ARTICLE IN PRESS

Renewable Energy 32 (2007) 474–479

www.elsevier.com/locate/renene

Modification of commercial briquetting machine to

produce 35 mm diameter briquettes suitable for
gasification and combustion
R.N. Singh, P.R. Bhoi, S.R. Patel
Thermo chemical Conversion Division, Sardar Patel Renewable Energy Research Institute (SPRERI),
Vallabh Vidyanagar, 388 120 Gujarat, India

Received 15 April 2005; accepted 1 February 2006

Available online 3 April 2006

Abstract

This paper describes an experience on producing 35 mm dia briquettes with a modified commercial
briquetting machine and the results of studies on the combustion and gasification behavior of
briquettes. Study reveals that at 12% (w.b.) moisture content of groundnut shell powder
(1180–150 mm), good quality briquettes can be made, but it reduces the production rate and
increases the power requirement. Combustion as well as gasification studies revealed that biomass
briquettes of 35 mm diameter do not crumble or disintegrate during the conversion process, therefore
these are suitable as feedstock for gasifiers.
r 2006 Elsevier Ltd. All rights reserved.

Keywords: Biomass briquette; Combustion; Gasification

1. Introduction

Diesel-oil-powered irrigation pumps presently irrigate millions of small farms in India.

These dispersed diesel irrigation pumps can potentially be fueled by producer gas obtained
from gasifying biomass feed stocks. The most common size of these diesel engine-operated
pumps falls between 5 and 10 hp [3]. Most of the gasifiers installed in India are of down
draft type and properly sized wood pieces are commonly used as the fuel. In the present
Corresponding author. Tel.: +91 2692 231332/235011; fax: +91 2692 237982.
E-mail address: thermo@spreri.org (R.N. Singh).

0960-1481/$ - see front matter r 2006 Elsevier Ltd. All rights reserved.
doi:10.1016/j.renene.2006.02.001
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energy scenario, the forest resources are diminishing and the requirement for wood is
increasing day by day due to the increase in population. However, the production of
firewood is decreasing due to the destruction of our forest cover. The gap between
consumption and recorded production of fuel wood seems to be widening. Urgent steps are
needed to stop unscrupulous felling of trees to prevent more damage to environment and
destruction of our forests. Fortunately availability of agricultural and agro-industrial
residues is increasing day by day due to increase in agricultural production. In spite of very
high-energy potential of these residues, it cannot be used in small/medium gasifiers. The
ideal answer in this situation is to convert these residues into high density (1200 kg/m3) and
high-value solid fuel (3500 to 5000 kcal/kg), i.e. briquettes [5]. According to our survey of
Gujarat state, it was found that most of the briquetting plants situated in this state have a
die and punch mechanism. The diameter of briquettes produced is 60 and 90 mm size.
These sizes of briquettes are difficult to use in small/medium gasifiers [2]. There is a need to
produce biomass briquettes of smaller diameter.

2. Materials and method

The commercial die unit consists of a holder block wherein a taper die with a wearing
ring and a split die are fitted. Diameter and length of punch are 60 and 360 mm,
respectively. The material used for both, taper die and punch is high carbon high
chromium steel. The complete briquetting machine consists of briquetting press, material
handling equipment, hammer mill, hot air generator and dryer.
To produce 35-mm-dia briquettes, a punch and die unit was designed and developed.
Schematic diagram of the commercially available briquetting plant is shown in Fig. 1.
Negotiations were initiated with some briquetting plant owners to replace the common 60-
mm-dia unit with the smaller punch and die set so that sufficient quantity of 35-mm-dia
briquettes could be produced for combustion and gasification trials. Finally, an agreement

Hopper Screw conveyor Gear box Motor

Hopper

Feeder box

Die holder

Split die
Taper die
Wear ring
Ram
Scrapper ring

Fig. 1. Schematic diagram of briquetting plant.

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was made with M/s Vishal Briquettes of Nadiad for this purpose and the 35 mm size punch
and die unit was retrofitted in the commercial briquetting machine.

3. Results and discussions

In the initial trials making of briquettes with sawdust was tried. The results were not
satisfactory. Then a little amount of burnt engine oil was mixed with sawdust. The result
was encouraging. It may be because pure saw dust is not a good conductor of heat. By
adding small quantity of burnt engine oil, thermal conductivity of sawdust improved and
heat penetrates up to the center of briquettes thus uniform temperature distribution exist
and better quality briquettes were obtained. Further trials were taken with groundnut shell
powder (1180–150 mm size). The results were satisfactory. About 8–10 kg briquettes of the
required 35 mm diameter were made. It was observed that the feeder box bolt was breaking
frequently. This was due to excess backpressure developed due to reduction in size of the
ram. Corrective measures were taken and the ram was again modified and retrofitted to the
briquetting machine. Moisture content of raw biomass was increased up to 12% (w.b.)
while previously it was up to 7.73% (w.b.). Some more trials were taken with modified ram
at 12% moisture content of the groundnut shell. Sufficient quantities of briquettes were
made and brought back to the SPRERI for laboratory studies. The proximate analysis of
briquette is given in Table 1 [1,4]. It was also observed that with 35 mm briquettes
production was reduced from 800 to 270 kg/h and power requirement increases from 56.25
to 66.67 kW/tonne. The reason for increasing the power requirement was due to reduction
in the production rate of briquettes and due to over ratting of electric motor as
modification was carried out on 60-mm-dia punch unit. The comparative photographic
view of 35-mm-dia briquette with 60 and 90 mm dia are shown in Fig. 2.

3.1. Combustion study of 35 mm groundnut shell briquettes

Combustion study of 35 mm diameter briquettes made from groundnut shell was carried
out in the improved metal Chula having thermal efficiency of 24%. Firstly a single layer
(35 mm diameter and 12–18 mm length) was maintained in the Chula. A small amount of
diesel was spread over it for easy firing. It took 10 min for initial combustion. It was found
that 1.04 kg briquettes took around 30 min for complete combustion. During combustion

Table 1
Physical and proximate analysis of briquettes

Properties Corresponding value

Specific density (kg/m3) 1225

Bulk density (kg/m3) 618
Moisture content, % (wb) 9.02
Ash content, % (db) 7.92
Volatile matter, % (db) 80.5
Fixed carbon, % (db) 11.58
Calorific value (MJ/kg) 18.6
Size 35 mm j
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Fig. 2. Photographic view of the 90, 60 and 35 mm dia briquette from left.

the briquettes did not crumble and maintained their original shape. Diameter of charcoal
was found around 29 mm. Its strength was as good as wood charcoal.

3.2. Gasification study of 35 mm groundnut shell briquettes

An open core down draft gasifier having capacity of 50 kW was selected for gasification
studies of 35 mm groundnut shell briquettes. The gasifier consists of a well-insulated
cylindrical reactor with air nozzles and open top, manually operated rotating type cast iron
grate, an induced draft fan and nozzle type producer gas burner as the major components.
Initially 43 kg charcoal was loaded in the gasifier up to the air nozzles level. Thereafter
the gasifier was loaded with 133 kg groundnut shell briquettes. The gasifier operation was
initiated using suction of electrical blower. It takes around 15 min to generate flammable
gas, which was burnt using naturally aspirated nozzle type burner attached after the
electrical blower. The system was operated continuously for about 180 min without any
problems.
U tube manometer was used to measure the pressure drop across the gasifier. Digital
multi-channel temperature indicator with Cr–Al thermocouples was used to measure the
temperature profile. Calibrated orifice plate was used to determine the flow rate of
producer gas.
The gas flow rate was 182.81 m3/h at 300 1C and 700 mm of W.G. pressure. The
variation of temperatures with time is shown in Fig. 3. The pressure drop across the
gasifier was 6 mm W.G. The flame temperature was consistent within the range of 869 to
929 1C. After stabilization of the operation a producer gas sample was collected by water
displacement method and it was analyzed with the help of a gas chromatograph. The
results are tabulated in Table 2.
Thus, the calorific value of the producer gas was 1144.54 kcal/m3 at 30 1C, which was
calculated from the above composition (HHV). No fuel flow problems were noticed during
the operation.
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At 700mm Height from the grate

At 530mm Height from the grate
At 430mm Height from the grate
At 250mm Height from the grate
1200 Producer gasTemperature at the exit of gasifier
Producer gasTemperature at Orific plate
1000 Flame
Temperature, °C

800

600

400

200

0
0 15 30 45 60 75 90 105 120 135 150 165 180
Time, Minutes

Fig. 3. Variation of temperatures with time.

Table 2
Composition of producer gas (groundnut shell briquettes)

Component Percentage

H2 17.18
CO 17.53
CH4 1.82
N2 48.12
CO2 15.35

4. Conclusions

(1) Production of 35 mm briquettes made from groundnut shell using 35 mm die and
punch unit was satisfactory. Energy requirement per tonne of briquettes was more
(67 kWh) compared to 60 mm briquettes (56 kWh). The reason for increasing the power
requirement was due to reduction in the production rate of briquettes and due to over
rating of electric motor as modification was carried out on 60-mm-dia briquetting
plant.
(2) Combustion as well as gasification studies revealed that biomass briquettes of 35 mm
diameter that had not crumbled or disintegrated during the conversion process were
found suitable as feedstock for gasifiers.

Acknowledgements

The authors are grateful to the Director and the management of SPRERI for providing
the facilities and valuable guidance to carry out this project work. Authors are also
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R.N. Singh et al. / Renewable Energy 32 (2007) 474–479 479

grateful to the Indian Council of Agricultural Research, New Delhi, for providing the
financial assistance.

References

[1] ASTM. Annual book of ASTM standards. American Society for Testing of Material:Philadelphia;1983.
p. 199103.
[2] Modification of commercial briquetting machine for producing agro-residues briquettes suitable for
gasification. Final report submitted to ICAR. V V Nagar:SPRERI.
[3] Patel SR, Rao CS. Performance of a 20 kW agricultural residues-based gasifier system for power generation.
Proceedings of solar energy on role of renewable energy in energy policy held in Vadodara, 1993. p.248–54.
[4] Singh RN, Patil KN. SPRERI method for quick measurement of moisture content of biomass fuels. SESI J
2001;11(1):25–8.
[5] Singh RN, Patel SR. Potential feed stocks for gasifier—biomass briquettes. Proceedings of two days national
workshop on role of renewable energy in 21st centaury held at BN College of Engineering, Pusad (MS) 2001.
p. 1–11.