BRIQUETTING MACHINE

Senior Project

by

Kamal Mohammad Harb, 41810059

Jamil Joseph Nohra, 41730335

Submitted to the School of Engineering of the

Lebanese International University

Nabatieh, Lebanon

in partial fulfillment of the requirements for the degree of

BACHELOR OF SCIENCE IN MECHANICAL ENGINEERING

Spring 2019 – 2020

Approved By

Dr. Tala Moussa

Supervisor Date Signature

Dr. Mohammad Hammoud

Committee Member Date Signature

Title 1st_name last name

Committee Member Date Signature

 DEDICATION

«You can’t have a better tomorrow if you’re always thinking about

yesterday».

Words said to me by my beloved grandfather who died recently. I dedicate

this project to you Grandpa so you were the one who inspired me in life and taught

me that nothing is impossible. May god rest you in peace.

We also dedicate our project to our supportive families and beloved friends.

And we cannot forget our doctors, especially to our brother and friend the

assistant dean Dr. Mohammad Hammoud.

Last but not least, we dedicate everything that we have accomplished to our

University, its president Minister Abdul Rahim Murad and its director Dr. Wael

Rabah.

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 ACKNOWLEDGEMENTS

“You can only develop by yourself, be the author of your own development.”

In the world of mechanical engineering, competition is fierce and success is

difficult, but nothing is impossible.

First of all, we would like to thank God that we have been able to complete

this project with success.

Secondly, we would like to thank our families who have always supported us

and who have given us advices and suggestions that keep us one step ahead.

And we cannot forget our advisor Dr. Tala Moussa who was always ready to

help and provide us with ideas and information.

We also want to thank our university, its president, Minister Abdel Rahim

Murad and its director Dr. Wael Rabah.

Finally, our thanks, appreciation and respect to our doctors: Dr. Mohammad

Hammoud, Dr. Ali Hallal, Dr. Samer Ali, Dr. Hassan Jaber and Dr. Ibrahim Mjallal

for their efforts and support to us. They are a real image of the successful engineer,

sincerely in their work, moral in their performance and human in their relations with

students.

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 ABSTRACT

Fossil fuels are the main source of energy. Excessive use of these fuels will

lead to serious environmental problems such as –global warming and air pollution. As

fossil fuels are being depleted day by day, it is high time to convert biomass waste

into useful biomass briquettes that will replace some of the fossil fuels.

Biomass energy is the use of organic material to produce energy.

Anything that is biomass and waste can be converted into high calorific fuel

briquettes. This can be mustard waste, rice husk, coffee husk, sugarcane, pressed olive

residue, etc… Similarly, forest waste such as wood chips, wild grasses, shrubs, leaves

and trash can also be made into briquettes.

The briquetting machine is also called briquette maker or briquette press. It

is an energy –saving machine and renewable energy source that uses very high

pressure to compress the waste by the impact force of the piston and turn it into bio –

fuel briquettes.

Biomass briquettes, mainly composed of green waste and other organic

materials, are commonly used for electricity generation, heat, and cooking fuel …

Compared to fossil fuels, briquettes produce low total net greenhouse gas

emissions because the materials used are already part of the carbon cycle.

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TABLE OF CONTENTS

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LIST OF FIGURES

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LIST OF TABLES

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LIST OF SYMBOLS AND ABBREVIATIONS

In alphanumerical order.

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 CHAPTER 1. INTRODUCTION

1.1. BRIQUETTING MACHINE

The biomass briquette press is the machinery that can convert agricultural or

forestry materials or any organic matter that is biomass and waste into solid briquettes

by giving them high pressure and temperature.

Agricultural waste can be peanut shells, mustard waste, rice husk, coffee

husk, sugarcane, pressed olive residue, etc… Similarly, forest waste such as saw Dust,

wood chips, wild grasses, shrubs, leaves and rubbish can also be briquetted.

1.2. PROBLEM STATEMENT

The growth of the world’s population and, consequently, the increase in

energy demand, as well as the growing global awareness of the scarcity of the earth’s

natural resources, have turned energy into a precious good - so precious that

nowadays international geopolitics are largely associated with access to and control of

energy sources. Traditional energy sources are characterized as being exhaustible and

some of them, particularly fossil fuels, have considerable impact on the natural

environment and are the main cause of climate change. As a global solution,

renewable energies play a key and unique role, since they are obtained from natural,

regenerative sources that do not deplete; and they also cause minimal or no

environmental problems, such as climate change, radioactive waste, acid rain and air

pollution. The renewable energy that have reached full commercial maturity are: sun,

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wind, tides and waves, rivers, geothermal energy, organic waste and energy stored in

vegetation and forests (biomass).

How to obtain biomass? Biomass briquettes are a bio –fuel that replace coal

and charcoal. Biomass briquettes are made from agricultural and forestry waste. Low

density biomass (agricultural and forestry waste) is converted into high density

biomass briquettes using a briquetting machine.

Thus, the development of the biomass briquetting machine is to overcome

the problems to become worst. The product that forms is called briquettes have many

advantages which will not emit fly ash, smoke with sulphur or phosphorus. Thus, it is

not harmful to the environment [1].

1.3. OBJECTIVES

Basically, this project would be done for fulfill the following:

 To design and analysis the piston type briquetting tool.

 To fabricate a briquetting machine prototype of piston type

briquetting tool.

1.3.1. Overall objective

To identify appropriate fuel briquetting technologies for sustainable

environment and social-economic benefits.

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1.3.2. The specific objectives were to:

I. Evaluate fuel briquette production technologies and their effects on

energy efficiency.

II. Determine social-economic benefits of the production and use of fuel

briquettes.

III. Assess the potential environmental impacts in the production and use

of fuel briquettes.

1.4. HYPOTHESIS

 Fuel briquette production technologies have impacts on energy

efficiency and emissions of carbon dioxide (CO2) and, carbon

monoxide (CO).

 There are socio –economic benefits from the production and use of

fuel briquettes.

 There are potential environmental impacts in the life cycle of fuel

briquettes from production to use.

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 1.5. OUTLINES

In the following chapters we will go into the full details of the project,

starting with a literature review in chapter 2, and then in chapter 3, the implemented

design will be detailed and discussed. In chapter 4, a prototype of the design will be

explained in detail, and a conclusion on the use of this briquetting machine in real life

will be presented.

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 CHAPTER 2. LITERATURE REVIEW

2.1. INTRODUCTION

A briquetting machine is used to turn the waste materials to a regular shape

block, which can help to improve the conditions for those materials, make them easy

for transportation, storage, and more useful for further usage.

The briquetting system is able to deal with all kinds of materials with

suitable size and moisture.

Briquetting always work with the binder as it needs the binding effect to get

enough strength for the finished briquette. Biomass and industrial waste are different

from each other due to their binder sources.

2.2. TYPES OF BRIQUETTING MACHINES

2.2.1. Screw type

Figure 2.1. Screw briquetting machine [2]

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 The screw type briquetting machine uses the auger to press the raw material,

with different, it can be equipped with or without the heating system to produce

briquettes.

The heating system is a special design for briquettes whose materials contain

lignin, as –the lignin is always found on biomass. So the heating system is usually

used for the –biomass briquetting. Other materials such coal, charcoal, etc… Binders

are always required when briquetting with the screw type briquetting machine.

The suitable material is fed to the hopper and then conveyed by the screw

inside the briquetting machine. The rotating screw takes the material from the feed

port, and compacts it against a die which helps to create a pressure gradient along the

screw.

Outlet of the finished briquette output from the end with stick type. The

normal cross-sectional-shapes can be find as square, round, plum blossom, etc…

As the screw briquetting machine works with a pressure not very high,

binders are always needed to form the briquette. The heating system will help the

biomass material to melt the internal lignin and turn it to a high-performance binder.

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2.2.2. Hydraulic type

Figure 2.2. Hydraulic briquetting machine [2]

The hydraulic type works with a hydraulic pumping station has a wide range

of pressure for you to choose the perfect briquette as per you need. The max pressure

can up to 600 tons. Due to its high pressure, almost any material can be briquetted

with this system.

Metal, as a raw material that reflects plasticity under high pressure, is

particularly suitable to be briquetted by the hydraulic type briquetting machine.

The briquetting process takes place in a chamber where the materials are

introduced and briquetted under high pressure. It causes their plasticity and makes

them stable as a block.

The hydraulic type takes a long time to maintain the pressure on the

briquette, which prevents the short –time material deformation rebound and will cause

a special heating for these materials such as sawdust to melt its internal lignin, which

makes the briquette more resistant.

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2.2.3. Piston type

Figure 2.3. Piston briquetting machine [2]

The piston type uses the rotational power of the mechanical device or the

thrust of the hydraulic cylinder to reciprocate the piston (or plunger), and the piston

(or plunger) drives the ram to reciprocate in the forming sleeve to generate a pressing

force to form the briquette material.

A large pressure (up to 300 tons) will be generated because the movement of

the flywheel and the punch of the briquette several times in a short period, will

increase the temperature of the raw material. As the raw material moves, it splits with

the inside, which generates another type of heat –the frictional heat. With the action of

these two types of heat, the material raises its own temperature to a high level (around

150-200ºC) and melts the lignin. The particle materials then bind together and become

sufficiently solid.

The honeycomb briquetting machine is a simple type of piston briquetting

machine; it also uses the wheel, but the briquette is punched only once to form.

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2.2.4. Roller type

Figure 2.4. Roller briquetting machine [2]

The roller press operates with two closely spaced rollers rotating at the same

speed but in opposite direction. Both rollers, of the same width and diameter, have

holes on the surface. As they move, the same two holes on the different roller

coincide at the intersection of the midline and the briquette is pressed there.

With different pressure requirements, the roller press can be designed in

several types.

A normal roller press will use a wedge iron to fix the movable roller, as it

works at low pressure. The hydraulic pumping station can also be used to fix the roller

and supplies a much larger but flexible support for the roller to work stably at high

pressure (around 22 tons).

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 2.3. CONCLUSION

There are several types of briquetting machines with different operating

principles, they operate at different pressures and are suitable for different –materials.

As the briquettes produced by a piston press are completely solid, we choose the

piston type that will help us to produce high quality briquettes.

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 CHAPTER 3. PROJECT SPECIFICATIONS

3.1. LEVEL 2 SECTION

The project specifications and requirements are the topic of this chapter. We

don’t expect a long chapter here (around 2 pages).

Figure 3.5. First figure in chapter III

3.2. EQUATIONS

For the equations, the best practice is to Copy-Paste-Edit the equation below

then updates it by selection the number and hitting F9 on your Keyboard, then Edit

the equation.

A=π r 2 (3.1)

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 CHAPTER 4. DESIGN

4.1. INTRODUCTION

In this chapter, a dimensional analysis was done on the components of the

machine, where each part of the machine was designed using Solidworks software, to

complete the prototype.

4.2. COMPONENTS

1.1.1. Frame

It is the main metallic base chassis for the machine, then all the accessories

are attached and fixed to this frame. It was designed to carry the loads of all the parts,

it is of 1000mm length, 560mm width and 100mm height.

Figure 4.6. Frame

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1.1.2. Outer cover

It is a rectangular metallic cover, used to protect the internal parts of the

machine, it is of 902mm length, 560mm width and 300mm height.

Figure 4.7. Outer cover

1.1.3. Hopper

This is where the material is fed into the machine. It is an inverted square

pyramid bottom design with an open top to deposit materials in the hopper.

Figure 4.8. Hopper

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1.1.4. AC Motor

It is 5 horsepower AC motor that fed that system with the needed torque and

rotating speed in order to press the waste materials with high pressure.

Figure 4.9. AC Motor

1.1.5. Screw conveyor

It is snail shaped, vertically attached inside the hopper, used to mix the waste

materials before they entering the pipe and get pressed.

Figure 4.10. Screw conveyor

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1.1.6. Cylinders

It is a set of 3 consecutive cylinders designed from largest diameter (100mm)

to smaller (80mm), then to smallest (50mm). At its end, there is a square exit of

30mm side in order to obtain square shaped compressed materials.

Figure 4.11. Cylinders

1.1.7. Piston

These three are the moving components in the machine showed in the figures

below. The piston slides freely left and right inside the first cylinder of 100mm

diameter. It compresses the waste materials, that delivered by the screw conveyor, to

the second cylinder by its flat head. The piston is connected to the crankshaft arm by a

connecting rod. The crankshaft arm is attached to the rotating pulley in order to

deliver motion to the piston.

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 Figure 4.12. Piston

Figure 4.13. Connecting rod

Figure 4.14. Crankshaft arm

1.1.8. Belt-pulleys system

The Belt-Pulleys system is consisting of two identical steel pulleys

connected by a rubber conveyor. The first pulley is connected to the shaft of the motor

in order to feed the second pulley with rotating motion, and then the second pulley

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will deliver this rotary motion to the crankshaft arm that also deliver this motion to

the piston in order to slide inside the cylinder.

Figure 4.15. Pulley

Figure 4.16. Belt

1.1. CONCLUSION

After describing each part of the designed assembly, by using Solidworks

software, with its calculated dimensions, now the parts are ready to assemble then the

assembly will be able to be tested.

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CHAPTER 5. NON-TECHNICAL ASPECTS

5.1. INTRODUCTION

The non-technical aspect is important for the success of a project. A

successful project must respect many conditions such as economic/financial aspects,

project management, ethical and social aspects, environment and sustainability, and

standards. In this chapter we will therefore discuss these requirements.

5.2. ECONOMICAL/FINANCIAL

Economics and finance are essential to the success of an engineering project.

As mentioned in Chapter 3, our project will cost $373 and take two weeks to

complete. On the revenue side, this machine will make it easy to earn money; our

machine can produce 1000 briquettes per day. On the market, every 10 briquettes are

sold for $1. If we make a simple calculation after two days of sale, we will get back

the money we put in. Then every purchase will be a net profit.

Note that the materials used to make the briquettes are almost free.

5.3. PROJECT MANAGEMENT

Defining the briquetting machine is a machine mainly designed to save the

purchaser money and be environmentally friendly by replacing wood and taking

advantage of agricultural waste. Therefore, from the very beginning, we have worked

carefully to achieve our main goals and present a suitable machine that can fulfill the

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expected functions. To be professional, we started researching similar machines after

the idea was clear. Using Solid works, the design of our machine was made and then

the necessary materials and parts were selected. Finally, our machine is assembled

and tested.

5.4. ETHICAL AND SOCIAL

This project respects all the principles of ethics, from honesty to clean work

and transparency. From a social point of view, our project is one of the most sociable

projects nowadays. Many people are looking for a machine similar to ours in order to

reduce tree felling and avoid fuel combustion emissions.

5.5. ENVIRONMENTAL AND SUSTAINABILITY

From the very beginning, the environmental aspect has been one of the

objectives of our project. Our machine can help reduce pollution for many reasons.

The briquettes produced can replace firewood, so the rate of cutting down trees is

reduced. On the other hand, the use of briquettes for fire instead of fuel will limit

emissions.

5.6. STANDARDS

Our machine is subject to all international and local standards. We have

always been concerned to comply with all standards, especially those relating to

safety. In this project, engineering codes have been perfectly used. In addition, this

machine has been tested by official bodies.

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 CHAPTER 6. RESULTS

6.1. INTRODUCTION

This chapter presents the whole assembly that results from fixing and

attaching all the parts and accessories. The piston briquetting machine is modeled

using Solidworks software 2019 as shown in the figures below.

6.2. ASSEMBLY OF THE MACHINE

Figure 6.17. Piston briquetting machine model

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Figure 6.18. Top view of the machine

Figure 6.19. Side view of the machine

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 1.1. CONCLUSION

In this chapter, we introduce the briquetting machine design, with a three

figures sketched using Solidworks software. A 3D model of the machine was

proposed, showing the final design of the prototype.

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 CHAPTER 7. CONCLUSION

The time for theoretical work is over, and the time for practical work has

come. For the engineer, there is no more beautiful than graduating from the College of

Engineering with a small and innovative project, based on an important creative idea,

which can be developed and utilized in major projects.

A recent economic a study issued by the League of Arab States estimated the

large losses of Arab countries resulting from their negligence in recycling waste by an

amount above five billion annually, indicating that the amount of waste in the Arab

world exceeds 89.6 million tons annually, 60% of all general waste in Arab countries

is organic waste like agricultural and animal waste and food waste from restaurants

and homes.

As fossil fuels are being depleted day by day, it is high time to convert

biomass waste into useful biomass briquettes that will replace some of the fossil fuels,

in order to reduce the percentage of pollution resulted from these fossil fuels and other

petroleum products that produce toxic and harmful gases.

Biomass energy is the use of organic material to produce energy.

Anything that is biomass and waste can be converted into high calorific fuel

briquettes.

Briquetting Machine is used to make Biomass Briquettes out of any

agricultural or forest waste without any need of binder or adhesive.

The dried and granulated raw - material is fed into the machine with the help

of an in-feed screw conveyor. Further, the material enters into the machine keep, the

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keep worm pushes the material into the briquetting chamber. The bio fuel briquettes

are formed in the briquetting chamber without the need of any binder with a high-

pressure mechanical punch. Next, the briquettes come out from the cooling line and

are ready to use.

Any agricultural or forest waste in the granulated form with moisture content

up - to 12 % can be used for making Biomass Briquettes and Biomass Pellets.

Raw materials can be forest waste and residues (Saw Dust, Wood chips &

Shavings, Tree bark, and Twigs, Pine needles, Wild grasses, Shrubs, and Bamboo

leaves, etc…) Similarly, agricultural waste and residues (Rice husk, Sunflower,

Groundnut shells, Almonds shells, Coconut shells, Cotton stalks, Sugar cane leaves

and trash, Mustard stalks, etc…).

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 APPENDIX A. TITLE OF THE APP A

A.1. LEVEL 2 IN APPENDIX, APPLY HEADING 6

For the captions in Appendices, you must use copy-paste from the figures

and tables below.

Figure A.1. First figure in appendix A

TABLE A.1. FIRST TABLE IN APPENDIX A

A-D A B C D
1 A1 B1 C1 D1
2 A2 B2 C2 D2
3 A3 B3 C3 D3

A.1.1. Level 3 in Appendix, Apply Heading 7

A.1.1.1. Level 4 in Appendix, apply Heading 8

A.1.2. Equations in Appendix A

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 For the equations in Appendix, the best practice is to Copy-Paste-Edit the

equation below then updates it by selection the number and hitting F9 on your

Keyboard, then Edit the equation.

A=π r 2 (A.1)

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 APPENDIX B. TITLE OF THE APP B

B.1. LEVEL 2 SECTION, APPLY HEADING 2

For the captions in Appendices, you must use copy-paste from the figures

and tables below.

Figure B.20. First figure in appendix B

TABLE B.1 FIRST TABLE IN APPENDIX B

A-D A B C D
1 A1 B1 C1 D1
2 A2 B2 C2 D2
3 A3 B3 C3 D3

B.2. FOR THE REFERENCES:

References must be entered in “REFERENCES” section before they are

cited. The style is “references”. The template will number citations consecutively

within brackets [1]. Refer simply to the reference number, as in [2]—do not use “Ref.

[2]” or “reference [2]” except at the beginning of a sentence: “Reference [2] was the

first ...”

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 Unless there are six authors or more give all authors’ names; do not use “et

al.”. Papers that have not been published, even if they have been submitted for

publication, should be cited as “unpublished” [3]. Papers that have been accepted for

publication should be cited as “in press” [4]. Capitalize only the first word in a paper

title, except for proper nouns and element symbols.

B.2.1. To Cite a New Reference

Insert Cross-reference  select: Reference Type= numbered item 

select: Insert reference to: Paragraph number  in “For which numbered item”, scroll

to your reference  select your reference  click Insert

B.2.2. Equations in Appendix B

For the equations in Appendix, the best practice is to Copy-Paste-Edit the

equation below then update it by selection the number and hitting F9 on your

Keyboard, then Edit the equation.

A=π r 2 (B.2)

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 REFERENCES

[1] MOHAMMAD KHAIRULNIZAM BIN IBRAHIM ‘‘DEVELOPMENT OF

THE SMALL SCALE PISTON TYPE BRIQUETTING TOOL’’.
[2] https://briquettesolution.com/how-does-a-briquette-machine-work-types-and-
making-process/
[3] K. Elissa, “Title of paper if known,” unpublished.
[4] R. Nicole, “Title of paper with only first word capitalized,” J. Name Stand.
Abbrev., in press.

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