concentration of ethanol will be 6.8% (sugar cane) and 6.8% (sweet potato). Mixing feedstock will benefit the fermentation of molasses because thiamine is abundantly present in sweet potato but not in sugar cane or sweet sorghum juice. Thiamine stimulates yeast development and general efficiency of each module of EMD is also higher because the higher the ethanol concentration in the wine, the less equipment is needed and more importantly less energy is needed during distillation.
3.2 Process description and equipment list
Higher purity (concentrations as high as 95% v/v) of ethanol production needs significantly more amount of energy, compared to lower ethanol at concentrations lower than 90%. To produce 1,000 bioethanol at 90% an EMD needs approximately 500 kg of biomass. The combustion value of this amount of e.g. wood chips is approximately 8,100 MJ, which corresponds to 8,1 MJ/liter of bioethanol at 90%. The heat value of a liter of ethanol is approximately 23 MJ.
As a matter of fact, ethanol cook stoves operate well with ethanol of lower concentration, thus it is not necessity to go higher. Energy is expensive because boilers require dry biomass in the form of chips.
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Production facilities should be designed to scale up because cost of scaling up is much less than construction of a new facility. Production can be gradually increased to 3,200 L/day by operating with equipment such as two hammer mills, twelve fermentation tanks of 10,000 L each, four steam generators and two rectifying columns.
Figure 1 : Process scheme of production of bioethanol using different feed stock
Processes to produce bioethanol consists basically the following equipment/ components:
1. Safety
2. Utilities (water, electricity, compressed air)
3. General infrastructure
4. Monitoring
5. Reception and storage of raw materials (feedstock)
6. Preparation of raw materials
7. Yeast multiplication
8. Fermentation
9. Filtration of wine (wart, beer), sedimentation of solid particles, handling & storage of
filter cake
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10. Preheating of the wine
11. Steam generation
12. Distillation of bioethanol
13. Condensation of bioethanol
14. Reception and storage of bioethanol
15. Vinasses storage and treatment
16. Manufacture of co-products
Figure 2 : balance to production of 1,000 L bioethanol at 90% (v/v) using dry chips of tubers of
sweet potato and molasses
Local construction of these EMD components requires a strategy in the selection of materials. Thus it requires analysis and recommendations from expertise. Some of these include use of:
● Type 304 stainless steel at bodies and pieces of equipment in contact with ethanol vapor & liquid.
● Polyethylene (double layer) in the mixing, fermentation, filter and sedimentation tanks. ● Stainless steel (canisters) for storage and distribution of bioethanol or polypropylene for
receipt, storage and transport of bioethanol. ● Iron for building structures and equipment not in contact with ethanol. ● Refractory bricks. ● Concrete bricks and gravel for floors (no poured concrete).
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3.3 Discussion on EMD list of equipment
A. Safety
Security is always first direct from the start and therefore during construction at the site of the bioethanol facility the providers of technologies should use tools for training and security protocols all written in Amharic. The elements to guarantee safe production:
● Personal protection of the constructors, operators and visitors: helmets, work shoes and
clothing, gloves, goggles and hearing protectors. ● General safety like alarms, smart phones, signs, floor markings, operation manuals,
pictograms on equipment, fire blankets and first aid kit. ● Fire suppression system consists of portable fire extinguishers, containers filled with sand
and water, water storage and hoses. ● Manual with protocols concerning operation, security and maintenance.
B. Water, electricity and compressed air
To produce 1,000 bioethanol 4,000 L per day of water is needed. Five plastic water storage tanks (incl. flanges, valves, fast couplings and hoses) can be sourced in Ethiopia. Chlorine treated water is required to dilute raw materials, and should be transported by gravity. Two centrifugal pumps (capacity of 6,000 L/hour) will be used to clean equipment and fire suppression. Two electricity generators fueled by gasoline and biogas are needed, each 8 kVA, to power equipment. Hydrogen sulfide filters allow connecting the motors of the generators directly on the biogas outlet of the bio digesters which are continuously feed with vinasses. The consumption of each motor is estimated to be four m3 of biogas per hour. The electricity consumption consists of pumps, valves, motors, fans, lighting, instruments and alarms.
It is recommended to use two reciprocating tank mounted air compressors of 1.75 kWh, capacity 275 L/min, max. 10 bars. The functions of the compressors are yeast activation; unclog/air testing of pipes and equipment and to power pneumatic variable speed motors for the screw augers of the mills and boiler(s).
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C. General infrastructure
● Living fences to produce biomass to be used as a fuel in the boiler(s). Note that wood shavings and sawdust from forester and woodworking in Addis Ababa, Wondo Genet, Shashamane, Gore, Bale and Nekemte can be used as fuels too. Demonstration plots of raw materials.
● Entrance, parking lot, evacuation area and simple housing of one operator. ● Roads for emergency transport of raw materials, bioethanol, vinasses and maintenance. ● Simple facility for eating (chairs and table), small office, meetings, resting, lavatories and
shower. ● Store for supplies, tools and spare parts of equipment. ● Electrical wiring, distribution board and nighttime lighting. Water connections. Masonry,
drainage, leveling and anchoring.
D. Monitoring The production facilities should have minimal automatic control and will be largely dependent on trained local operators to manually control processes. Advanced education will not be required of the operators. Annex 1 presents a list of instruments which are commonly used in EMDs.
E. Reception and storage of raw materials
Unloading of molasses from a truck requires pumping, valves, fast couplings and hoses. Molasses storage tanks can be provided locally. The production of each 1,000 L of bioethanol requires daily 1.7 MT of molasses combined with sweet potato tubers as presented in the mass balance. It is recommended using at least three 10,000 L plastic tanks to store molasses during 15 days of operation. Each tank should have at the bottom a tank fitting and a vented lid (available in Ethiopia). Tanks should have valves, fast couplings and hoses for transferring the molasses by gravity to the mixture tanks. Stems of sugar cane or sweet sorghum should be processed within six hours after receiving. Chips of dry roots/tubers and jaggery can be received/stored on floors in bags. Residues of fruit can be received too in bags but should be processed immediately. In the bioethanol production facility the bags will be transported from storage to the conveyors manually.
F. Preparation of raw materials
Molasses will be transferred by gravity to plastic dilution tanks. Each tank must have a capacity of 10,000 L. Tanks are equipped with valves, fast couplings and hoses. Inside each dilution tank low power but high capacity electric submersible pumps from outside Ethiopia can be used for mixing and transferring the prepared slurry to the fermentation tanks.
The chips of roots, tubers, rhizomes and biomass can be obtained by the farmers using portable chippers. Chips of dry roots, tubers and rhizomes will be grinded by hammer mills and powered by gasoline engines. Fruits will also be processed using these mills. Both chips and fruits will be transported to the hammer mill(s) using conveyor(s). If wished, fresh roots, tubers, rhizomes and fruits can also be processed by the mills.
Stems of sugarcane (4 MT per hour equivalent to maximum 6,000 L per day) or sweet sorghum can be processed using a cane press system which is described in 1.4 Roots vs. Stems.
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After obtaining the slurry of raw material in water, nutrients, chlorine, acid, enzymes (optional), yeast will be added. To increase the efficiency of fermentation and to save water, a relative small amount of vinasses and stillage will be added to the raw material. Hydrolysis of starch will be done by using enzymes at environmental temperature. This methodology saves energy compared to enzymes which require high temperature (more than 70° C or 158° F). The same submersible pumps, after mixing, will pump the slurry to fermentation vessels.
G. Yeast multiplication and activation
A two-stage yeast propagation system should be applied because it allows the yeast to be multiplied by 10 times after propagation. This system has temperature and air management features to be used in plastic tanks equipped with valves, fast couplings and hoses.
H. Fermentation
Plastic tanks available in Addis Ababa of 10,000 L capacity each will be used for batch fermentation. The tanks are equipped with valves, fast couplings, hoses, piping and metal support structures for the pipelines. Fermentation will be between 30 hours and three days. Portable lightweight ladders will be used to easy access the vessels for monitoring, agitation and cleaning. Electric agitators and include a heat exchanger, automatic temperature actuated modulating valves and recirculation by pumping water, this to maintain temperature of the wine optimal. The drainage of the fermentation tanks will take place by gravity which saves investment in pumps and electricity. Cleaning and disinfection methodology of the complete fermentation system includes portable electric pressure hot water washers.
I. Filtration, sedimentation, handling and storage of filter cake
Filters and traps will prevent that steam generator(s) and distillation column(s) receive particles which are too large. As a result of filtration and sedimentation of the wine, a nutrient-rich filter cake is produced. This section includes collection and storage of the filter cake that is processed to obtain a solid bio fertilizer. For each 1,000 L of bioethanol per day the filtering of wine will generate approximately 69 kg of solid fertilizer.
J. Preheating of the wine
This section applies to the system where a wine (beer) column is used as a boiler; it does not apply to high pressure water (vapor) boiler. By preheating, the wine is heated between 60° and 70° C (140° and 158° F) using hot stillage at 95° to 100° C (203° to 212° F).
K. Drying of biomass and steam generation
Boilers must function efficient using as fuel biomass: wood chips, wood shavings, sawdust, and small particles of bagasses of sugar cane or sweet sorghum. Chips of the stems of E. tirucalli and stems and leaves of P. tithymaloides grown as a living fence around the production facility- can be sun dried. The same applies to fragmented bagasses. The oven(s) can use agricultural harvest residues like rice, coffee husks, wooden stems of cassava, and pruning wood of e.g. coffee trees.
Owners of EMDs can choose from two types of technology to generate steam: steam generation of ethanol (not water), dosifying preheated wine to columns (boilers) controlled by automatic temperature actuated modulating valves; or steam generation of water using a high pressure
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water steam generation applying a mixed tubular, biomass fired boiler. More details of both systems are described in Annex 2.
L. Distillation
Two continuous distillation designs are available which are described in more detail in Annex 3.
M. Stillage recycle
Stillage will be drained by gravity from the bottom of the rectification column(s) to a temporal storage tank, pumped and mixed with the water which will be used to dilute/prepare raw materials for fermentation.
N. Condensation
Option 1: Each rectification column has three exchangers: 1, internal condenser inside each distillation column; 2, reflux condenser; 3, vapor to liquid ethanol condenser. By pumping wine or water the exchangers will reduce the temperature of the system. Each column also does have a control panel to adjust the exchangers. Included are interconnecting piping, valves, accessories and metal support structures. Option 2: In this case, it is assumed no pressurized water is available. Induced draft cooling tower of 25 m³ of water under cross flow system operation (ΔT of 8º C ΔT or 47° F). The system incorporates cooling water centrifugal pump and pipes.
O. Reception and storage of bioethanol
Bioethanol is recollected by gravity from the condensers. After filling plastic container the bioethanol is transported and stored in an enclosed area with a capacity for 15 days operation. For safety there is no electricity in this section and no bioethanol transfer pumps are used. Because of toxicity fusel oils are not stored but burned in the boilers together with biomass.
P. Treatment of vinasses
Vinasses treatment includes a concentrator of stillage which is equipment that uses the residual heat of the oven(s) to evaporate part of the water. Concentrated vinasses will be cooled from 100° C (212° F) to 35° C (95° F) using cascade cooling towers (aerators). Cooling and aeration is accomplished by natural draft units that mix cascading vinasses with air that is naturally inducted into the viansses flow. Cascade water is pumped to the top of the aerators, and cascades over a series of trays. Air is naturally inducted into the flow to accomplish cooling, iron oxidation and some reduction in dissolved gasses. The design of the coolers is a wooden construction and has no moving parts, making them free of cleaning and inexpensive to construct and operate. If capital allows the cooled vinasses can be stored and treated in anaerobic digesters which capacity can be of 170,000 L. The digester(s) additional will generate biogas to feed the electricity generators. The effluent (neutralized biological treated concentrated stillage) obtained from the bio digesters can be packed in plastic containers. The dry, solid bio fertilizer will be stored in sacks. These bio fertilizers can be sold to nearby farmers for ferti-irrigation and for animal feeding. At the start of bioethanol production a small facility vinasses can be digested in small holding pit(s) where storage will be one to four weeks which will stabilize the effluent.
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3.4 Plant layout
Including living fences an EMD requires an area of 0.5 ha for 2,400 L/day. More details are presented at Figure 3 and Annex 4.
The production of bioethanol is an agri-business/chemical activity and therefore it is recommended to install production facility in an industrial or rural area of the municipality; not too close to residents. Local people have to be careful with trucks which transport raw materials and ethanol. At a distance of 50 m away from production facility there should not be significant negative effects of noise, vapors and liquids on the health and welfare of inhabitants. This is because the EMD has a dense hedgerow of shrubs and trees which grows to a height of four meters. There could be release of smoke at a height of six meters. Before leaving chimneys it is recommended that smoke pass through wet filters (containing vinasses) to capture most of the particles. The smoke is white colored, not black. In relation to the environment within bioethanol production facility: the noise produced by hammer mill to process fruits, roots, tubers and rhizomes is loud. Milling capacities are large but usually enough to grind only for a couple of hours like four hours per day. The gasoline engine of chipper will cause some noise but it will operate only a few hours per day. The noise of electricity generator is minimal because it is usually located inside the hedge of biomass. The noise of electric pumps is minimal also because they are submersible and low power. Vinasses are treated with microorganisms and will not store for more than 10 days at facilities in some pits.
Figure 3 : Plant layout of an EMD to produce 2,400 L bioethanol per day
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Chapter 4
Technological and Manufacturing Capacity of EMDs in Ethiopia
Annex 5 presents details about questioners used and other formats which were applied to collect data from industries and suppliers in Ethiopia during 2014. It also presents the results of the interview questions.
The study has come to the conclusion that the following manufacturing capability and equipment supply is feasible in Ethiopia based on the interview result, observation and assessments. Table 3 presents in detail equipment manufacturing capacity in Ethiopia:
Table 3 : Technological and Manufacturing Capacity of EMD in Ethiopia
Can be manufactured locally Available in local retails Need to be imported
1 Biomass chippers, the drum system.
Safety equipment: industrial safety warnings, helmets, gloves, glasses, extinguishers.
Electricity generators suitable to use biogas as a fuel3.
2 Hand cutting of metal laminates, angles, bars and pipes/tubes
Corrugated zinc roofing. Copper tubing and accessories.
3 Rolling of laminates using a plate roller machine.
Electric motors. Hose Pe-al-pe or pealpex.
4 Bending of laminates using a bending machine.
Iron angles, structural metal profiles and other materials.
Mineral rock wool for thermal insulation of pipes/tubes .
5 Welding of iron laminates, pipes/tubes and profiles using ordinary welding equipment.
Tubing of stainless steel. Mineral rock wool for thermal insulation of laminate.
6 Perforation (drilling) of laminates and pipes/tubes.
Vessels (tanks; containers; vessels). PVC flanges.
Stainless steel valves.
7 Welding of stainless steel laminates, pipes/tubes and profiles using MIG or TIG applying argon gas.
Sheets (laminate) of stainless steel; type 304; thickness 1.9 mm (gauche no. 14; 0.075").
Stainless steel couplings or clamps for pipes/tubes.
8 Conveyors transporters. Sheets (laminate) of stainless steel; type 304; thickness 1.5 mm (gauche no. 16; 0.060").
Electric pumps4.
9 Hammer mills. Sheets (laminate) of cold-rolled steel/iron (CR), thickness 1/8" (approx. 3.2 mm; between gauche no. 10 and 11).
10 Diffuser system extraction of juice from sugar cane and sweet sorghum.
PVC tubing. Metal and PVC pipe/tube accessories (like elbows, tees).
11 Refractory bricks and cement for high temperature insulation.
3 All electricity needed at an EMD can be produced using biogas and a small amount of petrol 4 High durability, corrosion free, hot liquid tolerant (150° C; 302° F), explosion proof pumps
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Professionals available in Ethiopia: 1. Electricians, plumbers, construction master (a professional in pouring concrete etc.). 2. Experts who manage safety and environmental regulations of Ethiopia.
These activities should be done outside Ethiopia: 1. Milling equipment to extract juice from sugar cane or sweet sorghum. 2. Cutting of metal laminates using laser. It is observed that the Metals and Engineering
Corporation in Addis Ababa owns a laser cutting machine, but it was not functional by this time of study due to minor maintenance problem.
Detail contact address and further information on facilities under study is at Annex 7.
At Table 4 strength and weakness analysis is presented on fabrication facilities at Addis Ababa. Table 4 : Metal Workshops and Construction Facilities Strength - Weakness
Strength Weakness Infrastructure (i.e., machines, equipment, floor space) - Presence of adequate manufacturing workshops
and enough space for future expansion.
Infrastructure (i.e., machines, equipment, space) - Lack of organization in man and material
movement.
Flexibility and integration - Capacity to manufacture different types of
components for both EMDs and ethanol Cookstoves.
Flexibility and integration - Absence of properly laid out fabrication space for
process industries.
Quality - Relatively low rate of defects and rework.
Quality - Lack of in house NDT and material testing
equipment for quality control. Cost of fabrication - Different type of machineries like cutting,
rolling, and welding which creates an opportunity for selecting cost effective fabrication.
Cost of fabrication - Importing raw materials creates a burden in the
cost of fabrication such as the case observed at ethanol Cookstoves.
- The cost of fabrication being high for pre-engineering components such as ethanol Cookstoves due to lack of design capability.
- Lack of engineering design and product developing knowledge leads to relatively higher cost of EMD components and ethanol Cookstoves components such as canisters.
Productivity - Availability of young and energetic technical
and professional personnel in the field of mechanical engineering and manufacturing technology.
Productivity - Low rate of labor productivity compared to
foreign competitors. - Lack of mechanized cutting and welding
operations. Skill and knowledge - Certified TIG/MIG welders for stainless steel
components of EMDs.
Skill and knowledge - Gap in design and manufacturing metal forming
technology such as stove canisters, and lack of internalization to QMS.
Safety - Existence of safety departments, manuals and
operating procedure at some workshops.
Safety - Presence of unsafe grinding, assembling and
welding operations on the floor. - Low awareness to safety precaution.
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Chapter 5
Investment Cost, Production Cost, Identification of Providers and Bill of Quantities of EMDs
By detailing the capital cost of EMDs, it will be possible to invite different companies to construct the ‘perfect EMD’ according to the features presented at section 2.
INVESTMENT COST: Table 5 below shows the investment costs of developing EMD with a capacity to produce from 150 (startup) and 5,000 Lit/day ethanol (90%, v/v) processing feedstock of dry roots, tubers, rhizomes, fruits, juice and/or molasses on one group and stems on the other. The investment cost includes equipment of a complete bioethanol production facility: labor (coordination, construction, and training), masonry, materials, tax on labor and equipment.
Table 5 : Investment cost: 150 to 5,000 L/day roots, tubers, rhizomes, and molasses
Machine/ Equipment/ Item
Investment by: Liters/ day Ethanol capacity [Birr]
150 800 1,000 1,600 2,400 3,200 5,000 1 Industrial safety 20,000 140,000 175,000 220,000 300,000 380,000 593,750 2 Utilities and other
peripheral system (general infrastructure)
80,000 480,000 600,000 760,000 1,020,000 1,260,000 1,968,750
3 Tools and instruments (Process Monitoring and Maintenance)
20,000 80,000 100,000 120,000 140,000 180,000 281,250
4 Feedstock reception and preparation
120,000 420,000 525,000 660,000 900,000 1,160,000 1,812,500
5 Reception, storage, handling and preparation of feedstock
500,000 1,680,000 2,100,000 2,820,000 3,960,000 5,100,000 7,968,750
6 Equipment for the production of bioethanol
20,000 80,000 100,000 160,000 240,000 320,000 500,000
7 Vinasses conversion to low-grade fertilizer
20,000 100,000 125,000 200,000 260,000 32,000 50,000
8 Storage of bioethanol 60,000 200,000 250,000 340,000 460,000 580,000 906,250 9 Transport of
equipment, materials and supplies
20,000 140,000 175,000 220,000 280,000 340,000 531,250
10 Personnel travel 40,000 120,000 150,000 160,000 200,000 240,000 375,000 11 Labor cost at facility
for preparation of site, installing equipment, trainings and startup
20,000 40,000 50,000 60,000 80,000 100,000 156,250
12 Supplies for training of operators
40,000 160,000 200,000 280,000 380,000 480,000 750,000
13 Indirect costs 60,000 200,000 250,000 320,000 440,000 560,000 875,000 TOTAL COST
1,020,000 3,840,000 4,800,000 6,320,000 8,660,000 10,732,000 16,768,750
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Roots and tubers feedstock preparation is by hammer mill and chopper requiring investment that range from 500,000 to 7,968,750 Birr for 150 lit/day and 5000 lit/day EMD respectively. This is stated as item 5 in the above chart and is the primary difference in technology compared to other feedstock type processing EMDs. The investment in these equipments contributes to 50% of the total EMD expenditure cost. It is vital from cost point of view to produce these locally and there is a very positive survey result that it is possible to manufacture feedstock processing equipments for roots and tubers.
In the second category is a stem, using sugarcane and/or sweet sorghum as feedstock. The investment cost for EMDs processing stems is presented in two options below.
Table 6 : Investment cost: 150 to 5,000 L/day; stems
Machine/ Equipment/ Item
Investment by: Liters/ day Ethanol capacity [Birr]
150 800 1,000 1,600 2,400 3,200 5,000 1 Industrial safety 20,000 140,000 175,000 220,000 300,000 380,000 593,750 2 Utilities and other
peripheral system (general infrastructure)
80,000 480,000 600,000 760,000 1,020,000 1,260,000 1,968,750
3 Tools and instruments (Process Monitoring and Maintenance)
20,000 80,000 100,000 120,000 140,000 180,000 281,250
4 Feedstock reception and preparation
120,000 420,000 525,000 660,000 900,000 1,160,000 1,812,500
5 Equipment for the production of bioethanol
20,000 80,000 100,000 160,000 240,000 320,000 500,000
6 Vinasses conversion to low-grade fertilizer
20,000 100,000 125,000 200,000 260,000 32,000 50,000
7 Storage of bioethanol 60,000 200,000 250,000 340,000 460,000 580,000 906,250 8 Transport of
equipment, materials and supplies
20,000 140,000 175,000 220,000 280,000 340,000 531,250
9 Personnel travel 40,000 120,000 150,000 160,000 200,000 240,000 375,000 10 Labor cost at facility
for preparation of site, installing equipment, trainings and startup
20,000 40,000 50,000 60,000 80,000 100,000 156,250
11 Supplies for training of operators
40,000 160,000 200,000 280,000 380,000 480,000 750,000
12 Indirect costs 60,000 200,000 250,000 320,000 440,000 560,000 875,000 Juice extraction. 1.1 Option 1: Diffuser 4,200,000 4,200,000 4,200,000 4,200,000 4,200,000 4,200,000 4,200,000 1.2 Option 2: Milling
system. CIF. 3,300,000 3,300,000 3,300,000 3,300,000 3,300,000 3,300,000 3,300,000
TOTAL With: Diffuser 4,720,000 6,360,000 6,900,000 7,700,000 8,900,000 9,832,000 13,000,000 With: Milling 3,820,000 5,460,000 6,000,000 6,800,000 8,000,000 8,932,000 12,100,000
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Sugarcane and sweet sorghum feedstock juice extraction can be possible technologically in two options using diffuser or milling system. Diffusers are efficient thermal systems with long run economically justifiable thermal systems, but initial investment is even higher than mills (4,200,000 Birr compared to 3,300,000 Birr crush milling systems).
Other interesting fact worth to mention is both diffuser and milling systems are available for large scale feedstock processing, and initial investment is irrespective of EMD size, which makes EMD practically viable mostly for large size.
Total investment cost for EMDs processing stems (sugarcane /sweet sorghum) vary from 4,720,000 to 13,000,000 Birr, according to capacity with diffused technology used as juice extraction. Similarly, the cost ranges from 3,820,000 to 12,100,000 Birr if technology used is crush milling for juice extraction. This indicated for smaller capacity EMDs 150 to 1000 lit/day, the initial investment is enormous compared to feedstock of roots and tubers. But the investment closes to each other for higher capacity EMDs irrespective of the feedstock processed.
Additional, laboratory items and instrumentations such as thermometer and ph meter are estimated to cost around 41,190 Birr and their detail is presented at annex.
0
2,000,000
4,000,000
6,000,000
8,000,000
10,000,000
12,000,000
14,000,000
16,000,000
18,000,000
150 800 1,000 1,600 2,400 3,200 5,000Roots and tubers 1,020,000 3,840,000 4,800,000 6,320,000 8,660,000 10,732,00016,768,750
Stems - by Crush Mill 3,820,000 5,460,000 6,000,000 6,800,000 8,000,000 8,932,000 12,100,000
Stems - by Diffuser 4,720,000 6,360,000 6,900,000 7,700,000 8,900,000 9,832,000 13,000,000
Birr
Investment Cost
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PRODUCTION/VARIABLE COST: Ethanol production requires utilization of various consumables such as water, electricity, chemical and other utilities. The consumption and accordingly resulting expense (cost) is directly proportional to the capacity of EMD which is measured in liters per day. Also, the number and level of personnel (unskilled, semi-skilled and skilled) should be kept under consideration as an element of cost for ethanol production. Generally these are referred as operational or variable costs.
The study is based on Annual cost in all variable cost elements, and detail is present at annex 7.
Personnel Cost
In order to run an EMD it is required to have personals of coordinator, process engineer, boiler operator, fermentation and distillation personal, and cleaning and guards. Their annual expense considering current Ethiopian salary scale is summarized as:
Table 7 : EMD operation Cost Personnel
Personnel Cost /Annum
EMD Capacity Liter/day 150 800 1000 1600 2400 3200 5000
[Birr/Annum] 340,992 1,156,608 1,260,288
1,571,328 1,986,048 2,504,448
3,644,928
[Birr/lit] 6.69 4.25 3.71 2.89 2.43 2.3 2.14 The higher the capacity of EMD, the more economical the production of ethanol will be as it has been observed from personnel expense Birr/ lit of production.
Water Consumption Cost
An average of five times the ethanol production is the amount of water requirement on volumetric basis. This means five liters of water is consumed for every liter of ethanol production. With this empirical relation and average water tariff in most of Ethiopian regions (0.025 Birr/lit of water) the annual consumption of water and associated cost is presented for various EMD capacities.
Table 8 : EMD operation Cost Water
Water Cost /Annum
EMD Capacity Liter/day
150 800 1000 1600 2400 3200 5000
[Birr/Annum] 6,375 34,000 42,500 68,000
102,000
136,000 212,500
Water cost per liter of ethanol production is 0.13 Birr/ lit in all cases. Electric Consumption Cost
EMDs processing multiple feedstocks at various scales consume equipment and electricity at different scale. The summarized date indicates electric consumption by major ethanol production equipments and utilities used during, and equivalent cost according to Ethiopian tariff. For convenience feedstock type is used as major criteria in roots and tubers class and stems (sugarcane and sweet sorghum), and capacity of EMD as second criteria.
24
Table 9 : EMD operation Cost Electricity
Electric Cost /Annum [Birr]
EMD Capacity Lit/day 150 800 1000 1600 2400 3200 5000
1 Sweet Potato and /or Taro 3,798 12,363 15,454 21,762 35,355 97,321
2 Opunita 4,384 14,745 18,431 25,951 98,469 153,857
3 Sugarcane / Sweet Sorghum
122,039 832,443 926,266 937,325 1,036,898 2,274,658 2,330,046
It is notable electricity consumption in case of stem (sugarcane and sweet sorghum) feedstock is considerably high than other feedstock for juice extraction. Again detail of equivalent KWHr is presented at annex section of the feasibility. Chemical Consumption Cost EMDs processing uses Chemicals such as yeast, urea, Zinc and Magnesium Sulphate, Phospheric and Sulphuric acid, detergent and lime materials, and more. Below is presented the summary of total chemical consumption per annum.
Table 10 : EMD operation Cost Chemical
Chemical Cost /Annum
EMD Capacity Lit/day 150 800 1000 1600 2400 3200 5000
[Birr/Annum] 42,840 228,480 285,600 456,960 685,440 913,920 1,428,000 Chemical cost per liter of ethanol production [Birr/lit] is an average of 0.84 Birr/liter.
-
500,000
1,000,000
1,500,000
2,000,000
2,500,000
150
800
1000
1600
2400
3200
5000
Birr
Annual Electric Cost
Stem
sweet potatao/taro
Opunnita
25
TOTAL EMD VARIABLE/PRODUCTION COST
Variable costs of an EMD are personal, water, electricity and chemical costs as presented above. Total operational cost is the sum of the above and is presented here per annum based.
As it has been stated, electricity cost is the main reason for higher total production cost in stem feedstock. If all elements of variable costs personnel, electricity, water and chemical are compared to each other, personnel cost takes the lion share at around half of the totals in most EMD capacities. Even more it is observed personnel cost is critical for EMDs with smaller capacities such as 150 and 800 lit/day.
-1,000,000 2,000,000 3,000,000 4,000,000 5,000,000 6,000,000 7,000,000 8,000,000
150 800 1000 1600 2400 3200 5000Sugarcane or Sweet Sorghum 512,246 2,251,5312,514,6543,033,6133,810,3865,829,0267,615,474
Sweet Potato and/or Taro 390,400 1,422,8861,600,7512,111,7422,795,2503,589,7235,382,749
Opunita 394,591 1,433,8331,606,8192,122,2392,871,9573,708,225
Birr
/Ann
um
Total Production Cost
26
Chapter 6
Cost of Manufacturing EMDs in Ethiopia vs. Import
It is important to construct in Ethiopia because the expected impacts of manufacturing most components of the EMDs locally are:
1. Availability of equipment at a lower cost than options by import. 2. Creation of new jobs, improvement of working conditions, education and motivation of
workshops (and to a lesser extent suppliers of material) to realize that renewable energy is a way to increase economic benefits and to take care of their society.
3. Increase of food processing and agro-industrial production, and conception of economic activities other than only agricultural production. Example: distilleries & food processing industry use stainless steel; integrating manufacturing capacity of both will benefit significantly.
4. Climbing the eco pyramid of value and learn how to develop EMDs at an even higher value than only for cooking fuel.
Because of low cost of plastic containers (1,250 USD for 10,000 L tank) manufactured in Addis Ababa compared to the cost of imported plastic vessels a cost reduction of 15,000 USD for each 1,000 L/day, production capacity is feasible. The use of plastics instead of metal vessels for water storage, mixing, fermentation, filtering and sedimentation is technically desirable because there is no heat involved on these processes.
Activities in metal workshops are relatively expensive compared to other countries. This could be because workshops are not used to prepare product quotations based on technical drawings. Also unavailability of experience on requested items may have significant effect on price ranges.
It is reasonable to assume construction cost for further expansion is viable and significantly lower since reverse engineering the existing one is much easier and less costly for different workshops.
Investment cost to process roots and tubers range from 1,020,000 to 16,768,750 Birr for equipments and machinery. Considering local manufacturing capacity, more than 80% of this investment can be on locally manufactured products with the exception for measuring and instrumentation devices. For EMD processing stems (sugarcane or sweet sorghum), investment ranges from 4,720,000 to 13,000,000 Birr (with Diffuser) and from 3,820,000 to 12,000,000 Birr (with milling). Local manufacturing capacity in this case will be at lower percentage according to our survey, because of the demanding large scale production facility for milling and thermal diffuser juice extraction mechanisms.
The table below summarizes comparison on equipments locally manufactured versus import ones.
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Table 11 : Summary Locally manufactured, supplied or imported
Can be manufactured locally Available in local retails Should be imported Biomass chippers, the drum system. Safety equipment Biogas electricity
generators. Cutting of metal laminates, angles, bars and tubes by hand.
Corrugated zinc roofing. Copper tubing and accessories.
Rolling of laminates using a plate roller.
Electric motors. Hose pe-al-pe or pealpex
Bending of laminates using a bending machine, for boiler components.
Iron angles, structural metal profiles and other materials.
Mineral rock wool for thermal insulation of tubes.
Welding of iron laminates, tubes and profiles using ordinary welding.
Tubing of stainless steel. Mineral rock wool for thermal insulation.
Perforation of laminates and tubes. Vessels. PVC flanges. Stainless steel valves. MIG or TIG welding of stainless steel laminates tubes and profiles.
Sheets of stainless steel and iron/steel
Stainless steel couplings or clamps for tubes.
Conveyors transporters. PVC tubing. Metal and PVC tube accessories.
Electric pumps5.
Hammer mills. Refractory bricks and cement. Diffuser system for extraction of juice from sugar cane and sweet sorghum.
As a reference, a 1000 lit/day EMD price quotation was collected from six different suppliers and compared with local cost considering equipments manufactured, locally supplied and some components imported. Table below summarizes the costs of investment. The total costs were ranging between 119,010 USD and 543,797 USD. The authors recommend (based on calculations and the recollection of data in Ethiopia) an investment cost of 160,663 USD. Interesting to observe is that the cost of the distillation system is a minor cost compared to the total cost in all price indications analyzed. There is not one provider which offers a complete production system and only one company constructs locally. This company is also the only company which system is compatible with different types of feedstock. The final column of the table presents what the authors recommend to budget, 160,663 USD, for a complete EMD constructed.
Table 12 : Summary of 1000 lit/day interanational quotation
1000 lit/day A B C D E F If Locally
USD 462,800 357,992 403,370 119,010 169,750 543,797 240,000 Birr 9,256,000 7,159,840 8,067,400 2,380,200 3,395,000 10,875,940 4,800,000
Refer annex 6 for detail of international quotation gathered for 1000 lit/day. Comparison may not be one to one criteria here because for some of the quotations supplied by providers, the full package of EMD may not be available.
5 High durability, corrosion free, hot liquid tolerant (150° C; 302° F), explosion proof pumps
28
Chapter 7
Alcohol Stoves
Cooking is considered as a major consumption of energy in most of developing countries rural area Biomass wood and coal are the most common source of energy, but from indoor air pollution point of view they are dangerous and health concerns for residents. Besides, collecting firewood is a hectic and time consuming task for women and children in countries such as Ethiopia.
Clean cooking using clean fuels such as biogas, methane and ethanol is alternative besides clean cooking using electricity and clean cooking using biomass burning. According to the Global Clean Cooking Fuel Initiative (GCCFI), clean cooking fuels are considered as those that reduce indoor air pollution while addressing social and developmental issues. Alcohol stove cooking is cleaner compared to biomass burning, such as wood and charcoal, and can also be accessible in rural areas of developing countries. According to report by WHO 2006:‘By 2015, to reduce the number of people without effective access to modern cooking fuels by 50%, and make improved cooking stoves widely available’.
But Alcohol Stoves technology is more expensive than traditional biomass, both in terms of purchasing the stoves and the costs related to the supply chain for the ethanol. Its nature will allow to replace an electric cook stove, the cleanest alternative for cooking but rarely used in the developing world, due to the high costs of electricity and limited access in rural areas (Anonymous2014b).
Alcohol cook stoves are pressurized or non-pressurized and can burn ethanol in liquid or in gelled or waxy forms. Most alcohol stoves can successfully combust ethanol in a fuel-water ratio of 80% and above, but some stoves endeavor to burn ethanol with higher water levels. Alcohol stoves do not require anhydrous ethanol (with the water removed), which is typically what is required for gasoline blending. Critical concerns and issues to address with CCS according to above cited source are:
Health Impacts: Ethanol and methanol burn very cleanly. Studies conducted in a number of countries, both in the laboratory and in household field tests, have shown the benefit of alcohol stoves in dramatically reducing indoor air pollution as compared to wood, charcoal and kerosene stoves. Alcohol stoves tend to produce significantly less CO (carbon monoxide) than stoves using kerosene or solid fuels and alcohol stoves that incorporate adequate oxygen in the combustion process achieve extremely low levels of CO.
Climate Impacts: Greenhouse gases released in the production and consumption of ethanol fuel are reabsorbed during the growth cycle of the plant material used to make the fuel. Especially damaging greenhouse gases like carbon monoxide and VOCs (volatile organic compounds) are not produced or produced only at extremely low levels. Black carbon aerosols, a potentially potent climate forcer, are essentially not produced by the combustion of ethanol and methanol.
Efficiency: Alcohol stoves function in a range of efficiencies with gel-fuel stoves generally less efficient than liquid fuel stoves. The most efficient ethanol stoves are more efficient than solid fuel stoves and kerosene wick stoves and generally comparable to LPG and pressurized kerosene stoves (Anonymous2014c).
29
The above points and issues are a clear guide in targeting a feasibility study and capacity building program to produce ethanol stoves in Ethiopia and disseminating them all around. Besides, it has been proved by the work of Gaia Association in studying the social response of rural Ethiopian’s to accept CS as alternative energy source by distribution of sample ethanol stoves.
A number of factors though will influence the effective dissemination of Alcohol Stoves in Ethiopia. Figure next summarizes these areas of concern and conditions. Further details are in marketing section of this holistic study.
Figure 4: Factors influencing Ethanol Cook Stove expansion program in a country (Zuzarte 2007).
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Chapter 8
International Trends & Technological Options of Alcohol Stoves
The technology of alcohol burning stoves is developing all the time and there is a variety of stoves available. Alcohol stoves are predominantly used in Europe and USA for marine and mobile leisure applications. It is also used for the purpose of trip, as camping and hiking stove mainly made of can, at pleasure boats, to boil water at house, and to rehydrate dehydrated meals. It is found more in developing countries specifically used for cooking.
Basically Alcohol Stove comprises components of: 1. Fuel container (canister), 2. Heat shield, and 3. Main body
For proper functionality additional part details are included especially for heat shield. This includes:
2.1 Fuel chimney seat 2.2 Flame Chimney tube 2.3 Mechanically operated flame regulating valve 2.4 Clamping mechanism for canisters
There are a number of manufacturers with efficient alcohol stoves. All web references are in August 2014.
- White Box Alcohol Stoves TM Company produces light weight open top back backing can types, which can boil up to eight cups of water in one fill (Anonymous 2014d).
- Marko Superblu stove is manufactured in Malawi – southern Africa by a company BLUWAVE Ltd. The company has developed a novel burner technology that heats and then vaporizes liquid ethanol with the aim of greater safety and economy (Anonymous2014e).
- Ethanol Lanstove by NARI ve Nimbkar Agricultural Research Institute is an Alcohol Stove that runs on a low concentration [55-60% (w/w)] ethanol-water mixture. It is a non pressurized type stove that is made by modification of previous pressurized kerosene stoves and is distributed to rural areas of India (Anonymous2014f).
The institute has also performed a number of researches on Alcohol Stoves that work in low concentration of ethanol such as (Rajvanshi et al. 2004).
Alcohol Stove
Canister
Base can Can cover
Heat Shield
Fuel chimney seat
Flame chimney
tube
Flame regulating
valve
Canister clamper
Body
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- Project Gaia alcohol studies stove manufacturing capacity building programs at its project countries, basically based on reverse engineering of specifically spirit stove by Dometic (pty) Ltd, in Ethiopia, Brazil, Haiti and Madagascar (Anonymous 2014g).
- Study by Duke University (Anonymous 2014h) performed rural village based EMD and alcohol stove model in Kenya. According to the study, rural Kenya is modeled to have an average of 7,000 people village, and 1,160 households that will consume an average of 1.2 Lit/day of ethanol for cooking.
- Green-heat Manufacturing Pvt./ Ltd works with gel fuel imitative in both Zimbabwe and South Africa for local use and export. The company works on gel ethanol fuel as a replacement for paraffin household users. Even though the use of gel fuel increases total cost of fuel consumption for their alcohol stove, the company opted to proceed considering safety issue due to slippage problem of conventional/ normal ethanol alcohol.
- In Mozambique, fuel plant for sustainable ethanol cooking is developed and is inaugurated in March 2014. (Anonymous 2014i).
- A private owned shop in Ethiopia that runs the business for long period of time now. They produce single burner alcohol stoves made from mild steel. In addition to fabricating and selling of the stoves, the company involves in ethanol refilling for their stove customers.
Table 13 : Summary of various alcohol stoves
Name of Alcohol Stove Manufacturer Alcohol Concentration
required
Η Remark
1 Dometic Clean Cook Stove
Dometic AB (ptv) Ltd >= 80 % (v/v) 60% Great repeatability in Ethiopia
2 Daksha Alcohol Stove Daksha Bio power Pvt Ltd (India)
3 Marko Superblu Ethanol Stove
Marko Superblue (Malawi)
4 Ethanol Lanstove NARI (India) 55 – 60 % (w/w)
Operates at low concentration
5 Green Heat Ethanol Stove
Green Heat Manufacturing Pvt. /Ltd (Zimbabwe & South Africa)
Only gel ethanol fuel
6 Local stove (Ethiopia) >= 80% v/v
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Chapter 9
Selection of Suitable Alcohol Stoves Technologies to Ethiopia
There are various alcohol stoves all over the world both in developed and developing countries. Considering the following factors as selecting criteria, the holistic technological feasibility study team has come up to narrowing to two options of design. The factors are:
i. Functionality for intended purpose of cooking in Ethiopia ii. Safety
iii. Design features iv. Simplicity for both reverse design and manufacturing v. Availability of material
vi. Aesthetic value
Among selection criterion, simplicity for both design and manufacturing are critical from reversing point of view in Ethiopia. These factors depend largely on capability of skilled and semi skilled man power. Workshop facility, equipment, and raw material availability are also significant factors. Safety and functionality weigh next. Considering end users standard of living (environment and household condition), alcohol stoves need to be safe from burn out and any other hazard. This is a high risk level with catastrophic level of consequence due to volatility behavior of the fuel. Awareness level of end user is also a probable cause for damage and operational hazard in alcohol cook stove.
Accordingly, based on the review of both local and international alcohol stove technology, Dometic’s and Daksha’s Alcohol Stove stood out in weighted average products selection.
1. Dometic (Ptv) Ltd
Made by Swedish based Dometic AB, this stove is also produced by business partners of the company in Africa. The product is tested under a number of researched topics, more specifically by Gaia Association, and is proven safe, and efficient up to 65%. (Anonymous 2014j)
2. Daksha Bio power Pvt Ltd (India) picture at far right (Anonymous 2014k)
Gaia Association has worked extensively in promoting and disseminating Alcohol Stoves in Ethiopia for the past nine years. Considering its reputability at areas such as Kebribeyah and Teferi Ber refugee camp, Addis Ababa, and other parts of the country, and a number of researches by Gaia association, the Dometic stoves are best suited. Gaia Association has experience of working with these stoves and the technological feasibility study team has observed the stove fulfils the above stated basic criteria for ease in design and manufacturing.
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Chapter 10
Alcohol Stove Components, Manufacturing Process, Cost, and Plant Layout 10.1 Equipment List, Material Balance and Manufacturing Methods Manufacturing Alcohol stove is economically viable if and only if quantity of demand is high. Accordingly this study utilizes batch type manufacturing process with 20,000 piece double burner alcohol stove. This number is used for all bills of material and cost element study, and later extrapolated to single burner stove option.
A. Fuel Container
It has been observed in this feasibility study that even though there are a number of factories here in Ethiopia with all the required machine tool capacity, there is a difficulty in producing sound canisters. But this could be improved with proper engineering capability development and specialized training in sheet metal forming and die design. In the next part of this document it is reported considering in Medium term period of time it is possible to produce canisters for Alcohol stove using the following technical methodologies.
Basic components and feature from manufacturing point of view:
1. Cylindrical can shaped lower part 2. Top side cover
- Centrally hollow opening - Rimmed between diameter 1 and diameter 2 in order to support gritting net
3. Net at top side - Also protrude wider at underside of cover
4. Spacer between cover and net 5. Fiber absorbing mass 6. Opening between cover and net for alcohol refilling
Material selection:
All metallic parts of the fuel container are made from stainless steel grade 304 (according to ASTM A 240 and ASTM A 666) to minimal corrosion during service period. Composition is %C 0.08max, %Mn 2max, %P 0.04max, %S 0.03max, %Si 0.75max, %Cr 18-20, %Ni 8-12. Aluminum is also a low cost alternative material. Also: low carbon steel can be used for Mild steel made stove body.
Fiber absorbing mass is selected to be Mineral wool, preferably glass wool type.
Manufacturing Method Study:
The viable manufacturing method for alcohol stove canister is deep drawing, and it requires careful parametric analysis for quality manufacturing. This includes selection and implementation of proper press tool tonnage, holding force, blank to punch diameter drawing ration, reduction ratio, and sheet metal thickness to blank diameter ratio.
34
Base can manufacturing undergo:-
- Blanking out of can’s base plate (A) - Can base deep drawing (B)
Can cover manufacturing undergo:-
- Blanking out of can cover plate (C) - Piercing central fuel refill hole opening (D) - Press forming of cover rims (E) - Press forming of cover plate lock (F)
Material preparation and Assembly processing include
- Materials preparation of absorbing mass and wit and assembly with base can (G) - Material preparation of net and assembly with base can (H) - Air tight lock assembly/circular continuous seam weld of base can & can cover
plate (I) Finishing operations include
- Cleaning such as sand blasting and washing (J) - Labeling (K)
Other operations include
- Inspection and quality control (L)
Figure 5 Manufacturing method process flow fuel tank
35
Table 14 : Bill of Quantity Canister
Bill of Quantities CANISTER (C)
Date: August 2014 Work center
Amio Engineering, Makubu, Ethiopia can and cork, OTHERS..
Row material Item/s
Stainless steel, Aluminum Other raw material
1000x2000x1mm Form Number
Product: fuel tank/ canister
Batch Number: 1
Batch size: 20,000
No Code No
Part description
Material specification U.O.M Total per quantity
Remark
size Material quality
1 Stove C0001
Base can Sheet metal
2000x1000x1 mm
St. steel 304
Pcs 2500 Considering 8 cans / plate
2 Stove C0002
Can cover Sheet metal
2400x1000x1 mm
St. steel 304
Pcs 1250 Considering 16 can cover per plate
3 Stove C0003
Net Diameter 2 plus spacer
St. steel 304
Kg 2,000 0.1 kg per canister
5 Stove C004
Fiber absorbing mass
80 mm high, 200mm wide
Mineral wool
Kg 20,000 0.1 5kg per canister
Machine tool capacity, specification requirement to canister deep drawing process; and circular seam welder for base cane and cane cover:
Machine tools are:
1. Mechanical or hydraulic press machine 2. Circular continuous seam welding
Machine-tool specification and information in this subject is attached at Annex 9 Machine Tools Canisters Production
36
B. Heat Shield
The heat shield and stove body are stainless steel structures. The heat shield with-hold with it primarily the following four items:
- Stainless steel fuel chimney seat - Stainless steel flame chimney tube - Stainless steel mechanically operated flame regulating valve - Clamping mechanism for canisters
Material selection Heat Shield:
Heat Shield is made from stainless steel grade 304 or mild steel. → Heat shield main structure (Code HS 0001)
Manufacturing Method: The stove’s main shield structure manufacturing undergoes sheet metal processing technologies:
I. Laser/ Plasma arc / oxy acetylene numerically controlled cutting of shown profile with over all dimension of about 600x500x1.5mm stainless steel
II. Press machine guided piercing processes of rectangular and other sections shown sections III. Press tool machine guided pierce-drill of holes (for chimney tube) IV. Vee and edge bending processes at four section to obtain base structure shape
→ Fuel chimney seat (Code HS 0002) Manufacturing Method: Chimney seat manufacturing undergoes sheet metal processing technologies:
I. Blanking basic dimension with diameter of 180mm and three legs II. Piercing central hole to position flame chimney tube
III. Drilling of three holes for leg clamping with main structure IV. Twice Edge bending for each of the three leg sections
→ Flame chimney tube (Code 0003) Manufacturing Method:
Chimney seat manufacturing undergoes metal processing technologies:. I. Pipe 110mm, 1.5mm thickness power hacksaw cutting
II. Finishing lathe turning at both side → Mechanically operated flame regulating valve (Code HS 0004)
Manufacturing Method:
Flame regulating valves manufacturing undergo basic sheet metal processing technologies: I. Circular plate diameter 110mm blanking with double corrugation, using press tool
II. Arm plate blanking 200x20mm, using press tool III. Circular handle plate diameter 30mm blanking, using press tool IV. Spot welding of handle plate with arm plate V. Spot welding of handle-arm plate with valve plate
→ Clamping mechanism plate for canister holder (Code HS 0005)
Manufacturing Method:
Flame regulating valves manufacturing undergo metal processing technologies in sequence. I. Strip shear cutting of material at the required width 35mm and total length of 350mm
II. Sheet metal angle bending at four stations III. One hole drilling diameter 6mm for riveting with base structure
37
Table 15 : Bill of Quantity Heat Shield
Bill of Quantities HEAT SHIELD (HS)
Date: August 2014 Work center
Amio Engineering, Moges, Ethiopia can and cork,
Row material Item/s
Stainless steel 1000x2000x1.5mm Form Number
Product: Heat Shield structure
Batch Number: 1 Batch size: 20,000
No Code No Part description Material specification U.O.M Total per quantity
Remark
size Material quality
1 HS 0001 Heat shield main structure
600x520x1.5 mm
St. steel 304
Pcs 3000 utilization of 90%
2 HS 0002 Fuel chimney seat (2 required)
φ180mm with 52mm legs
St. steel 304
Pcs 800 utilization of 78.5%
3 HS 0004 Mechanically operated flame regulating valve
Variable St. steel 304
Pcs 366 utilization (>90%)
4 HS 0005 Clamping mechanism plate canister holder
350x35x1.5mm St. steel 304
Pcs 260 utilization (>90%)
Total 4426 5 HS 0003 Flame chimney tube Pipe
φ110mm,80mm high, 1.5mm
St. steel 304
Pcs 270 pipe 6000mm; 98% utilization
Machine tool capacity, specification requirement to Heat Shield fabrication; Machine tools are:
1. Portable CNC Laser/ Plasma arc cutter/ oxy acetyl machine 2. Mechanical or hydraulic press machine 3. Hydraulic bending machine 4. Manual Rolling machine 5. Power hacksaw machine 6. Small lathe machine 7. Radial drilling machine 8. Spot welding machine 9. Rivet gun
Machine specification, further information at Annex 10 Machine Tools Heat Shield Production
38
C. Stove Body
The outer astatically sound and sharp edge free, quality and rigid part of alcohol stove is its body. It is either stainless steel made material in order to give prolonged service with minimal corrosion. Besides supporting cooking pots and make accessible flame regulating valve, the stove body is also with perforation holes at both sides of stand and a couple of holes at front section.
Manufacturing Method:
Stove body manufacturing undergo sheet metal processing technologies in sequence:
I. Blanking of developed body section II. Rectangular section piercing of flame regulating valve stations
III. Drilling of air perforations at front, left side and right side (total of about 48 holes φ4mm) IV. Bending of four main top side edges V. Bending of basement seat edges
VI. Finishing such as chamfering and fillet making to remove sharp corners
Table 16 : Bill of Quantity Stove Body
Bill of Quantities STOVE BODY (SB)
Date: August 2014 Work center
Amio Engineering, Moges,
Row material Item/s
Stainless steel 1000x2000x1.5mm Form Number
Product: Stove main body
Batch Number: 1
Batch size: 20,000
No Code No Part description
Material specification U.O.M Total per quantity
Remark
Size Material quality
1 SB 0001 Heat shield main structure
620x900x1.5 mm
St. steel 304
Pcs 5714 utilization 97.65%
Machine tool capacity, specification requirement to stove body components manufacturing:
Machine tools required for fabrication of stove body are: 1. Mechanical or hydraulic press machine 2. Hydraulic bending machine 3. Radial drilling machine 4. Spot welding machine
The required specification is stated at the previous section of heat shield manufacturing.
39
D. Flame Spreader The flame spreader having shape of omega (W) will be secured with stove body; butterfly section is in line with top of canister opening and chimney tube. The main objective of incorporating flame spreader is in order to promote flame propagation by dividing to several sections, so that combustion air will be fed and circulated in abundance.
Manufacturing Method:
Stove body manufacturing undergoes sheet metal processing technologies:
I. Blanking of butterfly shaped profile II. Bending at four stations to clamp with
III. Drilling at two holes φ4mm
Table 17 : Bill of Quantity Flame Spreader
Bill of Quantities FLAME SPREADER (FS)
Date: August 2014 Work center
Amio Engineering, Moges, Ethiopia can and cork,
Row material Item/s
Stainless steel
1000x2000x1.5mm Form Number
Product: Flame spreader
Batch Number: 1
Batch size: 20,000
No Code No Part description
Material specification U.O.M Total per quantity
Remark
size quality
1 FS 0001 Flame spreader
140x35x1.5 mm
St. steel 304
Pcs 101 utilization 97.75%
10.2 Process Planning Activity for Alcohol Stove Production
All Sheet metal fabrication processes such as for Alcohol stove requires prior to fabrication set forth conditions; such as quality and standard, and detail operation sheets used in actual manufacturing process. This technical information is enclosed at Annex 11 Process planning activities and operation sheet.
Job Shop Layout for Alcohol Stove Manufacturing
A manufacturing facility for Alcohol Stove performs a number of activities that interact with each other from raw material receiving area/station through various processing shops to finished product inspection station. Besides, other facilities such as offices for supervision, design, and production control; and space for inventory and aisles, dressing rooms, lunchrooms, and restrooms for employees is considered in Stove production facility layout preparation.
Due to the type of components possessed by Alcohol stove (see Bill of Material section), the process layout is used on general –purpose machines [such as cutter, shearing, rolling, bending
40
and welding machines] that can be changed over rapidly to new operations for different product designs. These machines are usually located in different shops and arranged according to type of process being performed.
Figure 6: Basic product/material flow and production operation for Stove
Table 18 : Factory Job Shop / Fabrication Floor Plan Machine tools
Factory Job Shop / Fabrication Floor Plan Machine tools
Facilities and stations
MACHINE TOOL TYPE/ PURPOSE Estimated price
[FOB] Birr
1.1 Shear Cutter Mechanical 18,500 1 Raw materials store 1.2 Power hacksaw Machine 72,620 2 Assembly stations 2 Bending Machine Hydraulic 120,000 3 Cleaning station 3 Press Machine Hydraulic 30 ton 70,000 4 Painting Station 4 Deep Drawing Press Hydraulic 100 ton 180,000 5 Inspection Station 5 Rolling Machine Mechanical /
Hydraulic 130,000 6 Product Inventory Store
6 Vertical drilling Machine
Vertical drill 35,000 7 Consumable Materials Store
7 Spot Welding Machine 13,400 8 Superintendent Office 8 Oxy Acetylene cutter 25,000
Approximately 660 m2 land 9 Grinding Machine 22,000 10 Riveting Machine 8,000 11 Piston Compressor 7 bar Used at cleaning and
painting Department 13,000
707,520
41
Figure 6: Plant layout recommended, Alcohol stoves production
10.3 Cost Study of Alcohol Stoves Cost Estimation Elements considered are Material Cost and Production Process Cost. Details and cost computation is based on a double burner stove. Material Cost Consumable materials for the production of Alcohol stove is basically stainless steel. Other material inputs to the system consist of Mineral wool. The following cost analysis of material consumption during stove manufacturing is based on the Bill of quantity developed for Dometic type Alcohol Stove 2- Burner Free Standing type. Material price is based on quotation, submitted on July 27-2014. In the feasibility study, two kinds of engineering materials are used in order to have options with respect to quality of product and cost consideration. As a matter of fact, affordability is a very critical issue from Ethiopians point of view, and Alcohol stoves with mild steel as material for production seem the more practicable. Below in the next table is presented the summary of material cost for both Mild-Steel and Stainless Steel. Process Operation Cost, Consumable Cost, and Time Cost
In this study Process operation cost, consumable cost, and time costs to produce double burner
alcohol stove is performed and summarized elements of costs, and the result is utilized in
estimating overall cost of Alcohol stove.
42
TOTAL COST
With stainless steel material cost for double burner is 3226.8 and 1774.7 Birr for single burner. With mild steel cost reduces to 548.1 for double burner and 301.5 for single burner.
Table 19 : Stove Material Cost Analysis based on BOQ
Double Burner [DB] and Single Burner [SB] Material Cost (Stainless , and Mild Steel made)
Stainless Steel Mild Steel
Component Part and its Number Material Detail Unit Cost [Birr] DB SB DB SB
Canister
Base can (C0001) Steel 1mm thick 402.5 221.4 68.3 37.5 Can cover (C0002) Steel 1mm thick 201.3 110.7 34.1 18.8 Net (C0003) Meshed steel 4.0 2.2 4.0 2.2 Fiber absorbing mass (C0004) Mineral wool glass 3.8 2.1 3.8 2.1
Heat Shield
main structure (HS0001) Steel 1.5mm thick 759.0 417.5 127.4 70.0 Fuel chimney seat (HS0002) Steel pipe 1.5mm 202.4 111.3 34.0 18.7 Flame chimney tube (HS0003) Steel pipe 1.5mm 24.3 13.4 3.2 1.8 Flame regulating valve (HS0004) Steel 1.5mm thick 92.6 50.9 15.5 8.5 Clamping mechanism (HS0005) Steel 1.5mm thick 65.8 36.2 11.0 6.1
Body Stove body (SB0001) Steel 1.5mm thick 1445.6 795.1 242.6 133.4 Flame Spreader Spreader (FS0001) Steel 1.5mm thick 25.6 14.1 4.3 2.4
3226.8 1774.7 548.1 301.5 Each component of stove is considered in production cost study. Cost is estimated considering elements such as professional cost, machine cost, machine consumable cost, material handling cost and other miscellaneous cost. The result is summerised and presented in the next table.
SUMMARY: Stove Production Cost
DOUBLE BURNER COST SINGLE BURNER COST 1 Canister 170.5 Canister 85.26 2 Heat Shield 299.9 Heat Shield 299.99 3 Body and flame spreader 148.7 Body and flame spreader 148.68 Total (Birr) 619.2 Total (Birr) 533.925
% of total cost
% of total cost
Canister 27.5
Canister 15.9
Heat Shield 48.5
Heat Shield 56.2
Body and flame spreader 24.0
Body and flame spreader 27.8
100.00
100.00
Material and Production cost elements are considered as total stove manufacturing cost.
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Table 20 : Summarized Stove Total Cost, raw material and production costs
TOTAL STOVE LOCAL MANUFACTURING COST
Double Burner Single Burner
Stainless Steel Cost Element Birr Birr
Raw Material 3226.77 1774.7
Production Canister 170.5 85.25 Heat Shield 298.2 298.2 Body and Spreader 148.7 148.7
TOTAL 3,844.17 2,306.9 Mild Steel Stove
Cost Element Birr Birr Raw Material
548.1 301.5
Production Canister 170.5 85.3 Heat Shield 298.2 298.2 Body and Spreader 148.7 148.7
TOTAL 1,165.50 833.6 Import cost Price quotation for Alcohol Stove is based on Dometic Clean Cook Stove. Price is as of October 2014.
STOVE IMPORT COST
Double Burner Single Burner
Stainless Steel 1,933.50 1,289.00 Aluminum body 1,701.00 1,005.42
Comparing import versus local manufacturing, stainless steel stove is considerably expensive if locally manufactured. This is basically due to expensive material cost. On the other hand, local manufacturing using mild steel material is feasible and less expensive compared to imported Aluminum made stoves.
Alcohol stove manufacturing is very much feasible in Ethiopia considering both the availability of equipment, facility and personnel. Local manufacturing of Alcohol stove is better economically compared to current market of importing. This is more observed considering material used is conventional mild steel.
In local manufacturing of Alcohol stoves, quality for some of critical components such as canister may be an issue. But with proper capacity building and training in the method of manufacturing, the problem can be avoided.
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Chapter 11
Recommended Technology Transfer Options
11.1 Technological requirements A preferred strategy is the introduction of a business driven model in which an entrepreneur will lead the production and sales of bioethanol. To start production of bioethanol at different sites in Ethiopia many activities will be realized including the production of raw materials, and its conversion in to bioethanol by a process which includes milling, fermentation, distillation and then filling to stove canisters. The production of ethanol for stoves in Ethiopian requires a system integrating:
1. A team whose mission is to startup the business with motivated and active local entrepreneurs guided by Project Gaia Inc.
2. An online calculator to predict the investment, revenues and impacts. 3. EMDs should be: - complete - as safe as possible - easy to operate - multi feedstock –
multiple output - locally constructed – decentralized – autonomous - low capital investment initially – with certified technology.
4. Prepare 3D designs, modules and manual for safety, training, operation and maintenance. 5. Knowledge on how to produce and process raw materials to bioethanol which will not
compete with local food production. Production will be achieved by applying sustainable agriculture and restoring the natural resources present at the farms.
6. Standard documents: license application, protocols for construction/training and contracts. 7. The management of fund to improve access in financing local entrepreneurs who want to
startup production and sale.
11.2 Risks and challenges
How can it be justified to both the local community and the entrepreneur that the probability of successful production and marketing of bioethanol will be very high? Similar to many projects, several risks and challenges in sparking this revolution in renewable energy production must be faced. For examples the following could be some challenges:
● Local entrepreneur (ethanol producer) may not understand how to use equipment of EMD; also they may complain about farmers and does not understand stove market.
● Lack of capital, raw material and supplies for operation after a difficult and slow start. ● Problems with sales because raw materials for production are not available yearlong, which
results to high losses during storage. ● Shortage of raw materials because farmers prefer to dedicate their time to other activities.
Example not recollecting the harvest residues of mango trees. ● Minister offices that require legal procedure for permits to extract ethanol.
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11.3 Recommendations and technology transfer methods
This section will list recommendations to tackle the above mentioned challenges.
To successfully transfer appropriate technology from other countries to Ethiopia and to transfer technology between regions in Ethiopia it will be fundamental to create an interdisciplinary team. By applying a holistic approach it will be possible to scale-up a national program for the production of bioethanol for stoves using a network of EMDs. Focused on this study, it is important that Gaia Association will partner with several constructors of distillery equipment. It will also be essential to involve experienced ethanol producers.
The authors propose to invest a relative small startup capital and after demonstration of proven experience during e.g. nine months of production and sales, the entrepreneur should receive more financial help and increase sales from 90 (first semester) to 4,000 ethanol stoves (from year 3). To make sure EMDs will be technically effective, it is recommended to go to extraordinary intensive design sessions and trials resulting in a complete production experience. Some elements are:
● Each process (milling, fermentation, pumping, steam generation, distillation) will have an intuitive, simple to use, plastic covered operation sheet.
● Raw materials will be dried by the farmers nearby their houses this to cheapen transport to the distillery, allow storage and a high ethanol concentration during fermentation.
● Develop EMD system able to process all kind of raw materials (roots, fruits) and alternative raw materials, such as residues of fruit processing, using flexible equipment for feedstock.
● Basic tools need to be used for the construction and maintenance of the equipment. ● EMD should be engineered to be mobile: e.g. concrete tiles combined with gravel instead of
concrete floors; and plastic tanks which can be transported pushed into one another. Being mobile increase flexibility which site in the region is the best to produce.
● Need to incorporate measurement and monitoring instruments for parameters such as: acidity, concentration of ethanol, tank levels, pressure, temperature, augers speed to feed mills and ovens.
● Based on production capacity EMDs have flexibly one to four ovens and steam generators. ● Ovens can be fueled with different types and qualities of biomass, e.g. stems of E. tirucalli,
wood, and agricultural harvest residues like pruning wood of mango, rice husks, and stems of cassava.
● Use of distillation columns & reflux includes piping, plates, flanges, fittings and thermometers.
● Use of automatic valve-control systems6 to feed steam generators and condensing of ethanol. ● The concentrator of vinasses is equipment that uses residual heat of ovens for production of
concentrated liquid bio-fertilizer (neutralized vinasses).
6 Temperature actuated modulating water valves regulate the flow of water to maintain a desired temperature; these valves open slowly on a temperature increase at the bulb.
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Chapter 12
Capacity Building Needs for Local Manufacturers
During the visits to the metal workshops in Ethiopia it was observed that there are gaps from standards expected in the manufacturing sector. As a result the following list of recommendations should be implemented by the Ethiopian industries. Based on priority and current technological capacity of the country, a time frame for improvement implementation is also presented.
12.1 Capabilities to be addressed in the short term
1. Lack of technical capacity to design, adjust and construct equipment related to ethanol production.
2. Most workshops need to improve safety concerns at shop floors: it is observed that there are no floor markings of machining territory, and the use of personal protective equipment is limited.
3. Arrangement of facilities with proper plant layout should be improved so that efficient man and material movement can be experienced.
4. Raw materials inventory and product warehouses should be updated using technology. This can be implemented with the recruitment of appropriate personnel and use of inventory management tools, which is not observed in most of the workshops studied.
5. Use of proper jigs and fixtures, and tolerance technology should be practiced by workshop technicians in order to meet quality and accuracy demand of EMDs and ethanol cookstoves products. This is not observed in most of the industries studied; but can be improved with specialized trainings, and procurement of equipment.
6. Quality of welding for stainless steel products (applying MIG and/or TIG) requires improvement which can be achieved with proper short term, but frequent welders training. Quality control and inspection departments need to be established too in most of the visited Ethiopian industries.
7. Metal workshops should be aware that the use of web based communication such as email, cloud storage of data and 3D drawings are very useful to interact with clients. Thus awareness of the technology and implementing by building capacity in communication should be addressed for use such as: responding on requests for quotes, sharing designs and monitoring of progress of fabrication activities.
Implementation of recommendations can be a responsibility of the interdisciplinary team which is going to implement the national program. Learning by doing is essential in this process e.g. construction of several EMDs and intensive guidance by experienced constructors; proper short term training on Information and Communication Technology and other software applications; and use of company level small packages of Enterprise Resource Planning software.
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12.2 Capacity-capability that need to be addressed in medium and long term
12.2.1 Capacity building issues
Capacity building programs crafted based on weakness analysis of local manufacturers should address the following issues:
● Utilization of existing manufacturing capacity and expansion. ● Increasing productivity, by behavior and/or culture based approaches. ● Skill and knowledge gap filling in manufacturing processes. ● Creating effective organization structure and retention of professional employees such as for
stainless steel welders, and process industry technicians.
12.2.2 Strategic objectives For each critical issue identified, strategic objectives were developed. The strategic objectives are presented as follows.
Critical issue 1 - Utilization of existing manufacturing capacity and expansion ● Utilization of idle facilities on national wide drafted products such as EMDs and ethanol
Cookstoves. Critical issue 2 – Increase productivity
● Improvement of layout and shop floor transportation. ● Re-organization of production planning and control and improvement of process planning. ● Internalization of QMS and Kaizen7. ● Implementation of activity based costing.
Critical issue 3 – Skill and knowledge gap filling
● Conducting short term trainings in house and abroad in the area of manufacturing, and process plant design.
● Technology transfer through employing foreign professionals for short term trainings and establishing partnership with foreign companies.
Critical issue 4 – Creating Effective Organization Structure and Retention of Employees
● Creating effective organization structure
7 A business philosophy or system that is based on making positive changes on a regular basis, as to improve productivity
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Chapter 13
Policy Analysis on Manufacturing EMD and Ethanol CS in Ethiopia 13.1 General policies in Ethiopia on projects requiring EIA & labor regulation
Section III, Sectoral Environmental Policies of ‘Environmental Policies of Ethiopia’ under 3.5 states government policies are on: promoting energy renewability, ensuring sustainability, support organizations with large wood fuel have their own plantation, review community energy need & reforms, and locate, develop, adopt or adapt energy sources & technologies to replace biomass fuels.
The Government policy also promotes and explicitly states the need for institutional harmonization, legislative frame works, and controlling methods under section V ‘Policy Implementation’. It is required to have environmental permits for any discharge into water bodies, for collection and disposal of solid or hazardous waste, for operating businesses that cause air or water pollution, and for starting a project or business that has environmental impacts and requires an Environmental Impact Assessment (EIA). Permitting serves the function of registration as well as control, and provides the government with a record of potential threats to the environment and a starting point for inspections. The Ministry of Water Irrigation and Energy [MoWIE] has legal authority to issue permits for the discharge of waste into water resources but does not issue any such permits in practice. Instead, the Federal Investment Commission, the Ministry of Trade and Industry, and regional government bureaus exercise permitting power over business activities and, through this permitting power, effectively decide whether or not to apply environmental criteria.
This study recommends further reference of the document by the Minister office for detail information on Environmental Policies, or can refer the web (Anonymous 2014k).
The Ethiopian Ministry of Labor and Social Affairs [EMLSA] also regulates occupational health and safety for companies. Harmonization of Occupational Health Policy is in beginning. According to Article 42/2 of the constitution of 1995 workers has right for healthy and safe work environment. Detail information on such requirements from proclamation no. 4/1995 by the Minister Office.
Entity which is going to involve contractors for the construction of EMDs need to take in account the standard conditions binding on all contractors engaged. Ethiopian Ministry of Works and Urban Development [EMWUD] has a guideline on general contract terms and conditions which are applicable to all contractors. The standard conditions govern matters like the responsibility of the contractor, responsibilities and duties of the consultant/engineer and detailed procedures for effective performance of the contract according to the technical specifications. It also provides general rules regarding materials, workmanship, general time provisions for commencement of work and delays, modification of contract, time and mode of payment for work done by the contractor etc.
13.2 MoWIE and MEF in the area of CS
The Federal Democratic Republic Ethiopia Ministry of Water and Energy has established a directorate office, Alternative Energy Technologies Promotion and Dissemination Directorate (MoWIE-AETPDD). Among the duties of the office are development, promotion and dissemination of CCS in which the National Cook Stove Program started back in 1980 (Anonymous 2014l).
49
The office has disseminated about seven million household cook stoves, and planed to distribute nine million by 2015 and thirty million by 2030. The plan of working with increased involvement of private sectors in production of cook stoves, and its initiation to promote supply & demand of the market is considered as positive policy by the Minister office in motivating local private sectors. Also MoEPF has national interest towards the development of CS in Ethiopia.
13.3 Tax incentives by Ethiopian government on machinery & raw materials manufacturing/ importing for developmental projects
The manufacturing sector is one of the eligible areas where the Ethiopian government gives incentives of various types. The incentive applies to both foreign and local investors in a scheme of ‘Fiscal’ and ‘Non Fiscal’. The following is a summary of these tax exceptions and reductions. Fiscal
A. Customs duties exemption To encourage private investment and promote the inflow of foreign capital and technology in Ethiopia, the following incentives are provided for both domestic and foreign investors engaged in eligible new enterprises or expansion projects.
→ 100% exemption from payments of customs duties and other taxes levied on imported is given to all granted capital goods, such as plants, machinery, & equipment, and construction materials
→ Spare parts worth of 15% of the total value of imported investment capital goods → An investor granted of customs duty exemption will be allowed to import capital goods duty
free any time during the operational phase of his enterprise → Investment capital goods imported without the payment of custom duties and other taxes levied
on imports may be transferred to another investor enjoying similar privileges.
B. Income tax exemption
If an investor engaged in new manufacturing, agro processing, production of agricultural products: → Exporters 50 % his products or services ,or supplies 75% of his products or services as
production or services input to an exporter will be exempted from income tax for 5 years → Exports less than 50% of his products or services of his products or supplies only to the
domestic market will be exempted from income tax for 2 years → Investors who invest in priority areas such as textile and garments leather products agro
processing etc to produce mainly export products will be provided land for their investment necessary at reduced lease rate
Non- Fiscal → Investors who invest to produce export products will be allowed to import machinery and
equipment necessary for their investment projects through their supplier’s credit → Investors who invest in areas of agriculture manufacturing and agro industry will be eligible to
obtain loan up to 70 % of their investment capital from development bank of Ethiopia. If threat investment is feasible
→ Government will cover 30% of the cost of infrastructure (access to road, water supply, electricity, % telephone lines) for investors investing in the industrial zone development
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Loss carry forward
Business enterprise the suffer losses during the income tax exemption period can carry forward such losses following the expiry of the exemption period
Export Incentives
The Fiscal incentives given to all exporters will be the following:
→ Duty draw back Scheme: it offers investors an exemption from the payment of customs duties and other taxes levied on imported and locally purchased raw materials used in the production of export goods. Duties and other taxes paid are drawn 100 % at the time of the export of finished goods
→ Voucher scheme: A voucher is a printed document having monetary value which is used in lieu of duties and taxes paid on imported raw material. The beneficiaries of vouchers scheme are also exporters
→ Exporters are allowed to retain and deposit in a bank account up to 20 % of their foreign exchange export earnings for future use in their operation of their enterprises and no export price control is imposed by the National bank of Ethiopia
Franco valuta import of raw materials is allowed for enterprises engaged in export processing.
13.4 Ethiopian government support & action to enterprises and individuals working on CS
The study has considered only one alcohol stoves, since it is the only existing local private owned fabrication facility. According to interview and discussion with the project owner it has been observed the following are the current facts on government support and affirmative action.
- Tax exemption is experienced only for machine tools (applicable for all sectors in time of establishment), but raw material which is consumable brought including taxation.
- Like other Micro financed manufacturing enterprises, the government of Ethiopia supports in delivering land for establishment of workshop and sales center.
- Government facilitates the availability of ethanol from sugar industries for stove manufacturer, through the tariff set by water and energy Minister.
- Sale price of ethanol by government do not have a special consideration for alcohol stove manufacturers, rather the same tariff is set for all sectors.
- All in all, it can be stated that there is no specific support or any other action for those who are working in the production of cook stoves, and they are only supported in the same way as other manufacturing sectors.
13.5 Project area and land availability for EMD and Stove projects in Ethiopia
Micro enterprises are motivated largely in recent years here in Ethiopia. Municipalities at different regions of the country facilitate processes investment license, and land lease. The availability of land for industries set up is encouraging considering industry village establishments around Addis Ababa and other regions of the country. Agricultural lands tough are difficult to get comparatively since the sector is predominant and around 80% of population is dependent on the sector.
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13.6 Expected challenges and bottlenecks towards working EMD and CS in Ethiopia
Implementation of both EMD and CS manufacturing in Ethiopia may have a challenge in the following areas of concern based on the current situations in the country, and market trends.
- All round professionals availability for manufacturing, erecting and training on both EMD and CS may be a challenge which could determine efficacy of the project
- Row material availability both in quality and cheap price is a challenge towards customizing both EMD and CS; especially considering their continuous demand.
Both quality and accuracy issues in manufacturing processes of EMD and CS. The current trend, specifically in small scale manufacturing facilities in Ethiopia lacks these cultures and may hamper the effectiveness of the project.
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REFERENCES 1. Anonymous.2007a. Definition of micro, small and medium-sized
enterprises.http://europa.eu/legislation_summaries/enterprise/business_environment/n26026_en.htm
2. Anonymous. 2007b. Energy and Transport Branch Division for Sustainable Development United
Nations Department of Economic and Social Affairs. 2007. Small-Scale Production and Use of
Liquid Biofuels in Sub-Saharan Africa: Perspectives for Sustainable Development. Background paper
no. 2.DESA/DSD/2007/2.
3. Anonymous. 2009. Ironware piece unearthed from Turkey found to be oldest steel. The Hindu
(Chennai, India).2009-03-26.
4. Anonymous.2014a. http://www.alibaba.com.
5. Anonymous.2014b. www.cleancookstoves.org
6. Anonymous.2014c.
http://www.cleancookstoves.org/our-work/the-solutions/cookstove-technology.html
7. Anonymous.2014d. White Box Alcohol Stoves.http://whiteboxalcoholstoves.com/.
8. Anonymous.2014e.http://www.hedon.info/TheSuperBluStove.
9. Anonymous.2014f.http://nariphaltan.org/research/renewable-energy/lanstove/.
10. Anonymous.2014g.http://www.projectgaia.com/.
11. Anonymous.2014h. http://sites.duke.edu
12. Anonymous 2014i
https://www.dometic.com/enza/Africa/South-Africa/Products/CleanCook-Alcohol-Stoves/Alcohol-
Fueled-Stoves/
13. Anonymous 2014j. http://www.dakshabiopower.com/products/gel-stove
14. Anonymous.2014k.Environmental Policy of Ethiopia.29 p.
http://www.mfa.gov.et/docs/ENVIRONMENT%20POLICY%20OF%20ETHIOPIA.pdf.
15. Anonymous.2014l. Ministry of Water and Energy. http://www.mowr.gov.et/.
16. Blume, D. 2007. Alcohol can be a gas! Fueling an Ethanol Revolution for the 21st Century.
17. Bromberg, J. 1991. The Laser in America, 1950-1970.MIT Press.p. 202.
18. España-Gamboa, E., J. O. Mijangos-Cortés, G. Hernández-Zárate, J. A. Domínguez Maldonado, and
L. M. Alzate-Gaviria. 2012. Methane production by treating vinasses from hydrous ethanol using a
modified UASB reactor. Biotechnology for Biofuels 2012, 5:82.
19. Fiona Zuzarte, Ethanol for Cooking: Feasibility of small-scale ethanol supply and its demand as a
cooking fuel – Tanzania Case Study
20. Goldman, S.L. and C. Kole. 2014. Compendium of Bioenergy Plants: Corn. 398 p.
21. Lammers, D. 2007.Gasification may be key to U.S. Ethanol. CBS News.
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22. Lantero, O. J., M. Li, J. K. Shetty. 2006. Process for conversion of granular starch to ethanol. Patent.
Publication number US 20070281344 A1.
23. Nagy E., Boldyryev S., 2013, Energy demand of biofuel production applying distillation and/or
pervaporation, Chemical Engineering Transactions, 35, 265-270 DOI:10.3303/CET1335044. Askin.
2012. Nigerian Government Agency Launches Micro distillery and Stoves to Provide Sustainable
Ethanol Fuel for Household Cooking, Lighting and Small-Scale Power Generation.
24. Ortega, E., Wanatabe, M., Cavalett, O. 2007. Production of ethanol in micro and mini distilleries.
Laboratorio de Engenharia Ecologica, internal publication, UNICAMP, Campinas, Brasil.
25. Pernick, R. and C. Wilder. 2007. The Clean Tech Revolution p. 96.
26. Rajvanshi, A.K., S. M. Patil and B. Mendoca. 2004. Development of Stove running on low
ethanol concentration. Nimbkar Agricultural Research Institute (NARI),Phaltan-415523,
Maharashtra, India.
27. Royal Dutch Shell PLC. 2012. Sustainability Report.
28. Sanders J., E. Scott, H. Mooibroek. 2005. Biorefinery, the bridge between Agriculture and
Chemistry. Proceedings of the 14th European Biomass Conference and Exhibition, Paris,
France, pp 17–21 (October).
29. Toasa, J. 2009. Colombia: A New Ethanol Producer on the Rise? United States Department of
Agriculture. A Report from the Economic Research Service. 19 p.
30. Wang, Y. and Tai-Shung Chung. 2012. Membranes for Biofuel Separation. Asian Pacific Biotech
News. May 2012 Vol. 16. No. 5. p. 34-39.
31. Zuzarte, F. 2005. Ethanol for Cooking: Feasibility of small-scal ethanol supply and its demand as a
cooking fuel: Tanzania Case study. Master of Science Thesis. Stockholm, Sweden.
2007:700/EKV. KTH School of Energy and Environmental Technology. Heat and Power
Technology.
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APPENDIX Annex 1: Instruments required by operators for EMD.
Process Instrument Unit Dry matter content of raw material containing starch
Portable hook scale, tripod and metal canisters
% dry matter
Sugar content of raw material Refract meter Brix Adjustment of the acidity of the prepared suspension of raw materials
pH-strips and test or measure cylinders (polypropylene)
pH
Adding chlorine, nutrients, acid, enzymes (optional) and yeast to the suspension of raw material
Digital scales and measure cylinders (polypropylene)
Kg and L
Minimum and maximum temperature during fermentation
Digital thermometers with sensor alarms
Degrees Celsius
Monitoring equipment of the concentration of ethanol in the wine and stillage
Distillation equipment (stainless steel) with the capacity to obtain bioethanol using small samples. Includes measure cylinders and alcohol meters.
Maximum temperature during preheating of the wine
Digital thermometers with alarms Degrees Celsius
Combustion efficiency during steam generation (boilers)
Electronic combustion analyzer Flue temperature, oxygen and carbon dioxide
Minimum and maximum temperature of glycol and wine during steam generation of ethanol
Centralized digital system alarm included) using sensors
Degrees Celsius
Max. pressure during steam generation Pressure gauges PSI Minimum and maximum temperature rectifying ethanol
Centralized digital system alarm included) using sensors
Degrees Celsius
Minimum and maximum temperature of cooling water for condensers
Centralized digital system alarm included) using sensors
Degrees Celsius
Minimum and maximum temperature of ethanol
Centralized digital system alarm included) using sensors
Degrees Celsius
Concentration of ethanol Alcohol meter and test cylinders measuring specific gravity. Optional a digital densimeter can be used.
% (v/v)
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Annex 2: Specification for steam generator/ boiler to distillation. Option 1: Steam generation of ethanol (not water). Dosification of preheated wine to the wine column(s) controlled by automatic temperature actuated modulating valves). Specifications: - The feeding of biomass chips (0.5 MT/day; 0.35 kg/minute to produce 1,000 L/ day) to the oven is
automatic using a system which includes a storage container for the chips (the hopper), an iron screw conveyor driven by an electric motor which velocity is controlled by a thermostat.
- According to capacity a production facility can consist of one to four oven(s)/steam generator(s). - The oven(s) has (a) grill(s) where combustion takes place using the heat of biomass to produce
steam in the generator(s), partially heating the wine and ethylene glycol in the bath(s) (indirect combustion heating).
- The steam generator(s) receive 5.0 L of wine per minute and produce a mixture of about 30%-47% ethanol and 60-53% water (v/v), which contains 8%-16% ethanol using e.g. sugar cane (8%) or sweet potato (16%). The steam generator(s) realize the same function as the traditional first (beer) distillation column. Each generator is a closed vessel madeof stainless steel and each bath contains approximately 20 L of glycol (150° C or 302° F). The glycol is recirculated by 0.75 hp pumps in a closed copper tube heat exchange system inside each boiler. The steam generator(s) operate at a low ambient pressure as compared with boilers normally used in traditional industries. These types of boilers are more economic to build, are safer (low -atmospheric- pressure), require less maintenance and are the main reason why this type of EMDs can process different types of raw material.
- The steam generator(s) has a steam trap, drainage and concentrating of vinasses by water evaporator(s) using the hot gases which leave the chimney(s).
- One to four chimneys with a height of 6 m and a diameter of 10" (25.4 cm). Each two steam generators require one chimney.
- Interconnecting piping, valves, fittings, fast couplings, thermal insulation, digital temperature displays of thermal oil and vapor, pressure gauge(s).
- Vapor line which directs the ethanol vapor from the steam generator to the column. Includes tubing, fast couplings and thermal insulation.
Option 2: High pressure water steam generation applying a mixed tubular, biomass fired boiler: - Type: Vertical or horizontal - Steam production (capacity): between 150 and 300 kg/hour - Maximum water pressure in the boiler: between 8 and 10 bar or kgf/cm² - Circulation: Natural - Fuel consumption: 30 kg of wood chips per hour - Electro-pneumatic pressure reducing valve (carbon steel) for supplying steam at constant low
pressure to the beer column this to achieve uniform and continuous ethanol production. - Water treatment; feed water preheater (plate heat exchanger to preheat boiler feed water (stainless
steel type 316); water feed tank; furnace; pressure gauge; pressure release (safety) valves; piping; fittings; valves; multistage pump; automatic water supply; display level; deaerator; chimney; motor control center; electrical cabling; switchgear for all drives with in battery limits; instruments for local display; electronic instruments linked to a PLC system; industrial painting and other accessories.
A condensate recycling system (re-boilers on columns, steam condensate collection tank, condensate pump and associated piping and valves) with the boiler is not necessary because the steam boiler is of a very low capacity and does not justify the additional expenditure for this system.
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Annex 3: List of equipment of a double-column distiller design. Ethanol output per day: 1,000 L hydrated (hydrous), industrial grade alcohol between 92% and 95% (92°-95° G.L., degrees Gay-Lussac, v/v); optional the ethanol can meet ASTM standards. Two continuous distillation designs are available: Option 1: - According its production capacity a facility can produce bioethanol using one or two thermal
insulated rectification columns which receive ethanol vapor from one or two steam generators; these columns have a similar function as beer stripper columns.
- Flash, drainage at the bottom of the rectification column(s) and storage of stillage which is, it is not the same as vinasses which is an output of the steam generator(s). Includes: container, pipe, fittings and thermometer.
- Each column does contain a reflux system (condensers with internal cooling coils). - Includes concrete base, piping, plates, flanges, fittings and thermometers. Includes special
stainless steel laser cut parts and automatic temperature actuated modulating valves. - The higher the ethanol concentration in the wine, the higher the final concentration this because
steam rich in ethanol is produced in the steam generators. Therefore this option will produce bioethanol at a concentration which depends on the type of raw material to use: o Stems of sugar cane, sweet sorghum, juice, molasses, fresh roots, tubers, rhizomes, fruits:
85-90% ethanol (v/v). o Dry roots, tubers or grains; juice and/or molasses (not mixed): 88-92% ethanol (v/v). o Dry roots, tubers, grains or rhizomes mixed with juice and/or molasses: 90-94% ethanol
(v/v). Option 2: For each 1,000 L of ethanol per day, double-column distiller design: - 10,000 L wine holding tank with thermal insulation. - Pre-heater system – circulation heater with safety high limit trip point. - One column “A”, beer stripper column: stainless steel (304) distillation column, polished
externally, measuring 320mm diameter, 5 m height, featuring a set of plates (trays) arranged longitudinally and juxtaposed to its inner walls, and two temperature control units (thermometers) connected to control panel in its external part.
- One column “B”, rectification column: stainless steel (type 304) exhaustion and rectification column – polished externally, measuring 250 mm of diameter and 5 m of height, featuring a set of plates (trays) arranged longitudinally and juxtaposed to its inner walls, and two temperature control units (thermometers) connected to a control panel and three condensers in its external part, equipped with fusel removal.
- Fuel oil separation, filter and sampling port. - One digital control panel used to control the temperature of columns and to operate three pumps
(stainless steel type 304, 0.5 hp per engine, single phase, Viton sealed explosion-proof motors)., - One support base made of stainless steel (304), measuring 2.0 m long& 0.8 m width. - Automated temperature management system utilizing a closed loop cooling method.
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- Table shows all equipment needed to construct a double-column distiller design.
No. Equipment Specifications (all stainless steel type 304)
1. Degassing aldehyde column Column with baffle trays mounted on top of beer stripper column
2. Beer stripper Column with baffle trays
3. Rectification column Composite column with packed beds and trays in fusel and product draw zones
4. Fusel oil decanter With light/sight glasses
5. Beer heater Multi-pass shell and tube heat exchanger
6. Rectification main condenser Multi-pass shell and tube heat exchanger
7. Rectification vent condenser Multi-pass shell and tube heat exchanger
8. Degassing condenser Multi-pass shell and tube heat exchanger
9. Product cooler Multi-pass shell and tube heat exchanger
10. Piping, fitting and valves Interconnecting piping with valves and fittings in carbon or stainless steel
11. Instrumentation Instruments for local display and electronic instruments linked to the PLC system
12. Support skid To hold equipment, piping and cables
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Annex 4: Area (expressed in m2) needed by a bioethanol production facility. Activities (sections) of an 2,400 L of bioethanol per day EMD Width
(m) Length (m)
m2 %
Production of biomass by living fences of e.g. E. tirucalli (Et) and P. tithymaloides (Pt).
5.00 200.00
1,000 21
Entrance and house (simple) of one operator (incl. guardianship). 7.00 13.00 91 2 Parking lot and evacuation area. 9.00 23.00 207 4 Internal roads for emergency, transport of raw material, bioethanol, vinasses and realizing maintenance of equipments.
3.50 136.00
476 10
Simple facility (kiosk style) for eating, office work, meetings, resting, going to the toilet and showering.
5.00 10.00 50 1
Storage of water for emergency, condensers (backup if there is no wine) and preparation of raw material.
5.40 5.60 30 1
Electricity generation. 4.00 5.10 20 0 Generation of compressed air. 4.00 5.10 20 0 Demonstration plots of raw materials. 3.00 60.00 180 4 Storage of safety equipment, supplies, tool and spare parts. 5.40 5.60 30 1 Reception and storage of raw material(s) and biomass for boilers. 6.50 23.45 152 3 Monitoring (e.g. quality control) of processes. 2.00 4.00 8 0 Reception of raw material for milling. 4.90 6.00 29 1 Preparation of raw material (milling and mixing). 3.00 6.00 18 0 Yeast multiplication. 2.50 3.50 9 0 Hot hydrolysis (optional because Stargen enzymes will be used.) 3.70 3.70 14 0 Fermentation of raw material. 20.50 22.00 451 10 Filters, sediment traps and preheating of wine. 4.90 18.50 91 2 Filtration of wine, sedimentation, handling and storage of cake. 4.90 3.00 15 0 Preheating of the wine. 4.90 3.00 15 0 Drying of biomass chips and filter cake from wine. 12.00 12.00 144 3 Dosification of wine; steam generation (1st phase of distillation); drainage and concentrating of vinasses; chimneys.
3.60 8.70 31 1
Rectification (2nd phase of distillation); drainage of stillage; condensation and reception of bioethanol.
4.20 5.00 21 0
Cooling of vinasses (1st phase of distillation, steam generators) and stillage (2nd phase of distillation, rectification).
16.77 16.77 281 6
Filling bioethanol in vessels of 200 L and storage. 11.30 11.30 128 3 Filling bioethanol in stove canisters and storage. 3.60 8.70 31 1 Storage of stillage and concentrated vinasses. 6.00 6.00 36 1 Manufacture, packaging and storage of co-products. 4.00 6.00 24 1 Extra space (reserve). 34.19 34.19 1,169 25 TOTAL 4,732 100
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Annex 5: EMD, CCS components: technological and industrial manufacturing capacity in Ethiopia study format: Questionnaire, results of visited workshops and suppliers Investigator names: John Loke and Endalkachew Mekonnen Sample size: two providers per material or workshop activity. Content:
1. Juice extraction system for sugar cane and sweet sorghum 2. Biomass chipper 3. Identification of metal workshops and providers of materials 4. Metal workshops to construct bioethanol production facilities and cooking stoves 5. Metal workshops offering services to construct bioethanol production facilities 6. Metal workshops which offer services to construct bioethanol cooking stoves 7. Suppliers which can provide materials to construct bioethanol production facilities 8. Suppliers which can provide materials to construct bioethanol cooking stoves 9. Professionals
4.1 Juice extraction system for sugar cane and sweet sorghum ● Details of milling system to potential providers and request quotes. ● Details of sugar cane diffuser system to request quotes .
Provider USD Quote (link of scanned document; quote)
Milling system Tinytech Udyog, India 149,645 Quote.
Diffuser system Orlando González, Colombia
195,000 Quote
4.2 Biomass chipper ● Please facilitate these details of the chipper to the potential providers and request quotes.
Provider USD Quote (link of scanned document; quote)
Biomass chipper Amio Engineering PLC, Addis Ababa
5,200 Quote
ETAGRO & Cía S.C.S., Colombia
4,456 Quote
4.3 Identification of metal workshops and providers of materials (apply to the next sections)
● Addis Ababa and towns nearby the ethanol production facilities. ● Yellow pages (telephone directory, this localize providers). ● Universities and institutes related to technology. ● The sample size will be two providers of materials and two metal workshops to realize
activities related to metal and assemblage of equipment. Each metal workshop and material provider will be requested the following information:
● Contact information ● Quotes ● Photos of materials and/or workshop activities (optional) ● Catalogues of materials (optional)
4.4 Metal workshops to construct bioethanol production facilities and cooking stoves
60
Addis Ababa Name and contact information of metal workshop 1: Amio Engineering PLC Name and contact information of metal workshop 2: VONALL COM PLC Target region 1 Name and contact information of metal workshop 1: __________________________ Name and contact information of metal workshop 2: __________________________ 4.5 Metal workshops offering services to construct bioethanol production facilities Please indicate which metal workshops perform:
1. Cutting of metal laminates, angles, bars and pipes/tubes by hand 2. Cutting of metal laminates, angles, bars and pipes/tubes using plasma 3. Cutting of metal laminates using laser on a table Quote cutting these flanges using laser cutter:
Provider USD Quote (link of scanned document; quote)
72 Flanges Amio Engineering PLC, Addis Ababa (no. 1)
16,058 (223 USD/flange)
Quote
Imporinox, Colombia (no. 2) 72 flanges at 1,253 USD (17 USD/flange)
Quote
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4. Rolling of laminates (width minimum 100 cm) using a plate roller machine 5. Bending of laminates (width minimum 100 cm) using a bending machine
● Please quote the construction of two chimneys:
62
Provider USD Quote (link of scanned
document; quote)
2 Chimneys Amio Engineering PLC, A.A 1,156 Quote
● Please facilitate these details of the boiler (the section made of iron) to the potential providers and request quotes.
Provider USD Quote (link of scanned document; quote)
Boiler (iron section) Amio Engineering PLC, A.A 1,146 Quote
6. Welding of iron laminates, pipes/tubes and profiles using ordinary welding equipment ● Nearby the bioethanol production facilities of the target regions: Two welders and
their assistants working three weeks at the bioethanol production site. 7. Welding of stainless steel laminates, pipes/tubes and profiles using MIG or TIG applying
argon gas ● In Addis Ababa:
○ Welding (using argon gas) of 1 meter of stainless steel sheet; type 304. ○ An example of welding to be done: flanches (thickness 1/4", 6.4 mm; inner
diameter of 198 mm) to tubes (gauche no. 14, 1.9 mm), both of stainless steel.
63
8. Perforation (drilling) of laminates and pipes/tubes ● Please quote the construction of this structure made in stainless steel:
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Provider USD Quote (link of scanned document; quote)
Canoe of stainless steel Amio Engineering PLC, Addis Ababa
1,449 Quote
4.6 Metal workshops which offer services to construct bioethanol cooking stoves Please indicate which metal workshops perform:
1. Cutting of metal laminates by shear cutting (hydraulic or mechanical) 2. Cutting of metal laminates by laser or plasma 3. Deep drawing (cup drawing) of stainless steel sheet using a dye (press tool for the canisters) 4. Blanking of metal laminates 5. Bending using a plate roller machine 6. Perforation (drilling) of laminates 7. Spot welding 8. Riveting of metal sheet for joining ● Please request quotes from the canister according these instructions.
Provider USD Quote (link of scanned document; quote)
Canister … (no. 1) ... …
... (no. 2) ... …
For results see the section about Ethanol Cook Stoves. 4.7 Suppliers which can provide materials to construct bioethanol production facilities Please indicate (presence or absence) the suppliers:
1. Safety equipment: industrial safety warnings, helmets, gloves, glasses, extinguishers Industrial safety
warnings Helmets Gloves Glasses Extinguishers
Tiru Business PLC Available Available Available Available Available
2. Electricity generators suitable to use biogas as a fuel: Presence or absence
Senergam Soluções Energéticas e Ambientais, Brazil 15,418 USD (2 units)
3. Sheets of corrugated zinc roofing Presence or absence
Kaliti Metal Products factory Available
Ethio-steel PLC Available
4. Helical-helicoidal-spirals- worm-screw transporters, similar to:
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● Please facilitate these details of augers to potential providers and request quotes. USD Quote (link of scanned
document; quote)
Amio Engineering PLC, Addis Ababa 2,783 Quote
5. Hammer mills, similar to:
● facilitate these details of hammer mill to potential providers and request quotes:
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USD Quote (link of scanned document; quote)
Amio Engineering PLC, Addis Ababa 7,364 Quote
6. Electric motors Presence or absence
Hagbes PVT, LTD. CO Available
Haji Tourie and his Sons PLC Available
Sansem Business PLC Available
7. Iron angles, structural metal profiles and other materials
● Request to quote iron materials. Quote (link of scanned document; quote)
Vonall Com PLC Available
Hast Enterprize Available
8. Vessels (tanks; containers; vessels;) ● Request to quote plastic containers.
16 Plastic containers of
10,000 L (USD)
5 Plastic containers of approx. 4,000 L
(USD)
Quote (link of scanned
document; quote)
Roto PLC, Addis Ababa; shop 1 20,000 2,854 Quote
Roto PLC, Addis Ababa; shop 2 19,990 2,852. Quote
9. PVC flanges
48 Flanges Quote (link of scanned document;
quote)
Fanela International PLC, Addis Ababa 1,338 USD Quote
10. Sheet (laminate) of stainless steel; type 304; thickness 1.9 mm (gauche no. 14; 0.075").
USD Quote (link of scanned document;
67
quote)
Vonall Com PLC 378 Quote
Hast Enterprize 439 Quote
11. Sheet (laminate) of stainless steel; type 304; thickness 1.5 mm (gauche no. 16; 0.060")
USD Quote (link of scanned document; quote)
Vonall Com PLC 256 Quote
Hast Enterprize 351 Quote
12. Sheet (laminate) of cold-rolled steel/iron (CR), thickness 1/8" (approx. 3.2 mm; between
gauche no. 10 and 11) Quote (link of scanned document; quote)
Vonall Com PLC Available
Hast Enterprize Available
13. Tubing (tubes, pipes, piping) of stainless steel, copper and PVC
● Please facilitate these details of the stainless tubing to the potential providers and request quotes.
4 Tubes of stainless steel of 3/8" (USD)
24 Tubes of stainless steel of 1/2" (USD)
22 Tubes of stainless steel of 3/4" (USD)
10 Tubes of stainless steel of 2" (USD)
1 Tube of stainless steel of 3" (USD)
Quote (link of scanned document; quote)
… (provider 1) ... ... ... ... ... ...
● Details of copper tubing and accessories to the potential providers and request quotes.
47 Rolls of 3/8" (10 mm) (USD)
9 Bags of couplings, elbows and adapters of 3/8" (10 mm) (USD)
1 Roll of tubing of 1/2" (13 mm) (USD)
3 Tubes of 1/2" (13 mm) (USD)
5 Bags of couplings, elbows and adapters of 1/2" (13 mm) (USD)
Quote (link of scanned document; quote)
… (provider 1) ... ... ... ...
14. Hose Pe-al-pe or pealpex
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Presence or absence
… (provider 1) ...
15. Metal and PVC pipe/tube accessories (like elbows, tees) Presence or absence
… (provider 1) ...
16. Mineral rock wool for thermal insulation of pipes/tubes (tube shaped)
Presence or absence
… (provider 1) ...
17. Mineral rock wool for thermal insulation of laminate
Presence or absence
… (provider 1) ...
18. Stainless steel valves
● Detail to request quotes of valves to potential providers.
12 Ball valves of stainless steel 1.5" NPT (38 mm) (USD)
20 Ball valves of stainless steel 1" NPT (25 mm) (USD)
36 Ball valves of stainless steel 1/2" NPT (13 mm) (USD)
31 Ball valves of stainless steel 2" NPT (51 mm) (USD)
7 Ball valves of PVC 1", no NPT (25 mm) (USD)
2 Ball valves of PVC 2 ", no NPT (51 mm) (USD)
Quote (link of scanned document; quote)
… (provider 1) ... ... ... ... ... ... ...
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19. Stainless steel couplings or clamps for pipes/tubes:
20. Electric pumps, similar to:
21. Refractory bricks and cement for high temperature insulation:
Refractory bricks are available at Solomon Wondemagegn PLC in Addis Ababa.
4.8 Suppliers which can provide materials to construct bioethanol cooking stoves
1. Sheet (laminate) of stainless steel; type 304; thickness 1.9 mm (gauche no. 14; 0.075"). 2. Sheet (laminate) of stainless steel; type 304; thickness 1.5 mm (gauche no. 16; 0.060"). 3. Sheet (laminate) of cold-rolled steel/iron (CR), thickness 1/8" (approx. 3,2 mm; between
gauche no. 10 and 11). 4. Compact mineral rock wool. 5. White cover of the mineral rock wool inside the cover. 6. Stainless steel mesh. 7. Canister made from stainless steel.
4.9 Professionals The following professionals are required nearby the bioethanol production facilities of the target regions:
1. Electrician 2. Plumber 3. Construction master (somebody who is a professional in pouring concrete etc.) 4. Experts who manage safety and environmental regulations of Ethiopia
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Laboratory Equipments and Instruments
Lab Equipment / Chemicals List
Lab Equipment / Chemicals Unit Qty unit price [Birr]
Total price [Birr]
1 Measuring Cylinder 250ml 3 48 144.0 2 Measuring Cylinder 500ml 3 68 204.0 3 Beaker 250ml 3 48 144.0 4 Beaker 500ml 3 68 204.0 5 Weighing balance with 0.01 gm Nos 1 14,500 14,500.0 6 Volumetric Flask 250ml 3 65 195.0 7 Volumetric Flask 500ml 3 95 285.0 8 Thermometer 0-120°c [Nos] 3 200 600.0 9 Water Bath pcs. [Nos] 1 5,100 5,100.0
10 Chemical Flask 250ml [Nos] 3 40 120.0 11 Burret Size 0-50ml [Nos] 2 90 180.0 12 Pipette 1ml [Nos] 2 14 28.0 13 Pipette 2ml [Nos] 2 16 32.0 14 Pipette 5ml [Nos] 2 16 32.0 15 Hot Plate pcs. [Nos] 1 4,800 4,800.0 16 Round Bottom Flask 500ml [Nos] 2 46 92.0 17 S.G Hydrometer Of Range 1.000 to 1.100 [Nos] 2 300 600.0 18 S.G Hydrometer Of Range 1.100 to 1.200 [Nos] 2 300 600.0 19 Ph Meter pcs. [Nos] 1 7,800 7,800.0 20 Glass Rod pcs. [Nos] 2 3.4 6.8 21 Glass Condenser pcs. 1 300 300.0 22 Hydrometer For Spirit + Book 2 300 600.0 23 Fehling (A) Solution 500ml [Bottles] 4 180 720.0 24 Fehling (B) Solution 500ml [Bottles] 4 190 760.0 25 Phenaphthaline Indicator 100ml [Bottles] 1 148 148.0 26 Conc. HCL 500ml [Bottles] 1 148 148.0 27 H2SO4 (AR) 500ml [Bottles] 1 148 148.0 28 Sodium Hydroxide (NaOH) 500 gm [Bottles] 1 390 390.0 29 D-Glucose 250 gm [Bottles] 1 220 220.0 30 phosphoric acid 2.5L [Bottles] 1 1,700 1,700.0 31 Potassium Dichromate (K2lr2O7) 500 gm [Bottles] 1 390 390.0 Total 41,190.80
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Annex 6: EMD capital cost form interantional quotation:
Table: Price quotation submitted by six manufacturers 1000 lit/day EMDs processing roots, tubers and moloases
Component and cost USD per company (1,000 LPD)
A B C D E F If Local
Industrial safety 3,000 - 500 2,150 - -
Refer the section at
investment cost for detail
element of cost
Utilities and other 26,000 - 3,000 - 21,600 - Ethanol-powered generator
39,000 8,958 40,000 - - 9,866
Air compressor and pneumatic controllers
5,000 - - - - 41,200
Reception and preparation of feedstock
21,000 46,486 27,600 7,400 18,500 97,550
Fermentation system (includes yeast propagation)
30,600 12,436 53,600 15,300 26,300 33,900
Filtration and/or sedimentation of wine
- 2,750 - 5,800 - -
Preheating of the wine
- - - 4,450 - 52,250
Steam boiler/Steam generation
18,500 21,353 25,000 12,000 26,600 -
Distillation system (includes product storage for 15 days; operation includes pure and impure alcohols)
100,500 94,721 73,000 5,850 66,800 96,827
Fusel oil/aromatic removal
- - - - - 26,700
Condensation bioethanol
5,200 38,506 - 5,250 - -
Manufacture of co-products and services
21,000 4,600 56,000 1,800 - -
Other 11,000 45,161 - 44,010 - 62,864 Subtotal 280,800 274,971 278,700 104,010 159,800 421,157 Commissioning 144,000 66,624 88,000 15,000 0 105,140 Packaging & shipping 38,000 16,397 36,670 0 9,950 17,500 TOTAL [USD] 462,800 357,992 403,370 119,010 169,750 543,797 240,000 TOTAL [BIRR] 9,256,000 7,159,840 8,067,400 2,380,200 3,395,000 10,875,940 4,800,000
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Annex 7: List of organizations Visited and interviewed. The following persons/companies are contacted during the preparation of this study: 1. Akaki Basic Metals Industry (ABMI). Akaki near Customes Station. Addis Ababa 2. Amio Engineering PLC. Goffa Mazoria Road. Addis Ababa 3. Ecoenergy Business Group Ltda. Cra. 45 No. 2a - 13, Barrio Lido, Cali, Valle del Cauca,
Colombia. Tel. 57 312-213 1514. [email protected].
4. Ellis Trading House PLC. Mr. Elias Reshid; Director/CEO/General Manager. Addis Ababa. Tel. 21852-1000. [email protected].
5. ETAGRO & Cía S.C.S. Avenida 6N Calle 49 Norte Esquina Junto a Las Vallas, Santiago de Cali, Valle, Colombia. Tel. (57-2) 665 2415. [email protected].
6. Ethio-steel PLC, Addis Ababa 7. Fanela International PLC. W/ro Mareg. Kasanchise road. Addis Ababa. Tel. 251-115585198 or
251-118493806. 8. Hagbes PVT, LTD. CO, Addis Ababa 9. Haji Tourie and his Sons PLC, Addis Ababa 10. Hast Enterprize. Mifta Mohammed. Merkato- Chid tera. Addis Ababa. Tel. 251-911529188.
[email protected]. 11. Hibret Metal Manufacturing and Machine Building Company. A.A Mexico AAU Road. Addis
Ababa 12. Imporinox S.A. Carrera 3 No. 24-28, Cali, Valle Del Cauca, Colombia. Tel. 57 2 4877000. 13. Kaliti Metal Products Factory, Kaliti , Addis Ababa. http://www.kalitimetal.com.et/ Tel. +251-114-342410 14. Ketema Yilma Sanitary and Pipe Fittings Shop. Kasanchise road. Addis Ababa. Tel. 251-
115155109. 15. Orlando González. Cra. 45 No. 2a - 13, Barrio Lido, Cali, Valle del Cauca, Colombia.
[email protected]. 16. Products Factory, Addis Ababa 17. Riva Trade and Services PLC. Kirkos Kifle Ketema. Kebele 10, House No. 403; Tin No:
0029160775; Addis Ababa, Ethiopia. Tel. 922115295. 18. Roto PLC, Urael Atlas Road, Addis Ababa 19. Roto Satelite. Ato Solomon. W/t Hanna at Uruael Church area. Addis Ababa.
Tel. 251-116186131. [email protected]. www.rotomoulders.com. 20. Sansem Business PLC, Addis Ababa 21. Selam Technical & Vocational Center. Kotebe. Addis Ababa 22. Senergam Soluções Energéticas e Ambientais, Brazil 23. Sintec Ethiopia Electro Mechanical Engineering PLC. CMC to Jacros Road. Addis Ababa 24. Solomom Wondemagegn PLC.. Tel: 251-114346591. Fax 251114340338. P.O.Box 965 AA. 25. Tinytech Udyog. Service Rd, Mahavir Park, Rajkot, Gujarat 360001, India.
[email protected]. 26. Tiru Business PLC, Kasanchise road. Addis Ababa. Tel. 251-111556664. 27. Tiya General Trading PLC. Ketema Yilma. Kasanchise road. Addis Ababa. Tel. 251-115523971. 28. VONALL COM PLC. Mikre Tesfaye. Mexico Near to Coeffee and Tea building. A.A near
Mexico, Bunana Shaie. Addis Ababa. Tel. 251-911131941. [email protected]. 29. Water Fit General Trading. Ato Amanuel Tesfaye. Urael to Bole Medhanialem Road near Atlas
Hotel. Addis Ababa. Tel. 251-116613539. [email protected].
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Annex 8: Machine Tools requires for Alcohol Stove Canister production
Mechanical or hydraulic press machine
Both Mechanical press machine or Hydraulic press machine are feasible for the intended purpose of deep drawing can production. Hydraulic press is recommended for close control.
Machine specification is prepared based on a preliminary consideration; canister is made of stainless steel, with basic dimension of can up to 250mm diameter and 80mm height. Also standard press tools tonnage capacities is kept under consideration
C Type Power (Mechanical) Press Frame: The frame need to be all steel construction, fabricated from Rolled steel plates with suitable cross ribbings. Clutch: The clutches of pin/rolling key-type. The clutch is rigid and well supported. Crank Shaft: Crank shaft made of special alloy steel machined to closed accuracy and fitted in bronze bushes for smooth working, longer life and accuracy. Flywheel: Properly sized flywheel made of high-grade cast iron, Gears: Gears of steel castor fabricated. Table and Ram: Table and Ram made of high-grade heavy-duty cast iron. Lubrication: efficient shot lubrication system for lubricating sliding surfaces & moving parts.
Tonnage 75 100 Crank Shaft Diameter 121 134 Stroke Length 115 127 Stroke Adjustment 13-115 13-127 Bed Size 863×596 914×635 Distance Bed to Ram 483 483 Hole in Ram 45 51 Hole in Bed (Blanking Aperture) 152 178 Fly Wheel Diameter 910 1016 Motor H.P. 7.5 10 Length 1760 1850 Width 1700 1825 Height 2950 3050
Also:
Provide ISO and CE quality certificate with OEM
Voltage: 220 V/ 380V
74
C- Type Four Column Hydraulic Press Capacity 1000 KN (112 ton) Ejection Force (KN) 190 Return Force (KN) 165 Sliding stroke (mm) 500 Max. shut height (mm) 800 Slide speed (mm/sec) Idle 120 Press 7-15 Return 90 Size (mm) FB 1430 AF 3250
Maximum oil pressure should be 30 MPA Hydraulic pressure need to be adjustable Working speed of slider need to be adjustable Non CNC Voltage: 220 V/ 380V, Provide ISO and CE quality certificate with OEM
All standard hydraulic ancillary equipments or part need to be incorporated.
Equipments manufacturer and supplier can be referred such as: http://www.industrialmachinerycorporation.com/
Estimated FOB price range is 200,000 to 300,000 Birr according to web sites survey
1. Circular continuous seam welding
The circular continuous seam welding machine for canister production should have features of:
Welding machine used for non-pressure type cover circle welding. High power modular circuit. The main transformer uses copper winding yarn package. The welding copper wheel uses for CuCrZr Copper Chromium Zirconium. The cylinder pressure, pressure regulation is convenient and precise.
Equipments manufacturer and supplier can be referred such as :
http://www.ewm-sales.co.uk/online-shop/mechanisation/ewm-circumferencial-seam-welding-unit/ewm-circular-seam-welding-unit-type-s.php
http://www.alibaba.com/product-detail/stainless-steel-sink-special-seam-welding_354666165.html
Estimated FOB price range is 150,000 Birr according to web sites survey
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Annex 9: Machine Tools requires for Alcohol Stove Heat shield and Body production Machine tool capacity, specification requirement to heat shield components fabrication: Machine tools are:
1. Portable CNC Laser/ Plasma arc cutter/ oxy acetyl machine 2. Mechanical or hydraulic press machine 3. Hydraulic bending machine 4. Manual Rolling machine 5. Power hacksaw machine 6. Small lathe machine 7. Radial drilling machine 8. Spot welding machine 9. Rivet gun
Portable CNC Laser/ Plasma arc cutter/ oxy acetyl machine Effective cutting width : 1500mm Effective cutting length: 1000mm Maximum travel speed: 2000mm/min Flame cutting thickness: Max 5mm stainless steel
Web based exemplary of the equipment at here: http://www.directindustry.com/prod/vanguard-machinery-international/plasma-cutting-machines-oxyacetylene-cnc-53700-601142.html
Hydraulic bending machine Nominal force: 1000 KN (100 ton) Working length: 2000mm Ram travel distance: 100mm Motor rating: 5 KW (3.73 HP)
Manual rolling machine Rolling thickness capacity: 3mm stainless Rolling length: 1000mm
Power hacksaw machine Cutting capacity steel: 40mm round, and 30mm square Approximate stroke per minute: 70 stroke/min Motor rating 0.5 Horse power Example; Cromwell industrial Tools power hacksaw machine
Small lathe machine Distance center to center: 1000mm Diameter chuck: 200mm Swing over bed: 400mm
Radial drilling machine Minimum drilling capacity: 15mm Work table swivel angle: (+or-450) Dimension of work table surface: 900x750mm
Spot welding machine Rated power capacity: 35 KVA Minimum short circuit current: 16,000 Amp
Screw rivet gun Portable one
