Gasifier for crumb rubber drying
Ideal Crumb Rubber Factory
Sreekrishnapuram, Mannarkkad
Present Scenario in operation
Optimisation of working results
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Increase in Productivity.
Reduction in cost of Production.
Reduction in waste.
Cost components
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Raw Material cost - Not controllable
Cost of drying the rubber
Cost of Electrical energy
Other costs of wages, Maintenance etc.
Drier Cost Component
Type of drier
Fuel Consumption
Specific fuel consumption
Average fuel cost
Cost of operation of dryer
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Continuous trolley type tunnel dryer
22 lts / Hr of HSD or SKO
36.6 Lts per Ton of crumb rubber
Rs. 18 per Ltr
Rs.396 /hour of operation
Rs.659/- per ton of rubber dried
Fuel cost reduction in the drier was the primary
objective to reduce the overall cost of final product
Process towards cost reduction
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Non conventional energy ?
Consultant in the area?
Seminars by MNES / Agencies
Manufacturers of gasifier
Site Visits
Technology provider
Analysis of technology
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Economy of operation.
Safety of installation as well as people working.
Ease of Maintenance.
Trouble free performance.
Continuous operation.
Lower down time for maintenance.
Low emission of tar or any other pollutants.
After visit to IISc, Bangalore and various installations the
order was placed on Bioresidue Energy Technology (P) Ltd.
Positive features we noticed
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Flame trap to arrest flame flash back.
PP valves to ensure long and trouble free operation.
Brick lined inner and SS construction.
Servicing platforms to facilitate easy servicing.
Audiovisual alarms for critical parameters.
Oxygen sensor-Offline to ensure safety of oxygen ingress.
Screw conveyor for ash removal & Biomass flexibility.
Technological back up from the premier institution
Indian Institute of Science,Bangalore
Maintenance of the gasifier
Total hours of operation
Total No. of stoppages
Continuous operation
Replaced components
Cost of maintenance
Post supply additions
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5000 Hours
6
Up to 1250 hours
Air nozzles
Rs.28,300/- till date
Flame failure system
Timers for screw operation
Post supply replacements : Valve – 1 No.
Cost of maintenance
: Rs. 5=66 per hour
Economics of operation
Operation of the gasifier
Average cost of biomass
Biomass consumed
Fuel oil replaced
HSD Cost (W/O Gasifier)
Biomass Cost
Additional power cost
Net Saving
Savings as percentage
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5000 Hours (98% up time)
Rs. 2=50 per kg
347279 kgs
109846 lts
Rs. 19,77,228
Rs. 8,68,198
Rs.
79,888
Rs. 10,29,143
52%