Summary : Technologies for better utilization of Rice Husk as source of Energy in rural areas

are detailed in this report.

Year of Publication : 1993

Table Of Contents :

• Executive Summary
• Introduction
• Research design & methodology
• Present status of technologies for use of rice husk as energy source and technological
development
• India & abroad
• Selected sub-set of technologies and technology assessment
• Techno-Market Survey findings
• Technological options for India
• Preferred Options suggested action plan

Techno-Market survey on Technologies for use of rice husk as source of energy in rural
area

1.1 With the fast depletion of non-renewable sources of energy i.e. coal, oil, etc. the importance
and relevance of biomass which is a renewable resource of energy is increasing day by day.

1.2 Rice husk is a by product of rice milling. It constitutes about 20% of paddy by weight, has a
calorific value of about 3500 k cal /kg., low bulk density of 110 kg/m3, ash content of 16.5% and
high silica content of 15%.

1.3 In India approx. 110 million tonnes of paddy is produced annually, yielding about 20 mt. of
rice husk. If utilized as fuel, this can replace about 10 mt of coal or about 5 mt of oil. Major rice
producing states include West Bengal, Uttar Pradesh, Andhra Pradesh, Bihar and Punjab.

1.4 Techno-Market Survey – Objectives

The techno-market survey report on Technologies for use of Rice Husk as Energy Source in
Rural Areas covers the following:

The relationship and importance of selected subset of technology (gasification, briquetting etc.)
to the broad one to which it belongs (Energy: Rice husk)
Assessment of technologies and options available to India.
Assessment of associated environmental pollution, Socio-economic aspects of technologies.
The economic aspects of technologies their feasibility and preferred options.
Forecast and impact of preferred options, linkages to broad area of technology and spin-off.
Suggested action plan for promotion and greater dissemination of technologies in rural areas and
identification of relevant agencies. Individuals etc.
1.5 Techno-Market Survey – Methodology

i) Desk Research

An initial desk research was done through published sources, government sources (DNES),
organizations (TERI etc.). to gather information on biomass programme of Government of India,
major rice husk generation states and sources (modern mills, hullers, shellers etc), present
utilization of rice husk for energy related applications ( India & Abroad), major
technology/equipment suppliers (India & Abroad), R&D Organizations, Association etc.

ii) Field Survey

A detailed field survey was conducted with the help of pre-tested structured questionnaire;
contacts were included R&D organizations, equipment manufacturers, experts, government
departments, etc.

iii) Mail Survey

Indian organizations who could not be contacted personally and foreign organizations, were
contact through mail survey with the help of structured questionnaires.

iv) Total Contacts

In all about 33 Indian organizations and 21 foreign organizations were contacted.

v) Report Preparation

The information/ data obtained through desk research, field contacts, mail survey was collected,
edited and analyzed. Since thrust is on rural area’s technological options, which were
economically feasible and offered other advantages like ease of maintenance, easy to replicate,
generation of gainful employment, improvement of standards of living in rural areas, were given
preference for determination of preferred options.

1.6 Techno-Market Survey Findings

India

i) For energy related applications, rice husk is being utilized as a fuel for various applications i.e.

* As a fuel in rice mill furnaces, especially in mills producing parboiled rice, energy is utilized
for Steam/Hot water and hot air for dying. Inclined step grate type rice husk furnaces are in use
at majority of installations although high efficiency cyclone/ suspension furnaces are being
designed & developed. This is the largest single source of rice husk consumption for energy.
* As a fuel in boilers for steam generation in rural based industries, generally Lancashir type
boilers are in use, although trend is towards fluidized bed combustion boilers. This constitutes
the second largest application of rice husk for energy.
* As a fuel in rice husk gasifier, for generation of producer gas used for various applications such
as electricity generation, running of diesel pumpsets, furnaces etc. Down draft design of rice
husk gasifier are popular.
* As a fuel in brick kilns, domestic stoves in rural areas.

ii) In India paddy is milled at various levels i.e. hand pounding, small hullers, shellers, modern
rice mills. Modern rice mills account for about 55% of paddy processed.

iii) The husk price varied from Rs. 300 -Rs. 800/t and is high in industrialized states/regions. The
average husk price would be around Rs. 400/t.

iv) Major non-energy applications of rice husk include animal feed, filling of low lying lands,
particle boards/chemical manufacture.

v) Rice mills producing parboiled rice utilize 40-45% of husk generated at mill itself for energy
whereas mills producing raw rice sell 100% of rice husk generated. Approximately 50%of total
rice produced in India is consumed as parboiled rice.

vi) Major R&D Organizations/institutes/private organizations working in the field of

development and commercialization of rice husk energy utilization systems include:

A) Energy Efficient Furnaces

* Punjab Agricultural University, Ludhiana
* IIT, Kharagpur

B) Gasifiers
* Grain Processing, Calcutta
* Punjab Agricultural University, Ludhiana
* Associated Engineering Works, A.P.
* IIT, Bombay
* IIT, Delhi

C) Briquetting Machines
* Solar Sciences Consultancy (P) Ltd., New Delhi
* School of Applied Research, Sangli
* NRDC, New Delhi.

D) Stoves
* IIT, Delhi
* IISc, Bangalore
* Central Fuel Research Institute, Dhanbad

E) Utilization of Ash (Cementitious Materials)

* Central Building Research Institute, Roorkee
* IIT, Kharagpur

F) Fluidized Bed Combustion Boilers

* Thermax, Pune
* Cethar Vessels Ltd., Delhi
* Since rice husk is utilized for various applications (mills, non-energy related applications,
boilers, kilns, etc.) it is estimated that out of 20 mt of husk generated per annum about 40% i.e. 8
million tonnes would be available for energy related uses in rural areas.

Abroad

vii) Total Production of rice in the world during 1989 was estimated at 473 mt. generating about
140 mt. of husk. China is the world leader with about 37% share.

viii) The utilization pattern of rice husk differs from country to country but major end uses
include fuel for rice mill furnace boilers, stoves, gasifiers etc. and briquetting. Countries in which
rice husk is being utilized on large scale include China, Philippines, Thailand, Japan Italy Brazil,
Korea, etc.

ix) China is the world leader in rice husk gasification technology, open more (throat less, topless)
down draft gasifiers of capacity 60 kW/160 kW have been commercialistic. More than 100 rice
husk gasifiers are working at present in China, basically for electricity generation at rice mills.
Other major countries where rice husk gasifiers have been developed include Thailand,
Philippines, Japan, Indonesia, USA.

x) Rice husk stoves are being used in Indonesia, Thailand, Philippines. Three types of stoves are
being manufactured i.e. packed, natural draft and smouldering.

xi) Rice husk briquetting machines have been designed and commercialized in Japan,
Switzerland, Thailand, USA etc. Briquetting machine based on ‘Fred Hausmann’ design are
popular.

1.7 Preferred Options for India

The preferred options in India for effective utilization of rice husk for energy in rural areas
include:

i. Electricity generation from medium capacity rice husk gasifiers (50 kW capacity systems)
specially in isolated villages where electricity from grid is not available.

ii. Installation of rice husk based stirling engines/small gasifiers pumpsets (5 HP capacity), for
irrigation purposes.

iii. Promotion of rice husk briquetting units as a rural industry especially in industrialized rural
areas where these briquettes could be used as fuel in boilers, brick kilns etc.

iv. Installation of rice husk stoves in place of stoves utilizing wood /dung cakes as fuel, since
these stoves have higher thermal efficiency and result in smokeless cooking.

A) Electricity Generation form Rice Husk Gasifiers

Forecast
The electricity generation potential from rice husk gasifiers in rural areas is estimated as:

Year Electricity Potential (MW)

1992-93 5
1995-96 28
1999-2000 84

Impact
The annual savings of diesel oil by preferring rice husk gasifiers over diesel gensets for
electricity generation in rural areas is estimated at:

Year Savings-Diesel Oil (Rs. Crores)

1992-93 3
1995-96 16.5
1999-2000 52

* Cost of electricity generation in rice husk gasifiers systems is low by about 4% when compared
to diesel gensets.
* Greater assurance of electricity in remote rural areas.
* Employment generation to be extent of 18 persons (directly & indirectly) per 50 MW capacity
gasifiers system.
* Cottage industries could also be promoted based on useful gasifier system by products (tar &
cinder)< for rural upliftment.
* Better impact on environment by power air pollution when compared to diesel gensets which
run on 100% diesel.

B) Stirling Engines for Irrigation

Forecast
Estimated potential for installation of rice husk based stirling engines (5 HP capacity) in rural
areas is:

Year Stirling Engines (Thousand Nos)

1992-93 6.5
1995-96 40
1999-2000 142

Impact
Estimated saving of diesel by replacing diesel pump sets by Stirling Engines:

Year Diesel Saving (Rs. Crores)

1992-93 7
1995-96 42
1999-2000 18

* Better impact on environment, lower pollution when compared to diesel pump sets.
* Reliable sources of irrigation in recent areas.

C) Rice Husk Briquetting

Forecast
Potential for promotion of rice husk briquetting plants (500 kg/h capacity) are estimated as:

Year Briquetting Plants (Nos)

1992-93 40
1995-96 55
1999-2000 100

Impact
Savings of coal if rice husk briquettes are used as alternate fuel are estimated as:

Year Coal Saving (Rs. Crores)

1992-93 14
1995-96 66
1999-2000 160

* Rice husk briquettes are economical by about 20% compared to coal.

* Lower pollution while briquette burning due to low ash, sulphur content compared to coal.
* Generation of employment in rural areas, is to the extent of 40 persons (directly & indirectly)
per 500 kg/h capacity briquetting plant.
* Easy storage, handling transportation of rise husk briquettes, higher combustion efficiency and
sustained high intensity burning compared to loose husk.

D) Rice Husk Stoves

Forecast
Potential for installation of rice husk stoves in rural areas is estimated as below:

Year Rice husk Stoves (Lacs Nos)

1992-93 1
1995-96 1.3
1999-2000 2.2

Impact
Saving of wood by substituting rice husk stoves is estimated as:

Year Firewood Saving (Rs. Crores)

1992-93 9
1995-96 45
1999-2000 115

* Smokeless cooking, thus eliminates eye and lung diseases caused due to smoke among women
in rural areas.
* Better hygiene and environment in rural areas.
* Stoves are simple in design, and could be fabricated at village level, creating additional
employment opportunities.
* Rice husk stoves are about 10% more economical compared to improver wood stoves, and
provide economical cooking.

E) The anticipated availability ad utilization of rice husk in preferred options for various years
are summarized below:

Year Rice husk

Availability (Lac t) Utilization (Lac t) % Utilization
1992-93 81 4.5 5.5
1995-96 85 20.5 24
1999-2000 91 68 75

1.8 Suggested Action Plan

i. In order to promote rice husk utilization technologies for energy, greater awareness will have
to be created in rural areas regarding their advantages vis-avis other options.

ii. Promotion and demonstration of feasible rice husk energy utilization technologies in rural
areas, could be achieved through rural exhibition/melas, T.V. Programmes, establishment of
technology demonstration centers etc. DNES, NRDC etc. can play a vital role in technology
promotion.

iii. The commercialization of technologies developed by R&D institutions is on a low scale,

which could be enhanced by greater interaction between technology development organizations
and manufacturers/fabricators of equipment. Commercialization of technologies would lead to
greater propagation of technologies. DNES, NRDC, R & D institutions, private entrepreneurs
can contribute in this report.

iv. High cost of technologies / equipments has been one of the major hindrance in wide scale
adoption of technologies in rural areas. It is recommended that low cost technologies/equipment
should be developed by R & D institutions by way of usage of cheaper materials, design
improvement etc.

v. It is recommended that capital subsidy of 30-40% should be provided on biomass briquetting

equipments as briquettes are renewable form of energy and helps in conservation of coal, in line
with government policy of providing subsidies to biomass gasifiers, stoves, etc.
vi. A few R & D areas identified with respect to rice husk energy utilization technologies of
energy.

vii. Development of special alloy dyes for briquetting machines which can withstand highly
abrasive nature of husk.

viii. Development & commercialization of technologies which utilize maximum rice husk energy
and also generate useful by products i.e. white ash out of which other useful products like
amorphous silica could be extracted. Organizations such as IIT-Delhi. IIT-Bombay; DAV,
Ludhiana (gasifiers), SAR, Samgli; Solar Sciences Consultancy Pvt. Ltd. Delhi (briquetting
machines). CFRI-Dhanbad; IISc-Bangalore (Stoves), CBRI-Roorkee, IIT-Kharagpur (Ash
Utilization) can contribute in R&D activities development.

ix. Rice husk gasifier based electricity generation systems (50kW capacity) are ideal for isolated
rural areas. Since cost of these systems is high (50 kW system costs Rs. 7 lacs), these could be
promoted by State Governments / State Electricity Boards. North Eastern States such as Assam,
Arunachal Pradesh, Manipur, etc. offer lot of potential for such systems. These systems would
lead to lots of benefits like employment generation, diesel oil savings etc.

x. Rice husk briquetting units would be a viable option for industrialized rural areas where
briquettes could be used as boiler fuel in place of coal. Entrepreneurs could be encouraged by
State Financial Institutions, State Industrial Development Corporations, District Industrial
Centers etc., to establish such units in rural areas thereby generating employment. Loans on
liberal terms could also be provided by financial institutions.

xi. Stirling engines (5 HP) can be promoted for irrigation in place of diesel pump sets. High cost
of stirling Engine could be brought down by mass production of these engines.

xii. Rice husk stoves are much more energy efficient than improved wood stoves and lead to
smokeless cooking, reduces deforestation. Such systems could be promoted on a larger scale
under ‘National Programme on Improved Chulhas’ by DNES. These systems can be fabricated at
village level.

xiii. Maximum co-operation is required between Nodal Agency (DNES). Voluntary

Organizations, technology/equipment suppliers, village Panchayats etc. for greater promotion
and dissemination of technologies in rural areas.

xiv. Training is very essential for effective dissemination of technologies, and can be imparted to
rural youth/people in technology demonstration cum training centers by representatives of
technology/equipments suppliers.

xv. International cooperation between leading foreign countries, i.e. China, Philippines, Thailand
etc. and India is very essential in this field, for development of rice husk utilitarian technologies,
updating of technologies based on experiences, technology transfer etc. International
Organizations such as FAO, UNIDO, UNDP etc. can promote greater international cooperation.

xvi. It is recommended that further in-depth studies should be initiated to identify appropriate
rice husk energy utilization technologies for major regions (region wise) since feasibility of
various identified technologies would vary from place to place, state to state and would depend
on a number of factors, like husk prices, extent of industrialization in area, husk generation
source in area etc.