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PERFORMANCE OF THE MICROGASIFIER USED AS POWER SOURCE FOR RUBBER CREEPING MILL by Alexis T. Belonio and Ted Redelmeier Rubber in the Philippines is mainly produced in Mindanao Island which supplies 99% of the national rubber production. This is especially more so in Zamboanga Peninsula that sets the national production of 41.68 thousand metric tons of rubber annually. Producing rubber blankets from coagulated freshly harvested rubber latex is the main livelihood of the rural folks in the region. For every hectare of rubber plantation, around 20 kgs of fresh rubber latex is collected every day. Processing 20-kg fresh rubber latex which include pressing the coagulated latex from formic acid in a creeping mill and then air drying can produce 6 kgs of rubber blanket (pale creep no. 1 and 2) that is ready formarket. Fresh latex harvested during the day needs to be immediately processed into rubber CNC Technical Bulletin No. 36 Figure 2. The Diesel Engine Operated Creping Mill to Produce Rubber Blanket. Figure 1. The (a) Fresh Rubber Latex, (b) Newly Pressed Rubber Blanket, and (c) Rubber Blanket Being Dried (a) (b) (c)

PERFORMANCE OF THE MICROGASIFIER USED AS POWER …...Gear, Chain & Sprocket, and Belt & pulley Throughput Capacity 86 to 92 kg/hr Water Dripping Rate 5 liters per hour Manpower Requirement

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Page 1: PERFORMANCE OF THE MICROGASIFIER USED AS POWER …...Gear, Chain & Sprocket, and Belt & pulley Throughput Capacity 86 to 92 kg/hr Water Dripping Rate 5 liters per hour Manpower Requirement

PERFORMANCEOFTHEMICROGASIFIERUSEDASPOWERSOURCEFORRUBBERCREEPINGMILLbyAlexisT.BelonioandTedRedelmeier

RubberinthePhilippinesismainlyproducedinMindanaoIslandwhichsupplies99%ofthenationalrubberproduction.ThisisespeciallymoresoinZamboangaPeninsulathatsetsthenationalproductionof41.68thousandmetrictonsofrubberannually.Producingrubberblanketsfromcoagulatedfreshlyharvestedrubberlatexisthemainlivelihoodoftheruralfolks

intheregion.Foreveryhectareofrubberplantation,around20kgsoffreshrubberlatexiscollectedeveryday.Processing20-kgfreshrubberlatexwhichincludepressingthecoagulatedlatexfromformicacidinacreepingmillandthenairdryingcanproduce6kgsofrubberblanket(palecreepno.1and2)thatisreadyformarket.Freshlatexharvestedduringthedayneedstobeimmediatelyprocessedintorubber

CNCTechnicalBulletinNo.36

Figure2.TheDieselEngineOperatedCrepingMilltoProduceRubberBlanket.

Figure1.The(a)FreshRubberLatex,(b)NewlyPressedRubberBlanket,and(c)RubberBlanketBeingDried

(a) (b)

(c)

Page 2: PERFORMANCE OF THE MICROGASIFIER USED AS POWER …...Gear, Chain & Sprocket, and Belt & pulley Throughput Capacity 86 to 92 kg/hr Water Dripping Rate 5 liters per hour Manpower Requirement

blanketstoproducequalitypalecreepno.1&2,whicharehighlysuitablefortheproductionofqualityrubberproducts.Pressingthelatextoformrubberblanketisusuallydoneonasmallrollerpressorcreepingmillthatismadeoftwo15cm-diameterby45cm-longcylindricalmetals.Onerolleroperatesfasterthantheothertocreatepressingandstretchingofmaterialsasitpassesthecreepingmill.Themainrollerrunsataspeedofaround5to10rpmandtheotherrunstwotimesslowerthanthemainroller.Airdryingtherubberblankettakesaround15daysbeforeitissoldtothemarket.Ifafarmerdoesalltheactivitiesfromtappingthelatex,mixingchemicaltocoagulate,pressingthecoagulatedlatexinthecreepingmill,andairdryingtherubberblankets,hecanearnP75.00perkg.Ofthedifferentactivitiesintheproductionofair-driedrubberlatexblanket,themosttediousactivityisthepressingofrubberlatexwhichisdonebypedalingthecreepingmachineorbyusingapetrol-fueledengine.Inordertorelievefarmersfromthetediousmanuallabor,fromhighcostofpetrol,andfromhighcostofelectricityassociatedwiththeproductionofrubberblanket,therecentlydevelopedmicrogasifierthatusesricehuskasfuelwasinstalledatarubberprocessingplantinZamboangadelSurandwasusedtoruntherollerpressforrubber.

MicrogasifierUnit

RubberCreepingMill

GasFueledEngine Rubber

Latex

RubberBlanket

Figure3.TheMicrogasifierCoupledtoRubberCreepingMill.

Page 3: PERFORMANCE OF THE MICROGASIFIER USED AS POWER …...Gear, Chain & Sprocket, and Belt & pulley Throughput Capacity 86 to 92 kg/hr Water Dripping Rate 5 liters per hour Manpower Requirement

AsshowninFigure3above,themicrogasifierconsistsofafuelreactorwheregasisgeneratedthroughgasificationofricehusks,agasconditioningunittoremoveparticulatesandtocoolthegasbeforeitisfedintotheintakemanifoldoftheengine,apowergeneratingunitthatconvertsthegasintomechanicalpowerwhichissubsequentlyusedtodrivethecreepingmill.Figure4showtheschematicoftheoperationofthemicrogasifierasusedtodriverubbercreepingmill.AsshowninTable1,thefuelreactorhasaninnercylinderdiameterof30cmandaheightof120cmandismadeof3mm-thickmildsteelplate.Itisshieldedwithanoutercylinderhavingadiameterof50cmandaheightof180cm.Beneaththeinnercylinderisapocket-typegratethatgraduallydischargesthecharduringoperation.Thegasconditioningunit,ontheotherhand,ismadeofthesamesizeofsteelplatewiththeoutercylinderofthefuelreactor.Insideitisapipewithholesdrilledalongitslengthwith10-cmspacingtospraywatertothestreamofgasasthelatterentersthegasconditioningcylinder.

Reactor Downdraft0.30mDx1.20mH

CharGrate 8semi-circularpocketstype

ConditioningUnit ScrubberandFilterEngine 16hpfourstrokespark

ignitionOperatorRequired

1person

Figure4.SchematicofthePrincipleofOperationoftheMicrogasifier.

Table1.DesignSpecificationoftheMicrogasifier.

PackedBedFilter

WetScrubber

WaterCoolingPond

FuelReactor

GasStorage

InternalCombustion

Engine

SuctionBlower

Pump

ColdWater

HotWater

RiceHuskorOtherBiomass

PressedRubberLatex

RawRubberLatex

Page 4: PERFORMANCE OF THE MICROGASIFIER USED AS POWER …...Gear, Chain & Sprocket, and Belt & pulley Throughput Capacity 86 to 92 kg/hr Water Dripping Rate 5 liters per hour Manpower Requirement

Attheupperportionofthecylinderisaperforatedsheetthatholds40-cmthicklayerofpebbles(with3-to10-mmdiameter),whichserveasfilterforthegas.Waterissprayedintothegaswiththeuseofagearpumpdrivenbythemainshaftofthethepowerunit.Boththefuelreactorandthegasconditioningunitareseatedinarectangularconcretetankfilledwithwatertopreventthegasfromescapingduringoperation.Thewaterinthetankisusedtoquenchburningricehusksfromturningintoashand,atthesametime,tocirculatethewaterforcleaningandcoolingthegas.Thepowergeneratingunitconsistsofa16-Hpspark-ignitionengineretrofittedtouseeithergasolineorgasasfuel.Itsmainshaftisdirectlycoupledintotheenginedrivetotransmitpowertoasuctionblowerthatsucksthegasfromthefuelreactorandfromthegasconditioningunit.Thepowergeneratingunitalsoconsistsofapumpthatcirculateswaterfromtheconcretereservoirtothescrubberandviceversa.Thesteelrollermillusedtopresstherubberlatexiscoupledtotheendoftheshaftwitha3in.-diameterV-pulleyandbeltdrive.Resultsofperformancetestsfor2hoursoperationsshowninTable2,revealthattheunitrequiresastart-uptimeof4to7mininordertoproducethegasfromricehusk(@9–12%MC).Itconsumesricehuskfuelatarateof9.3to10.5kgperhourwithacomputedspecificgasificationrateof132.85-150.00kg/hr-m2.Thereactorconsumes4.3-5.1m3ofair/hrinordertogasifythefuel.Thecomputedsuperficialgasvelocityatthefuelbedofricehuskrangesfrom1.71-2.02cm/sec.Theair-fuelratioatthegasifierreactorrangesfrom0.58-0.61kgairperkgoffuel.TheenginespeedwasmeasuredusingExtechLaser/ContactTachometerModelRPM33attherangeof2437-2531rpm.Thespeedofthesuctionblowerandofthegearpumpusedwasmeasuredusingthesameinstrumentat5147-5356rpmand1043-1218rpm,respectively.Thetemperature,whichwasmeasuredusingTypeKthermocouple-wireandExtechMulti-ChannelDataloggerModelTM500thermometer,atthegasifierreactorfuelbedwasrecordedattherangeof353°to698°Cfromthetimecombustiblegasisgenerated.Thetemperatureofthegasleavingthereactorwasmeasuredrangingfrom51°to165°Cwhilethatofthegas

Feedstock RiceHuskMoistureContent 9-12%Start-UpTime 4-7minFuelConsumptionRate 9.3-10.5kg/hrSpecificGasificationRate 132.85-150.00kg/hr-m2AirFlowRate 4.3-5.1m3/hrSuperficialVelocity 1.71-2.02cm/secAir-FuelRatio 0.58-0.61kgair/kgfuelEngineSpeed 2437-2531rpmBlowerSpeed 5147-5356rpmPumpSpeed 1043-1218rpmTemperature Reactor 353-698°CGasLeavingtheReactor 51-165°CGasEnteringtheEngine 36-41°CWaterBin NoiseLevel 92.4-94.7Db

Table2.PerformanceTestingoftheMicrogasifierUnit.

Page 5: PERFORMANCE OF THE MICROGASIFIER USED AS POWER …...Gear, Chain & Sprocket, and Belt & pulley Throughput Capacity 86 to 92 kg/hr Water Dripping Rate 5 liters per hour Manpower Requirement

enteringtheenginewasmeasuredattherangeof36°to41°C.Thisisbecausethegaswascooledbeforeitenterstheengine.Thetemperatureofwaterenteringandleavingthescrubberranges30°to39°Cand34°to39°C,respectively.Thetemperatureofwaterinthebinwasmeasuredattherangeof27°to30°C.Thenoiseleveloftheenginewasrecordedrangingfrom92.4to94.7dBat1.5meterdistancefromtheengine.Table3showsthedesignspecificationsoftherubbercreepingmillanditsperformanceduringoperation.Bothrollershave15cm-diameterand45cm-length,however,theyhavedifferingspeedinordertocausepressingandstretchingoftherubberlatexsubsequentlyproducingrubberblankets.Thetransmissiondriveofthemachineisacombinationofgearsandbelt&pulley.Duringpressing,waterisallowedtodripontopoftherollerstopreventthelatexfromstickingintotherollersurfaces.Resultsofthetestsshowthatthecreepingmachinecanproducerubberblanketatarateof86to92kgperhour.Onepersonisneededtooperatethemachinebyfeedingitwithrubberlatex.Thegasifierunitperformssatisfactorilywhenusedasdriveorpowersourceforthecreepingmill.Operationofthemachinecanbedonebyonepersonfromstarting-upoftheunittoloadingricehusksanddischargingchar.Startingtheoperationuntilthegasisgeneratedismuchsimplerinthismodel.Thechardisposalmechanismisnottedioustotheoperatorbecauseitonlyneedsswingingtheleverupto45degreesforwardandbackwardtodischargethechardirectlyintothewaterinordertoquenchburningcharandpreventitfromturningintoash.Duringoperation,thebedofricehuskwasobservedtohaveanevendownwardmovementinsidethereactoreverytimecharisdischarged.However,furtherrefinementinthedesignofthegasifierunitneedstobedonetoimproveitsoperationandperformance.Testingofthegasifierunitforotherfarmoperationslikeburrmilling,flutedricemillingarefurtherrecommendedforfutureapplicationsofthetechnology.Fordetailinformation,contact;www.carbonneutralcommons.orgReleased:September26,2017

CreepingMillDimension

15-cmdiameterby45-cmlongsolidmetal

GritShape DiagonalRollerMillSpeed Roller1 7rpmRoller2 4rpm

TransmissionDrive Gear,Chain&Sprocket,andBelt&pulley

ThroughputCapacity 86to92kg/hrWaterDrippingRate 5litersperhourManpowerRequirement

1persontofeedfreshlatex

Table3.DesignSpecificationandPerformanceoftheCreepingMill.