Automatic Agro-Waste Briquettes

Making Machine

A PROJECT BASED LEARNING-II REPORT SUBMITTED IN PARTIAL

FULFILLMENT OF
S.E. Mechanical Engineering
Submitted By

TEJAS GACHAKE B190310853

SHRILEEN DHARKAR B190310841

KEYUR TARE B190311013

ADITYA WAJPE B190311027

Under the Guidance of

Prof. G. S. Mahajan

Department of Mechanical Engineering,

PES’s Modern College of Engineering
Pune – 411 005
[2023-24]
 Progressive Education Society’s
Modern College of Engineering, Pune

CERTIFICATE
This is to certify that the A PROJECT BASED LEARNING-II REPORT entitled

AUTOMATIC AGRO-WASTE BRIQUETTES MAKING MACHINE

Has Successfully Completed By

TEJAS GACHAKE B190310853

SHRILEEN DHARKAR B190310841
KEYUR TARE B190311013
ADITYA WAJPE B190311027

Under the guidance of

PROF. G. S. MAHAJAN
During the Academic Year 2023-24

Prof. G.S.Mahajan Prof. Dr. S. Y. Bhosale

Asst. Professor HOD Mechanical
Guide
ACKNOWLEDGEMENT
I would like to express my heartfelt gratitude and appreciation to all those who have
contributed to the successful completion of the project titled "Automatic Agro Waste
Briquettes Making Machine."

First and foremost, I would like to extend my deepest thanks to our project guide Prof.
G.S. Mahajan Sir (Guide Name) for their invaluable guidance, unwavering support,
and continuous encouragement throughout the duration of this project. Their
expertise, knowledge, and constructive feedback were instrumental in shaping the
project's direction and ensuring its successful implementation.

I am immensely grateful to the members of my project team, whose dedication, hard

work, and commitment made this project a resounding success. Their collaborative
efforts, innovative ideas, and effective teamwork were crucial in overcoming
challenges and achieving the desired outcomes. Each team member's unique skills and
contributions played an integral role in the project's accomplishment.

I would also like to thank the experts and researchers in the field of briquette making
who generously shared their knowledge and insights. Their expertise and guidance
significantly contributed to the project's success and enhanced its overall quality.

Last but not least, I would like to thank to our respected HOD sir Dr. S.Y. Bhosale Sir
for their unwavering support, understanding, and encouragement throughout this
endeavor. Their belief in me and their constant motivation have been a source of
strength and inspiration.

In conclusion, the successful completion of this project would not have been possible
without the collaborative efforts and support of all those mentioned above. Each
individual's contribution, no matter how big or small, played a significant role in
making this project a reality. Thank you all for your invaluable contributions and
unwavering support.

TEJAS GACHAKE

SHRILEEN DHARKAR

KEYUR TARE

ADITYA WAJPE
 INDEX

Sr. Chapter/ Contents Page

No. No.
Acknowledgement
List of Figures
Nomenclature
Abstract
Chapter 1
z Introduction 1
Chapter 2
2 Literature Review 3
Chapter 3
3 Problem Statement 6
3.1 Objectives 7
3.2 Scope 7
3.3 Methodology 8
Chapter 4
4 Experimental Work 9
4.1 Main Components of Briquette Making Machine 9
Chapter 5
5 Design, Modelling and Simulation 22
5.1 Design Calculations 22
5.2 CAD Modelling 26
5.3 Structural Analysis on ANSYS Software 32
Chapter 6
6 Working and Manufacturing 39
6.1 Working of machine 39
6.2 Manufacturing Processes 40
Chapter 7
7 Cost Estimation 49
7.1 Purpose of Cost Estimation 49
7.2 Types of Cost Estimation 49
7.3 Procedure for Calculation of Material Cost 50
Chapter 8
8 Results 52
Chapter 9
9 Conclusion 53
References
LIST OF FIGURES
Figure 3.1 Methodology
Figure 4.1 Hollow M.S Pipes
Figure 4.2 Motor
Figure 4.3 Pneumatic cylinders
Figure 4.4 Pneumatic cylinders
Figure 4.5 Solenoid Valve
Figure 4.6 Ultrasonic Sensor
Figure 4.7 Arduino Uno
Figure 4.8 Arduino ATmega328p
Figure 4.9 A grinder with a lead screw
Figure 4.10 V-Belt and Pulley
Figure 5.1 Drafting Model
Figure 5.2 3D Isometric View
Figure 5.3 3D Top view
Figure 5.4 Drafting of Model Top View
Figure 5.5 Drafting of Model Front View
Figure 5.6 Geometry of biomass briquettes making machine
Figure 5.7 Material Properties
Figure 5.8 Finite elements mesh model of biomass briquettes making machine
Figure 5.9 Boundary Condition of biomass briquettes making machine
Figure 5.10 Boundary Condition of biomass briquettes making machine
Figure 5.11 Total deformation of biomass briquettes making machine
Figure 5.12 Equivalent Stress of biomass briquetting making machine
Figure 6.1 Cutting Operation
Figure 6.2 Welding operation
Figure 6.3 Drilling Operation
Figure 6.4 Drilling Tool
Figure 6.5 Finishing Operations
Figure 6.6 Polishing Machine
NOMENCLATURE

T1 Tension at slack side of pulley

T2 Tension on tight side on pulley
D1 Diameter of driver pulley
D2 Diameter of driven pulley
N1 Speed of driver pulley in rpm
N2 Speed of driven pulley in rpm
V Velocity of Belt Drive in M/s
L Length of Belt in mm
P Power in watt
C Centre Distance Between the pulley in mm
R1 Radius of driver pulley
R2 Radius of driven pulley
ABSTRACT

The project titled "Automatic Agro Waste Briquettes Making Machine" aims to
develop an innovative solution for transforming agricultural waste materials into
briquettes efficiently and automatically. The utilization of agro waste for briquette
production offers a sustainable alternative to traditional fuels and contributes to waste
management practices.

The automatic briquette making machine incorporates advanced technology and

engineering principles to streamline the briquette manufacturing process. The
machine is designed to handle various types of agro waste materials, such as rice
husk, straw, corn stalks, and sugarcane bagasse, among others. By automating the
process, it ensures consistent quality and higher production efficiency.

The successful completion of this project will result in an automatic agro waste
briquettes making machine that offers numerous benefits. Firstly, it provides an
environmentally friendly solution for utilizing agricultural waste, reducing its
negative impact on the environment. Secondly, the machine enables efficient
utilization of biomass resources, contributing to sustainable energy production.
Additionally, the briquettes produced possess higher energy content, lower moisture
content, and better combustion characteristics compared to traditional fuels, such as
firewood or charcoal.
1. INTRODUCTION

Briquettes making machines are innovative devices used to convert various types of
agricultural, forestry, and industrial waste materials into compressed solid blocks
known as briquettes. These machines are designed to reduce the volume of waste
materials and convert them into a convenient and energy-dense form for efficient
storage, transportation, and use.

Briquettes are typically made from materials such as sawdust, wood chips, agricultural
residues, charcoal fines, coal dust, and various biomass materials. By using a briquette
making machine, these raw materials are compressed under high pressure and without
the use of any binders or chemicals. The resulting briquettes have a uniform shape and
density, making them easy to handle and burn.

The process of making briquettes involves feeding the raw materials into the machine's
hopper, where they are then compressed by a mechanical or hydraulic press. The
pressure applied during the compression process causes the lignin present in the
biomass materials to soften and bind the particles together. This binding process
allows the briquettes to maintain their shape and integrity.

Briquettes offer several advantages over traditional fuels such as firewood and
charcoal. They have a higher energy content and burn more efficiently, resulting in
reduced smoke, emissions, and ash production. Briquettes also provide a sustainable
solution to waste management, as they utilize agricultural and industrial by-products
that would otherwise be discarded or left unused.[5]

The briquette making machines available on the market vary in size, capacity, and
operation. Some machines are manually operated, while others are fully automated.
The choice of machine depends on factors such as the scale of production, available
resources, and desired output.

Overall, briquette making machines play a crucial role in promoting sustainable energy
solutions and waste management practices. By transforming waste materials into
valuable fuel sources, these machines contribute to environmental conservation and
provide an alternative to traditional fuels, thereby reducing reliance on non-renewable
resources.

In the agricultural sector, the generation of agro waste such as crop residues, straw,
husk, and other agricultural by-products is a significant issue. The improper
`and health hazards. Currently, the majority of farmers resort to burning these
wastes, causing air pollution and contributing to climate change.[5]
Automatic agro waste briquette making machines are innovative and efficient devices
designed to convert agricultural waste into briquettes. These machines offer a
sustainable solution to the problem of agro waste management by utilizing the residual
biomass generated from various agricultural activities.

The process of agro waste briquette making involves compressing the biomass
residues, such as crop stalks, rice husks, straw, sawdust, or any other organic waste,
into compact and dense briquettes. These briquettes serve as an eco-friendly
alternative to traditional fuels like firewood or coal, offering several advantages.

Automatic agro waste briquette making machines are equipped with advanced
technology and components to automate the briquetting process. They typically consist
of a feeding system that delivers the agro waste into the machine, a compression
chamber where the biomass is compressed, and a heating element that helps bind the
biomass particles together to form solid briquettes.

These machines are designed to be user-friendly, with simple controls and operation.
They can produce briquettes in various shapes and sizes, depending on the
requirements. The automation feature allows for continuous operation and high
production rates, making it suitable for large-scale agricultural waste management.

The benefits of automatic agro waste briquette making machines are manifold. Firstly,
they provide a sustainable solution to the disposal of agricultural residues, reducing
environmental pollution and greenhouse gas emissions. Secondly, briquettes produced
from agro waste have higher calorific value than raw biomass, making them an
efficient fuel source for various applications, including heating and cooking.

Moreover, agro waste briquettes are compact and easy to handle, making them
convenient for storage, transportation, and distribution. They are also smokeless and
have lower ash content, resulting in cleaner combustion and reduced air pollution.

In summary, automatic agro waste briquette making machines offer an innovative and
eco-friendly approach to utilize agricultural waste effectively. They contribute to
sustainable waste management, energy conservation, and environmental protection
while providing an alternative fuel source for various industries and households.[6]
2. LITERATURE REVIEW

● K.Sahooa , E.Bileka etc. [2019] Techno-economic analysis of producing solid

biofuels and biochar from forest residues using portable systems.

In this study, the techno-economic assessment of three portable systems to

produce woodchips briquettes (WCB), torrefied woodchips briquettes (TWCB)
and biochar from forest residues were evaluated using pilot-scale experimental
data. A discounted cash flow rate of return method was used to estimate
minimum selling prices (MSPs) for each product, to conduct sensitivity analyses,
and to identify potential cost-reduction strategies.

● J.Orisaleye,, S.Ojolo, etc. [2019] Mathematical modelling of die pressure of a

screw briquetting machine

In this paper, mathematical models were developed to study the die pressure
using a plug flow theory. Effects of die entry angle, die reduction ratio, length of
briquetting die, biomass compact yield strength and friction on the die pressure
were investigated using the models. Increasing the die entry angle, reduction
ratio, compact yield strength and friction coefficient resulted in increase in the die
pressure.

● J.Arevalo G.quispe etc. [2017] Sustainable energy model for the production of
biomass briquettes based on rise husk in low income agricultural areas.

The design of the machine is based on the results of a comprehensive study of the
complicated process of biomass compaction. The patented structure meets two
main goals: the elimination of axial forces, leading to increased lifetime of the
bearings, and the new modular design of a pressing chamber and tools with their
geometry based on the application of a mathematical model.
● M.Hamid, M.YusofIdroas,, etc [2017] An Experimental Study of Briquetting
Process of Torrified Rubber Seed Kernel and Palm Oil Shell

There was a significant effect of optimizing the composition of starch as binder

and water to the physical characteristics of the biomass briquettes. In fact, the
stronger and more stable particles of the biomass briquettes that improved their
hardness and durability was realized by adding the starch as the binder, which
controlled its composition together with the composition of water in the mixture
prior to the briquetting process.

● D.Madariya, [2017] Production of loose biomass briquettes from agricultural

and forestry residues, International Conference on Food, Agriculture, and
Natural Resources,
Sustainable agriculture production is a key on achieving food consumption
adequacy in developing country but many farmers should struggle more in
fulfilling production sustainability whilst keeping on with the economical
target. The research was endeavored to seek a viable application on achieving
agricultural sustainability and recognizing farmers and community
biggestobstacles such as energy by turning agricultural waste such as corn cob
and rice husk into bio briquettes.

● G.Ngusale ,[2014] “Briquette Making in Kenya; Nairobi and Peri-Urban

Areas”
The key findings from this literature are Survey covered 18 briquette
entrepreneurs; Charcoal dust was the most common feedstock for briquette
production; Consumers are the schools, churches, hotels and some
households; Barriers identified included; technological challenges (lack of
briquetting machines, low quality binders and lack of appropriate feedstock),
lack of finance to grow the business, and lack of briquette standards.
● M.Njenga , [2013] “Evaluating Fuel Briquette Technologies and their
Implications on Greenhouse Gases and Livelihoods in Kenya”,
The key findings from this literature are Study of briquette production
methods in Nairobi and surroundings; A Focus Group Discussion (FGD)
with 8 self-help groups and one private company was carried out;
Additionally, laboratory experiments on ash contents, volatile matter and
calorific values for the different types of briquettes were conducted; Fuel
briquettes made from charcoal dust and soil as the binder performed the best
in terms of combustion and emission qualities; Type of tree species
determine the quality of charcoal dust produced during charcoal production;
Carbonizing sawdust increased calorific value of the briquette by 40%,
reduced Indoor Air Concentration (IAC) of CO by 67% and P.M 2.5 by
98%; Adopting improved wood production and wood carbonization systems
will result in additional cooking fuel supply and reduced Global Warming
Potential; Trainings to community groups were recommended to aid in
improving the quality of briquettes produced.
● T,Owen.. and M .Pighart., [2012] “Opportunities, challenges and way forward for
the charcoal briquette industry in Sub-Saharan Africa”,
Study covered charcoal producers in Kenya, Rwanda, Uganda, and Tanzania;
Briquettes have displaced only small volumes of charcoal demand; Main barriers
in the sector include; low prices of wood charcoal, fiscal requirements for
briquette producers, and supply-driven (versus market-led) approaches to industry
development.
3. PROBLEM STATEMENT
The existing methods of manually converting agro waste into briquettes are
time- consuming, labor-intensive, and inefficient. These manual processes
require a substantial amount of manual labor, and the produced briquettes may
not be of consistent quality. Moreover, the lack of access to appropriate
briquetting machinery poses a significant challenge for small-scale farmers and
rural communities, restricting their ability to convert agro waste into valuable
biomass fuel.

Therefore, there is a need for an Automatic Agro Waste Briquettes Making

Machine that can efficiently and effectively convert agro waste into high-quality
briquettes. This machine should be user-friendly, portable, and capable of
handling a variety of agro waste materials. It should have automated features to
reduce human intervention and increase productivity. The machine should also
address the concerns of environmental sustainability by utilizing agro waste as a
renewable energy source and reducing the emission of greenhouse gases caused
by the burning of agricultural residues. It should provide an eco-friendly
solution to manage agro waste and promote sustainable agriculture practices.
3.1 OBJECTIVES
The objective of an automatic briquette making machine specifically designed for
agriculture waste is to efficiently convert agricultural residues and waste materials into
briquettes. The machine aims to address the following objectives:

● Waste Utilization
● Energy Generation
● Waste Management
● Cost Savings
● Automation and Efficiency
● Efficiency
● Consistency
● Versatility
● Automation and Control
● Quality Control
● Safety

3.2 SCOPE
● Brick Making Unit
● Milk Plant
● Lamination Industries
● Textile Processing Industries
● Rubber Industries
● Ceramic Industries
● Dyeing Industries
3.3 METHODOLOGY

Figure 3.1 Methodology

4. EXPERIMENTAL WORK

4.1 Main Components of Briquettes Making Machine

The model consist of following components :

● Frame

The frame is usually made of mild steel. It is strong enough to withstand all types of
loads in working condition. All other parts are fitted to the frame. Frame is helping the
supporting of the various light load support. Frame shows the good aesthetic loop.
every machine should have required the good frame design. Frame material should
have high strength because frame balancing of another machine load. in ours project
the frame showing important role. the vertical pulley and sprocket are mounted on
vertical support of the frame. Main whole project assembly our project mounted on
frame. The proper selection of material for the different part of a machine is the main
objective in the fabrication of machine. For a design engineer it is must that he be
familiar with the effect, which the manufacturing process and heat treatment have on
the properties of materials. The Choice of material for engineering purposes depends
upon the following factors: Availability of the materials. Suitability of materials for the
working condition
in service. The mechanical properties of the metals are those, which are associated
with the ability of the material to resist mechanical forces and load. We shall now
discuss these properties as follows: Strength: It is the ability of a material to resist the
externally applied forces Stress: Without breaking or yielding. The internal resistance
offered by a part to an externally applied force is called stress.

Properties of Mild Steel: M.S. has a carbon content from 0.15% to 0.30%. They are
easily wieldable thus can be hardened only. They are similar to wrought iron in
properties. Both ultimate tensile and compressive strength of these steel increases with
increasing carbon content. They can be easily gas welded or electric or arc welded.
With increase in the carbon percentage weld ability decreases. Mild steel serves the
purpose and was hence was selected because of the above purpose

Figure 4.1 Hollow M.S Pipes

The hollow square pipes of material of mild steel are selected for the frame. The pipes
are cut into required size by cutting machine. The end of the pipes cut into 45 degree
(angle) to form rectangular frame. After cutting, the end of the square pipes is grinded
so that it became smooth and convenient for welding. The square pipes are welded
together to form a rectangular basic frame.
● Motor
A 0.5 HP motor used for crushing and mixing agricultural waste in a briquette
making machine is a relatively small motor with a power rating of 0.5 horsepower.
Here is some specific information about the motor for this application:

Figure 4.2 Motor

1. Power Rating: The motor has a power rating of 0.5 HP, which means it can
deliver half a horsepower of mechanical power. This power rating is suitable for the
crushing and mixing tasks involved in briquette making using agricultural waste.

2. Voltage and Current: The motor typically operates on a standard voltage of

either 110V or 220V, depending on the specific application and location. The current
required by the motor depends on the voltage and the motor's efficiency but is
generally in the range of a few amperes.
3. Speed: The motor's rotational speed, measured in revolutions per minute
(RPM), is an important consideration for efficient crushing and mixing of agricultural
waste. The speed should be chosen based on the specific requirements of the briquette
making machine and the desired particle size and mixing quality.

4. Enclosure: Since the motor will be used in a briquette making machine, it is

crucial to ensure it has proper protection from environmental factors such as dust,
moisture, and vibrations. An appropriate enclosure, such as an IP55-rated enclosure,
will help extend the motor's lifespan and ensure reliable performance in the crushing
and mixing process.

5. Efficiency: The motor's efficiency is a significant factor to consider, as it

determines how effectively it converts electrical power into mechanical power. Higher
efficiency motors are desirable as they minimize energy losses, reduce operating costs,
and contribute to environmental sustainability.

6. Mounting: The motor should be designed for easy mounting onto the briquette
making machine. It may have mounting brackets or a base that allows secure
installation and integration with the rest of the equipment.

When selecting a motor for a briquette making machine, it is important to consider the
specific requirements of the application, such as the type and quantity of agricultural
waste to be crushed and mixed, the desired output capacity, and any other operational
parameters. This will ensure that the motor chosen is suitable for the project's needs
and can deliver reliable performance over time.
● Pneumatic Cylinders:
Pneumatic cylinder(s) (sometimes known as air cylinders) are mechanical
devices which use the power of compressed gas to produce a force in a
reciprocating linear motion. Like hydraulic cylinders, something forces a piston
to move in the desired direction. The piston is a disc or cylinder, and the piston
rod transfers the force it develops to the object to be moved. Engineers
sometimes prefer to use pneumatics because they are quieter, cleaner, and do not
require large amounts of space for fluid storage. Double-acting cylinders (DAC)
are use the force of air to move in both extend and retract strokes. They have
two ports to allow air in, one for outstroke and one for in stroke. Stroke length
for this design is not limited, however, the piston rod is more vulnerable to
buckling and bending. Additional calculations should be performed as well.

Figure 4.3 Pneumatic cylinders

Figure 4.4 Pneumatic cylinders

Specification:
Product Name - Air Cylinder Model MAL25x50
Action Type -Double Action
Material - Aluminium Alloy
Bore - 25mm ; Stroke ; 50mm
Max Pressure – 1 MPA ; End Cap- Thread M22x1.5
Rod Thread Diameter - M10x1.25 ; Air Hole Diameter - PT1/8

● 1/4 Inch 5/2 Way 12V DC Single Solenoid Valve

5/2 solenoid valves and 5/3 solenoid valves are most often used as directional
control valves for double-acting pneumatic actuators. The single-coil type of 5/2
valve usually has a spring or pilot air return so that when de-energised, the valve
returns to it's starting function. Dual coil valves do not have this return facility and
require the second coil to be energised to return the valve to the start position. 5/3
valves have 2 coils and if neither is energised, the default state it returns to in the
centre position can either be all ports blocked, all ports open or pressure applied in
that the inlet pressure is connected to both outlet ports. Manual reset valves require
operator intervention in order for the valve to maintain the energised position.

Figure 4.5 Solenoid Valve

Specifications:

Brand Name : TECHNO

Valve Type : 5/2
Thread Size : 1/4 Inch
40 Micron Filtered Lubricated
Working Medium : Air
Applicable Temperature : 5-50°C
Voltage : 12 VDC

● HC-SR-04 Ultrasonic Sensor

Figure 4.6 Ultrasonic Sensor

Specifications:

This is the HC-SR04 ultrasonic distance sensor. This economical sensor provides 2cm
to 400cm of non-contact measurement functionality with a ranging accuracy that can
reach up to 3mm. Each HC-SR04 module includes an ultrasonic transmitter, a receiver
and a control circuit.

● Arduino ATmega328p
Nowadays, with Microcontrollers being relatively cheap and readily available in
the market, making a purchase decision on a suitable one to pick might a hard task
to handle. However, there’s one particular model that’s good to start with for users.
That model is the ATmega328p, an 8-bit AVR microcontroller.

Figure 4.7 Arduino UNO

 ATmega328P is a high performance yet low power consumption 8-bit AVR
microcontroller that’s able to achieve the most single clock cycle execution of 131
powerful instructions thanks to its advanced RISC architecture. It can commonly be
found as a processor in Arduino boards such as Arduino Fio and Arduino Uno.

Features:

● In system self-programmable flash program memory

● Programming Lock for software security
● High endurance non-volatile memory segments

Figure 4.8 Arduino ATmega328p

Peripheral features

● Two 8-bit Timer/Counter with separate prescaler, compare mode.

● One 16-bit Timer/Counter with separate prescaler, compare mode, and capture mode
● Temperature measurement
● Programmable serial USART and watchdog timer with separate on-chip oscillator.
 Unique features compared to other microcontrollers (ARM, 8051, PIC):

● Power-on reset and programmable brown-out detection

● Internal calibrated oscillator
● External and Internal interrupt sources
● Six sleep modes: Idle, ADC noise reduction, power-save, power-down, standby
● extended standby

Advantages:

● Processors are simpler to use, with the usage of 8bit and 16bit instead of 32/64bit
which are more complex
● Readily usable without additional computing components with 32k bytes of
onboard self-programmable flash program memory as well as 23 programmable I/O
lines

● Grinder with Lead Screw

Figure 4.9 A grinder with a lead screw

A grinder with a lead screw, used in a briquette making machine to grind and mix
agricultural waste, typically consists of the following components:

1. Lead Screw: The lead screw is a threaded rod that converts rotary motion into
linear motion. It is an essential component in the grinder, providing the mechanism to
advance the grinding and mixing process.

2. Grinder Body: The grinder body houses the internal components and provides
structural support. It is typically made of sturdy materials such as cast iron or steel to
withstand the forces involved in grinding agricultural waste.

3. Grinding Chamber: The grinding chamber is the enclosed space where the
agricultural waste is fed and processed. It contains various grinding elements, which is
a lead screw.

4. Hopper: The hopper is a container located above the grinding chamber, where
the agricultural waste is loaded for processing. It allows for controlled and uniform
feeding of the waste into the grinder.

5. Motor: The motor provides the power necessary to drive the grinder and the
lead screw. It can vary in power rating depending on the size and capacity of the
grinder, but for this specific application, a motor with suitable power, such as 0.5 HP,
can be used.

6. Belt or Gear Drive: The motor is typically connected to the lead screw and
grinder mechanism using a belt or gear drive system. This system transfers the motor’s
rotational motion to the lead screw, allowing for precise control and movement of the
grinder.

7. Control Mechanism: A control mechanism, such as a switch or control panel, is

provided to start, stop, and control the operation of the grinder. It may include features
such as speed control or safety mechanisms to ensure proper and safe operation.

8. Discharge Mechanism: Once the agricultural waste is ground and mixed, a

discharge mechanism is employed to remove the processed material from the grinding
chamber. This can be in the form of a chute, conveyor, or other suitable means of
material transfer.
The specific design and construction details of the grinder with a lead screw may vary
depending on the manufacturer and the requirements of the briquette making machine.
It is important to ensure that the grinder is robust, efficient, and capable of handling
the grinding and mixing process for agricultural waste effectively.

● V- Belt and Pully

Figure 4.10 V- Belt and Pully

Specifications:

Outer diameter of Driven Pulley : 250 mm

Outer diameter of Driver Pulley : 50 mm

Centre to Centre Distance: 300mm

Type of Belt Used : V- Belt

A belt and pulley drive is commonly used in briquette making machines to transmit
power from the motor to the grinder. Here is some information about the belt and
pulley drive system:
1. Motor: The motor provides the power to drive the grinder in the briquette
making machine. It is typically an electric motor with a suitable power rating, such as
0.5 HP, to meet the requirements of the grinding process.

2. Pulleys: The drive system consists of two pulleys: a driver pulley connected to
the motor shaft and a driven pulley connected to the grinder shaft. The pulleys are
typically made of durable materials such as cast iron or steel and have grooves or teeth
on their outer circumference to grip the belt.

3. Belt: The belt is a flexible loop made of materials like rubber or synthetic
polymers. It connects the driver and driven pulleys, transmitting the rotational motion
and power from the motor to the grinder. V-belts or timing belts are commonly used in
such drive systems, depending on the design and requirements.

4. Tensioner: A tensioner mechanism is often incorporated to maintain the proper

tension in the belt. It helps ensure that the belt remains in contact with the pulleys and
prevents slippage or loss of power transmission.

5. Adjustability: The position of the driven pulley can often be adjusted to control
the speed or torque transmission ratio between the motor and the grinder. This
adjustability allows for optimization of the grinding process based on the specific
requirements of the briquette making machine.

The belt and pulley drive system is commonly used due to its simplicity, cost-
effectiveness, and reliability. It offers flexibility in adjusting the speed and torque
transmission ratio, allowing for customization according to the specific grinding
needs. However, it is important to properly maintain and periodically check the tension
and condition of the belt to ensure efficient power transmission and minimize
downtime.
5. DESIGN, MODELING AND SIMULATION

5.1 DESIGN CALCULATIONS

● Motor design calculations

The general torque required for breaking at the solid cow dung and its mixing is 8N-m

So the pulley connected to the conveyor must or at least produce, a torque of 10N-m

1. Now considering a motor for 0.5hp for driver

pulley Now 0.5hp = 372 Watt

372N-m/S

RPM at a general= 0.5 Hp motor

1440rpm

∴ Torque required,

We know,

Power=2𝜋𝑁𝑇
60

∴ 372 = 2𝜋×1440×𝑇
60

∴ T = 2.466N-m

● Pulley and belt design calculations

Now, the available diameter of pulley we have – a) 50mm diving pulley

b) 250mm driven pulley

Speed at driven pulley

We Know,
𝐷(𝐷𝑟𝑖𝑣𝑒𝑟) = 1440
𝐷(𝐷𝑟𝑖𝑣𝑒𝑛) 𝑥

∴ 250 = 1440
50 𝑥
 ∴ x = 288 rpm

∴ RPM at driven pulley = 288 rpm is,

Now, Power required to produce a torque of 10N-m with 288 rpm is,
∴ P = 2𝜋𝑁𝑇
60

2
∴ 𝑃𝑜𝑤𝑒𝑟 = 𝜋
×
2
8
8
×
1
0
6
0
∴ Power needed = 301.59watt

Power produced at the driver pulley = 372watt

So motor with 0.5Hp with pulley of diameter 250 mm and 50 mm can be used.

Now,

Center distance between the pulley © is given by

C=𝐷1+𝐷2 +𝑅1 + 𝑅2
2

Where
D1= Diameter of driver pulley
D2= Diameter of driven pulley
R1= Radius of driver pulley
R2= Radius of driven pulley

∴ C=250+50 + 125 + 25
2

∴ C=300mm
● Length of the belt = L is given by,
𝑫𝟏+𝑫𝟐
L=2×c+π×

( )
𝟐

L=2×300+π(𝟏𝟓𝟎+𝟓𝟎)
𝟐
 L= 110 mm

● Here the driven pulley is larger than the river pulley, therefore the tight side of the belt
will be on driven pulley.
Let,
T1= Tension in the tighter side
T2= Tension in the slack side

Now, the torque needed at the driven pulley is 10N.m

And radius of driven pulley is 0.125m

We have

Torque= Force ×Radius

∴ 10 = T1 × 0.125

∴ T1 = 10
0.125

∴ T1= 80N

Let the tension factor between the tighter and slack side be 1.4

∴ 𝑇1=1.4
𝑇2

T1= 1.4×T2

∴ T2 =80
1.2

∴T2= 63.22N

Power transmitted by the pulley is

P = (T1 –T2) × V

Where V= Velocity of belt drive in m/s.

We have,
V= 𝜋×𝐷×𝑁
60

∴V=𝜋×0.250×1440
60

∴V= 18.84 m/s.

Power transmitted by the belt drive = (80-63.22) × 18.84

= 316 Watt

The power needed at the driven pulley was 302 Watt, The selected belt drive
arrangement is providing 316 Watt power so this system is implemented.

● Briquette calculations

The required output from the machine is 10 kg/hr

In other words it needs 1000×10 = 167 gm/min
60

The dimension of 1 briquette which is made is (50×50×65) mm

And the mass density of the briquette produced is around 800kg/m3

We have
𝑀𝑎𝑠𝑠Densi
𝑣𝑜𝑙𝑢𝑚𝑒

∴800=𝑀𝑎𝑠𝑠
0.05×0,05×0.065

∴ Mass= 800×0.05 × 0.05 × 0.065

∴ Mass= 130 gm

The mass of 1 briquette is 130 grams and amount of material required per minute
is 167 grams
5.2 CAD MODELING

Introduction:

Computer-aided design (CAD) is the use of computer systems (or workstations) to aid
in the creation, modification, analysis, or optimization of a design. CAD software is
used to increase the productivity of the designer, improve the quality of design,
improve communications through documentation, and to create a database for
manufacturing. CAD output is often in the form of electronic files for print,
machining, or other manufacturing operations. The term CADD (for Computer Aided
Design and Drafting) is also used.

Its use in designing electronic systems is known as electronic design automation

(EDA). In mechanical design it is known as mechanical design automation (MDA)
or computer-aided drafting (CAD), which includes the process of creating a technical
drawing with the use of computer software.

CAD software for mechanical design uses either vector-based graphics to depict the
objects of traditional drafting, or may also produce raster graphics showing the overall
appearance of designed objects. However, it involves more than just shapes. As in the
manual drafting of technical and engineering drawings, the output of CAD must
convey information, such as materials, processes, dimensions, and tolerances,
according to application-specific conventions.

CAD may be used to design curves and figures in two-dimensional (2D) space; or
curves, surfaces, and solids in three-dimensional (3D) space.

CAD is an important industrial art extensively used in many applications, including

automotive, shipbuilding, and aerospace industries, industrial
and architectural design, prosthetics, and many more. CAD is also widely used to
produce computer animation for special effects in movies, advertising and technical
manuals, often called DCC digital content creation. The modern ubiquity and power of
computers means that even perfume bottles and shampoo dispensers are designed
using techniques unheard of by engineers of the 1960s. Because of its enormous
economic importance, CAD has been a major driving force for research in
computational
geometry, computer graphics (both hardware and software), and discrete differential
geometry. The design of geometric models for object shapes, in particular, is
occasionally called computer-aided geometric design (CAGD)

Uses:

Computer-aided design is one of the many tools used by engineers and designers and
is used in many ways depending on the profession of the user and the type of software
in question.

CAD is one part of the whole Digital Product Development (DPD) activity within the
Product Lifecycle Management (PLM) processes, and as such is used together with
other tools, which are either integrated modules or stand-alone products, such as:

● Computer-aided engineering (CAE) and Finite element analysis (FEA)

● Computer-aided manufacturing (CAM) including instructions to
Computer Numerical Control (CNC) machines
● Photorealistic rendering and Motion Simulation.
● Document management and revision control using Product
Data Management (PDM).

CAD is also used for the accurate creation of photo simulations that are often required
in the preparation of Environmental Impact Reports, in which computer-aided designs
of intended buildings are superimposed into photographs of existing environments to
represent what that locale will be like, where the proposed facilities are allowed to be
built. Potential blockage of view corridors and shadow studies are also frequently
analysed through the use of CAD.

CAD has been proven to be useful to engineers as well. Using four properties which
are history, features, parameterization, and high-level constraints. The construction
history can be used to look back into the model’s personal features and work on the
single area rather than the whole model. Parameters and constraints can be used to
determine the size, shape, and other properties of the different modelling elements.
The features in the
CAD system can be used for the variety of tools for measurement such as tensile
strength, yield strength, electrical or electromagnetic properties. Also its stress, strain,
timing or how the element gets affected in certain temperatures, etc.

Types:

There are several different types of CAD, each requiring the operator to think
differently about how to use them and design their virtual components in a different
manner for each.

There are many producers of the lower-end 2D systems, including a number of free
and open-source programs. These provide an approach to the drawing process without
all the fuss over scale and placement on the drawing sheet that accompanied hand
drafting since these can be adjusted as required during the creation of the final draft.

3D wireframe is basically an extension of 2D drafting (not often used today). Each line
has to be manually inserted into the drawing. The final product has no mass properties
associated with it and cannot have features directly added to it, such as holes. The
operator approaches these in a similar fashion to the 2D systems, although many 3D
systems allow using the wireframe model to make the final engineering drawing
views.

3D “dumb” solids are created in a way analogous to manipulations of real-world

objects (not often used today). Basic three-dimensional geometric forms (prisms,
cylinders, spheres, and so on) have solid volumes added or subtracted from them as if
assembling or cutting real-world objects. Two-dimensional projected views can easily
be generated from the models. Basic 3D solids don’t usually include tools to easily
allow motion of components, set limits to their motion, or identify interference
between components.

There are two types of 3D Solid Modelling

1. Parametric modelling allows the operator to use what is referred to as “design

intent”. The objects and features created are modifiable. Any future
modifications can be made by changing how the original part was created. If a
feature was intended to be located from the centre of the part, the operator
should locate it from the centre of the model. The feature could be located

using
 any geometric object already available in the part, but this random placement
would defeat the design intent. If the operator designs the part as it functions
the parametric modeler is able to make changes to the part while maintaining
geometric and functional relationships.
2. Direct or Explicit modelling provide the ability to edit geometry without a
history tree. With direct modelling, once a sketch is used to create geometry
the sketch is incorporated into the new geometry and the designer just
modifies the geometry without needing the original sketch. As with parametric
modelling, direct modelling has the ability to include relationships between
selected geometry (e.g., tangency, concentricity).

Figure 5.1 Drafting Model

Figure 5.2 3D Isometric View

Figure 5.3 3D Top View

Figure 5.4 Drafting of Model Top View

Figure 5.5 Drafting of Model Front View

5.3 STUCTURAL ANALYSIS ON ANSYS SOFTWARE

FEA solution of engineering problems, such as finding deflections and stresses in a

structure, requires three steps:

1. Pre-processing

2. Solution

3. Post processing

A brief description of each of these steps follows

Step1: Pre-processing

Using a CAD program that either comes with the FEA software or 3D CAD modelling
tools like Pro-E, Catia, and solid Edge etc. provided by another software vendor, the
structure is modelled. The final FEA model consists of several elements that
collectively represent the entire structure. The elements not only represent segments of
the structure, they also simulate its mechanical behaviour and properties.

Regions where geometry is complex (curves, notches, holes, etc.) require increased
number of elements to accurately represent the shape; whereas, the regions with
simple geometry can be represented by coarser mesh (or fewer elements). The
selection of proper elements requires prior experience with FEA, knowledge of
structure’s behaviour, available elements in the software and their characteristics, etc.
The elements are joined at the nodes, or common points. In the pre-processor phase,
along with the geometry of the structure, the constraints, loads and mechanical
properties of the structure are defined. Thus, in pre-processing, the entire structure is
completely defined by the geometric model. The structure represented by nodes and
elements is called “mesh”.
Step 2: Solution

In this step, the geometry, constraints, mechanical properties, and loads are applied to
generate matrix equations for each element, which are then assembled to generate a
global matrix equation of the structure. The form of the individual equations, as well
as the structural equation is always,

{F} = [K] {u}

Where

{F} = External force matrix,

[K] = Global stiffness matrix,

{u} = Displacement matrix.

The equation is then solved for deflections. Using the deflection values, strain, stress,
and reactions are calculated. All the results are stored and can be used to create graphic
plots and charts in the post analysis.

Step 3: Post processing

This is the last step in a finite element analysis. Results obtained in step 2 are usually
in the form of raw data and difficult to interpret. In post analysis, a CAD program is
utilized to manipulate the data for generating deflected shape of the structure, creating
stress plots, animation, etc. A graphical representation of the results is very useful in
understanding behaviour of the structure.
In present research for analysis ANSYS (Analysis System)software is used. Basically
,its present FEM method to solve any problem. Following are steps in detail

1. Geometry
2. Discretization (Meshing)
3. Boundary condition
4. Solve (Solution)
5. Interpretation of resul

ANSYS Workbench 21.0 platform to perform modal analysis of thrust coupling.

ANSYS Workbench 21.0, as the most advanced CAE software, provides users with
simulation modules including: structure, fluid, electromagnetic, heat transfer, and other
fields. It is the industry’s most advanced engineering simulation technology integration
platform, with intuitive and friendly interface, convenient pre-processing and post-
processing functions, and its extensive solution functions.

Figure 5.6 Geometry of biomass briquettes making machine

 Figure 5.7 Material properties

Meshing:

As the main link of finite element analysis, grid division can best reflect the idea of
finite element. The quality of the web site not only affects the efficiency of model
analysis, but also directly affects the accuracy of analysis results. Therefore, according
to the existing hardware, without affecting the accuracy of the calculation results, the
method of dividing the mesh can be appropriately selected to save calculation time.

Figure 5.8 Finite element mesh model of biomass briquettes making machine
Element Types

When geometries are complex or the range of length scales of the flow is large, a
triangular/tetrahedral mesh can be created with far fewer cells than the equivalent
mesh consisting of quadrilateral/hexahedral elements. This is because a
triangular/tetrahedral mesh allows clustering of cells in selected regions of the flow
domain. Structured quadrilateral/hexahedral meshes will generally force cells to be
placed in regions where they are not needed. Unstructured quadrilateral/hexahedral
meshes offer many of the advantages of triangular/tetrahedral meshes for
moderately-complex geometries.

● For simple geometries, use quadrilateral/hexahedral meshes.

● For moderately complex geometries, use unstructured quadrilateral/hexahedral
meshes.
● For relatively complex geometries, use triangular/tetrahedral meshes with
prism layers.
● For extremely complex geometries, use pure triangular/tetrahedral meshes.
Boundary condition:

Figure 5.9 Boundary condition of biomass briquettes making machine

Figure 5.10 Boundary condition of biomass briquettes making machine

Results:

Figure 5.11 Total deformation of biomass briquettes making machine

Figure 5.12 Equivalent Stress of biomass briquettes making machine

6. WORKING & MANUFACTURING

6.1 WORKING OF MACHINE

1 The raw material enters the machine through a hopper. At the exit of the hopper a
conveyor screw is placed which rotates with the help of power provided by the pulley.

2. The driver pulley is powered by the driven pulley which rotates by the torque
provided by the 0.5 Hp motor .i.e The machine is powered primarily by the motor.

3. The conveyor crushes the raw material and mixes the material properly in the
chamber. The material moves forward with the help of the conveyor screw.

4. At the end of conveyor screw material in powdered form is collected. This

material then goes in the cavity in which the it gets compressed.

5. For the compression of that material pneumatic cylinders are used which are
operated by an automatic valve controlled by Arduino.

6. As the required amount of material is collected in the cavity that is after a

particular cycle time the pneumatic cylinders gets actuated. Then the briquette of
required dimensions is obtained by the compressive force by the pneumatic cylinder.

7. Then the pneumatic cylinders are separated by the return stroke and the
briquette is collected.
6.2 MANUFACTURING PROCESS

Following operations were performed while fabricate the project:

1. CUTTING

Figure 6.1 Cutting Operation

Cutting is the separation or opening of a physical object, into two or more portions,
through the application of an acutely directed force.

Implements commonly used for cutting are the knife and saw, or in medicine and
science the scalpel and microtome. However, any sufficiently sharp object is capable
of cutting if it has a hardness sufficiently larger than the object being cut, and if it is
applied with sufficient force. Even liquids can be used to cut things when applied with
sufficient force (see water jet cutter). The material as our required size. The machine
used for this operation is power chop saw. A power chop saw, also known as a drop
saw, is a power tool used to make a quick, accurate crosscut in a work piece at a
selected angle. Common uses include framing operations and the cutting of moulding.
Most chop saws are relatively small and portable, with common blade sizes ranging
from eight to twelve inches.
The chop saw makes cuts by pulling a spinning circular saw blade down onto a work
piece in a short, controlled motion. The work piece is typically held against a fence,
which provides a precise cutting angle between the plane of the blade and the plane of
the longest work piece edge. In standard position, this angle is fixed at 90°. A primary
distinguishing feature of the mitre saw is the mitre index that allows the angle of the
blade to be changed relative to the fence. While most mitre saws enable precise one-
degree incremental changes to the mitre index, many also provide "stops" that allow
the miter index to be quickly set to common angles (such as 15°, 22.5°, 30°, and 45°).
The time required for this operation is 50 minutes.

2. WELDING

Figure 6.2 Welding Operation

Welding is a fabrication or sculptural process that joins materials, usually metals or

thermoplastics, by using high heat to melt the parts together and allowing them to cool
causing fusion. Welding is distinct from lower temperature metal-joining techniques
such as brazing and soldering, which do not melt the base metal.

In addition to melting the base metal, a filler material is typically added to the joint to
form a pool of molten material (the weld pool) that cools to form a joint that, based on
weld configuration (butt, full penetration, fillet, etc.), can be stronger than the base
material (parent metal). Pressure may also be used in conjunction with heat, or by
itself, to produce a weld. Welding also requires a form of shield to protect the filler
metals or melted metals from being contaminated or oxidized.

Square pipes of different lengths to make frame. The machine used for this operation
is electric arc welding. Electrical arc welding is the procedure used to join two metal
parts, taking advantage of the heat developed by the electric arc that forms between an
electrode (metal filler) and the material to be welded. The welding arc may be
powered by an alternating current generator machine (welder). This welding machine
is basically a single-phase static transformer Suitable for melting RUTILE (sliding)
acid electrodes. Alkaline electrodes may also be melted by alternating current if the
secondary open- circuit voltage is greater than 70 V.

The welding current is continuously regulated (magnetic dispersion) by turning the

hand wheel on the outside of the machine, which makes it possible to select the current
value, indicated on a special graded scale, with the utmost precision. To prevent the
service capacities from being exceeded, all of our machines are fitted with an
automatic overload protection which cuts of the power supply (intermittent use) in the
event of an overload. The operator must then wait for a few minutes before returning
to work. This welding machine must be used only for the purpose described in this
manual. Read the entire contents of this manual before installing, using or servicing
the equipment, paying special attention to the chapter on safety precautions. Contact
your distributor if you do not fully understand these instructions. The time required for
this operation is 120 minutes.

.
3. DRILLING

Figure 6.3 operation

Drilling is a cutting process that uses a drill bit to cut a hole of circular cross-section in
solid materials. The drill bit is usually a rotary cutting tool, often multi-point. The bit
is pressed against the work-piece and rotated at rates from hundreds to thousands of
revolutions per minute. This forces the cutting edge against the work-piece, cutting off
chips (swarf) from the hole as it is drilled.

In rock drilling, the hole is usually not made through a circular cutting motion, though
the bit is usually rotated. Instead, the hole is usually made by hammering a drill bit
into the hole with quickly repeated short movements. The hammering action can be
performed from outside the hole (top-hammer drill) or within the hole (down-the-hole
drill, DTH). Drills used for horizontal drilling are called drifter drills.

In rare cases, specially-shaped bits are used to cut holes of non-circular cross-section;
a square cross-section is possible.
 Figure 6.4 Drilling Tool

Drilled holes are characterized by their sharp edge on the entrance side and the
presence of burrs on the exit side (unless they have been removed). Also, the inside of
the hole usually has helical feed marks.

Drilling may affect the mechanical properties of the work piece by creating low
residual stresses around the hole opening and a very thin layer of highly stressed and
disturbed material on the newly formed surface. This causes the work piece to become
more susceptible to corrosion and crack propagation at the stressed surface. A finish
operation may be done to avoid these detrimental conditions.

For fluted drill bits, any chips are removed via the flutes. Chips may form long spirals
or small flakes, depending on the material, and process parameters. The type of chips
formed can be an indicator of the machinability of the material, with long chips
suggesting good material machinability.
4. FINISHING

Figure 6.5 Finishing Operation

Finishing is a broad range of industrial processes that alter the surface of a

manufactured item to achieve a certain property. Finishing processes may be employed
to: improve appearance, adhesion or wettability, solder ability, corrosion resistance,
tarnish resistance, chemical resistance, wear resistance, hardness, modify electrical
conductivity, remove burrs and other surface flaws, and control the surface friction. In
limited cases some of these techniques can be used to restore original dimensions to
salvage or repair an item. An unfinished surface is often called mill finish.

The edges with grinder using grinding wheel. The machine used for this operation is
hand grinder. An angle grinder, also known as a side grinder or disc grinder, is a
handheld power tool used for cutting, grinding and polishing. Angle grinders can be
powered by an electric motor, petrol engine or compressed air.

The motor drives a geared head at a right-angle on which is mounted an abrasive disc
or a thinner cut-off disc, either of which can be replaced when worn. Angle grinders
typically have an adjustable guard and a side-handle for two-handed operation. Certain
angle grinders, depending on their speed range, can be used as sanders, employing a
sanding disc with a backing pad or disc. The backing system is typically made of hard
plastic, phenolic resin, or medium-hard rubber depending on the amount of flexibility
desired. The time required for this operation is 20 minutes.
5. POLISHING

Figure 6.6 Polishing Machine

Polishing is the process of creating a smooth and shiny surface by rubbing it or using a
chemical action, leaving a surface with a significant specular reflection (still limited by
the index of refraction of the material according to the Fresnel equations.) In some
materials (such as metals, glasses, black or transparent stones), polishing is also able to
reduce diffuse reflection to minimal values. When an unpolished surface is magnified
thousands of times, it usually looks like mountains and valleys. By repeated abrasion,
those "mountains" are worn down until they are flat or just small "hills." The process
of polishing with abrasives starts with coarse ones and graduates to fine ones.

The welded joints with hand grinder using grinding wheel. The machine used for this
operation is hand grinder. With refinement, grinding becomes polishing, either in
preparing metal surfaces for subsequent buffing or in the actual preparation of a
surface finish, such as a No. 4 polish in which the grit lines are clearly visible.
Generally speaking, those operations which serve mainly to remove metal rapidly are
considered as grinding, while those in which the emphasis is centred on attaining
smoothness are
classified as polishing. Grinding employs the coarser grits as a rule while most
polishing operations are conducted with grits of 80 and finer. If polishing is required,
start with as fine a grit as possible to reduce finishing steps. There is a wide range of
grinding and polishing tools on the market and advice is available from ASSDA
members to assist in particular applications. Polishing operations are conducted with
the abrasive mounted either on made-up shaped wheels or belts which provide a
resilient backing. The base material may be in either a smooth rolled or a previously
ground condition. If the former, the starting grit size may be selected in a range of 80
to 100. If the latter, the initial grit should be one of sufficient coarseness to remove or
smooth out any residual cutting lines or other surface imperfections left over from
grinding. In either case, the treatment with the initial grit should be continued until a
good, clean, uniform, blemish-free surface texture is obtained. The initial grit size to
use on a pre-ground surface may be set at about 20 numbers finer than the last grit
used in grinding, and changed, if necessary, after inspection. Upon completion of the
initial stage of polishing, wheels or belts are changed to provide finer grits. Polishing
speeds are generally somewhat higher than those used in grinding. A typical speed for
wheel operation is 2500 meters per minute. The time required for this operation is 20
minutes.
SAFETY PRECAUTIONS:

The following points should be considered for the safe operation of machine

And to avoid accidents: -

● All the parts of the machine should be checked to be in perfect alignment.

● All the nuts and bolts should be perfectly tightened.
● The operating switch should be located at convenient distance from the operator so
as to control the machine easily.
● The inspection and maintenance of the machine should be done from time to time.
● All the nuts and bolts should be perfectly tightened.
● The operating switch should be located at convenient distance from the operator so
as to control the machine easily.
The inspection and maintenance of the machine should be done from time to time.
7. COST ESTIMATION:

Cost estimation may be defined as the process of forecasting the expenses that
must be incurred to manufacture a product. These expenses take into a consideration
all expenditure involved in a design and manufacturing with all related services
facilities such as pattern making, tool, making as well as a portion of the general
administrative and selling costs.

7.1 PURPOSE OF COST ESTIMATION:

1. To determine the selling price of a product for a quotation or contract so as to

ensure a reasonable profit to the company.
2. Check the quotation supplied by vendors.
3. Determine the most economical process or material to manufacture the product.
4. To determine standards of production performance that may be used to control
the cost.

7.2 TYPES OF COST ESTIMATION:

1. Material cost
2. Machining cost

1. Material Cost Estimation

Material cost estimation gives the total amount required to collect the raw
material which has to be processed or fabricated to desired size and functioning of the
components.
 These materials are divided into two categories.

1. Material for fabrication:

In this the material in obtained in raw condition and is manufactured or
processed to finished size for proper functioning of the component.

2. Standard purchased parts:

This includes the parts which was readily available in the market like Allen
screws etc. A list is forecast by the estimation stating the quality, size and
standard parts, the weight of raw material and cost per kg. For the fabricated
parts.

Machining Cost Estimation

This cost estimation is an attempt to forecast the total expenses that may
include manufacturing apart from material cost. Cost estimation of manufactured parts
can be considered as judgment on and after careful consideration which includes labor,
material and factory services required to produce the required part.

7.3 PROCEDURE FOR CALCULATION OF MATERIAL COST:

The general procedure for calculation of material cost estimation is after designing a
project,

1. A bill of material is prepared which is divided into two categories.

a. Fabricated components
b. Standard purchased components
2. The rates of all standard items are taken and added up.
3. Cost of raw material purchased taken and added up.
S/N Particulars Specification Rat Unit Total
e
(Per
Unit)
1. Arduino AtMega 328p 1500 1 1500

2. Frame MS 1000 1 1000

3. AC Motor 3000 1 3000

4. 5/2 Way 12V DC 1000 1 1000
Single Solenoid Valve
5. HC-SR-04 100 1 100
Ultrasonic Sensor

6. 800 2 1600
Pneumatic cylinders
7. Adaptor 300 1 300

8. Mixer 1000 1 1000

9. Other 1500
Total Cost 11000

Manufacturing Cost 4000

Material Cost 11000
Total Cost Rs.15000
8. RESULTS:

● Production capacity of the machine: The required capacity of the machine was
10Kg/hr. This capacity can be easily fulfilled by the machine as it produces a
briquette of mass 234 grams in a single cycle. Also the production of the
machine highly depends on the raw material provided.
● Briquette quality: The dimensions of the briquette produced by the machine are
(50×50×65) mm, where 50 is length and breadth of briquette and height of the
briquette produced is 65 mm.
● Energy produced: Considering the output of 10 kg/hr. The calorific value of
briquette is approximately equal to 4000 kcal/kg. So for 10 Kg the calorific
value becomes 40000 kcal.
And 40000 Kcal is equal to 46.489 Kwh. So 46 units of electricity can be
produced by the machine in 1 hr which is quite good comparing the inputs are
only 0.5 Hp motor and a pneumatic cylinder.
● User friendliness: The briquette making machine is quite user friendly. It can
even be operated by an unskilled person or by any farmer from rural area.
9. CONCLUSION:

● We can use this machine for domestic (cooking, heating) as well as industrial
purpose (agro industries, food industries).
● Recycling biomass materials into briquettes contributes to solving rural needs
by generating income, providing a new cheap alternative source of cooking
energy, avoiding to having to cut down more forests for fuel wood and
ultimately promoting a sound environment.
● Fuel briquettes could present multiple benefits: It could (a) be a cheap and
sometimes cleaner source of cooking fuel, (b) generate income through sales,
and (c) reduce household expenditure on energy for cooking.
● Generating income and reducing household expenditure are critical to
achieving poverty reduction, and the money can be invested in other
productive activities such as agriculture and commercial enterprises.
● Since briquettes are affordable, it can contribute to food and nutrition security.
Families are able to cook food types of their choice, especially traditional food,
that take long to prepare and consume a lot of fuel.
● Partnership with the private sector for waste pre-processing and delivery, for
instance, significantly reduces the cost of production, which can also be
reduced by partnering with municipalities or other organizations for obtaining
the required land area.
● It can be easily fabricated with materials sourced locally. This project will
provide job opportunity to the unemployed graduates, and small-scale
entrepreneurs can be empowered by the government by making briquette from
sawmill wastes.
REFERENCES:

1. Kamalakanta Sahoo, Edward Balaka, Richard Bergman, Sudhakar Mani,

“Techno-economic analysis of producing solid biofuels and biochar from forest
residues using portable systems”, science direct,2019. Baohui Wen, Liang Liu,
Kaixuan Zheng, “Analysis and Research of Force and motion of screw type
extrusion molding biomass” Science Direct, Aadvanced Research Volume 614-
615,2013.
2. Joseph Ifeolu Orisaleye, Sunday Joshua OjoloJoseph S. Ajiboye,
“Mathematical modelling of die pressure of a screw briquetting machine”,
science direct, 2019/4/9.
3. Juan Arevalo, Grimaldi quips, Carlos Raymundo, “Sustainable energy
model for the production of biomass briquettes based on rise husk in low income
agricultural areas.”, 2017/01/10.
4. M.FadzliHamid,M.YusofIdroas,M.ZulfikarIshak, “An Experimental
Study of Briquetting Process of Torrified Rubber Seed Kernel and Palm Oil
Shell “,2016/04/14.
5. Daniel S Madariya, Production of loose biomass briquettes from
agricultural and forestry residues, International Conference on Food, Agriculture,
and Natural Resources, FANRes2017
6. GVEP (now Energy 4 Impact) , “Assessment of the briquette market in Kenya”
, (2013)
7. George Ngusale , “Briquette Making in Kenya; Nairobi and Peri-Urban
Areas” (2014)
8. Mary Njenga , “Evaluating Fuel Briquette Technologies and their
Implications on Greenhouse Gases and Livelihoods in Kenya”, (2013)
9. Article on Energy for Sustainable Development-
(Mwampamba,T.,Owen.M. and Pighart.M), “Opportunities, challenges and way
forward for the charcoal briquette industry in Sub-Saharan Africa”, (2012)
10. Briquettes making machine for industrial and agricultural purpose by
¹Nikhil J. Gajbhiye, ²Laukik P. Raut
11. Design and Fabrication of Automated Biomass Briquetting Machine by
Prof. Swapnil Solanki1, Dhruvil Kotadia2, Priyam Shah3, Sarthak Soni4, Smit
Shah5
12. AUTOMATIC SCREW PRESS BRIQUETTE MAKING MACHINE by
1Ravina Sanap, 2Madhuri Nalawade,
13. Design and Fabrication of a Briquetting Machine by Francis Inegbedion
14. The Preliminary Design and Fabrication of a Manually Operated
Briquetting Machine by OSARENMWINDA
15. A Review: Design and Fabrication of Coir Pith Briquetting Machine
Sanket Gunjal1 , Santosh Gushinge