Heated-die Screw-press

Biomass Briquetting Machine:

Design, Construction and Operation Manual

Prepared under

Renewable Energy Technologies in Asia:

A Regional Research and Dissemination Programme
(RETs in Asia)

Funded by

Swedish International Development and Cooperation Agency

(Sida)

Energy Field of Study

School of Environment, Resources, and Development
Asian Institute of Technology
Thailand
1

Heated-die Screw-press
Biomass Briquetting Machine:
Design, Construction and Operation Manual

Renewable Energy Technologies in Asia:

A Regional Research and Dissemination Programme
(RETs in Asia)

Energy Field of Study

School of Environment, Resources, and Development
Asian Institute of Technology
Thailand
3

RENEWABLE ENERGY TECHNOLOGIES IN ASIA

A Regional Research and Dissemination Programme
Heated-die Screw-press Biomass Briquetting Machine:
Design, Construction and Operation Manual
PUBLISHED BY
Regional Energy Resources Information Center (RERIC)
Asian Institute of Technology
P.O. Box 4, Klong Luang
Pathumthani 12120
Thailand
E-mail: enreric@ait.ac.th
Website: http://www.serd.ait.ac.th/reric/

Copyright 2003. Regional Energy Resources Information Center (RERIC),

Asian Institute of Technology. All rights reserved.

No part of this book may be reproduced by any means, stored in a retrieval

system, or transmitted in any form or by any means, electronic, mechanical,
photocopying, recording, or otherwise, without the written permission of the
publisher.

Printed in Thailand

Neither the Swedish International Development Cooperation Agency (Sida) nor

the Asian Institute of Technology (AIT) makes any warranty, expressed or
implied, or assumes any legal liability for the accuracy or completeness of any
information herein provided. References herein to any apparatus, product,
trademark or manufacturer do not constitute or imply its endorsement,
recommendation or favouring by Sida or AIT.

Preface
This work is a result of adaptive research and development activities carried out
within a regional programme entitled Renewable Energy Technologies in Asia: A
Regional Research and Dissemination Programme (RETs in Asia). The
programme was sponsored by the Swedish International Development
Cooperation Agency (Sida), and was coordinated by the Asian Institute of
Technology (AIT). Thirteen national research institutes from six Asian countries:
Bangladesh, Cambodia, Lao PDR, Nepal, Philippines and Vietnam were involved
in the programme. It promoted three technologies: solar photovoltaics, solar
drying and biomass briquetting.
This booklet contains the design, construction and operation details of an
improved heated-die screw-press type biomass briquetting system developed
within the biomass briquetting project. The major improvements achieved in the
present design compared to existing briquetting systems of similar type are (i)
reduction in electrical energy consumption, (ii) enhanced screw life, and (iii)
smoke reduction. With these improvements, the system is expected to produce
cheaper briquettes, which can effectively replace fuelwood, which are currently
the dominant cooking fuel in rural households. With lesser smoke released during
the improved briquetting process, it is also less harmful to the operator.
Prof. S.C. Bhattacharya
RETs in Asia Coordinator

December 2003

Table of Contents
Page
No.
1. Introduction

2. Design and Construction Details

2.1 Briquetting Machine
2.2 Biomass Pre-heater
2.3 Biomass Die-heating Stove
2.4 Smoke Removal System

6
6
6
6
7

3. Design Drawings

4. Operational Details
3.1 Effects of Biomass Pre-heating and Screw
Speed on Briquetting Energy Consumption
3.1.1 Introduction
3.1.2 Testing with Wide-pitch Screw
3.1.3 Testing with the Close-pitch Screw
3.1.4 Performance of the Biomass Stove Die
Heater
3.1.5 Conclusions
3.2 Effects of Raw Material Type on Briquetting
Energy Consumption and Screw Life
3.2.1 Introduction
3.2.2 Rice husk as raw material
3.2.3 Mixed Raw Materials of rice husk and
saw dust
3.2.4 Conclusions

25
25

25
25
26
27
27
29
29
29
32
33

1. Introduction
Biomass briquetting research within the RETs in Asia programme has been
conducted with two main objectives: (i) to improve the biomass briquetting
system by reducing the electrical energy consumption, enhancing the screw
life, and by incorporating a smoke removal system, and (ii) to develop
domestic as well as institutional type biomass stoves which can burn
briquettes. Towards achieving these objectives, several prototype designs
were developed and tested at AIT. Based on the experimental results, final
designs of a biomass pre-heater, biomass die-heating stove and a smoke
removal system were developed. Additional experiments were carried out to
investigate their performance and to find the optimum operating parameters.
This report presents the details of the design and the results experiments
thus carried out.
2. Design and Construction Details
The improved briquetting system developed at AIT consists of the following:
a briquetting machine, a biomass pre-heater, biomass die-heating stove and
a smoke removal system.
2.1 Briquetting Machine:
The briquetting machine used in this study was a Bangladeshi design, the
major components of which were imported by AIT from BIT. All planned
improvements were implemented on this machine, and tests were conducted.
Table 1 presents the technical specifications of the machine. Figure 1 shows
the improved briquetting system configuration; while drawings of the
machine, screw and die are given in figures 2, 3 and 4 respectively.
Table 1. Technical specifications of the basic biomass briquetting machine
S. No.

Item

1.
2.

Induction motor
V-Belts

3.

Pulleys (Cast iron)

Bearings

7
6

Main power transmission

shaft (Bright steel)
Die (Cast iron)
Screws (Mild steel)

Bush (Cast iron)

Description
20 HP at 1450 rpm, 380 volts/ 3 phase
B-90
12.5 cm dia.
47.0 cm dia.
N 6312
N 6311

Quantity
1 unit
2 pcs
1 no.
1 no.
1 no.
1 no.

3" dia.

1 no.

9.7 cm dia., 30 cm long

2 1/4" dia., 45 cm long
Dia: 73 mm outside x 59 mm inside
Length: 32 mm

1 no.
1 no.

1 no.

2.2 Biomass Pre-heater:

The biomass pre-heater is essentially a shell and tube heat exchanger.
Biomass is passed through the tube by a motor-driven screw feeder, while
hot flue gases from a biomass gasifier passes through the shell.
Temperature of the flue gases could be controlled by mixing cold air with the
hot gases. The preheater was 1.2 m long and 42 cm wide and consisted of a
feeder drum placed on a rectangular chamber. The raw material was
preheated while being conveyed through the feeder drum by means of a
screw. The preheater screw was rotated by a variable speed motor. The hot
flue gas from the combustion chamber was passed through the space
between the feeder drum and the rectangular chamber and discharged to the
atmosphere. Thus, the feeder drum was heated by the flue gas at the bottom.
The rectangular chamber was insulated by a 2.5 cm thick layer of rockwool
insulation to reduce heat loss to the surroundings. Pre-heated raw material
from the preheater exit was fed directly to the briquetting machine.
The speed of the preheater screw feeder could be selected based on the
required biomass flow rate into the briquetting machine. Electrical energy
consumption by briquetting machine, die heaters and preheater motor may
be recorded from energy meters installed for the purpose. Figures 5-8
present the detailed design of the pre-heater assembly developed at AIT.
2.3 Biomass Die-heating Stove:
After conducting extensive studies with a biomass gasifier stove and a
combustion stove, the later was found to perform better, by offering steady
die temperature and better temperature control. The stove was of mild steel
(1.5 mm sheet) construction, with a furnace of 20 cm x 35 cm x 40 cm (w x b
x h) volume and 2 m long chimney attached to it at the top. The die of the
briquetting machine passes through the furnace, exposing its outer surface to
the flames inside the furnace. The furnace was insulated with a 30 mm
refractory lining at its inner surface. Doors were provided for loading the fuel
as well as to remove the ash. An ash scraper was fixed below the grate to
remove excess ash from the furnace, which will fall through the grate.
Two steel baffles were fixed just above the die, to converge the flames
towards the die surface. They were insulated at both sides using refractory
cement. The baffles were found to improve the heat transfer from the flames
to the die considerably.The design details of the stove has been given in
Figure 9.
Fuel (briquette pieces of size 40 x 40 mm size) is loaded through the side
doors upto the bottom level of the die and ignited using some wood chips and
kerosene. When the die temperature reached 350C, the briquetting machine
is started. During production, the temperature drops to 320-330C, and this

10

can be maintained by adding fuel periodically (every 5 minutes) to the stove.

Primary air for combustion is taken through the ash pit door, which is kept
open during operation. Secondary air is taken through the fuel doors, which
also are kept open partially. Figures 10 and 11 show the stove during
operation.
2.4 Smoke Removal System:
The system has three main components: (i) a smoke collection box, (ii) a
suction line connecting the primary air supply port of the biomass stove to the
smoke collection box at the top, and (iii) another suction line which connects
the exhaust of the die-heating stove to the biomass pre-heater. The metal
box traps the smoke during the briquetting process, the deflector mechanism
breaks the briquette into certain lengths, and the smoke is sucked through
the biomass stove, whose exhaust is connected to a chimney through the
biomass pre-heater. The schematic diagram of the system is given in Fig 12.
The exhaust from the stove is used for pre-heating the biomass raw material.
Smoke produced from briquettes is collected in the box and burnt up in the
stove. Unburned gases, along with the exhaust flue gas of the stove, are
sucked through the biomass pre-heater using a suction blower, and
exhausted through a chimney; Figure 13 presents the system configuration.
The smoke collection box is constructed of mild steel sheet of 1.5mm
thickness. A circular conduit is fixed at one end of the box, where briquette
from the die of the briquetting machine enters the box. The edge of the
conduit welded to the metal box serves to snap the briquette which comes
out of the die, assisted by the deftector plate as shown in Figure 14. The
deflector plate is rigidly fixed to the body of the metal box. A strip of MS sheet
is fixed below the path of briquette, and another perforated sheet above, to
guide the briquette straight. A slider plate is provided below the path of the
briquette so that the broken piece of briquette slide through the plate and
exits the box at the bottom. A conical cover (hood) is fixed to the box using a
water-seal, which prevents smoke from escaping the joint.
The exhaust from the smoke collection box is connected to a flexible
aluminum duct (commonly used in air condition ducting), the other end of
which is connected below the grate of the die-heating stove. The smoke thus
enters the stove along with its primary air supply, and is burnt up in the stove.
It was found that occasionally, the briquette entering the smoke collection
box tends to bend sideways, thus affecting normal operation. Two guide
plates, one below and the other above the briquette, fixed along the path of
the briquette, eliminate this problem. The top plate is perforated so as not to

11

obstruct the flow of smoke upwards. Handles are provided to the metal box
for easy handling.
Figure 14 presents the detailed drawing of the smoke collection box. The
isometric view of the box is given in Figure 15. Figures 16-19 illustrate the
design and operation of the system in detail. A suction blower of 150W, fixed
at the pre-heater exit provides the required suction to overcome the
resistance for the flow of flue gas inside the pre-heater. The capacity of the
blower was selected such that the airflow provided the required pre-heat
temperature (110-120C), while maintaining the die temperature at 300320C. (It has been found, from experimental results, that a pre-heat
temperature of 110-120C for a screw speed of 370 rpm is the optimum in
terms of less briquetting energy consumption for the particular briquetting
machine).
During operation, the die temperature is maintained at 300-320C by
adjusting the fuel feeding to the stove. The pre-heat temperature, however,
fluctuates more (in the range of 90-130C), as there is no provision in the setup to control it independently. It is felt that the benefit from such a system to
independently control pre-heat temperature will not be economically
justifiable. It may also add to operational difficulties and require fairly skilled
technicians to operate the briquetting system.
Care should be taken while operating the machine using raw material with
moisture content in excess of 7%. Briquettes tend to shoot through the die
as the steam trapped inside the die tries to escape. Raw material should
therefore be dried sufficiently before using, so that moisture levels are below
7%. Sufficient protection should be provided to avoid damage that may be
caused by flying pieces of briquettes through the mouth of the die in case of
shooting.

12

3. Design Drawings

1. Biomass Pre-heater
2. Screw feeder
3. Biomass stove for die heating
4. Smoke collection box
5. Main bearing for screw
6. Motor of briquetting machine

7. Flexible pipe
8. Flue gas suction blower
9. Raw material hopper
10. Motor for feeder screw
11. Conduit pipe

Figure 1: Schematic Diagram of the Improved Briquetting System incorporating the

Biomass Pre-heater, Biomass Die-heating Stove and the Smoke Removal System

12
5

67

100
160

All dimensions are in centimeters

Figure 2. Design details of the briquetting machine

13

15

Grooving: R7
All dimensions are in
Figure 3. Briquetting Die (Bangladeshi Design)

37
6

All dimensions are in

Figure 4. Briquetting Screw (Bangladeshi Design)

14

Raw
material
FEEDING HOPPER

OUTER PIPE

INNER PIPE

SCREW

From
Gasifi
er

740
Preheated
biomass

43
Note: All dimensions are in millimeter

Figure 5. Biomass Preheating System: General View

15

FLUE GAS EXIT

(L100 GI PIPE)

BAFFLE

II

60

160

D1=210

500

500

500

500

Figure 6. Biomass Preheating System: Outer Pipe

16

D2 =350

SECTION I

SECTION II
BAFFLE

WELDING
LINE
WELDING
LINE
R:10

D2 =

R:170

Note:
- Material: Mild Steel Sheet, = 3 mm
- Welding of two end flanges will be done after fixing the inner pipe inside the outside tube
- All dimensions are in millimeters

Figure 7. Outer Pipe: Details of sections I and II

17

A
FLANGE

100

250,
8 HOLES

BEARING
30

BEARING
30
D 210
24

2.4
2,300

250

A-A

80

Note: All dimensions are in millimeter

Figure 8. Biomass Preheating System: Inner Pipe

18

66

66

66

66

66

66

30

23

20

2,400

R = 100

40

A-A

R = 35

Figure 9. Biomass Preheating System: Feed Screw

19

BAFFLE

Note: All dimensions are in millimeter

Chimne

Refractory
insulation
3 thick

15

10

10

Die dia. + 0.2

12
12

Rods for
grate
15

15

1
Ash pit door
20 x 13
22

35

Figure 10. Die Heating Stove for Briquetting Machine

20

Figure 11. Biomass Die Heating Stove in Operation

Figure 12. Combustion inside the stove

21

Smoke Exhaust
Chimney

Suction Blower

Smoke
Collection
Box

Biomass
Die-heater
Stove

Biomass Preheater

Figure 13. Schematic diagram of the Smoke Removal System

Chimney

Flexible
Aluminium Duct
Conical Hood

To
Preheating
System

Die of
Briquetting
Machine

Smoke
Collection
Dieheating
Stove

Exit for
briquette

Conduit

Grate

Figure 14. Schematic diagram of the Smoke Removal System

22

Section A-A
14

Perforated
guide plate

Briquette

Slider
Briquette Exit
8
45

View B-B

Deflector
Plate

52

R12

59

Smoke
Collection
Box

Handles

Circular opening,
9 cm dia.

Briquette
Sheet Metal Box (59x45x52

Conduit, 9
Die of Briquetting
Machine

Top View

Figure 15. Final Design of the Smoke Collection Box

23

Connection to stove
primary air inlet
Hood

Deflector Plate
Water seal
(2 cm wide x 2cm deep)

Conduit 9 cm

52

45
8

59

Figure 16. Isometric view of the smoke collection box

Figure 17. Smoke collection box - inner details

24

Figure 18. Smoke collection box - assembled view

Figure 19: Smoke Removal System in Operation

25

4. Operational Details
4.1 Effects of Biomass Pre-heating and Screw Speed on Briquetting
Energy Consumption
4.1.1 Introduction
A detailed analysis was done on the improved briquetting system to study the
effects of biomass pre-heating and screw speed on the energy consumption
of the briquetting process. The electrical coil heaters were used for die
heating since measurement of energy consumption is easier and more
accurate than if a biomass stove die-heater is used.
Two designs of briquetting screws were developed by BIT, for higher and
lower screw speeds. The design variation was only on the pitch of the screw,
which was wider in one design than the other. Experiments were conducted
on both the designs, to analyse their technical performance. This report
presents the experimental data, results and analysis.
4.1.2 Testing with the Wide-pitch Screw
First, the briquetting experiments were performed using the wider pitch screw
with and without biomass preheating. Ricehusk was used as raw material.
Tables 2 and 3 present the summary results of the experiments. Average
total electrical energy consumption by the briquetting machine without
biomass pre-heating was 0.20 kWh/kg at an average production rate of 85.4
kg/hr (Table 2) whereas, briquetting with biomass preheating consumed an
average of 0.178 kWh of electrical energy for each kg of briquettes produced
(Table 3).

Table 2. Briquetting with wider pitch screw, without biomass pre-heating

Run
No.
1
2
3
4
5

Average
die
Temp. (C)

Production

Electricity consumption (kWh/kg)

rate (kg/hr)

Heater

Motor

Total

440
430
440
410
410
Average

84.6
84.0
81.4
85.0
92.0
85.4

0.077
0.074
0.070
0.071
0.065
0.0714

0.128
0.126
0.140
0.123
0.126
0.1286

0.206
0.200
0.210
0.194
0.191
0.2002

26

Table 3. Briquetting with wider pitch screw, with biomass pre-heating

Run
No.

1
2
3
4
5

Average
die
temp,
C
420
410
410
410
410
Average

Avg.
biomass
temp,
C
110
120
125
130
150

Production
rate

Electricity consumption
kWh/kg

kg/hr

Heater

Motor

Total

87.7
81.0
78.5
80.6
83.9
82.34

0.068
0.059
0.064
0.061
0.061
0.0626

0.106
0.115
0.104
0.112
0.109
0.1092

0.179
0.178
0.176
0.179
0.177
0.1778

Average savings in the electrical energy consumption due to pre-heating

were 12.3% at heater and 15.1% at motor respectively. The average total
energy saving (electrical heater and motor) was about 11.2%.
For briquetting with preheating, the highest and lowest electrical energy input
to the system were found to be 0.18 kWh/kg and 0.17 kWh/kg of briquettes
produced, respectively. The highest and lowest electrical energy
consumption for briquetting without biomass preheating was found to be 0.21
kWh/kg and 0.19 kWh/kg of briquettes produced, respectively.
Production capacity was in the range of 80 - 90 kg/hour and good quality
briquettes could be produced at a die temperature of around 410-440C.
Nevertheless, electrical energy was saved at the heater, motor and overall
system. When the die temperature was below 400C, the quality of briquettes
produced was poor, as indicated by many cracks on the briquette surface.
4.1.3 Testing with the Close-pitch Screw
Briquetting experiments were also carried out with the screw having closer
pitch. The results of the experiments are presented in Table 4 and 5.
Table 4. Briquetting with close-pitch screw, without biomass pre-heating
Run
No.
1
2
3
4

Average die
temp. (C)
390
390
365
380
Average

Production
rate (kg/hr)
91.6
87.7
85.9
88.3
88.38

Electricity consumption (kWh/kg)

Heater
Motor
Total
0.060
0.112
0.172
0.071
0.113
0.184
0.071
0.110
0.181
0.070
0.110
0.180
0.068
0.111
0.179

27

Table 5. Briquetting with close-pitch screw, with biomass pre-heating

Run
No.

1
2
3
4

Average
die
temp:
C
390
370
390
390
Average

Average
biomass
temp:
C
100
115
130
140

Production
rate

Electricity consumption
kWh/kg

kg/hr

Heater

Motor

Total

82.2
81.2
80.0
84.5
82.0

0.058
0.053
0.045
0.052
0.052

0.094
0.105
0.097
0.101
0.099

0.168
0.165
0.150
0.161
0.161

In the case of closer pitch screw, average electrical energy savings at the
heater, motor, and overall system were 23.5%, 10.8%, and 10.2%
respectively. The production capacity was also slightly higher than that for the
wider pitch screw.
4.1.4 Performance of the Biomass Stove Die Heater
The briquetting machine was tested with a biomass stove die-heater as well,
the fuel for the stove being ricehusk briquette chips. The briquette quality was
very good at a temperature of around 320C, in the beginning of the
operation. With the passage of time, the temperature gradually came down to
250C and briquettes could still be produced only with a change of color of
briquette surface from black (at higher temperature) to gray (at lower
temperature). It takes around 35 minutes to bring the die temperature to
320C, when briquetting could be started. The die temperature was noted to
often go out of control, irrespective of primary air supply control. It was found
that this was due to fuel blockade inside the pyrolysing chamber. An ash
scraper was then introduced, which could be operated at regular intervals
(once in 15-20 minutes) to clear the accumulated ash. The stove performed
remarkably well after this modification.
4.1.5 Conclusions
Experiments were conducted to investigate the effect of raw material preheating, screw speed and screw pitch on the overall energy consumption.
Two screws - a wide-pitch screw and a close-pitch screw - were used in the
experimentation. It was observed that the close-pitch screw design performed
better than the wide-pitch screw. It consumed lower electrical energy for both
with and without biomass pre-heating compared to the other. Moreover, in
the case of close-pitch screw, the briquetting could be accomplished at
comparatively lower temperature. The following observations were made
while using ricehusk as briquetting raw material:

28

Average savings in the electrical energy consumption due to

pre-heating were 23.5% at heater and 10.8% at motor
respectively, with close-pitch screw. The average total energy
saving was about 10.2%.

The lowest electrical energy consumption for rice-husk was

0.172 and 0.150 kWh/kg of briquettes produced, without and
with preheating respectively.

The above results do not take into account the electrical energy consumed by
the motor, which feeds the raw material through the biomass pre-heater. If
that is taken into account, the net energy saving due to pre-heating ricehusk
may not be significant.
It was found that the moisture content of ricehusk should not be more than 78% for smooth operation of the machine. At higher moisture levels, shooting
occurs from the die outlet while the briquetting operation was on, and
briquettes could not be produced both with and without biomass preheating.

4.2 Effects of Raw Material Type on Briquetting Energy Consumption

and Screw Life
4.2.1 Introduction
Experiments were conducted on the final design of the improved briquetting
system, integrating the biomass pre-heater, die-heating stove and smoke
removal system, to investigate the effect of raw material type on the
performance of the integrated system. This section presents the test results
and operating parameters of the improved briquetting system based on the
experiments conducted.
A set of experiments were carried out without pre-heating the biomass, and
another set with pre-heated biomass, to measure the energy savings due to
pre-heating as well. Other parameters such as screw speed and die
temperature were maintained constant in both cases, to the possible extent,
for a consistent comparison. Biomass stove was used in both the cases for
die heating.
Two sets of experiments were conducted: (1) with ricehusk, and (2) with
mixed raw materials, of ricehusk and sawdust, at 1:1 ratio, to investigate the
energy consumption of the briquetting process as well as the life of
briquetting screws.

29

4.2.2 Ricehusk as raw material

The briquetting machine was run at three different screw speeds, 370 rpm,
465 rpm, and 560 rpm, and its performance evaluated. Tables 6 and 7
present the experimental results at a screw speed of 370 rpm, with and
without pre-heating.
Table 6. Briquetting without preheating. Screw speed: 370 rpm
Expt. No.

Production
rate (kg/hr)

1
2
3
Average

68.5
64.8
68.0
67.1

Total energy
consumption
(kWh/ kg)
0.107
0.103
0.103
0.104

Moisture
content (%)

Average Die
Temp. (C)

9.6
9.3
9.1

260
237
248
248

Table 7. Briquetting with preheating. Screw speed: 370 rpm

Expt. No.

Production
rate (kg/hr)

1
2
3
Average

63.0
66.0
68.9
66.0

Total energy
consumption
(kWh/ kg)
0.121
0.088
0.137
0.115

Moisture
content (%)

Average Die
Temp. (C)

9.3
9.3
9.7

266
273
226
255

It may be noted that the total electrical energy consumption of the briquetting
process actually increased with pre-heating the ricehusk, indicating a
possible mis-match between the screw speed and optimum loading of the
electrical motor. The screw speed was therefore increased to 465 rpm, and
the experiments were continued. Tables 8 and 9 present the results of the
experiments.
Table 8. Briquetting without preheating. Screw speed: 465 rpm
Expt. No.

Production
rate (kg/hr)

1
2
3
Average

66
70
84.5
73.5

Total energy
consumption
(kWh/ kg)
0.152
0.133
0.116
0.133

30

Moisture
content (%)

Average Die
Temp. (C)

9
9
11

224
251
253
243

Table 9. Briquetting with preheating. Screw speed: 465 rpm

Expt. No.

Production
rate (kg/hr)

1
2
3
Average

73.0
76.3
69.6
73.0

Total energy
consumpn.
(kWh/ kg)
0.131
0.133
0.115
0.126

Moisture
content
(%)
8.5
6.1
9.1

Average Die
Temp. (C)
253
248
271
257

At a screw speed of 465 rpm, the total electrical energy consumption slightly
decreased with pre-heating the ricehusk. The decrease was however not
significant. Also, there was a general increase in energy consumption at this
screw speed, both with and without pre-heating, when compared to screw
speed of 370 rpm. No significant difference was noted in the production rate.
The screw speed was further increased to 560 rpm and the results analysed.
Tables 10 and 11 present the results of the experiments at 560 rpm.
Table 10. Briquetting without preheating. Screw speed: 560 rpm
Expt. No.

Production
rate (kg/hr)

1
2
3
Average

78.0
80.6
87.4
82.0

Total energy
consumption
(kWh/ kg)
0.131
0.150
0.130
0.137

Moisture
content (%)

Average Die
Temp. (C)

11.0
9.0
9.5

237
238
230
235

Table 11. Briquetting with preheating. Screw speed: 560 rpm

Expt.
No.

Production
rate (kg/hr)

1
2
3
Average

79.6
73.7
61.0
71.4

Total energy
consumption
(kWh/ kg)
0.113
0.135
0.163
0.137

Moisture
content (%)

Average Die
Temp. (C)

8.7
9.2
8.6

230
225
246
234

Figure 20 illustrates the relationship between the screw speed, production

rate and energy consumption, with ricehusk as raw material.

31

Screw Speed Vs Production Rate and Power

Consumption(100% rice husk)

80

0.100

70

0.080
0.060

60

0.040
50

0.020

40

0.000

370

465

0.130
80

0.125
0.120

70

0.115

60

0.110
50

0.105

40

560

0.100

370

Screw speed (rpm)

Production rate

0.135

90

Power consumption
(kWh/Kg)

0.120

Production rate(kg/hr)

0.140

0.140

100

0.160

90

Power consumption
(kWh/kg)

Production rate (kg/ hr)

100

Screw Speed Vs Production Rate and Power

Consumption (100% Rice husk)

465

560

Screw speed (rpm)

Power consumption

Production rate

Power consumption

(b) With preheating

(a) Without pre-heating

Figure 20. Screw speed Vs. Production Rate and Specific Energy Consumption,
with ricehusk as raw material

Energy Consumption:
With ricehusk as raw material, the energy consumption figures with and
without pre-heating show inconsistent results, with no direct correlation
between energy consumption, production rate and screw speed.
While pre-heating results in a slight reduction in energy consumption by the
electrical motor driving the screw, the saving, in most cases, is more than
offset by the energy consumed by the motor driving the conveyor screw in
the biomass pre-heater. Thus, the experimental results so far indicate that
pre-heating ricehusk does not seem to offer definite energy saving
advantages.
Briquetting Screw Life:
It has been noted that a higher briquetting screw speed reduces the screw
life and therefore is not a preferred option to increase production rates. Screw
life was found to be highest at a screw speed of 370 rpm while it was lowest
at 560 rpm. Pre-heating the ricehusk seems to decrease the screw life by
about 25% for screws made of mild steel, and tempered in oil.
Briquette Quality:
Briquette quality is inspected visually, and judged in terms of the
smoothness, cracks, and colour of the briquette surface. Without pre-heating,
the quality of ricehusk briquettes is generally better than that with preheating. This may be due to drying of the ricehusk during the pre-heating
process to below a minimum level of moisture, which is required for good
binding of the ricehusk particles.

32

It was found that fresh ricehusk is a better raw material than that which is
kept in storage for prolonged periods, in terms of briquette quality, production
rate and energy consumption. The old ricehusk releases a powdery dust
around the machine during the briquetting process, which may be harmful if
inhaled. Also, old ricehusk produces low quality briquettes, with cracked
surfaces and small pieces of briquettes.
4.2.3 Mixed raw materials, of ricehusk and sawdust, at 1:1 ratio by
volume.
Ricehusk and sawdust were mixed at 1:1 ratio by volume, and the briquetting
experiments were continued. Tables 12 and 13 present the results for a
screw speed of 370 rpm while Tables 14 and 15 furnish the test results at a
screw speed of 465 rpm.
Table 12. Briquetting without preheating. Screw speed: 370 rpm
Expt. No.
1
2
3
Average

Production
rate (kg/hr)
89.5
98.2
93
93.6

Total energy
Moisture
consumpn. (kWh/ kg) content (%)
0.0849
10.5
0.0678
6.85
0.0785
8.8
0.0771

Average Die
Temp. (C)
225
241
229
232

Table 13. Briquetting with preheating. Screw speed: 370 rpm

Expt. No.
1
2
3
Average

Production
rate (kg/hr)
81.1
74.33
72
75.81

Total energy
Moisture
consumpn. (kWh/ kg) content (%)
0.0877
5.9
0.0867
6.6
0.095
5.6
0.0898

Average Die
Temp.(C)
282
264
258
268

Table 14. Briquetting without preheating. Screw speed: 465 rpm

Expt. No.
1
2
3
Average

Production
rate (kg/hr)
66.4
87.69
96
83.36

Total energy
Moisture
consumpn. (kWh/ kg) content (%)
0.0864
8.6
0.0877
9
0.0778
10
0.0839

33

Average Die
Temp. (C)
258
211
225
231

Table 15. Briquetting with preheating. Screw speed: 465 rpm

Expt. No.
1
2
3
Average

Production
rate (kg/hr)
100.5
99.8
98
99.43

Total Energy
consumpn. (kWh/kg)
0.0955
0.0804
0.1008
0.0922

Moisture
content (%)
8.5
7.6
8.4

Average Die
Temp.(C)
263
247
235
248

Figure 21 illustrates the relationship between the screw speed, production

rate and energy consumption, with mixed raw material, of ricehusk and
sawdust, at a ratio of 1:1 by volume.
Screw speed Vs Production Rate and Power
Consumption (50%rice husk-50%sawdust)

100

0.086

100

90

0.084

90

0.078
60

0.076

50

80

0.089
0.089

70
0.089
60

0.089
0.089

0.074

50

Power consumption (kWh/kg)

0.080
70

0.090
Production rate(kg/hr)

0.082

80

0.090
0.090

Power consumption
(kWh/kg)

Production rate(kg/hr)

Screw speed Vs Production Rate and Power Consumption

(50% rice husk-50% sawdust)

0.088

0.072

40
370

465

40

560

Screw speed (rpm)

Production rate

0.088
370

465

560

Screw speed (rpm)

Power consumption

Production rate

(a) Without pre-heating

Power consumption

(b) With preheating

Figure 21. Screw speed Vs. Production Rate and Specific Energy
Consumption, with mixed raw material, of ricehusk and sawdust.

Energy Consumption:
Mixing sawdust with ricehusk has resulted in an overall reduction in energy
consumption by the briquetting process, when compared to pure ricehusk as
raw material. While the specific energy consumption without pre-heating
dropped by about 25%, energy consumption with pre-heating also came
down by about 22%, for a screw speed of 370 rpm. Similar trend was also
noted for the screw speed of 465 rpm.
Briquetting Screw Life:
In general, the screw life with the mixed raw materials was significantly
higher compared to that with pure ricehusk. A 25% increase in screw life was

34

realised for a screw speed of 370 rpm, while the increase was 60% for a
screw speed of 465 rpm.
Briquette Quality:
Unlike in the case of pure ricehusk, pre-heating offers better quality
briquettes with the mixed raw materials. The production rate is lower at 370
rpm, while it is higher at 465rpm.
4.2.4 Conclusions
Several experiments were carried out to evaluate the effect of raw material
type on the performance of the integrated biomass briquetting system,
consisting of the biomass pre-heater, die-heating stove and smoke removal
system. Results indicate considerably less energy consumption when mixed
raw materials (ricehusk and sawdust, at 1:1 ratio by volume) are used in
comparison with pure ricehusk as raw material. Significant reductions in
electrical energy consumption have been realised with the introduction of the
die-heating stove to replace the electrical coil heaters. The smoke recycling
system has also improved the working environment at the briquetting plant,
by significantly reducing smoke in the vicinity.

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39

About RETs in Asia

The
project
Renewable
Energy
Technologies in Asia: A Regional Research
and Dissemination Programme (RETs in Asia)
was initiated in 1997 with the broad aim of
contributing to sustainable development of
the Asian region through promoting the
utilization of renewable energy resources for
meeting indigenous energy needs of the
countries in Asia. The project promoted the
diffusion of selected renewable energy
technologies in a group of six Asian countries
through
a
regional
research
and
dissemination program. Regional approach
and institutional co-operation remained in
the forefront of strategies adopted by the
project. Photovoltaics, solar and biomassbased drying, and biomass briquetting are
the technologies selected for promotion. The
project is supported by the Swedish
International Development Cooperation
Agency (Sida) and coordinated by the
Asian Institute of technology (AIT).
For further information, please contact:
Prof. S.C. Bhattacharya
Coordinator, RETs in Asia Programme
Energy Field of Study
Asian Institute of Technology
P.O. Box 4, Klong Luang
Pathumthani 12120, Thailand
Tel: +66-2-524 5403
Fax: +66-2-524 5439
E-mail: bhatta@ait.ac.th

A publication of RETs in Asia

http://www.retsasia.ait.ac.th/
40