AGRICULTURAL ENERGY & POWER DIVISION

( Thrust Areas for XIth Plan )

 Liquid fuel from biomass (biodiesel, bio-
oil, alcohol)

 Thermo chemical conversion of biomass

 Efficient utilization and management of

farm power sources

10th Plan Achievements (2002-2007)

Solar Energy

Development of solar tunnel dryer for horticultural crop/fruits

A batch type pilot scale solar tunnel dryer of about 100 kg per batch capacity was developed and
evaluated. The dryer was evaluated by drying unripe mango, Amla and chilli. Drying
temperature in the dryer varied from 45 to 71°C. Reduction in drying time was about 50-60%
drying time in the tunnel dryer as compared to open sun drying. Microbial count of the dried
products in the solar dryer was lower than the sun dried products. The scaled up unit of the solar
tunnel dryer (250 kg per batch capacity) was also fabricated, demonstrated and evaluated in a
forest village by drying Amla and Mahua flower. Results were obtained in the scaled up dryer
were similar to pilot solar dryer.

Design refinement of CIAE solar tracking device for commercialisation

The CIAE solar tracker was refined and modified for easy adoption with 900 W p capacity SPV
panel. Components of the tracker such as timer circuit, gearbox, pawl and ratchet device and
mounting systems, SPV panel frame etc. were modified suiting to the requirement. The tracker
was evaluated extensively for about 1000 h and performance was found satisfactory. Power
output from the tracked panel was about 25% more than the untracked SPV panel. Five prototype
sun tracker with SPV frame were fabricated in liaison with the local manufacturer. The prototype
sun tracker was sent for multi-location trial at three different centers of the AICRP on
Renewable Energy Sources.

Evaluation and field demonstration of the PAU domestic and farm solar dryers

The natural convection based PAU domestic and farm solar dryers were evaluated by drying
amla and cauliflower. The drying time in the solar dryer were reduced by 50-60% in the
domestic solar dryer and 35-45% in the farm solar dryer. Microbial counts in the solar dried
products were lower as compared to the open sun dried products. The solar dryers were
demonstrated to the user in the field. The dryer was used to dry chilli, safed musli, green leaves
available at the farm. Operations of the solar dryers were found satisfactory.
Biogas Technology

Development of a system and equipment for de-watering and handling of spent slurry of
biogas plant

A slurry dewatering system of 2 m2 (2x1m) filter bed area was developed. It was provided with
sieve of 85 mesh size. The unit was able to filter 200 litre of spent slurry within 3 hour yielding
65-100 litre of filtrate and the residues of 79-83% moisture content (wet basis) on top of the
sieve. The residue found in handable form. The filtrate is being used for re-feeding as input to
the biogas plant. The unit was demonstrated at user’s site and operation of the system was found
satisfactory.

Development and evaluation of a family size solid-state anaerobic digester for agro-
residues

A solid-state digester anaerobic digester of 1.18 m3 capacity was developed with leachate re-
circulation system and suitable emptying system of the digested bio-mass. Performance of the
digester was evaluated by charging the cattle dung [CD] alone, mixture of cattle dung & water
hyacinth [Wh] and cattle dung & parthenium foliage [Pf] in 1:1 proportion maintaining TS in the
range of 16 - 19 %. After leachate re-circulation, the gas production was found to be
comparatively higher than without leachate re-circulation. The gas production during first week
were found to be 168, 170 and 160 l/kg dm fed in cases of CD, CD:Wh and CD: Pf, respectively.
The gas production during fourth week were found to be 216, 218 and 212 /kg where as those
were found to be 258, 282 and 251 l/kg dm fed in the sixth week. The nutritive value analysis of
the substrates in terms of NPK indicated that the digested mass was considerably rich as
compared to fresh substrate.

Alternate fuels for IC engines

Evaluation of selected vegetable oils as alternate fuel for the IC engines

The engine testing and fuel properties determination facilities were developed by procuring and
installing the AG - 20 Eddy Current Dynamometer, Volumetric fuel consumption measuring
system, Universal Test Bed, Flue Gas Analyser, Data Logger, Automatic Bomb Calorimeter
and Smoke Meter. Two vegetable oils namely Soybean oil (Crop-origin) and Mahua oil (Forest-
origin) were selected for blending with High Speed Diesel in 0:100, 20:40, 40:60, 60:40, 80:20
and 100:0 proportion by volume in the 5 hp diesel engine. The study revealed that the blends of
selected vegetable oils with high speed diesel in 20:80 ratio could be used to energise the
commercial diesel engine without any modification in engine components. The 20:80 blend of
the vegetable oils and high speed diesel has advantage of emission characteristics as compared to
high speed diesel with nominal increase in specific fuel consumption and the blend can be used
to without any modification in engine components. The viscosity of vegetable oils has been main
limiting factor for their use as fuel and the use of higher proportion of vegetable oil based fuels
in the diesel engines.
 Esterification of non-edible oils for production of quality biodiesel to energize stationary
IC engines and tractors

A Laboratory scale esterification unit of 5 liter per batch was developed. About 90 % recovery
of the biodiesel was obtained. A stationary diesel engine (3.7kW size) was evaluated by using
blends fuel prepared from mixture of bio diesel and HSD in proportion of 20, 40 , 60, 80 and
100% bio diesel in High speed diesel. The BSFC at Max power with 100% biodiesel was 361.7
g/kWh which was 15% higer than the HSD fuel. Maximum efficiency of 29.1% was observed
with 100% bio diesel as compared to 24.8% with High speed diesel. The CO, NOx and SO2
were observed during the engine testing on blended fuels. The CO emission increase as load was
increases. The values for SO2 were very low i.e. negligible Nitrous oxides did not show very
clear trend for different Blends whereas NOx was found to increase with increase in brake power
and was highest at 100% brake power for each blend.

Biomass Gasification Technology

Development of engineered prototype of CIAE updraft gasifier

Design of the CIAE updraft Gaisfier was refinements by providing better biomass feed port and
insulation. The feed port lever supported screw tightening system was replaced with lid cover
and water sealing conduit. The refined version of CIAE up draft gasifiers were tested and
biomass consumption was found to vary from 10 to 12 kg/h wood chips having moisture content
of 8.8-10.3%. The SGR was varied from 105 to 117kg-h/m2. The insulation have shown the
improvement in SGR by 9.5 to 12.3%. The gasification was found to be effective and the
problem in intermittent feeding could be reduced.

Development of natural draft gasifier of 100 kW for wood and crop residues

Based on various design consideration and findings of CIAE natural draft gasifier, a scaled up
natural draft gasifier for 100 kW thermal capacity was developed. The developed gasifier was
having cylindrical shape with 700 mm diameter and height of 1260 mm. The airflow to the
gasifier is controlled by gate valve provided at air inlet pipe. Provision for ash removal was
incorporated having 220 mm diameter below the grate. This provision imparts the facility for
removal of ash and for firing of biomass while starting the gasifier. Gas outlet 300 mm dia was
provided at 800 mm above the grate. The height of the chimney was 1.26 m from the grate.
Gasifier was evaluated on crop residues ground nut shell and soybean straw.

Development of technology package for briquetted fuel for effective gasification

The study was undertaken to utilize the briquettes made from various agro-residues as substitute
of wood for gasification and thus providing an energy efficient gasification system. The
briquettes were prepared from charred agro residue (soybean stalk) using cattle dung as binder
and were evaluated in CIAE portable gasifier . It was also observed that the sustainability of gas
after one hour of operation was poor. The flame temperature was found to varying between 845
to 937 oC. The open core gasifier of 600 MJ/h capacity developed by SPRERI was evaluated
with binderless briquettes prepared from mixture of saw dust and sunflower oilcake. The
briquettes consumption rate was 45.6 kg/h. The calorific value of producer gas was found to vary
from 860 to 1125 kcal/m3. The average thermal output of gasifier was 400 MJ/h.

Design and development of 20 kW producer gas cooling and cleaning system

Three types of bio-degradable materials were used as filtering material for absorption/ removal
of tar present in the raw gas to study the effect of filtering materials on tar absorption. The
performance of cooling and cleaning system developed for 20 kW gasifier engine system was
evaluated using wood chips. Gas flow in the filter varied from 20.5 to 30.1 m3/h. The tar content
in producer gas at outlet of cleaning system was 24 to 53.5 mg/m3. The filter unit was able to
absorb 98.49 to 99.14% tar. The pressure drop across the filter was found to vary from 13 to 23
mm of water column. The dust particulates in the producer gas were 11 to 18 mg/m3. The
cooling and cleaning system can be used for cleaning the producer gas suitable for engine
application.

Integrated Bio-Fuel Cell Technology

Under Asian Swedish Collaborative Research Project on Integrated Bio-Fuel Cell Technology, a
tar cracking unit developed for cleaning the producer gas was evaluated with dolomite as catalyst
at temperature range of 700-840oC. The tar content in the producer gas at the outlet of cracking
unit was found to vary from 0.02 to 0.03g/m3. The intermittent temperature solid oxide fuel cell
(ITSOFC) electrodes fabrication and testing facilities were developed. Few samples of ITSOFC
cell were fabricated using nickel as anode material prepared from the decomposing the nickel
oxide (30%) and nickel carbonate (70%). The anode material was used to fabricate of cell
prepared from precipitation method containing Barium (Ba) of 0.5 mole, Serum (Sr) of 0.5 mole,
cobalt (Co) of 0.8 mole and Ferrous (Fe) of 0.2 mole concentration. The open cell voltage
generated by the cell was 0.7 – 0.8 Volt.

Farm Power Sources

Development of tractor operator’s workplace layout based on ergonomic considerations

The anthropometric data of Indian male agricultural workers (N=5434) were compiled and used
in the study. The mean, 5th percentile and 95th percentile values of the selected data were
calculated. The workplace layout of five tractors were measured using 3-D digitiser in the
laboratory. The positions of important controls and their locations with respect to SRP were
measured in addition to seat dimensions on these tractors. The methodology given by Matthews
and Knight for British tractor operators was followed for developing hand and leg reach
envelopes. The location and control dimensions of some of the important frequently operated
controls like steering wheel, hand accelerator lever, brake pedals, clutch pedal, gear shifting
lever, accelerator pedal etc. were designed based on compiled anthropometric and strength data
of agricultural workers, existing tractor work place layout of some tractors and users feed back.

Ergonomic assessment of existing tractor seats

The five tractor seats used on tractors manufactured by M&M, HMT, Sonalika, Escorts and
Eicher were procured and ergonomically evaluated using freeware 3 D digitiser based on
BIS/ISO standards. The anthropometric data of 5434 male agricultural workers were compiled
and used in this study. The mean, 5th percentile and 95th percentile data of age, weight, stature,
knee height sitting, sitting popliteal height, buttock popliteal length, hip breadth sitting etc were
calculated. The tractor seat vibration were measured and evaluated as per BIS/ISO standards
under the laboratory and field conditions. The design dimensions for the appropriate design was
optimized based on compiled anthropometric data and ergonomic evaluation of five commercial
tractor seats.

Demonstration of renewable energy technologies

ORP on Selected renewable energy gadgets

The prototypes of the CIAE double reflector solar cookers (20 nos), CIAE improved stoves (45
nos), charring drums (4 nos) and briquetting machine (1 no) were fabricated and demonstrated
and evaluated at the user levels. About 20% saving of the conventional fuel was reported by use
of the solar cookers. One kg of the charred briquettes from agricultural waste replaced the 2.5 kg
wood required in the kitchen. There was no smoke observed in the kitchen by use of the stove
with charred briquettes. Carbon-monoxide level in the kitchen (in the breathing zone) were
reduced from 12 to 2 ppm by use of the briquette stoves. The feed back from the users were
favourable.

ORP on the step type solar cocoon stifler

The solar cocoon stifler developed earlier was refined and modified for better mounting
arrangement of stifling box on the stand, increased air exit to escape evaporated moisture and
user friendliness. Ten prototypes of the solar stifler were fabricated in liaison with the local
manufacturer. The solar stiflers were demonstrated and evaluated at five Silk Reeling Centres.
Operation of the solar stiflers were found satisfactory. In the summer month, 40-50 kg cocoon
stifled per day (in 4-5 batches) and 20-30 kg cocoons per day in the autumn months. The quality
of the stifled cocoons in the solar stifler were at par to the cocoons stifled in the electrical ovens.

Demonstration and field evaluation of fixed dome type family size biogas plant under
vertisol conditions

Five units of the fixed dome family size biogas plant (2m3 size) under solid digestion conditions
were constructed at users’ site in the villages. Suitable pile foundation was provided at the
bottom of the bio-gas plant for bearing load of the plant on the black cotton soil. There was no
problem observed in the plants during last four years. The biogas plants cared the need of 5-8
members in the family yielding 1500-1800 l biogas/day. The feed back from the user were
satisfactory.

Operational research demonstration of 100 kW CIAE natural draft gasifier

Five units of 100 kW CIAE natural draft gasifier were fabricated. Performance of the gasifiers
were evaluated using wood chips (50–100 mm length) at CIAE, Bhopal. The biomass
consumption rate was from 22-24 kg/h. A Gasifier was installed at a residential School run by
NGO located near Bhopal for supply of hot water in the hostel and for cooking food. Two
gasifiers were supplied to Tamil Nadu Agricultural University, Coimbatore, and Punjab
Agricultural University, Ludhiana for multi-location testing were reported to be satisfactory.