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Table of contents Acknowledgement2 Literature Review3 Problem definition..4 Product Design competition...5 Concept generation7 Evaluation Matrix..15 Conclusion .16 References..17

Acknowledgements I thank our lecture Dr. Ben for the knowledge he imparts on us. I also thank my parents for assisting me with knowledge on how a screw jack.

LITERATURE REVIEW Briquetting is the process of converting low density biomass into high density pieces through compression. When a mass of substance remains the same and volume decreases density increases. Density = mass / volume. Briquettes are easy to transport and to use. When a motor is used power is proportional to torque. Power = torque angular velocity.

DESIGNING A BRIQUETTING MACHINE PROBLEM DEFINITION There are usually frequent black outs in developing countries. This is a great problem most especially in urban areas since many people there cannot use firewood indoors because of smoke produced after burning firewood. In the past people opted for charcoal however with the increased deforestation policies are being made in order to ban charcoal production. Hence it is very important to find an alternative source of energy that can be used as charcoal. This alternative source can be briquettes. Briquetting is the process of converting low density biomass into high density pieces through compression. Therefore since many developing countries generate enormous quantities of agro residues such as rice husk, bagasse, groundnut shells, maize stalk, it is easy to produce briquettes. Also paper is another residue available in large quantity. The direct burning of loose biomass in conventional grates is associated with very low thermal efficiency and widespread air pollution apart from the problems of transportation, storage, and handling, The briquettes can be used for cooking and heating even indoors since briquettes make little amount of smoke. Also briquettes being of high density provide large calories of heat. The main constraints and factors to consider during developing this product include cost, moisture of raw material, source of power, environment and ergonomics. Cost is a major factor and a constraint since if production cost is high then the cost of briquettes will also be high.this may cause people to choose other cheaper sources of energy.

PRODUCT DESIGN SPECIFICATION PERFORMANCE the machine should produce briquettes of acceptable quality it should also be easy to operate it should have a fast speed: producing between 600 and 1000 briquettes per hour the machine should be robust ENVIRONMENT the temperature range is -15C to 60C humidity of 100% The machine should not corrode when in contact with moisture or water. +The machine should have a house to protect it from rain The machine should be designed to resist fatigue arising from vibration

LIFE EXPECTANCY the life expectancy should be between 7 to 11years MAINTENANCE the machine should be maintainable it should have spare parts TARGET PRODUCT COST Between MK70,000 to MK200,000. QUANTITY production of 2000 units per months MANUFACTURE the machine will be manufactured using conventional methods such as welding, casting milling and other conventional machining process

SIZE OF BRIQUETING MACHINE approximately 8m^3 WEIGHT should weigh 100kg and 200kgs MATERIALS materials should be strong also the materials should be corrosion resistant PRODUCT LIFE average of 8 years ERGONOMICS Switching on/off button and other controlling SAFETY The machine should be free from sharp edges The machine should not heat up The noise level should be acceptable, not causing any hearing problems PROCESSES Welding, milling and casting TESTING PROTOTYPE Fatigue test Non destructive test PRODUCTION function and performance

CONCEPT GENERATION There were six concepts developed from a morphological analysis shown in Table 1 below:

Table1: Morphological analysis of briquetting machine PART Power source Power transmission Speed control Stability Compaction tool Ground support Packaging Residue crusher Input holder CONCEPT ONE HUMAN OPERATED VERTICAL COMPACTION BRIQUETTING MACHINE Principle of operation Initially the powder from biomass such as sawdust is poured into the cylinders. As shown in figure 1a, in this concept a person rotates the arm hence causing the screw to move downwardly. This downward movement causes the top plate attached with piston also to move downwardly. Thereafter the pistons squeeze the powder into the cylindrical dies. Due to this compaction, biomass powder particles deform and interlock. Hence there is no need for binders for a briquette to be formed. The compressed powder remains intact and takes the shape of the cylindrical die. This final compacted solid body is called briquette. POSSIBLE CONCEPTS Electric induction motor, human, animal, battery, solar Chains, belts, gears, clutches and propeller Automatic, manual Low centre of gravity, automatic balance Screw, pistons Heavy Flat base, wheel support, light base with bolt slots, Automatic, manual Hummer mill, jaw crusher Cylindrical hopper, rectangular hopper

Figure 1: Human operated vertical compaction briquetting machine

Advantages of this concept 1. It is cheap since it requires few materials 2. It is easy to manufacture since the materials can be made from the traditional methods such as welding, turning and milling. 3. It is safe to use since there are no sharp and high speed rotating parts. 4. It is reliable because it does not require the use of electricity hence it can be used almost in all areas. 5. it is easy to operate since it involves few stages to complete the briquetting task hence it does not require high skilled labor Disadvantages of concept one 1. It is tiresome because it operated manually. 2. It is limited to the strength of the user hence some weak people may not use it.

CONCEPT TWO HUMAN POWERED HOLIZONTAL SCREW BRIQUETTING MACHINE Principle of operation in this concept the machine consists of hopper, threaded metal bar (screw), pedals, chain, handles and base. As shown in figure 2 a person operates this machine just as one operates a bicycle. A person rotates the jockey wheel using the pedals. The power of the person is the transmitted from the jockey wheel to the sprocket attached with a screw. Hence the screw rotates in the same direction as the jockey wheel. The rotation of the screw causes the powder in the hopper to be trapped by the thread. Further rotation causes the powder to be transmitted towards the outlet. Before the powder gets out the outlet it is compacted hence causing the particles to interlock and form one solid body. This solid body is then extruded through the outlet as briquettes.

Figure 2: human powered horizontal screw briquetting machine

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Advantages of concept two 1. It is easier to operate as compared to concept one, hand operated vertical briquetting machine. 2. It is faster as compared to concept one. Disadvantages of concept two 1. More expensive as compared to concept one.

CONCEPT THREE HUMAN POWERED RECIPROCATING BRIQUATING MACHINE In this concept the machine consist of hopper, pistons, cylinders, pedals, chain, handles and base. As shown in figure 3 the biomass powder falls into the holizontal cylinders by virtue of gravity. Thus when a person rotates the jockey wheel the power will be transferred to the crank shaft. The crank shaft causes the pistons to reciprocates hence causing the pistons to compress the powder. It is this compression that causes briquettes to be formed.

Figure 3: Human powered reciprocating briquetting machine

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Advantages of concept three 1. It is easier to operate as compared to concept one, hand operated vertical briquetting machine. 2. It is faster as compared to concept one. Disadvantages of concept three 1. Less efficient because of so many moving parts causing more energy loss.

CONCEPT FOUR MOTORISED SCREW PRESS BRIQUETTING MACHINE As shown in figure 4 in this concept the machine consists of induction motor, heating electric coil, feed (hopper), screw, cylinders, pedals, v-belts, and a stand. The induction causes the pulley attached to the screw to rotate by means of transmission v-belts. Hence the rotating screw takes the material from the feed port, through the barrel hence it compacts the biomass powder against a die which assists the build-up of a pressure gradient along the screw. During this process the biomass is forced into intimate and substantially sliding contact with the barrel walls. This also causes frictional effects due to shearing and working of biomass. The combined effects of the friction caused at the barrel wall, the heat due to internal friction in the material and high rotational speed (~600 rpm) of the screw cause an increase in temperature in the closed system which helps in heating the biomass. Then it is forced through the extrusion die, where the briquette with the required shape is formed. At this stage just before entering the die, the pressure exerted is at maximum. If the die is tapered the biomass gets

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further compacted. Usually the die is heated using heating electric coil for the smooth extrusion of the briquette.1

Figure four: Motorised screw press briquetting machine Advantages of concept four 1. it is very fast as compared to concept one to three because this concept uses electric motor 2. it can be automated using computer Disadvantages of concept four 1. it is not economical when producing afew briquettes

CONCEPT FIVE

BIOMASS BRIQUETTING: TECHNOLOGY AND PRACTICES http://wgbis.ces.iisc.ernet.in/energy/HC270799/RWEDP/acrobat/fd46.pdf

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MOTORISED PISTON PRESS BRIQUETTING MACHINE Principal of operation This concept consist a combination of pistons, cylindrical dies, induction motor, vbelts, feed, and crank mechanism.

As shown from figure 5 the motor operates causes the crank mechanism to rotate hence causing the pistons to reciprocate. The forward movement compresses the biomass hence producing the briquettes. The briquettes are unpacked automatically.

Figure 5: motorized piston press briquetting machine

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Advantages of concept five 1. it is very fast as compared to concept one to three because this concept uses electric motor 2. it can be automated using computer

Disadvantages of concept four 1. it is not economical when producing a few briquettes

CONCEPT SIX HEAVY DUTY COMBINED BRIQUETTING MACHINE in this concept the machine combine hummer mill, shredding mechanism, electric motor, hydraulic mechanism, v-belts and compaction gears. As shown in figure 6 the shredding mechanism tears large particles of agroresidues. The small pieces are transmitted to the hopper of a hummer mill. In the hummer mill the pieces are ground into powder. The powder is fed into another chamber below which contain two compaction gears which make briquettes.

Figure 6: heavy duty combined briquetting machine.

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Advantages of concept six 1. it is very fast as compared to concept one to three because this concept uses electric motor 2. it can be automated using computer 3. it is very sophisticated hence it can convert any biomass into briquettes

Disadvantages of concept six 1. it is not economical when producing a few briquettes

EVALUATION MATRIX
CONCEPTS CRITERIA

COST NUMBEROF PARTS WEIGHT SAFETY AUTOMATI ON STABILITY SPEED

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CONCLUSION From the evaluation matrix the candidate solution to develop is concept four, the motorized screw type.

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REFERENCES
1. BIOMASS BRIQUETTING:TECHNOLOGY AND PRACTICES

http://wgbis.ces.iisc.ernet.in/energy/HC270799/RWEDP/acrobat/fd46.pdf 2. http://www.jjsmith.co.uk/customers/jjsmith/website.nsf/0/fcacd72476bedea0802577c20044a5 80/$FILE/JJ-Smith-Wood-Waste-Briquetting-&-Shredding-Systems.pdf 3. Koppem No. 11.7 HBI-Hot briqueting.http://www.koeppern.com/download/11_7.pdf

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