Phase 2: Designing and Constructing the Project

This chapter deals with the theoretical design considerations, assumption and
methodology adopted for design and development of briquetting machine based on carbonized
rice husk.

Stage 5: Designing and Calculating the Components of the Project

Theoretical Consideration of Briquetting Machine

The design of briquetting machine involves the relationship between screw and barrel
geometry and feed material properties with flow rate, pressure drop and power consumption. To
solve the basic flow equations, the following assumptions were considered:

1. Flow should be laminar.

2. Flow should be steady.
3. Flow should be fully developed.
4. Barrel should be stationary and the screw is rotating.
5. Slip should not occur at the walls.
6. Raw biomass should be incompressible.
7. Gravity forces should be negligible and
8. . Inertial forces should also be negligible.

Design of Screw Press Briquette Machine

The screw press extruder type briquetting machine mainly consists of driving motor,
screw, die, hopper and power transmission system. Pulley and belt were used to transmit power
from motor to the screw. Continuous pressing by means of expellers also known as screw press
is a widely applied process for the compaction of low bulk density waste to convert it in to a
solid form. The expeller consisted of a screw (or worm), rotating inside a cylindrical cage
(barrel). The raw material was fed to the hoppers, which convey it to screw by gravity. The
material was pushed forward due to geometry of screw. As the material was pushed, it got
compressed and bounded material comes out of die in the form of briquettes. The material to be
pressed was fed between the screw and barrel and propelled by the rotating screw in a direction
parallel to the axis. The configuration of the screw and its shaft was such that the material was
progressively compressed as it moved on, towards the discharge end of the cylinder.
 Design consideration

Basic design parameters considered were as follows:

 Machine Capacity (Q) = 100 𝑘𝑔 ⁄ ℎ𝑟
 Die diameter (Dd) = 60 mm
 Bulk Density (p) in 𝑘𝑔⁄𝑚3

Similarly, the assumed Parameters were

 Diameter of Screw in mm
 Pitch of the screw press in mm
 Shaft Diameter in mm

Components of briquetting machine

Essentially briquetting machine is having following components

a) Briquetting stand: A base is required which adequately supports the briquetting barrel & screw
assembly.
b) Drive mechanism: The briquetting machine is driven with electrical motor with the help of
pulley drive. The three groove pulley is mounted on motor as well as on the shaft of connecting
rod for power transmission to obtain desire speed.
c) Thrust bearings: The briquetting screw is normally supported with a bearing at the driven end.
A significant rearward thrust must be absorbed in the bearing to compensate for the force
imparted to the briquetted material as it is being moved forward along the length of the screw.
d) Feed hopper: The feed hopper provides the opening through which feed materials enter the
screw.
e) Barrel: The barrel of the extruder is often manufactured in sections which are bolted to clamp
together. Because barrel sections are heavy, such construction aids disassembly and allows for
replacement of sections without replacing entire barrel.
f) The internal diameter of the briquetting machine often denotes the basic size. Barrel length (L)
is also very important. The longer the barrel, the greater is the surface for heating or cooling and
coupled with longer residence time, leads to greater control. Extruders have varying L/D ratios,
ranging from 1 to 3: 1 for pallet extruder and 15 to 25: 1 for high shear extruders. Internal
operating pressures in the extruder barrel normally range from 1.5 to 7.5 Mpa with dry
extrusions.
g) Die: The extruder is normally equipped with a series of shaped holes where briquetting
material emerges from the machine in the form of briquettes. The die holes can take number of
shapes to form the briquettes into rods, spheres, denotes, tubes, strips etc

Calculation of Helix Angle

The briquetting machine consists of extruder screw rotating in a barrel, fitted tightly with
connecting rod. The briquetting screw consists of a central shaft upon which a helical flight is
wrapped. The open area bounded by the flights on the sides is lead. The root of the screw at the
bottom and the barrel on the top is known as the channel. The diameter of the screw (D) is the
inside diameter of the barrel and the flight height (H) is the distance from the root of the screw to
barrel. The helix angle (θ) is the angle that the helical flight makes with the vertical. If pitch S is
known than helix angle can be determined from the correlation.
𝑆
(θ)= 𝑡𝑎𝑛−1 𝜋𝐷

Determination of theoretical screw volume per pitch

The basic design consideration for the screw design is the capacity of the waste process
and the average bulk density of the raw waste after size reduction. We know that the theoretical
screw volume is given by:
Vs = Area x Pitch
𝜋
Vs = 4 (𝐷2 − 𝑑 2 ) x S
Where, Vs = Theoretical volume of screw, 𝑚3
D = screw diameter, m
d = shaft diameter, m
S = Pitch of the screw, m

Determination of screw revolution

Speed of screw is dependent on mass flow rate, product density, theoretical screw volume
per pitch (Vs) and filling.
𝑄
m = 60

𝑚
N = Vρφ
Where, N = Screw revolution, rpm
m = Mass flow rate, kg/min
ψ =Filling efficiency, %
ρ=Bulk density of biomass, kg/𝑚3

Determination of drive power

Drive power is dependent on flow rate, gravity, displacement length, and resistance.

P (m, Vs, L, ρ, fi, nd )

Drive Power (Pd) is

𝑓
Pd = m x L x 𝑛 𝑖 x g
𝑑

Torque on the screw,

𝑝𝑑 30 000
τ= 𝑁
x 𝜋
, N-m
 Where, L = Length of the screw press, m
nd = Efficiency of drive, %
fi = Factor of Safety

Pulley shaft power

Shaft Power (P s) required for briquetting machine after considering the pulley efficiency.
𝑃
Ps = 𝑛 , KW
𝑝
Where, np= Efficiency of pulley, %

Motor power
Motor power Pm is estimated from the given equation.
Pm = Ps (1 + δ)
The factor δ is the allowances made for motor efficiency taken from Appendix I.
Actual motor speed
The actual motor speed (n) is given by selected slip factor" s".
n=N(1-s)
It is selected from Appendix II on the basis of calculated capacity of electrical motor.

Design of pulley
The diameter of smaller pulley was determined by applying Saverin's empirical formula.
Pulley design is mainly dependent on the power to be transmitted and required revolution of the
machine. The simple drive mechanism was selected for the design.
Small pulley diameter is

3 𝑃
d2 = 630 √2𝜋𝑛𝑚
𝑚𝑎𝑥
Where, Pm = Power to be transmitted, kW
nmax = Maximum speed of shaft, rpm

Now the big pulley diameter is calculated by following formula

N2/N1 = d1/d2

Where, N1 = Revolution of machine shaft, rpm

N2 = Revolution of motor shaft (known), rpm
d2 = Diameter of pulley on motor shaft, mm
d1= Diameter of pulley on machine shaft, rpm

Design of Connecting Shaft

Diameter of connecting shaft of the machine can be calculated using belt velocity, power
transmitted and the torque transmitted by the shaft. Thus firstly the belt velocity (V) is:

𝜋 𝑁1 𝑑1
V= m/s
60
Where, V = Belt Velocity
 d1 = Diameter of Pulley, mm
N1 = rpm of machine shaft

Power Transmitted
(𝑇1 −𝑇2 )𝑉
Pm = 1000

Where, Pm = Power needed, KW

T1= Tension in tight side of belt, N
T2 = Tension in slack side of belt, N
V = Velocity of belt, m/s
Applying the relation,
𝜋
T = 16 𝑑3 𝑓𝑠 (Considering only twisting moment)
Where, T = torque transmitted by shaft, N mm
T = (T1 – T2) r
fs= Shear stress of mild steel, N/mm2
ds = Shaft diameter, mm
r = radius of pulley, mm

Selection of Bearing
The bearing selection was made on the basis of the diameter of shaft. Bearing life (L10) is
the factor of durability of bearing as per the total usage of the component. Thus the bearing life is
as follows
L10 = years of use (approx.) x Days in a yr x hours/day x min x rpm of shaft

Selection of Belt
Belt design is possible after consideration of parameters like power to be transmitted by
belt (kW) and revolution per minute of faster shaft (rpm). The belt length was selected for
required power from the cross section selection chart given in the Appendix III.

Estimation of speed of screw conveyor

The screw conveyer was designed after considering the parameters like material
to be handled, lump size, capacity required, length of conveyor (inlet center to outlet
Center) and the other properties of the raw material like bulk density, material class and H.P.
Factor.
𝜋𝑁𝑐
C= x (Dc2 – dc2) x sc x k x ρ x 60
4
Where,
C= Capacity of screw conveyer, TPH
Dc= Screw conveyer diameter, m
dc= Conveyer shaft diameter, m
p = Density of material kg/m3
k = Power Factor
Nc = Revolution of screw conveyer, rpm
Sc = Screw conveyer pitch, m
 Estimation of Horsepower Required
Keeping in view 100% loading the capacity can be calculated. Using this
calculated capacity one can calculate the required horsepower for the machine. All other
rated power parameters were calculated for the drive in the same process as described in the
design of screw press.

Design of Prototype Briquette Machine

The properties of rice husk and the basic assumption listed below were
considered for design of 100 kg/hr capacity screw press briquetting machine.
Basic design parameters considered were as follows:

 Machine Capacity (Q) = 100kg/hr

 Die diameter (Dd) = 60 mm
 Bulk Density (ρ) (for loose biomass after experimentation) = 100 kg/m3
Similarly, based on required capacity assumed parameters were:

• Diameter of Screw (D) = 100 mm

• Shaft Diameter (d) = 30 mm
• Pitch of the screw press (S) = 0.35D= 35 mm

Die of Briquetting Machine

The cylindrical shape briquette of diameter 60 mm with a concentric hole of 30

mm and length 110-150 mm. The tapered die of round shape was fabricated in the workshop by
cutting a solid mild steel rod on lathe machine.

Die diameter = 60 mm
Die length = 200 mm
Die material = Mild steel
Die thickness = 15 mm

The taper die having outlet diameter of 60 mm while the other end diameter
was of 100 mm. The die length was design as per screw length so that the briquette
should be formed. Thus, the die length was of 200 mm with a thickness of 15 mm
which was having sufficient strength provided for the process.

Calculation of Helix Angle

The helix angle for the screw design mainly depends on the diameter of the
screw and the pitch of Screw press. It was calculated from the given formula below.
 𝑆
(θ)= 𝑡𝑎𝑛−1 𝜋𝐷
35𝑚𝑚
(θ)= 𝑡𝑎𝑛−1 𝜋(100𝑚𝑚)
(θ)= 6.35 degrees

Determination of theoretical screw volume per pitch

The volume of biomass carried out through one pitch was calculated to know the
material holding capacity of the screw
It was as follows:
Vs = Area x Pitch
𝜋
Vs = (𝐷2 − 𝑑 2 ) x S, m3
4
𝜋
Vs = 4 (. 12 −. 032 ) x .035
Vs = 2.5014 x 10-4 m3

Determination of Screw Revolution

Speed of screw is dependent on mass flow rate, product density, theoretical screw volume per
pitch, and filling.

𝑄
m = 60
Mass flow rate of rice husk waste provided to 100kg/hr capacity machine was

100
m = 60
Mass flow rate, m = 1.67 kg/min
𝑚
N = Vρφ rpm
Where, ρ is the density of rice husk which is 100 kg/m3 and ψ is the filling efficiency of 30 %. From
above formula the revolution required was estimated

1.67
N = (2.5014 x 10−4 )(100)(.30)
N= 222.54 rpm
N≈ 223 rpm

Determination of Drive Power

The power required to transfer the material from first flight to the die was
estimated by the formula given below
 𝑓
Pd = m x L x 𝑛 𝑖 x g
𝑑
Considering the drive efficiency as 75 % and Factor of Safety of 3 for rotating components
Drive power calculated is
𝑓
Pd = m x L x 𝑛 𝑖 x g , kW
𝑑
3
Pd = 1.67 x .1 x .67 x 9.81
Pd = 7.34 kW
Torque on the Screw,
𝑝𝑑 30 000
τ= x , N-m
𝑁 𝜋
7.34 30 000
τ = 223 x 𝜋 , N-m
τ = 314 N-m
Pulley Shaft Power
Power required for briquetting machine after considering the pulley efficiency as 67% for
pulley and belt drive.
𝑃
Ps = , KW
𝑛𝑝
7.34
Ps = .67
Ps = 11 kW
Where, np is the pulley efficiency in %

Motor Power
The factor δ is the allowances made for motor efficiency. Motor allowance
factor for 11 kW motor is selected from the chart in Appendix 1(δ = 0.23)

Pm = Ps (1 + δ), kW
Pm = 11kW (1 + .23)
Pm = 13.53 kW
Thus, the available motor power of 20 HP, 3 Phase and 900 rpm was adopted for the design
operation.

Actual Motor Speed

The actual motor speed is given by selected slip factor "s". From Appendix II
slip factor for 13.53 kW motor is 5.75 %
n=N(1-s)
n=900 rpm (1-.0575)
n=894 rpm

Design of Drive Pulley Diameter

Saverin's empirical formula was used to determine the diameter of smaller
pulley. Pulley design is mainly depending on the power to be transmitted and required
revolution of the machine. The simple drive mechanism was selected for the design.
Small pulley diameter was estimated
3 𝑃
d2 = 630 √2𝜋𝑛𝑚 , mm
𝑚𝑎𝑥
 3 13.53
d2 = 630 √2𝜋(894)
d2 = 84.45 mm
Thus, small pulley of standard diameter was selected as d2 = 100 mm

Driven Pulley Diameter

Now, the big pulley diameter was estimated by substituting the calculated values of
rated motor speed, actual motor speed and diameter of big pulley in following formula
N2/N1 = d1/d2
d1 = d2N2/N1
d1 = 84.45(894)/223
d1 = 339 mm
Design of Shaft
Thus, firstly the belt velocity (V) was calculated as

𝜋 𝑁1 𝑑1
V= , m/s
60
𝜋 (.339)(223𝑟𝑝𝑚)
V= m/s
60

V= 3.96 m/s

Power Transmitted,

(𝑇1 −𝑇2 )𝑉
Pm = 1000

(𝑇1 − 𝑇2 ) = 1000 Pm / V
(𝑇1 − 𝑇2 ) =1000(13.53)/3.96
(𝑇1 − 𝑇2 ) = 3416.7 N
Whereas, (𝑇1 − 𝑇2 )𝑟 = 𝑇
r is the radius of bigger pulley
T = 3416.7 N (339mm/2)
T = 579 125 N-mm
Applying the relation,
𝜋
T = 16 𝑑𝑠 3 𝑓𝑠 (Considering only twisting moment)
ds3 = 16T/πfs
ds3 = 16(579 125 N-mm)/π(42 N/ mm2)
ds = 41 mm say 45 mm

Where, T = Torque transmitted by shaft, N mm

fs = Shear stress of mild steel = 42 N/mm2
ds = Shaft diameter, mm

Selection of Bearing
L10 = years of use (approx.) x Days in a yr x hours/day x min x rpm of shaft
 L10 = 10 years x 300 days/year x 8 hrs/ day x 60 mins/hr x 223 rpm
L10 = 321 x 106 revolutions (Bearing Life)

Selection of Belt
The belt length for the given power motor was selected from the cross-section
selection chart given in the appendix III.
So, Power to be transmitted by belt = 13.52 kW i.e. 20 hp motor
rpm of faster shaft = 900 rpm
From cross section selection chart, B section belt was selected for 900
revolution/min.
Length of belt = 1290 mm. Standard belt according to length of belt = B 90

Estimation of Conveyor Speed

The screw conveyer was design after considering the parameters like material to be
handled, lump size, capacity required, length of conveyor (inlet center to outlet center) and the other
properties of the raw material like bulk density, material class, H.P factor. The filling efficiency of
screw conveyer was also considered in the design to get the required flow rate.
𝜋𝑁𝑐
C = 4 x (Dc2 – dc2) x sc x k x ρ x 60
Considering, screw conveyor diameter= 0.15 m;
shaft diameter= 0.030 m;
pitch of screw conveyer = 0.1 mm;
K factor = 0.2;
density of rice husk = 100kg/m3 = .2 tonne/ m3
required capacity of screw conveyer = 100kg/hr = .1 tonne/hr

𝜋(𝑁𝑐)
.1 = x (.152 – .032) x .1 x .2 x .1 x 60
4

Nc = 49 rpm

Developed Briquette Machine

Overall specifications of the developed screw press are given in Table X

Number of Screw 1
Diameter of Shaft 30 mm
Length of Die 200 mm
Diameter of Die 60 mm
Overall width of machine
Overall height of machine
Overall length of machine
Capacity of machine 100 kg/ hr
Stage 6 : Doing the lay-out of the project via Solid Works

A 3 Dimensional View of Briquette Machine Side View of Briquette Machine

Top View of Briquette Machine
Stage 7: Preparing for the materials based on the design calculations.

The machine designed for briquetting was of single extrusion heated-die screw-press
type. The main parts of the machine are motor, pulleys and belts, screw, barrel, die and briquette
die. Power is transmitted through pulleys and belts from the motor to screw. After starting the
motor, raw material is fed into screw that compressed it and extruded through die.

Procurement of Materials

Following materials were purchased to fabricate the extruder type briquette machine.

Part Name Quantity Description

Electric Motor 1 No 900 rpm 20 HP
Power Screw 1 No High carbon steel
Barrel 1 No 150 mm
Die 1 No 60 mm
V-Pulleys 2 No’s
V-Belts 4 No’s B 90
Bearings 2 No’s
Angle Bars and Metal Sheets - Main frame and body
Table Y: Materials purchased to fabricate the extruder type briquette forming machine.